TITLE OF DOCUMENT: CGD PROJECT MANAGER'S HANDBOOK

SURESH ZANWAR DGM (GAS), SOUTH

VIVEK VOHRA DGM (GAS), WEST

DGM PROJECT COORDINATION

PREPARED BY MANOJ GUPTA
(GAS)

RAJINDER KUMAR CHIEF MANAGER (GAS), NORTH

CHIEF MANAGER MIS, PNGRB &

DIPANKAR SAHA
STATRY. COMPLIANCE(GAS)

REVIEWED BY PARDEEP GOYAL HEAD CGD PROJECTS (GAS)

APPROVED BY P. ANILKUMAR EXECUTIVE DIRECTOR I/C (GAS)

Note: This document is property of Bharat Petroleum Corporation Limited and strictly
confidential. Any unauthorised use of this document is strictly prohibited.

Version No. 1 Release Date : 12 th March 2023

 INDEX
Sr No. TOPICS PAGE Chapter
C.G.D OVERVIEW OF CGD PROJECTS
1.0.0 DESIGN BASIS OF CGD NETWORK 1
1.1.0 DEMAND STUDY 1
1.1.1 DEMAND ASSESSMENT IN DOMESTIC SEGMENT 1
1.1.2 DEMAND ASSESSMENT IN TRANSPORT SEGMENT 1
1.1.3 DEMAND ASSESSMENT IN COMMERCIAL SEGMENT 1
1.1.4 DEMAND ASSESSMENT IN INDUSTRIAL SEGMENT 2
1.2.0 UPSTREAM SIDE STUDY 2
1.3.0 ROUTE SELECTION 2
1.4.0 STEEL NETWORK DESIGN 2
1.4.1 PRELIMINARY SELECTION PIPELINE SIZE 2

STEEL PIPELINE
1.4.2 DECIDING PIPELINE GRADE & WALL THICKNESS 3
1.4.3 ADDITIONAL CHECK FOR PIPELINE STRENGTH CONSIDERING STRESS DURING HYDROTEST 4
1.4.4 ADDITIONAL CHECK FOR PIPELINE STRENGTH CONSIDERING STRESS DURING PULLING IN HDD 4
1.4.5 DECIDING INTER-DISTANCE BETWEEN TWO SECTIONALIZING VALVE 4
1.4.6 LINE-PIPE MATERIAL 5
1.4.7 CATHODIC PROTECTION 6
1.4.8 ANTI-BUOYANCY MEASURE 9
1.4.9 PIPELINE CROSSINGS METHODOLOGY 9
1.4.10 PIPELINE CONSTRUCTION 9
2.0.0 DESIGN OF HOOKUP FACILITY 11
2.1.0 Design of STPL 12
2.2.0 Design of CGS 13

CGS
2.2.1 PRESSURE REDUCTION SKID 13
2.2.2 CUSTODY TRANSFER METERING SKID 13
2.2.3 ODORIZATION UNIT 14
3.0.0 DESIGN BASIS OF MDPE PIPELINE NETWORK 15
3.1.0 MDPE LAYING 16
3.2.0 DETAILED LAYING PROCESS 24
3.2.1 LOCATION OF UNDERGROUND UTILITIES 24
3.2.2 PROTECTION OF STRUCTURES AND UTILITIES 24
3.2.3 INTERFERENCE WITH TRAFFIC, STREET DRAINAGE AND GENERAL PUBLIC 25
3.2.4 TRENCHING 25
3.2.5 CLEARANCES 27
3.2.6 UNDER GROUND INTERFERENCES 27
3.2.7 OTHERS 28
3.2.8 BEDDING 28
3.2.9 LAYING 29
3.2.10 JOINTING OF POLYETHYLENE PIPE 30
3.2.11 BACK FILLING
PIPELINE
31
3.2.12 MOLING 32
3.2.13 BORING/RAMMING/DIRECTIONAL DRILLING 33
3.2.14 CASING PIPE 33
3.2.15 RESTORATION 33
MDPE

3.2.16 TESTING 34
3.2.17 PURGING 35
3.2.18 VALVE PIT 35
3.2.19 LIST OF VARIOUS STANDARDS RELATED TO MDPE PIPELINE LAYING 35
 INDEX
Sr No. TOPICS PAGE Chapter
4.0.0 GUIDELINES FOR LAST MILE CONNECTIVITY (LMC) WORKS 36
4.1.0 REGISTRATION OF PNG CUSTOMER 36
4.2.0 PREPARATION OF ISOMETRIC DRAWING 37
4.3.0 LAYING OF 20 MM MDPE PIPE & INSTALLATION OF GI PIPE. 38
4.4.0 PNEUMATIC TESTING OF 20 MM MDPE PIPE & GI PIPE 38
4.5.0 RESTORATION 39
4.6.0 NATURAL GAS CONVERSION (NGC) AND ACTIVATION OF PNG CUSTOMER 39
4.7.0 DETAILED CONSTRCUTION PROCEDURE FOR LAST MILE CONNECTIVITY 39
4.7.1 MATERIAL, PLANT AND EQUIPMENT 40
4.7.2 REFERENCE SPECIFICATION, CODES AND STANDARDS 40
4.7.3 PROTECTION OF STRUCTURES AND UTILITIES 41
4.7.4 G.I ABOVE GROUND SERVICE PIPE 41
4.8.0 TESTING OF GI INSTALLATION 42
4.8.1 INSPECTION 44
4.8.2 PURGING & COMMISSIONING 44

LMC
4.9.0 INSTALLATION OF METERS 45
4.10.0 PAINTING OF GI PIPES 45
4.11.0 INSTALLATION OF REGULATORS 47
4.12.0 CONVERSION OF DOMESTIC APPLIANCES 47
4.13.0 RESTORATION 48
5.0.0 CNG PROJECTS 49
5.1.0 COMPRESSORS 49
5.2.0 CASCADES 50
5.3.0 DISPENSERS 52
5.4.0 SS TUBING 52
5.5.0 ELECTRICAL WORKS 52

CNG STATIONS
5.6.0 Mother Station 52
5.7.0 CONSTRUCTION OF CNG STATIONS 53
5.7.1 SAFETY DISTANCES & OTHER REQUIREMENTS 53
5.7.2 STATUTORY REQUIREMENTS 54
5.7.3 GENERAL ASPECTS 54
5.7.4 EQUIPMENT DESCRIPTION 55
5.7.5 DESIGN BASIS 56
6.0.0 GUIDELINES FOR SELECTION OF SITE FOR CITY GATE STATION 56

LAND SELECTION
6.1.0 SITE SELECTION 57
6.2.0 LOCATION OF SITE 57
6.2.1 LOCATION OF CGS 57
6.2.2 LOCATION OF ODOURIZATION UNIT 57
6.2.3 LOCATION OF MOTHER STATION UNIT 58
6.3.0 LAND REQUIREMENTS 58
6.4.0 CHECKLIST FOR TECHNICAL SUITABILITY 58
7.0.0 STATUTORY APPROVALS IN CGD 60
8.0.0 CGD PRESENTATION 70
9.0.0 LIST OF DRAWINGS
1) COMPRESSOR SOIL BEARING CAPACITY MORE THAN 10T/M2 137
2) COMPRESSOR DETAIL SOIL BEARING CAPACITY LESS THAN 10T/M2 139
3) CASCADE FOUNDATION 141
4) SS TUBE TRENCH DETAIL 143
5) CGS ANDCASCADE FILLING 145
6) DRAWINGS RELATED TO LMC 146
7) DRAWINGS RELATED TO MDPE 169
8) ELEC PANEL-CNG_22-37.5 KW 179
9) ELEC PANEL-CNG_90KW 183
10) ELEC PANEL-CNG_160KW 187
PANEL GENERAL DOCUMENT 191
11) EARTH PIT DRAWINGS 193
12) LIGHT POLE FOUNDATION FOR 7M-TUBULAR 196
C.G.D OVERVIEW OF CGD PROJECTS
CGD projects is very much capital intensive and gestation period is more comparing to other
projects. So to protect the investor, PNGRB provides exclusivity rights of marketing by way of
granting authorization for a particular Geographical Areas (GAs). PNGRB select entity/company
through bidding to provide authorization for CGD network development and to market gas in a
particular GA. In the process of bidding (from 9th bidding round onwards), authorized entity
commits work-program or authorized entity agrees to predefined work-program (upto 8 th
bidding round).. This work-program refers to completion of certain number of PNG connections,
CNG stations & pipeline infrastructure in time bound manner which is is called MWP or the
Minimum Work Program. Another important obligation of CGD entity is reaching natural gas to
all Charge Areas (CAs) of the GA. One GA is divided into multiple CAs based on demand centres.
In general GA is based on one district or multiple adjacent districts and charge areas are Talukas.
Till 10th CGD bidding round, GA boundaries were defined by the GIS map provided by PNGRB
during bidding. However in recently concluded CGD bidding round no. 11 & 11A, GA boundaries
are district boundary in accordance with political map of Survey of India.
1.0.0 DESIGN BASIS OF CGD NETWORK
The CGD network is designed considering demand centre locations, peak demand in these
locations (M3/hr which is precisely SCMH), route to reach demand centre from tap-off point and
the available gas pressure at tap-off point. Tap-off points to demand centres are connected by
steel pipeline or primary network. These demand centres can be online CNG stations or DRS
locations or dedicated meters (MRS) of major industries. Further from DRS, MDPE (medium
density poly ethylene) pipeline networks connects PNG consumers.
1.1.0 DEMAND STUDY

Demand projection is done based on market survey, consumption of fuel which can be replaced
by Gas, assumption of growth over coming years in all the four segments i.e. House-holds or
Domestic, Transport, Commercial and Industrial segments.
1.1.1. Demand assessment in Domestic Segment starts with census data on urban & rural
population. Following assumption needs to be considered
 PNG (piped natural gas) can be provided only to permanent/pukka houses
 Congested area where Fire tender can’t reach, should be avoided for PNG connection.
Accordingly permanent houses with LPG are projected and PNG connection number is estimated
assuming certain conversion percentage. With this connection numbers (say N), peak load of
domestic segment of an area is estimated with considering consumption per household at a rate
of 0.4 SCMD and average hour of coking as 4 hours and assuming 50% of connections are active
at same time. Thus estimated peak load of PNG-Domestic for a demand centre works out to be
N*(0.4/4)*50% SCMH.
1.1.2 Demand assessment in Transport Segment starts with RTO data on vehicle population in
different category of vehicles. For the estimation of the realizable demand of CNG, switchover
factor based on the nature of vehicles is assumed, say 15% for private car, 70 % for auto-
rickshaws etc. After that based on running of vehicles and CNG demand is worked out. CNG
demand is validated or moderated based on fuel consumption in that area which covers demand
from locally registered vehicles (RTO data) as well as transit vehicles.
pg. 1
This daily CNG demand (say X) is required to be catered by multiple CNG stations (N nos. with
sales Xn) suitably located within city or along highways. Existing BPCL retail outlets are given
preference for setting up CNG stations. If same not available then suitable retail outlet of other
OMCs are selected for the CNG stations. Considering 16 hours working of a CNG station,
estimated peak load of CNG demand for a CNG stations out to be Xn/16 SCMH.

1.1.3 Demand assessment in Commercial Segment is done based on category wise universe i.e.
total numbers commercial establishments of each category within the GA and primary survey to
assess average consumption (SCMD) of each types of establishments, say 5 star hotel 350 SCMD,
restaurant 25 SCMD etc. Accordingly demand load per day (say C) is calculated summing up daily
demand of commercial establishment of all the categories. This demand is cross-checked from
consumption data of commercial LPG. It is assumed that kitchen of commercial establishment
operates for 12 hours, hence peak demand works out to be C/12 SCMH for that demand centre.

1.1.4 Demand assessment in Industrial Segment starts with identification of key industries that
may switch easily to Natural Gas. In this exercise personal interaction is required at appropriate
level for identifying current demand and its future outlook. Financial feasibility or cost-benefit
analysis to switchover to natural gas, mandate from pollution control authorities needs to be
considered in estimating industrial PNG. It is assumed that industry operates in two shifts, i.e 16
hours in a day, accordingly peak demand of an industrial cluster is ‘I/16’ SCMH if daily demand
is ‘I’ SCM.

1.2.0 UPSTREAM SIDE STUDY

At downstream side demand centre location and peak load is determined as mentioned above,
simultaneously at the upstream side location of tap-off from main gas transmission pipeline and
available pressure needs to be ascertained. It is always preferred to have multiple tap-off from
different SV of transmission pipeline to reduce steel pipeline cost of CGD network.

We also need to consider availability of future pressure in the transmission pipeline since the
pressure is likely to increase with increase in gas demand in country in coming years.

1.3.0 ROUTE SELECTION

Next activity is finding best route of steel pipeline to reach demand centre from tap-off points.
CGD network is laid along the existing roads taking permission from statutory authorities like
NHAI/PWD/Municipal Corporations. The route is selected based on connecting maximum charge
areas while catering to the various major demand centres with shortest pipeline length.

1.4.0 STEEL NETWORK DESIGN

The proposed pipeline route is optimized using simulation software like GASWORKS or SYNERGY.
These software works on various gas flow distribution equations like Colebrook, Mueller

pg. 2
Equation, Weymouth Equation, IGT Distribution Equation etc. All these equations are empirical,
hence based on selection of equation, there may be minor difference in simulation result.

1.4.1 PRELIMINARY SELECTION PIPELINE SIZE

In this software major inputs (other than temperature, viscosity etc.) are as below:

1. Pressure at tap-off points

2. GIS map of the pipeline routing
3. Pipeline size
4. Peak Loads at all the demand centres

With above Input, software will give gas velocity in the pipeline & pressure at demand centre as
Output. Smallest possible pipeline size is selected such that gas velocity in the pipeline is less
than 30 m/s and pressure in the steel pipeline remains between 49 bar to 7 bar (for online CNG
stations in the range of 15 to 20 bar).

Other approach of simulation can be providing input on pressure at demand centres instead of
pipeline size (refer 3rd input of above list), software will workout pipeline size as output and gas
velocity.

If we have clarity on future enhancement of pressure at tap-off , then we can design network
with smaller size pipe to cater small peak load of initial years, provided sufficiency of small size
pipe is ascertained in change scenario i.e. increase in peak load and increase in pressure with
the help of simulation software.

1.4.2 DECIDING PIPELINE GRADE & WALL THICKNESS

Once pipeline size is ascertained, pipeline thickness is calculated based on following formula
given in ASME B31.8.

t=(P*D)/(2*S*F*e*T)……………(Eqn no.1)

P = Design Pressure in the steel pipeline which is 49 Kg/cm2 or less in CGD network, for STPL
(line from tap-off to CGS) it is between 99 to 49 Kg/cm2.

D= Outer diameter of steel pipeline

S = SMYS or Specified Minimum Yield Stress (for X42 SMYS is 42 ksi or 42000 psi, for X52 SMYS is
52 ksi, other available grades are X56, X60, X65, X70 etc. 1 Kg/cm2 = 14.2233 psi)

F = Population density factor= 0.4 (0.4 for location class 4, location class 4 only to be considered)
However for STPL we can use other location class as applicable (please refer para no. 2.1.0 on
STPL for assessment of location class and corresponding Population density factor)

e = Joint factor =1 and T = Temp. factor = 1

pg. 3
Additional thickness is required for Mill Under tolerance (2%) and extra Corrosion Allowance
(0.5mm).

As per T4S regulation of PNGRB, minimum pipeline thickness is 6.4 mm. Accordingly grade of
pipeline should be selected such that thickness works out to be just below 6.4 mm and we can
select pipeline thickness of 6.4 mm. For smaller size of pipeline lower grade of steel is found to
be sufficient for higher sizes we should opt for higher grade of steel to same on cost without
compromising safety. It is observed that for higher grade of steel, SMYS increases thus wall
thickness or the steel reduces but cost per unit weight increases only by margin. Total cost saving
is 20% or more in case of selection of higher grade of steel.

1.4.3 ADDITIONAL CHECK FOR PIPELINE STRENGTH CONSIDERING STRESS DURING

HYDROTEST

During whole project life, lower portion of the pipeline laid using HDD method comes under
maximum stress during its hydrotesting. With decrease in radius of curvature, stress in pipeline
increases.
Allowed stress for bending (σ) = Maximum allowed stress i.e. 90% of SMYS – Hydrotest stress
Hydrotest stress is=PD/2t in line with Eqn. no.1, where P is hydrotest pressure which is 150% of
design pressure, little less than 75 Kg/cm2 for CGD
From bending formula (M / I = σ /y = E / R)……..(Eqn no.2), here y=D/2 for pipeline
σ /(D/2)=E/R or R=E*D/2S, in case actual or required radius is more than the worked out R from
this formula then pipeline is safe, otherwise we need to go for higher grade of steel or increase
thickness of pipe.
1.4.4 ADDITIONAL CHECK FOR PIPELINE STRENGTH CONSIDERING STRESS DURING PULLING
IN HDD
During pulling in HDD method, pipeline comes under huge pulling force and tensile stress in
addition to bending stress due to curvature.
Total longitudinal stress during installation= Bending stress + Tensile stress due to pulling force
From Eqn no. 2, Bending stress = E*D/2R and Tensile stress = Pulling force/ Cross sectional area
Pulling Force has three components, F1 due to friction, F2 due to curvature and F3 due to
cohesion.
F1=Coefficient of friction x (Reduced weight at down hole considering buoyancy)
F2=Force due to chance in elevation= Coefficient of friction x(Bending moment/elevation diff)
F3=coefficient of drag x (surface area i.e. πDL) which is around 90% of total pull force
For given length of HDD, if worked out longitudinal stress if found more than maximum allowed
stress i.e. 90% of SMYS then we have to go for higher grade of steel.
1.4.5 DECIDING INTER-DISTANCE OF TWO SECTIONALIZING VALVE
Sectionalizing valve is provided at certain distance so that the pipeline can be isolated without
disturbing gas supply to other part. As per latest amendment of T4S regulation, PNGRB allows
pg. 4
inter-distance between two sectionalising valve in CGD network outside the municipal limit as
applicable in natural gas pipeline, as tabulated below:

Location Class Maximum Distance in

Kms
1 32
2 24
3 16
4 8
However location class is to be determined every year based on para no. 2.1.0 and additional
number of sectionalizing valve is required if these is any change of location class based on
addition of new buildings in the area.

1.4.6 LINE-PIPE MATERIAL

Line pipe shall conform to latest edition of API 5L. Type of line pipe to be used shall be
Submerged Arc Longitudinal Welded (SAWL)/Submerged Arc Helical Seam Welded
(SAWH)/High Frequency Welded (HFW)/Seamless pipes. Line pipe material grade shall be
API 5L Grade X42/X52 /65/X70.
Line pipes are recommended to be hydrostatically tested in pipe mill using test pressure
that produces a hoop stress equal to 90% of SMYS irrespective of grade of pipe material.
Entire steel pipeline shall be provided with 3 Layer Polyethylene coating to protect against
external corrosion. Minimum thickness of coating shall be as indicated below.

pg. 5
 Type of Coating Minimum Coating
Thickness (mm)
3 Layer Polyethylene Coating 2.50 mm

No internal coating is required.

1.4.7 CATHODIC PROTECTION SYSTEM: This is to protect steel pipeline from external
corrosion.
Permanent Cathodic Protection (PCP) system in City Gas Distribution for the pipeline along
with associated facilities would be designed for a life of 40 years & would be protected by
impressed current method. During Construction the line would be protected by Sacrificial
anodes (TCP) for one year periodicity till 5 years of Steel execution plan or till the
Commissioning of PCP.

Cathodic Protection Design Parameters

Design Life of [TCP] System one year or till commissioning of PCP system

Design Life of [PCP] System (40 Years)

Anodes

[TCP] - Zn Anodes up to 10 Ώ m, Mg anodes up to 49 Ώ m

-Ribbon anodes (Mg) 50 Ώ M & above

Extensive Soil Investigations for Chemical and microbial loading, Strata & ground water level
will be carried out before deciding which anode to be used, by the CP Contractor.

[PCP] - Mixed Metal Oxide (MMO) LIDA single or String anodes.

The Sacrificial anodes to be installed for [TCP] at every 1.0 km post so that it can be easily
connected / disconnected in Test Lead Point [TLP] as required.

For [PCP], the anode beds will be designed based on site, soil resistivity, chemical and
microbial loading [data to be generated from site], in horizontal or vertical, deep well
configuration.

All the anodes to be installed in appropriate carbonaceous backfill, at appropriate distance

from the pipeline as per design requirement. [Mg-5 meter distance, Zn-2 meter distance and
depth of anode top shall be below the bottom of pipe]

Only One type of Anode [either Zn or Mg] to be used to eliminate Inter Anode Current flow.
pg. 6
Those parts of sacrificial anode cathodic protection system, which will be integrated, with the
permanent impressed current CP system shall be designed based on permanent CP
parameters.

Unless otherwise specified, following parameters shall be used for design of temporary
cathodic protection system.

Protective Current density

For the 3 layer polyethylene [3LPE] coated pipeline, the following protective current density
to be used:

Marshy Normal
Area Rocky
Soil Soil

For TCP
35 20 20
(µA/M2)

For PCP
35 20 20
(µA/M2)

Actual current density to be adopted shall be decided based upon soil and other
environmental conditions, proximity of foreign pipelines/ structures and other interference
areas affecting the installation. Where considered necessary for satisfactory protection of
pipeline the current density shall be suitable increased by contractor.

At HDD crossing, the pipe protection current density applicable for marshy area shall be
considered.

Test Lead Points (TLP)

To be installed at every 1.0 km [TLP] post besides the following additional locations:

i. Pipeline Crossings
ii. Railway Crossings
iii. Both sides of River Crossings
iv. Both sides of [Major] Highways
v. Bonding Stations
vi. At both sides of Cased Crossings
vii. At Overhead H.T. Crossings
viii. At Insulation Mono Block Joints
ix. At locations with very low resistivity soil
pg. 7
TLP of the following types to be installed:

A - for [P-S-P Monitoring] of pipe at every 1.0 Km post along ROU

B - for Current Measurement – every ten (10) Km along ROU

C - for Pipeline Crossings

D - for Cased Crossings

E - Insulation Mono blocks

Combinations of these TLP types may be permitted

Permanent Reference Electrode

In Soil-

CuSO4: 3 Nos. to be installed for each Cathodic Protection (CP) station, 1 no to be installed
midway between two CP stations and to be installed at extremely vulnerable position.

In Water-

Silver Chloride: Silver Chloride (Ag-AgCl) reference to be installed /used.

Temporary Cathodic Protection (TCP) System

Cathodic protection system shall be designed to meet the following criteria:

 The pipe to soil potential measurements shall be between -0.85V (ON) w.r.t Cu-CuSO4
reference electrode. In case sulphate reducing bacteria (SRB) are present in the soil the
minimum protective potential shall be -0.95V (ON), the maximum remaining the same -1.5
V (ON) w.r.t Cu-CuSO4 reference electrode. At the location of polarization coupons, the
coupon to soil potential measurement shall be between -0.85 V to 1.18V w.r.t Cu-CuSO4
reference electrode, both being OFF potential.

 In rare circumstances a minimum polarization shift of -100, mV w.r.t Cu-CuSO4

reference electrode shall indicate adequate level of cathodic protection for the pipeline.

 A positive potential swing of >20 mV (PSP) shall be considered as the criteria for
presence of an interaction situation requiring investigation and incorporation of suitable
mitigation measures by the CP contractor.

Permanent Cathodic Protection (PCP) System

pg. 8
  The pipe to electrolyte measurements shall be between -0.85V (ON) w.r.t Cu-CuSO4
reference electrode. PSP as measured between the pipe surface and a saturated copper –
copper sulphate reference electrode contacting the electrolyte.

 In rare circumstances a minimum polarization shift of -100 mV w.r.t Cu-CuSO4

reference electrode shall indicate adequate level of cathodic protection for the pipeline.
The formation or decay of this polarization shall be used in the criteria.

A positive potential swing of 20 mV and more shall be considered as sufficient the criteria
for presence of an interaction situation requiring investigation and incorporation of
suitable mitigation measures by the CP contractor. Discretion to use any of the criterion
listed above, shall solely rest with the owner / owners respectively.
1.4.8 ANTI-BUOYANCY MEASURE
Whenever up-floating of the pipeline after backfilling is to be reckoned with, anti-buoyancy
measures shall be provided. Anti-buoyancy measure shall be provided at the following
locations as a minimum.

 River crossing by open cut method.

 Unlined canals, nala, drain etc. installed by open cut method, with formation width
more than or equal to 10m.

The methods of anti-buoyancy measures can be as under:

 Use of Continuous Concrete Weight Coating for open cut river crossings.
 Use of geo-textile bags.
 Increased cover or select backfill.

1.4.9 PIPELINE CROSSINGS METHODOLOGY

Construction methodology for the pipeline crossing depends on the nature of crossing and on
the requirements of the authorities having jurisdiction over the facility being crossed. Typical
methodology for various crossings is briefly described below.
For HDD crossings, carbon steel conduit of size 6” shall be provided for Optical Fibre Cable.
Railway Crossings
All railway lines shall be preferably crossed by HDD Method or auger boring method
depending upon site condition. Approval of design and construction methodology shall be
obtained from concerned railway authorities & OISD STD 226. Crossing angle shall be close to
90° as far as possible.
National Highways and State Highways
Pipeline at National Highways and State Highways shall be preferably crossed by HDD Method
or auger boring method depending upon site condition. Use of casing pipe to cross National
pg. 9
Highways and State Highways shall be decided during the detailed engg stage and as per the
finalised crossing methodolgy. National Highways and State Highways crossing shall comply
with the requirements of concern authorities and requirements of OISD STD 226 & PNGRB
T4S.
Roads

Metalled roads other than National Highways and State Highways that includes but not limited
to Major District Roads (MDR), Other District Roads (ODRs) and Village Roads (VRs) shall be
crossed by Open Cut method only. No casing pipe shall be provided at such locations unless
directed otherwise by statutory authorities.
Canals & Nalas

Lined canals shall be preferably crossed by HDD method or auger boring method depending
upon site condition. Use of casing pipe to cross lined canal crossing shall be deicided during
the detailed engg stage and as per the finalised crossing methodology. Irrigation canals
(lined/unlined) shall comply with the requirements of concern irrigation authorities and
requirements of OISD STD 226.
All other minor canal & nala crossings shall be carried out with conventional open cut method
unless directed otherwise by the concerned authorities. No casing pipe shall be provided.
Rivers
River crossings shall be executed by HDD method or open cut method. Crossing methodology
shall be decided based on factors such as flow being seasonal or perennial, scour level etc.
Crossing specific methodology will be decided during detailed design.
In case of crossing executed by open cut method, continuous concrete coating shall be
provided for the pipeline upto HFL levels. Conduit for OFC shall be strapped with concrete
coated carrier pipe. Extent of concrete coating shall be 30m on either side from bank of river.
Banks shall be protected by using gravel and boulders filled embankment mattresses of
galvanized iron wire to be laid over the backfilled, compacted and graded banks.
In case of crossing executed by HDD method, separate HDD shall be done for CS conduit for
OFC.
Overhead Powerline Crossing
80mm thick concrete slab/neoprene sheet over pipeline as a protection at crossing locations
shall be provided for powerlines ≥ 11kV crossings. This will be detailed in specification based
on Cathodic Protection Interference Mitigation.

Foreign Pipeline Crossing

Specific requirement; if any, of Owner/Operator of existing pipeline shall generally be
followed. Minimum clearance between the existing and proposed pipeline shall be 5 m unless
specified otherwise and a physical barrier in the form of 80mm thick concrete slab shall be
provided. Existing pipeline shall be properly supported during and after the construction
activities.
pg. 10
Underground Cable Crossing/Proximity to HT Tower
In case pipeline is to be laid parallel to, along or near existing underground HT power cable
underground pipes should maintain a horizontal clearance of 5 m. Wherever this distance
cannot be met, a minimum 6mm thick and 5 meter width, Non Toxic Rodent Resistant PVC
sheet be continually installed between cable and pipe as a measure of preventing fault current
accessing pipeline. In any case this horizontal distance shall not be less than 3m.

In case of existing communication cables, conductors or conduit, underground pipes shall

maintain a vertical clearance of at least 500 mm and horizontal clearance of 500 mm. Where
these clearances cannot be maintained, extra precaution shall be taken to ensure the
maximum possible clearance and to prevent future contact.

A minimum separation of 3.0 meter should be maintained between pipeline and transmission
tower footings.
1.4.10 PIPELINE CONSTRUCTION
The pipeline shall be laid underground with minimum 1.0m cover in normal stretches and
suitably backfilled. Additional cover; whenever required shall be provided depending upon
soil condition. For more details, refer Clause 7 of this document.
Welding shall be carried out in accordance with API 1104. All welds shall be 100%
radiographed. Field joint coating shall be carried out by using Heat Shrinkable Sleeves.
After installation and backfilling, the entire pipeline system shall be hydrostatically tested with
corrosion inhibited water. The minimum hydrostatic test pressure in any section shall be 1.25
times the design pressure. The hoop stress, due to hydrostatic test section shall not exceed
95% of the SMYS of pipe material with the least wall thickness in the hydrostatic test section.
The test duration shall be 24 hours after stabilization.
Mainline valves assemblies shall be installed after successful completion of hydrostatic testing
along with its associated stubs. Flow Tees shall be used for stubs to be provided on either side
of mainline valves.
Whenever the pipeline route passes through the area with normal strata (soft soil/sand/clay/
silty sand/silty clay), conventional trenching and backfilling can be considered for laying of the
pipeline in such areas. Whenever the pipeline route passes through hard strata (soft
rock/Murrum/Laterite/Weathered rock/Gravels/Pebbles), excavation can be done with the
help of dozer-ripper and back hoes. In case of areas with hard rock, blasting can also be used
to speed up the excavation activities in the rocks.
Where blasting cannot be done due to close proximity of existing facilities, mechanical
equipment for rock excavation such as rock breakers can be used. Minimum 300mm thick
layer of soft back-fill material shall be provided all around the pipeline prior to back-filling the
trench with excavated material.
Pipeline trenching activity will be followed by pipeline stringing and pipeline laying &
backfilling activities.

pg. 11
In cultivable land and other specifically designated areas, the top 300 mm soil excavated from
the pipeline trench shall be stored separately. This top soil shall be replaced in original position
after backfilling and compacting of the rest of the trench.
The width of trench shall be such that a minimum clear distance of 200 mm for trench in
normal soil and 300mm for trench in rock is maintained between edge of pipe and the trench
wall at the bottom of trench.
Pipeline construction activities will be explained in detail in Pipeline Construction
Specification, which will be developed during Detailed Engineering.

2.0.0 DESIGN OF HOOKUP FACILITY

Hooking-up facility refers to facilities between tap-off point on transmission pipeline & CGD
network which is broadly STPL and CGS or City Gate Stations. Transmission pipeline company’s
involvement is upto custody transfer meter in CGS and the hooking-up facilities end at custody
transfer meter. Facilities downstream of custody transfer meter like odorization unit, check
meter and CNG facilities or DRS if any is not part of hooking-up facility.

2.1.0 DESIGN OF STPL

Design of STPL can be done using Eqn no. 1. But STPL is to be designed based on natural gas
pipeline which allows Population density factor in accordance with location class depending on
number of building along pipeline route.

To determine the number of buildings intended for human occupancy for a pipeline, layout a
zone 1/4 mile wide along the route of the pipeline with the pipeline on the centerline of this
zone, and divide the pipeline into random sections 1 mile in length such that the individual
lengths will include the maximum number of buildings intended for human occupancy.
Count the number of buildings intended for human occupancy within each I-mile zone. For this
purpose, each separate dwelling unit in a multiple dwelling unit building is to be counted as a
separate building intended for human occupancy.

Less Less than

Number of Building for Less than 25 than 45 65 More than
human occupancy building building building 65 building
Location class Class I Class II Class III Class IV
Population density factor 0.72 0.6 0.5 0.4

Spacing of Sectionalizing Valve should be as mentioned in para 1.4.4 above.

In case length of STPL is more than 10 km, pipeline should be piggable.
Optical cable should be laid in HDPE pipeline along with the STPL line so that valve at tap-off
location can be actuated remotely from CGS location in case of any exigencies in downstream.
Minimum 300 mm coating to be provided at interface of above ground & underground
mainline pipe. Also IJ (insulation joints) needs to be provided in these cases of interface.
pg. 12
2.2.0 DESIGN OF CGS
A typical CGS will have the following facilities:

- Filtering system
- Pressure Reduction Skid
- Custody Metering with Filtration Skid
- Odorisation unit
- Check Metering Skid (optional).

Other associated facilities are:

- Portable gas detection system
- Electrical load (LT) for lighting arrangement
- 1 KVA UPS with Battery bank for few hours backup
- Earthing grid /lightening grid and other accessories.
- Permanent Cathodic Protection system (PCP)

2.2.1 PRESSURE REDUCTION SKID : 100% redundancy pressure reduction system one
working and one stand-by stream.The pressure reduction system shall consist of the following:
Slam-shut valve actuated to close in case of downstream pressure increase above safe level;
it needs local manual reset; Fail-safe is to close
Pressure Control Valve (PCV) which takes over control in case the Active PCV fails to maintain
downstream pressure below required maximum pressure; Fail-safe is to open.
Active Pressure Control Valve (PCV) that regulates the downstream pressure as required: Fail-
safe position is to open.
Such concept is called "Non Venting Pressure Safety" and allows avoiding the "Safety Relief
Valves" more common in industrial plants. Indeed, large relieves as may be needed by the
"Venting Pressure Safety" is then avoided and relevant hazards suppressed.

2.2.2 CUSTODY TRANSFER METERING SKID

For CGD company capacity of meter is very important which is decided based on sum of peak
flow requirement of all the demand centre to be fed by hooking-up facility. Metering facility
always comes with gas filtration skid.
Filtration Skid -
Equipment like regulators and meters are quite sensitive to dirt and its accuracy gets affected
with particle in GAS hence metering system requires no particles presence in gas above
5 microns.
Hence Gas entering the CGS will be filtered through Cartridge type filters which will be
installed to remove entrained undesirable particles of size 5 micron & above (filtration
efficiency 99%), filters will have vent and drain. Level gauge and differential pressure indicator
will be also provided. These are of Borosilicate fiber glass cartridge type.
Figures for Filtration skid at CGS
Operating pressure : 50 - 90 barg (max.)

pg. 13
 Operating temp : 0 - 45 oC
Design pressure : 98 barg
Design temp. (Min / Max) : 0 / +65 oC
Pressure drop : 0.3 barg (max)
Filtration Type : Cartridge
Degree of filtration : > 5 micro meter particle size
No. of streams : 1+1

Figures for Metering skid at CGS

Operating pressure : 50 - 90 barg (max.)

Operating temp : 0 - 45 oC
Design pressure : 98 barg
Design temp. (min / max) : 0 / +65 oC
No. of streams : 1+1

2.2.3 ODORIZATION UNIT

Natural gas is, by nature, odourless that makes detection of leaks impossible without special
gas detection tools. Hence it is mandatory to add an odorant to the gas before it enters the
CGD System so as end-users connected to a Natural Gas Distribution System is able to notice
leakage of gas with odor.
Odorization shall be based on the injection of suitable sulphur compound in adequate
proportion (in function of actual flow) on the primary network system
The odorization unit will consists of a SS storage vessel with reserve vessel internal piping &
accessories, suitable cabinet & skid with dosing pumps with drivers, control system and
accessories such as pulsation dampers, flowmeter, external pressure relief valve, calibration
pot, Odorant unloading / storage system etc. This unit shall be designed to provide the desired
odour intensity for the entire gas stream.

Odorization dosing shall be synced with gas flow, based on the input provided by CRO for PPM
dosing shall adjust odorant pump flow to maintain the desired PPM level.

Figures for Odorization Skid at CGS

 Operating pressure : 45 bar (g) max.
 Operating temp : 0 – 45 oC
 Design pressure : 49 barg
 Design temp (min / max) : 0 / +65 oC

pg. 14
  Odorizing agent : Tetrahydrothiophene (THT), Ethyl
mercaptane, Tert-Butyl mercaptan (TBM)
 Dosing rate : 15 mg equiv. THT/Nm3 of gas
3.0.0 DESIGN BASIS OF MDPE PIPELINE NETWORK

MDPE pipeline network starts from DRS or District Regulating Stations. DRS is the transition
equipment between high pressure Steel pipeline network (primary network) & medium pressure
secondary network of MDPE pipeline

SL. TECHNICAL DETAILS of PARAMETERS

NO. DRS

1 Standard Capacity 500, 1000, 2500 & 5000 SCMH

 Design pressure 49 barg

 Upstream pressure 17 - 32 barg

2 Downstream pressure 6 / 4 barg

3 Design temp (min / max) 0 oC / +60 oC

4 No. of streams 1 + 1 or 2+1

5 Redundancy Minimum 50 %

6 Installation Above Ground / Under Ground

First activity to conceptualize MDPE pipeline network is Area Survey to find out followings
o Identify no. of households for Domestic PNG
o Identify no. of Commercial customers
o Identify the number of Industries
o Future expansions in the area
o Mark Roads, highways, canals, water bodies, railway tracks or any other possible
obstacles.
o Obtain requisite permission from local / statutory bodies.

pg. 15
  Design & simulation
o Based on demand and area survey report fix the capacity & locations of DRS.
o Based on area survey report & pipeline simulation design MDPE network.
 Ensure the system is closed loop.
 Should ease the future expansion
 Fix location and capacity of Service Regulators
 Mark Roads, highways, canals, water bodies, railway
3.1.0 MDPE LAYING
- Recognize MDPE pipe

6 7
2 3 4 5
1

1. _______________: Name of Company

2. DN-125 X 7.1mm : Nominal dia 125mm and material thickness - 7.1mm
3. SDR : Standard Dimension Ratio

4. PE-100 Gas : Material Specification & Grade

5. 29 06 083 : Lot no. / Batch no.
6. IS:14885 : Indian Standard
7. CM/I.7512264 : Company’s Certification Number
- Classification of PE Material for Pipeline system
o The MRS value represents the long term circumferential stress in the pipe
under which the break may occur after 50 years at the earliest.
o The MRS value multiplied by 10 results in the “classification” of material e.g.
Common PE material having an MRS of 10 MPa are called as PE 100.
o There are classification of PE material available ,
 PE 63
 PE 80
 PE 100
- Process Flow of Activities in MDPE Laying

pg. 16
 Route-marking Trenching Temporary Bridging
-

Electro-fusion joint Laying Sand padding

Warning tape Backfilling

Sand Padding / Covering

Documentation Marker installation Restoration

Res

- Major / Minor Crossings

o State Highway / Major Road Crossing – open cut / HDD / Molling method
o Highway crossing (cased crossing by HDD / Auger / Push method)
o Railway Crossing (cased crossing by HDD method)
o Nala crossing (cased crossing by HDD )
o City road crossing by moling system.
- Strategic Valves
• Valves shall be installed to facilitate maintenance of system and to allow for
speedy isolation in the event of damage.
• The location of the strategic valves shall be decided based on the risk associated
with maintaining the gas supply and to facilitate maintenance, repair,
modification, testing and commissioning etc.
• In no case, distance between two strategic valves shall exceed:
• 1KM for PE Pipelines of diameter 63 mm and above.
• For PE Pipelines less than 63 mm diameter, the distance between strategic
valves shall be based upon risk analysis.
pg. 17
 • Such valves of appropriate materials shall also be provided on each riser,
upstream of each meter and at both ends of river & railway crossing.

- Pipeline Markers (ref. Standard drawing)

o Route markers shall be placed on the entire pipeline at a distance not
exceeding 50 meter and also at bends in the city.
o Additional sign/ markers shall be installed to indicate the presence of a
pipeline at road, highway, railroad, stream crossings and locations where
there is a probability of damage or interference.
o Further, warning signs shall be displayed on the service line to consumer
premises.
o A marker shall be marked in easily readable local language with at least the
following:
 Name of PNG distribution company
 Contact telephone number(s) in emergency.
 Location code
 Warning- “High Pressure Gas Line” and “Other Utilities to take
permission from PNG Distribution Company before digging” etc.

- Laying of Pipelines (Compliances)

o T4S of PNGRB and OISD-GDN-192 (Safety Practices during Construction) shall
be complied.
o Road signs, warning lamps and barrier systems shall be provided on highway
or other work locations which are accessed by pedestrians or vehicles.

o Underground utilities shall not be disturbed or altered without the prior

consent and approval of the owner or authority concerned.
o Electricity cables shall be treated as "Live”, unless the owner certifies them
as "Dead".' The dead cable shall also be checked for any residual voltage.
o Where open cut techniques are used, a warning tape of Yellow colour shall
be laid above the pipe, the difference in elevation of the pipe and warning
tape shall be minimum of 200 mm.
o As built drawing and pipe book shall be maintained.
o Trench width shall be al least 300 MM. The bed of the trench shall be free of
sharp objects, stones etc. The trench should be padded with soft soil / sand
to minimum of 100 mm below the pipe.

pg. 18
 o At identified locations pipelines shall be provided with impact protection from
excavating machinery as indicated in the fig 1(a) where ‘h’ shall not be less
than 500 MM. & 1(b) where ‘h’ shall not be less than 250 mm.

- Where it is necessary to cross or run close to any other utility, a minimum of 250 mm
clearance shall be maintained. In case the clearance is less, appropriate protection
measures shall be taken. The relative position of PNG pipeline with respect to other
underground utilities shall be as shown alongside:

pg. 19
Provision shall be made for locating the buried PE pipe by installation of electrical conductive
trace wire or plastic coated metallic tape or any alternative proven method.

- Depth of Cover

Location Min. Cover in meter

Industrial, Commercial and Residential Areas

1. 0

Stream, Canal and other minor water

1. 5
crossings (below bed level)

Drainage ditches at roadways and railroads 1. 0

Rocky Areas 1. 0

Road Crossings 1. 2

Railroad Crossings 1. 7

Inside the building / society premises 1. 0

o Wherever the minimum depth of cover as above is not possible, a risk analysis shall
be carried out to determine the additional protection requirements.

pg. 20
 o The depth of cover shall be measured from the top of the pipe coating to the top of
the undisturbed surface of soil or the top of graded working strip, whichever is
lower.;
o The cover shall be measured from the top of road or top of rail, as the case may be;
o For river/watercourses that are prone to scour and erosion, adequate safe cover
shall be provided below the predicted scour profile expected during the life time of
the pipeline.

- Thermoplastic Fittings
• Polyethylene resin used for manufacture of thermoplastic fittings shall be
virgin, cadmium free pigmented compound.

• Anti-oxidant and UV stabilizers used in PE resin shall not exceed 0.3 and 0.5
percent respectively. Reprocessed material shall not be used.
• Grade of PE compound used for the fittings should not be less than that of PE
pipes. In case fittings are of different grade than that of pipes, compatibility of
the same with pipes shall be established prior to their use.
• The wall thickness of the fittings shall be more or equal to the wall thickness of
the pipe jointed.
• Heating element shall not be exposed and all coils are embedded into the body
of the fittings.
• Colour of fittings shall be yellow or black.
• Electro-fusion fittings complying with ISO 8085 Part 3 / EN- 1555 -3 shall be
used for all sizes of PE pipes.
• Fittings fabricated from pipe shall not be used. Only injection moulded fittings
are recommended.
• For fusion fitting up to 63 mm, pipe fixation device shall be an integral part of
the body of the fitting and for size above 63 mm external alignment clamp shall
be used.
• Each Electro Fusion fitting shall be bar coded. Fusion fittings shall have
permanent fusion indicator or a data card conforming to ISO-7810/ISO-7811.
• The fusion jointing shall be carried out as per the procedure outlined in the
standard DVS 2202 or equivalent.
• Carbon steel part of transition fittings used for connecting PE system with
Carbon Steel system may have butt weld/plain/flanged ends.
pg. 21
 - Electro Fusion Process

o Electro-fusion welding process is used for joining MDPE pipes. The pipes to be
joined are cleaned, inserted into the Electro-fusion fitting (with a temporary
clamp if required) and a voltage (typically 40V) is applied for a fixed time
depending on the fitting in use.

Cutting

Marking

Scrapping

Degreasing / Cleaning

Clamping

Welding

Cooling

pg. 22
pg. 23
3.2.0 DETAILED LAYING PROCESS

ROUTE SURVEY

Plans detailing the size, operating pressure and approximate location of the proposed mains,
connections and associated regulator installations will be issued to the contractor at the start of
the works.

The final alignment of mains will be worked out at site in consultations with the site engineers
after route survey and trial pits, at his cost, have been carried out. Any change in routing from
the issued drawings due to site constraint will be notified and approval shall be obtained before
carrying out the job.

Service Lines

A survey will be conducted jointly by at each premises or housing colony to be supplied. The
survey record will note customer details, the potential gas supply points and proposed regulator
positions and estimates of material quantities. The contractor’s representatives will make as
sketch of the agreed pipe routes if necessary.

The contractor will be responsible for contacting the customer and making the necessary
arrangements for access, and appointments to carry out the work.

3.2.1 LOCATION OF UNDERGROUND UTILITIES

Locate all buried utility pipes, underground cables, water mains and other obstructions
intersecting or adjacent to the Works, and shall make available the necessary labour to expose
and record the depth of cover over all obstructions in advance of excavation. This shall be done
far enough in advance of excavation to facilitate gradual change in grade or position found
necessary to clear any obstructions.

Excavate trial pits as necessary to determine the pipe route. The number of trial pits will be
agreed with the EIC in advance of any excavation. In any event, trial pits shall be made at
intervals of a maximum of 30 meters. Restoration of the abandoned trial pits and trenches shall
be the contractor’s responsibility. No payments shall be made for such type of jobs.

There will be no additional payments in respect of abandoned trenches incurred because of

insufficient or inadequate trial pits, or any associated lost time or delays.

3.2.2 PROTECTION OF STRUCTURES AND UTILITIES

The Contractor shall at his own cost, support and protect all buildings, walls, fences or other
structures and all utilities e.g. Electrical cables, Telephone Cables, Water pipelines, Sewer
pg. 24
pipelines etc., and property which may, unless so protected, be damaged as a result of the
execution of the works. He shall also comply with the requirements in the specification relating
to protective measures applicable to particular operations or kind of work. Special care shall be
taken while laying Pipelines near the trees.

3.2.3 INTERFERENCE WITH TRAFFIC, STREET DRAINAGE AND GENERAL PUBLIC

The Work shall be executed in such a manner as to cause a minimum of inconvenience to persons
requiring to use public or private roads, lanes, thoroughfares, walkways, rights-of use or
passages through which the Works are to be executed. The trench shall be back filled,
compacted, levelled and extra earth shall be removed immediately after laying of pipeline to
avoid public inconvenience. Closure of roads, etc, shall not be permitted without the approval
of the EIC.

The Contractor shall comply with all local Authorities requirements to traffic, and keep roads
open to traffic, and maintain access to and within any private property.

Wherever the pipe route crosses driveways, access tracks or entrances to private properties, the
Contractor shall give the owner, occupier or relevant authority at least 24 hours prior notice of
intended commencement of excavation and shall be restricted to pass through.

Provide suitable access where necessary in the form of temporary bridges, culverts, flumes, etc,
of a size and type approved by the EIC.

The Contractor shall comply with all relevant road Laws. Where limits and/or speed limits have
been placed in the vicinity of the Works, the Contractor shall provide for the necessary
movement of plant and equipment in accordance with the requirements of the relevant
authority.

Do not obstruct any drainage pipes or channels in any road but shall deviate them where
necessary and use all proper measures to provide for the free passage of water.

The Contractor shall deliver the completed works after proper cleaning of the site.

3.2.4 TRENCHING

The schematic diagram with the detail of trench is enclosed as Annexure.

Excavate so as to enable the pipe to be laid in conformity with the levels, depths, slopes, curves,
dimensions and instructions shown on the Drawings, Specifications.

Excavate and maintain the pipeline trench on staked center line as per approved alignment
sheets taking into account the horizontal curves of the pipelines.

pg. 25
While trenching care shall be taken to ensure that all underground structures and utilities are
disturbed to the minimum. Suitable crossing shall be provided and maintained over the ROU
wherever necessary to permit general public, property owners or his tenants to cross or move
stock or equipment from side of the trench or another.

Trenching shall be made with sufficient slopes on sides in order to minimize collapsing of the
trench. On slopes wherever there is danger of land slides, the pipeline trench shall be maintained
open only for the time strictly necessary.

Ensure that trench bottom is maintained in the square form as far as possible, with equipment,
so as to avoid/ minimize the hand grading at the bottom of the trench. The Contractor shall do
all such handwork in the trench as required to free the bottom of trench from loose rock, pebbles
and to trim protruding roots from the bottom and sidewalls of the trench.

Depth of Trench

The minimum depth of cover shall be measured from top of pipe to the top of undisturbed
surface of the soil or top of the graded working strip or top of road or top of rail, whichever is
lower.

The depth of the trench will be such as to provided minimum cover as stipulated below :

a) For Distribution Main and Service Lines

i) Minor Water Crossing/ Canal 1.5 meter

ii) Uncased/ Cased Road Crossing 1.2 meter
iii) Rail/ Road Cased Crossing 1.7 meter
iv) Normal Areas 1.0 meter

The minimum depth as mentioned above may be greater than as may be required by
Government/ Public authorities under jurisdictions. The Contractor shall perform such work
without extra compensation, according to the requirement of concerned authorities.

In cases of Drain/ Culvert crossing through open cut where excavation cut is more than 1.5m,
the extra excavation shall be paid in quantity basis. The rate shall include backfilling as specified.
No separate payment is chargeable for extra excavation and includes backfilling as well.

In case the depth could not be achieved due to practical problems and the same is demonstrated,
EIC after examining thoroughly and considering the codes and standards may allow the
contractor to provide suitable protection by way of concrete casing pipes or slabs without extra
cost.

Width of Trench

The width of the trench shall be wide enough to provide bedding around the pipe and to prevent
damage to the pipe inside the trench. Unless otherwise directed by the EIC and where ground

pg. 26
conditions permit, the minimum distance from the inside edge of the trench wall to the outside
of the pipe shall be as per drawing.

Trench Base

The trench bottom shall be cut or trimmed to provide a uniform bedding for the pipe, and shall
be free of stones, metal, wood, vegetation, clods of earth or other debris before placement of
the pipe.

Hard rock is defined as trench material with a single piece dimension exceeding 1.5 m in length
which cannot be removed other than by the use of pneumatic chisel/drill or sledge hammer and
chisel.

Excavation through soil mixed with boulders that have been used for a road base will not be
considered as hard rock for the purposes of payment.

3.2.5 CLEARANCES

Unless otherwise approved, the following clearances shall be maintained between the external
wall of the gas pipe and the external surface of other underground assets in the vicinity of the
Works.

• 150mm where the gas pipe crosses other assets, other than electric cables,
whereupon the clearance shall be 300 mm.

• 300mm where the gas pipe is on a similar alignment to the other assets.

Where the above clearances cannot be achieved, or in other special

circumstances, the EIC may approve/specify protection with concrete/MS coated
pipe, etc.

3.2.6 UNDER GROUND INTERFERENCES

The Contractor shall locate and expose manually all underground facilities if any during
trenching. Safety barriers, if required shall be erected to prevent any damages or accident. On
locations where pipeline is laid under the existing facilities and near the approaches to the
crossing, the trench shall be gradually deepened to avoid sharp bends.

All sewers, drains, ditches and other natural waterways encountered while trenching shall be
maintained open and functional by providing proper temporary installations if required. Suitable
dewatering pumps shall be deployed to dewater, if required.

Whenever it is permitted by Authorities and to open cut paved road crossing, or where line is
routed within the road pavement, the Contractor shall remove the paving in accordance with
the restrictions and requirements of the authorities having jurisdiction. After laying the pipeline,
pg. 27
backfilling shall be immediately performed and all the areas connected with the works shall be
temporarily restored.

In case of damage to any of above referred structures/ utilities the contractor shall be
responsible for repairs/ replacement at his own cost, which shall be carried out to satisfaction of
concerned authorities.

3.2.7 OTHERS

Throughout the period of execution of such work,provide and use warning signs, traffic lights or
lanterns, barricades, fencing, watchman etc. as required by the local authorities.

For all roads, paths, walkways etc. that are open-cut,providee temporary diversions properly
constructed to allow the passage of normal traffic with the minimum of inconvenience and
interruptions.

The paving shall be restored to its original condition after the pipeline is installed.

Excavate to additional depth at all the points where the contour of the earth may require extra
depth, or where as deep trench is required at the approaches to crossings of roadways, railroads,
rivers, streams, drainage ditches etc.

The trench shall be cut to a grade that will provide a firm, uniform and continuous support for
the pipe.

Where the pipeline crosses underground utilities/ structures, Contractor shall first manually
excavate to a depth and in a such a manner that the utilities/ structures are located, then
proceed with the conventional methods.

The locations, where the pipeline has to be laid more or less parallel to an existing pipeline cable
and/ or other utilities in the Right-of-way maintain proper distances and perform the work to
the satisfaction of CLIENT and other utility agencies. In such locations, perform work in such a
way that even under the worst weather and flooding conditions, the existing pipeline/ utilities
remain stable and shall neither become undermined nor have the tendency to slide towards the
trench.

3.2.8 BEDDING

Ensure that the pipe when placed in the trench is supported and surrounded by a bed of
screened excavated soil, which shall be stone free and have a maximum grit size of 5mm in order
to ensure no damage occurs to the pipe.

However in case of rocky soil, the bedding shall be done with approved/ good quality packing
sand, subject to the approval of the EIC, the size distribution of the sand/ shall be the same as
per soil. The packing sand shall be placed to a minimum thickness of 150mm around the pipe in
case of rocky terrain.

pg. 28
Bedding & surrounding sand shall confirm to specifications. There shall be no void space in
packing sand around the pipe.

3.2.9 LAYING

Laying of MDPE pipelines shall commence only after ensuring proper dimensions and clean
surface of the trench. The trench bottom shall be free from the presence of cuts, stones, roots,
debris, stakes, rock projections upto 150mm below underside of pipe and any other material
which could lead of perforation/ tearing of the pipe wall. After ensuring above the MDPE pipe
coil shall be uncoiled smoothly through proper equipment's/ care inside the trench ensuring no
damage to pipe coil during laying. Ensure that pipe caps are provided before lowering of pipeline.
The trench after this can be released for back filling leaving adequate lengths open at the ends,
for jointing.

Where given specific approval by the EIC a pipe may pass through an open drain or nallah. Where
this is permitted the pipe shall be installed inside a concrete or steel sleeve for protection. The
sleeve material shall be procured and laid by the Contractor. In general the GI Sleeve and MS
sleeves material specification shall be confirming to IS 1239 (Heavy Duty) specification of reputed
make. The payment for the length of pipe in the sleeve will be made as per SOR. All other work
necessary to break through the walls of the obstruction, and to seal the annulus between the
pipe and the sleeve and the sleeve and the wall, shall be deemed to be included in the rates.

Open ends of pipe placed in the trench shall be securely capped or plugged to prevent the ingress
of water or other matter. The Contractor is to ensure that nothing enters the inside of the pipe
during the laying process as this could cause a future blockage or regulator malfunction due to
dust, etc.

Note that the service pipe rises out of the ground at the customer’s premises within a GI sleeve
pipe. The vertical portion of the sleeve shall be fixed to the wall of the premises in a secure
manner. A bending tool shall be used to bend the GI sleeve pipe so that it has the appropriate
curvature and is free of kinks. The bending of the sleeve, it’s fitting and clamping, and the
installation of the transition fitting excluding service-isolating valve, is all included in the service
connection rate. A rate is included in the SOR for the provision of sleeves for PE laying. Any
installation without inspection and approval may lead to penalties as Special condition of
contract.

A bending tool shall be used to bend the GI sleeve pipe so that it has the appropriate curvature
and is free of Kinks. The installation of the GI sleeve for service lines shall be done by sealing the
annulus, firm fixing of the GI sleeves with concrete mix, breaking through any obstructions &
their subsequent restoration.

The contractor shall supply the GI sleeves (Heavy duty OF IS:1239 reputed make ) respectively
for domestic & commercial / Industrial installation. The vertical portion of the sleeves shall be
fixed to the wall of the premises in a secure manner. The service line shall be installed in
accordance with drawing enclosed. The material test certificates / inspection reports shall be
inspected by TPIA/PMC before installation.

pg. 29
Valves shall be installed at locations shown on the Design Plan or as directed by the EIC and
joined with PE pipes by electro-fusion techniques. The valves shall be supported on a bed of fine
fill of grit size not greater than 5mm to achieve equivalent support as the incoming and outgoing
pipe work.

Laying graphs with details of depth, length, offsets from fixed references, other utility crossings,
fittings, size of casing pipe used for the pipeline shall be prepared on daily basis and submitted
to Site Engineers of the Owner for approval. These details will be further incorporated into As-
Built Drawings.

3.2.10 JOINTING OF POLYETHYLENE PIPE

The procedure for jointing of PE pipe and fittings is enclosed. Only Bar coded electro-fusion
machine (Automatically Readable) that can read the bar code of the fittings automatically shall
be used for jointing of MDPE pipe / fittings. Manual feeding electro-fusion machines are not
acceptable for jointing purpose.

Obtain certificate of calibration from contractor of Fusion machine at the time of start of work
and at fixed intervals as per the instruction of owner. Contractor shall ensure that the machine
are always available at site, no stoppage of work due to the non availability of machines.

Flush the Pipeline with air to remove dust, water, mud etc. before fusing the joints.

Before jointing, ensure to place packing sand under the pipes on both sides of the joint to keep
the pipes in line and at the correct alignment during the jointing process. Alignment clamps with
the correct size shells should be used to align the pipe during the electro-fusion cycle.

Ensure that polyethylene pipe is only cut with an approved plastic pipe cutting tool. Before
fusion is attempted he shall remove the oxidized surface of the pipe to be inserted into the
electro-fusion coupling. The tool must remove a layer of 0.1 mm to 0.4 mm from the outer
surface of the polyethylene pipe. It may also be noted that no fusion will be allowed without
clamping device and only the approved cutting tools (Hack Saw shall not be allowed for cutting
the Pipe) shall be used.

The contractor has to supply all the consumables required for carrying fusion of the joints (like
cloth/ paper napkin, acetone etc.).

If, upon inspection, the EIC determines a joint is defective, Contractor shall remove the joint by
an approved method. The cost of this work shall be borne by the Contractor.

For electro-fusion jointing, the contractor must bring own tools, tackles and equipments.

Contractor shall arrange generator for power supply for fusion machine. Taking power
connection from electric poles ,connections without written permission from concerned
authorities or residential premises is strictly not permitted.

pg. 30
Only, Approved Jointers shall carry out fusion of all joints. Contractors shall provide the list of
jointers to be used on the job and make arrangements for qualification Testing of the jointers in
presence of Owner / Owner’s representative . All approved Jointers shall bear Identity cards
signed by Owner/Owner’s representative..

Taking power connection from electric poles , connection without written permission from the
concerned authorities or residential premises is strictly prohibited

3.2.11 BACK FILLING

Backfilling shall be done after ensuring that appurtenance have been properly fitted and the pipe
is following the ditch profile at the required depth that will provide the required cover and has
a bed which is free of extraneous material and which allows the pipe to rest smoothly and evenly.
Dewatering shall be carried out prior to backfilling. No backfilling shall be allowed if the trench
is not completely dewatered.

Prior to backfilling it should be ensured that the post padding where required of compacted
thickness 150mm is put over and around the pipe immediately after lowering.

Backfilling shall be carried out immediately after the post padding where required has been
completed in the trench, inspected and approved, so as to provide a natural anchorage for the
pipe, avoiding, sliding down of trench sides and pipe moment in the trench. If immediate
backfilling is not possible, a padding of at least 200mm of earth, free of rock and hard lumps shall
be placed over and around the pipe and coating.

The backfill material shall contain no extraneous material and/ or hard lumps of soil, which could
damage the pipe and/ or coating or leave voids in the backfilled trench. In case, it is required and
directed by EIC, screening of the backfill material shall be carried out with specified equipment
before backfilling the trench.

The surplus material shall be neatly crowned directly over the trench and the adjacent excavated
areas on both sides of the trench to such a height which will in opinion provide adequately for
future settlement of the trench backfill during the maintenance period and thereafter. The down
shall be high enough to prevent the formation of the depression in the soil when backfill has
settled into its permanent position should depression occur after backfill, Contractor shall be
responsible for remedial work at no extra cost to Company. Surplus material, including rock, left
from this operation shall be disposed off to the satisfaction of land owner or authority having
jurisdiction at no extra cost.

Where small pieces of rock, gravel, lumps of hard soil or like materials are encountered at the
time of trench excavation, sufficient earth or select backfill materials shall be placed around and
over the pipe to form a protective cushion extending at least to a height of 150mm above the
top of the pipe. Select backfill materials for padding that are acceptable shall be screened soil,
containing no gravel. All these works shall be carried out by Contractor at no extra cost. Loose
rock may be returned to the trench after the required selected backfill material has been placed,
provided the rock placed in the ditch will not interfere with the use of the land by landowner, or
tenant.
pg. 31
In case where hard rock is encountered or as desired by EIC sand padding is to be provided upto
height of 150mm around the pipe.

When the trench has been dug through drive ways or roads, all backfilling shall be executed with
suitable material in layers as approved and shall be thoroughly compacted. Special compaction
methods as specified may be adopted. All costs incurred there upon shall be borne by the
Contractor.

Trenches excavated in dikes which are the properties of railways or which are parts of main roads
shall be graded and backfilled in their original profile and condition. If necessary, new and/ or
special backfill materials shall be supplied and worked-upto.

PE Warning Grid/Mat 1mm thick and 300mm wide will be placed on distribution main and on
service lines inside premises, after backfill of the trench upto a height of 300mm on the top of
the carrier pipes. The warning grid is to be unrolled centrally over the pipe section and thereafter
further backfilling will commence.

Backfilling activity shall include proper compaction by jumping jack compactor and watering in
layers of 150mm above the warning mat.

Proper crowning of not more than 150mm shall be done. All the excavated material required to
be used during the Restoration process shall be stacked and kept separately and properly.
Wherever Road cutting/ Tiles removal/ PCC cutting has been done during excavation for laying,
the area shall be back filled and compacted immediately so that no inconvenience is caused to
the general public.

Electro-fusion of joints is to be undertaken immediately after lowering and the activity shall not
be kept pending for lack of Electro-fusion jointing. The backfilling shall be considered complete
only after the joint in completed.

Debris and other surplus material shall be removed immediately after the back filling.

3.2.12 MOLING:

The Moling shall be carried out as per the requirement specified and approved procedures. The
contractor has to carry out thorough survey of the under ground utilities before going for the
Moling, to avoid the damage to the other utilities.

No extra payment to be made for any trial/ abandoned pits made during the survey. The supply
of all equipment, power required for carrying out moling work, shall be in contractor’s scope.
The type of moling to be carried out i.e., Manual/ Machine with or without casing shall be at the
discretion. A prior approval is to be taken before starting the Moling.

For manual Moling the contractor shall ensure that the size of the hole shall not be more than
20% of the size of the casing / carrier pipe which ever is applicable. After completion of Manual
pg. 32
Moling the hole shall be properly compacted / filled with soil by watering and by approved
procedures, the pits shall be backfilled, compacted & restored .

Any damages occurred to other utilities during the Moling operation shall be immediately
notified and rectified by the contractor without any cost implication.

The length of the Hole (excluding the sizes of the pits on both ends) shall be considered for the
measurement of Moling length. However, intermediate pits will consider in the moling length.

3.2.13 BORING/RAMMING/DIRECTIONAL DRILLING

One of the above techniques is required to be carried out by the Contractor where conventional
trenching/Moling is not possible viz. railways, major waterways, highways, roads etc. Details of
such crossings shall be obtained by the Contractor, and construction drawings shall be prepared
by the Contractor. Execution of the work shall be based on the approved drawings. The
contractor has do the thorough survey of the under ground utilities before commencement of
BORING/ RAMMING/ DIRECTIONAL DRILLING to avoid the damage to the other utilities. No extra
payment will be made for any trail/ abandoned pits made during the survey. The supply of all
equipments is in Contractors scope. Work to be carried out in accordance with API - 1102.

Any damages occurred to other utilities during the HDD operation shall be immediately notified
and rectified by the Contractor without any cost implications.

The length of the HOLE (excluding the sizes of the pits on both ends) shall be considered of HDD
length.

3.2.14 CASING PIPE

The tentative sizes of the HDPE casing pipe for Moling/ HDD shall be as follows:-

Size of MDPE pipe Size of HDPE pipe

20 mm 75mm
32 mm 75 mm
63 mm 125 mm
90mm 180mm
125mm 250mm
180 mm 315 mm

However, size of the casing pipe may vary according to length of the carrier pipe and requirement
of laying of OFC Duct.

3.2.15 RESTORATION

pg. 33
Wherever the restoration is required, the roads, footpaths (including roads and footpaths inside
colonies) shall be restored to original condition, and the same shall be done as per concerned
local authorities norms and to the satisfaction of the concerned local Authority. To retard curing
of the installed concrete, wet sack cloth is to be placed on the finished surface and kept damp
for a period of 36 hours.

Where slabs and blocks are to be restored, the level of the compacted subbase is to be adjusted
according to the slab/block thickness. The slabs or blocks should be laid on moist bedding
material, which should be graded sand, mortar or mortar mix. The slabs or blocks should be
tapped into position to ensure they do not rock after laying.

The restored slabs or blocks should match the surrounding surface levels. Joint widths should
match the existing conditions, and be filled with a dry or wet mix of mortar.

The sketch for restoration of Road, Footpath, Channel is enclosed herewith and is indicative.
However, the restoration shall be done in accordance with the norms of concerned land owning
agencies.

Turf shall be replaced in highly developed grassed area. In lesser-developed grassed areas
topsoil should be replaced during the restoration process.

Where permanent surface restorations cannot be completed immediately, the Contractor shall
provide and maintain a suitable temporary running surface for vehicular traffic and pedestrians.
The Contractor will be responsible for the maintenance of all restoration carried out, for the
duration of the Contract guarantee period.

Ensure that the restoration work is properly supervised, and that the material used is suitable
for the purpose and properly compacted. Where the required standards are not achieved the
Contractor will be required to replace the defective restoration work.

Contractor has to obtain the clearance certificate from the concerned local authorities after
completion of the restoration work. The restoration specification specified in the tender is only
a typical specification and the contractor has to carry out restoration as per latest version of the
(PWD/ IRC) specification to its original condition and also to the entire satisfaction of land owner
(Private/Public).

3.2.16 TESTING

Pressure testing will be carried out with compressed air. Compressed air will be provided by
Contractor for testing purposes and is to be included in the rates.

Perform progressive pressure testing to avoid having to find leaks in long lengths of pipe. The
test pressure shall be 6.0 bar(g), and there shall be no unaccountable pressure loss during the
test period.

Test procedure with sketches showing the pipeline to be tested, vent points, gauge location, and
inlet pressure print is to prepared & got approved by EIC.
pg. 34
For main line the test duration shall be 24 hrs . With these tests the pressure should be allowed
to stabilize for a period of 30 minutes after pressurization. The holding period may then
commence and continue for 24 hours. Measuring instruments shall have been calibrated and
their accuracy and sensitivity confirmed. For testing of Network, calibrated pressure gauges of
suitable range shall be supplied by the contractor. The pressure gauges shall be calibrated from
time to time as desired by Engineer-in-Charge. All testing shall be witnessed and approved by
the EIC or his delegated representative. Tie-in joints may be tested at working pressure following
commissioning.

For service lines in some cases testing will be carried out independently of the testing of the
mains for which the test duration may be reduced to 4 hrs. The service testing in this case will
be performed after the service installation is complete but before the service tee has been
tapped. Also in some cases the tapping of the service tee will be delayed pending the completion
and purging of the main pipelines.

3.2.17 PURGING

Purging shall be carried out in accordance with the principles defined in the American Gas
Association publication ‘Purging Principles and Practice”.

Nitrogen required for purging will also be provided by the Contractor. Nitrogen shall be supplied
in labeled, tested and certified cylinders, and completed with all necessary regulators, hoses and
connections, which will be in good condition and working order.

In addition the Contractor shall submit and get approved a Purging Plan before commencing any
purging work. The Plan shall include, but not be limited to, the provision of the following
materials and equipment: Personal safety equipment, Fire extinguisher, Purging adapter, Purge
stack with flame trap and gas sampling point, Gas sampling equipment (may be gas leak
detector), squash-off tool, Polyethylene connecting pipe work.

The Plan shall also include the purging process along with detail on the sequence of events. The
process is to also specifically mention the need to lay a wet cloth over the PE main and in contact
with the ground, to disperse static electricity during the purging work.

A purge stack with flame trap shall be used when purging services. Care shall be taken to ensure
that the purge outlet is so located that vent gas cannot drift into buildings.

3.2.18 VALVE PIT

The valve pit shall be constructed in accordance with drawings.

3.2.19 LIST OF VARIOUS STANDARDS RELATED TO MDPE PIPELINE LAYING

MDPE Pipeline

pg. 35
ISO 4437 : Buried polyethylene (PE) pipes for the supply of gaseous fuels –
Metrics series -- Specifications
IS 14885 : Specifications for polyethylene pipes the supply of Gaseous Fuels
ASME B 31.8 : Specifications for PE piping, tubing, fitting and other components
Plastic Valves
ASME B16.40: Manually Operated Thermoplastic Gas Shutoffs and Valves in
Gas Distribution Systems
EN 10204 : Excess flow check valve
EN 1555-4 : Plastic piping system for supply of gaseous fuels polyethylene - Part 4
Plastic fittings
ISO -8085 -3 : International Standard for thermoplastic fittings
EN – 1555-3 : European standard for plastic piping system for supply of
gaseous fuels – Polyethylene (PE) Part -3: fittings

Standard Drawings : As already shared earlier.

4.0.0 GUIDELINES FOR LAST MILE CONNECTIVITY (LMC) WORKS

4.1.0 REGISTRATION OF PNG CUSTOMER

i. Scope of LMC work starts with registration of PNG customer. Registration process
comprises of collection of registration form & documents from customer’s doorstep after
feeding of registration data in registration form.
ii. LMC vendor also collects Identity proof & address proof from PNG customer in both soft
& hard copies.
iii. Security deposit and application fee payment is collected by vendor from PNG customer
by way of A/C Payee Cheque payable in favour of "Bharat Petroleum Corporation
Limited" as per the Scheme adopted by PNG customer.
iv. PNG domestic connection Charges & Security deposit scheme currently being followed
by BPCL is as below:

pg. 36
 1. Processing, Transaction and Document Fees 500
Scheme 1 (Non-Refundable)
2. Gas Security Deposit (Interest Free- 500
Upfront Refundable)
Payment 5000
3. Interest Free Security Deposit (Refundable)
4. Monthly Rental (Non Refundable) NA
Total 6000

1. Processing, Transaction and Document 600

Fees (Non-Refundable)
2. Gas Security Deposit (Interest Free- 500
Refundable)
Scheme 2 Collected @
Security 3. Interest Free Security Deposit Rs.500/- Bi-Monthly
(Refundable) billing cycle over 10
Deposit - EMI billing cycles
4. Monthly Rental (Non Refundable) NA
Total 6100

1. Processing, Transaction and 600

Document Fees (Non-Refundable)
2. Gas Security Deposit (Interest Free- 500
Scheme 3 Refundable)
3. Interest Free Security Deposit
Rental (Refundable)
NA
Option Rs. 100/- in bi-Monthly
4. Monthly Rental (Non Refundable) billing cycle till
Connection is active

i) All the cheques collected from PNG customers are submitted to BPCL Office. After receipt
of cheques, BPCL deposit the same in bank.

4.2.0 PREPARATION OF ISOMETRIC DRAWING

i) Post completion of registration process, LMC Vendor carries out the route survey and
prepare the rough isometric drawing for proposed GI gas pipeline laying between transition
fitting to cooking oven/stove/appliance and submits for approval.
ii) Once the isometric is approved, quantities of MDPE & GI pipes are worked out.
iii) As per the current connection policy of BPCL, 05 metres of U/G 20 mm dia MDPE pipe &
15 metres of GI pipe is being installed/laid in the customer premises without any additional
charges.

pg. 37
iv) If as per the isometric drawing quantities of MDPE & GI are more than the values
subjected above, PNG customer has to pay extra charges for additional length of MDPE & GI
pipe.
v) Rate for extra length is as per the existing tendered rates of LMC vendor. Generally these
charges are Rs. 390.00/RM for 20 mm MDPE pipe & Rs. 460.00/RM for GI pipe.
vi) Collection of Extra pay is done by LMC vendor from PNG customer in the form of cheque
prior to start of physical LMC work.

4.3.0 LAYING OF 20 MM MDPE PIPE & INSTALLATION OF GI PIPE.

As per the Graphs /As built drawing of main line MDPE pipeline, location of pit is decided
considering the minimum length of 20 mm MDPE pipe, U/G utilities & other site conditions.
i. Once the location of pit is decided, 20 mm MDPE pipeline is laid by either trench less
technology methods (Moling) with or without casing pipes or by open cut Method.
ii. Post laying, 20 mm MDPE pipe is connected to main MDPE pipeline by electro-fusion
jointing of MDPE pipe and Coupler/Tee fitting.
iii. Parallelly installation of GI pipes of ½”, ¾”, 1” & 1.5” dia. between transition fittings
to customer’s kitchen appliances is carried out including joining of various fittings
such as elbows, tees, appliance & isolation valves etc.
iv. GI pipes are supported on walls/beam/columns by GI clamping.
v. Post laying of GI Pipe, the scratched powder coated GI pipe and fittings are painted.
vi. GI pipe & MDPE pipe is connected by electro-fusion of Transition fitting. This
Transition fitting is safeguarded against any accidental damage by casing it in GI
Sleeve and construction of concrete block around the casing pipe.
vii. Installation of Plate markers having emergency contact nos., Isolation valves are
necessarily carried out keeping in view the safety of our PNG customers.

4.4.0 PNEUMATIC TESTING OF 20 MM MDPE PIPE & GI PIPE

i. Once the laying of GI/ MDPE pipe is completed, Pneumatic pressure testing is carried
out upto inlet of regulator at a pressure of 6 kg/cm2 for the duration of least 4 hours
and the necessary repair is done if any leakage is found in the pipe.
ii. The GI pipe installation from regulator outlet to appliance valve (except meter) shall
be tested at a pressure of 2.0 bar (g) for a holding period of 2 hour with no pressure
drop.
iii. Once the testing of GI pipe & MDPE pipe is carried out satisfactorily, Saddle installed
at main MDPE pipeline is cut for charging the GI installation.
iv. As built drawings are prepared for U/G MDPE pipeline & A/G GI pipe (If there is any
deviation from initial isometric drawing) for future reference & record.

pg. 38
4.5.0 RESTORATION

i. Post laying of MDPE pipeline & GI pipe, Restoration of existing ground features
such as roads, drains, flooring is carried out.
ii. Also restoration of walls and other damages while executing the above ground
installation is carried out.

4.6.0 NATURAL GAS CONVERSION (NGC) AND ACTIVATION OF PNG CUSTOMER

i. Prior to Natural Gas conversion, BPCL once again checks whether the registration
& applicable extra pay charges are cleared for the given PNG customer.
ii. Post confirmation from BPCL, LMC vendor starts the process of NGC.
iii. NGC process comprises of changing of nozzles and associated controls for
domestic burners/ovens/grills/hotplate and changing of old appliance connection
Reinforced rubber hose with new Reinforced rubber hose.
iv. Also Proper Instruction are conveyed to the Customer for safe use of natural gas.

4.7.0 DETAILED CONSTRCUTION PROCEDURE FOR LAST MILE CONNECTIVITY

The main intent of the specification is Supply and installation of above ground GI pipes, fittings,
valves, meters and regulators, from the outlet of 'PE/GI transition fitting' up to the DOMESTIC
consumers 'Appliance / stove/ oven valve' as per the Distribution Schedule.
The scope for commercial consumer includes installation of above ground GI pipes and
associated fittings, valves, regulator up to and including meter. However, the piping may have
to be carried out up to Appliance valve, in case of some commercial customers.
In case of large commercials and industries completely assembled metering skids would be
supplied to the contractor who would be required to install and provide inlet & outlet
connection.

List of Activities

a. Selection of route and marking on walls / floors between 'transition fitting' to

'cooking oven / stove / appliance' making openings and making provisions for
fixing clamps. Making temporary but stable platforms / scaffolding / rope ladder
etc., required for installation of pipes / fittings at all heights / multi storied flats
and locations. Providing safety equipment to workers / plumbers.

b. Contractor shall procure every material, from the outlet of PE/GI transition
fitting upto the Domestic/Commercial customers “Appliance/Stove/Oven valve
for satisfactory completion to the owner/Owner’s representative.

c. Installation of GI pipes of ½”, ¾”, 1” dia. between transition fittings (installed by

pg. 39
 PE contractor) and customer's kitchen which would include NPT threading of
pipes, and jointing of fittings such as elbows, tees, connectors, regulators,
meters, isolation valves etc., as per laid procedures and specification including
supply of GI fittings & Teflon tapes for sealing of joints. Painting of GI Pipes &
fittings as per specification.
d. Installation of GI pipes or copper pipe of ½” (12 mm) OD from the downstream
of Meter upto the isolation valve prior to the customers appliance.

e. Conversion of all types of LPG kitchen appliances to NG based appliances

inclusive of supply of nozzles. Signing of Joint Meter Records (JMRs).

f. To demonstrate to the customer regarding use, safety and maintenance related

aspects of NG based appliances and installations.

g. Testing & Commissioning of installations including purging as per specification

and handling over the installation of CLIENT/ customer to the entire satisfaction.

h. Dismantling of scaffolding / temporary structures and cleaning of site.

i. Restoration of walls, flooring and other damages while executing the above
ground installation.

j. Preparation and submission of above ground installation card for each house /
commercial establishment indicating the list of materials used, reasons of not
providing connections, testing pressure and date etc.. Deviation statements, if
any, on completion / commissioning of work.

4.7.1 MATERIAL, PLANT AND EQUIPMENT

The contractor has to supply all GI Fittings, flexible hose, suraksha hose, Valves, Fittings,
Clamps, GI Pipes, Appliance Valves ½” and isolation Valves ½” , ¾”, sleeves, etc. and other
materials required for said works.

The contractor shall provide the labour, tools (such as Hammer Drill, Piston Drill, Pipe cutters,
Dies for threading, Pipe wrenches, spanners, all types of clamps, Plant and equipment
necessary for the proper execution of the work. This will include but not be limited to list of
specialized tools & tackles enclosed herewith. Contractor shall submit the specification of all
the material to be supplied by him to EIC for approval and get the material checked & approved
by him before commencement of execution.

4.7.2 REFERENCE SPECIFICATION, CODES AND STANDARDS

pg. 40
The contractor shall carry out the work in accordance with this specification, ASME B31.8 - Gas
Transmission and distribution piping systems; Australian standard 3723 - Installation and
Maintenance of Plastics Pipe Systems for Gas; Oil India Safety Directorate Norms (OISD) , the
American Gas Association Document -Purging Principles and Practice and latest PNGRB
guidelines..

Should the contractor find any discrepancy, ambiguity or conflict in or between any of the
Standards and the contract documents, then this should be promptly referred to the Engineer
- in- charge(EIC) for his decision, which shall be considered binding on the contractor.

4.7.3 PROTECTION OF STRUCTURES AND UTILITIES

The contractor shall at his own cost, support and protect all buildings, walls, fences or other
structures and all utilities and property which may, unless so protected, be damaged as a result
of the execution of the works. He shall also comply with the requirements in the specification
relating to protective measures applicable to particular operations or kind of work.
While painting contractor must take care of the consumer premises while carrying out the job/
such as spillage on floor, walls, ceilings, sun shades etc. if the same does occur, the contractor
is to immediately make good to original.

4.7.4 G.I ABOVE GROUND SERVICE PIPE

The GI service pipe installation work includes all work necessary to connect from the PE / GI
transition fitting on the down-stream of the PE service, to the customers appliance, including
the installation of appliance valve and isolation valves, except, Suraksha hose, Meters,
Regulator for which separate rate shall be paid as per SOR Item of this document. The
contractor shall be required to provide all equipment, tools and materials necessary to execute
the work in an efficient and effective manner. Amongst other things he will be required to
provide ladders, scaffolding pipe, dies, tripods, vices, fittings and teflon tape, drills for concrete
and other masonry, drills for timber and laminated surfaces inside customers property,
bending tools, clamps, sleeves to facilitate the pipe passing through floors and walls, paint for
pipe marking etc.

All GI risers on the outside of buildings shall be fully supported to carry the weight of piping.
Risers shall be supported by a flanged foot, or similar device, capable of supporting the total
weight of the riser. The riser shall rise in a vertical line from its point of support to its highest
point with a minimum of changes in direction. The threading of GI pipe shall be NPT and
conforming to ASME / ANSI B1. 20.1.

Contractor has to supply different types / sizes of approved clamps (Mild Steel) for fixing GI
pipes suiting to the site conditions and the same shall be painted before fixing, as per the
painting specifications. Every fresh lot of the clamps, brackets, regulators boxes and other
pg. 41
consumables shall be approved by the EIC prior to start of installation. All riser and lateral pipe
shall be clamped to the building at intervals not exceeding two meters.

Where pipe passes through a balcony floor, the floor surface shall be made slightly elevated
around the service pipe or its surrounding sleeve to prevent the
accumulation of water at that point. Where a short piece of sleeve is used around the gas pipe,
the sleeve should be embedded in the concrete with a mix of mortar and the void between
the pipe and sleeve filled with a suitable sealant. The sealant should be beveled such as to
prevent an accumulation of water. Supply of clamps for all sizes of the GI pipes are in
contractor’s scope. Contractor has to take prior approval for design of clamps, paintings etc.

Pipe shall preferably enter a building aboveground and remain in a ventilated location. The
location for entry shall be such that it can be routed to the usage points by the shortest
practicable route.

The rates are to be paid in bands as shown in SOR e.g., the ground floor to 2 nd floor band covers
pipe work laid from the ground floor level to ceiling level on the 2nd floor. Payment will be in
incremental stages. e.g., if a pipe is laid from the ground floor to the 9 th floor of a building, the
length of pipe laid up to the 2nd floor will be paid in the first band, The length of pipe laid
between 3rd and 5th floor will be paid in second band and the length of pipe from the 6 th floor
and above will be paid for in the third band. However, it may be noted that all the piping done
inside the premises shall be considered as ground floor piping, the payment for such work shall
be as per first band. The Pipe installation includes all fittings, Flexible hoses, clamps, Regulators
etc.

4.8.0 TESTING OF GI INSTALLATION

a. The installation from PE/ GI transition fitting up to regulator shall be tested at

the [pressure of 6.0 bar(g)].

b. The testing of GI riser pipe up to regulator shall be done with the isolation valve
in open condition and open end plugged.

c. The GI pipe shall be painted with one coat prior to installation in riser, however
the ends / joints shall be painted only after carrying out testing of the
installation.

d. The GI installation from regulator outlet to appliance valve (except meter) shall
be tested at a pressure of 2.0 bar(g) for a hold period of 4 hours and all the joints
shall be checked with soap solution.

pg. 42
 e. The meter shall be removed while carrying out the testing and joints of the
meter shall be tested on line with soap solution after completion of the work.
Proper test ends shall be made along with gauges and got approved by EIC.

f. The calibrated pressure gauges of suitable range shall be supplied by the

contractor for testing.

g. The pressure gauges shall be calibrated from time-to-time as desired by Engineer

In- charge but positively once in every six months.

h. The details of testing shall be properly recorded in the measurement cards

pg. 43
4.8.1 INSPECTION

Any defect noticed during the various stages of inspection shall be rectified by the contractor
to the entire satisfaction of Engineer-in-Charge before proceeding further. Irrespective of the
inspection, repair and approval at intermediate stages of work, contractor shall be responsible
for making good any defects found during final inspection/ guarantee period/ defect liability
period as defined in general condition of contract.

4.8.2 PURGING & COMMISSIONING

The connection may involve the fitting of a temporary bypass, disconnection etc. Purging shall
be carried in accordance with the principles defined in the American Gas Association
Publication "Purging Principles and Practice".

In addition the contractor shall submit and have approved Purging Plan before commencing
any purging work. The plan shall include, but not be limited to the provision of the following
materials and equipment : personal safety equipment, fire extinguisher, Purging adapter, Purge
stack with flame trap and gas sampling point, Gas sampling equipment (may be gas leak
detector), squash-off tool, Polyethylene connecting pipe work etc.

The plan shall also include the purging process along with detail on the sequence of events.
The process is to also specially / mention the need to lay a wet cloth over the GI pipe and in
contact with the ground, to disperse static electricity during the purging work.

A purging stack with flame trap shall be used when purging services. Care shall be taken to
ensure that the purge outlet is so located that vent gas cannot drift into buildings.

The purging work should be performed as follows,

i. Ensure the method of purging is such that no pockets of air are left in any part
of the customer's piping.

ii. Ensure that all appliance connections are gas tight, all appliance gas valves are
turned off and there are no open ends.

iii. Where possible, select an appliance with an open burner at which to

commence the purge i.e., a hotplate burner.

iv. Ensure the area is well ventilated, and free from ignition sources.
pg. 44
 v. Ensure branches that do not have an appliance connected are fitted with a plug
or cap.

vi. Turn on one burner control valve until the presence of gas is detected. A
change in the audible tone and smell is a good indication that gas is at the
burner. Let the gas flow for a few seconds longer, then turn off and allow
sufficient time for any accumulated gas to disperse.
vii. Turn on one gas control valve again and keep a continuous flame at the
burner until the gas is alight and the flame is stable.

viii. Continue to purge until gas is available at other appliances.

4.9.0 INSTALLATION OF METERS

The work in this section includes :

Installation of domestic and commercial meters with associated inlet and outlet connections,
on the wall with approved meter brackets and angles.

Supply of approved meter brackets and angle brackets, properly painted with one coat of Zinc
Primer and two coats of synthetic enamel paint of approved make. A sketch of the brackets is
enclosed herewith. It is required that one sample of each type of bracket is got approved
beforehand.

Firmly securing the meters on the wall with good quality supply of proper rowel plugs, screws
etc. In case the rowel plugs are not holding than wooden blocks or other fixing arrangements
like cement etc. to be used for proper grouting.

The above activities along with restoration of the area to original shall be carried out to the
complete satisfaction of consumer and EIC.

4.10.0 PAINTING OF GI PIPES

The entire length of the pipeline along with fittings and clamps are to be painted after proper
surface preparation and painting as follows.

 One coat of Primer application (Appropriate Zinc based primer)

 Two coats of synthetic enamel paint – canary yellow of minimum of 30 microns
per coat of reputed make like Asian, Berger, Nerolac.

pg. 45
All painting materials including primers and thinners brought to site by contractor for
application shall be procured directly from manufacturers/ dealers as per specifications and
shall be accompanied by manufacturer's test certificates. Paint formulations without
certificates are not acceptable.

Engineer-in-Charge at his discretion, may call for tests for paint formulations. Contractor shall
arrange to have such tests performed including batch wise test of wet paints for physical &
chemical analysis. All costs there shall be borne by the contractor.

The painting work shall be subject to inspection and certification by Engineer-in- Charge at all
times.

pg. 46
After installation of the entire piping system, final touching shall be done to the satisfaction
of EIC.

4.11.0 INSTALLATION OF REGULATORS

1) Regulators (6 bar / 4 bar to 21 mbar)

Boxes for the regulators (6 bar / 4 bar to 21 mbar) shall be supplied and installed outside after
due approval of the sample. The boxes shall be installed as per requirement and as per
instructions of BPCL / Consultant.
The box brackets are to tightly secured to the wall with good quality proper Rowel plugs, screws
etc. Wooden blocks to be used in case rowel plugs, do not hold properly.
All the boxes shall be thoroughly cleaned, painted with approved colour code.
As the boxes are installed outside, it is to be ensured that they are painted properly to avoid
rusting / weathering.
A sketch of regulator box is enclosed herewith.

4.12.0 CONVERSION OF DOMESTIC APPLIANCES

The work in this section includes,

o The changing of nozzles and associated controls in accordance with

manufactures instructions for both domestic and imported burners/
ovens/grills/hotplate.

o The changing of old appliance connection hoses and nozzles and re-greasing
taps as necessary.
o The contractor has to supply all types of nozzles / jets required for all types of
appliances including imported burners, Grills, Ovens.
o Cleaning and performing minor maintenance of appliances.

pg. 47
 o Testing for gas escapes and the soundness and performance of the
appliance.
o Instructing the customer in the safe use of natural gas and for fixing of safety
and conversion labels.
o Contractor must attend the complaints regarding appliances till the total area
is handed over to CLIENT’s operation and maintenance.
o All consumables (Nozzles, greases etc.) are in contractor’s scope.
o Changing or repairing of any items damaged during conversion.

It may be noted that the rates will apply to all appliance found in both domestic and commercial
premises. The contractor will be required under the Rates to provide both Pin gauges and
standard sized nozzles.

4.13.0 RESTORATION

Contractor has to restore the area where ever he has carried out drilling, clamping etc. to its
original condition to the satisfaction of the consumer and to ensure no seepage to the premises.
If the work was carried out in Govt. Flats (PWD), contractor has to restore the area according
to CPWD specifications. For government flats the contractor has to obtain a clearance
certificate form the concerned authorities maintaining the flats, after completion of the work.

Where slabs and brick work are to be reinstated, the level of the compacted sub- base is to be
adjusted according to the slab / block thickness. The slabs or brick work should be laid on moist
bedding material, which should be graded sand, mortar or mortar mix. The slabs or brick work
should be tapped into position.

The restored slabs or brick work should match the surrounding surface levels. Joint widths
should match the existing conditions, and be filled with a dry or wet mix of mortar.

Wherever any items of the consumer is damaged / broken during working, the same will be
made good or replaced to the total satisfaction of the consumer.

The contractor will be responsible for the maintenance of all restoration carried out, for the
duration of the contract guarantee period.

The contractor is to ensure the restoration work is properly supervised, and that the material
used is suitable for the purpose and proper. Where the required standards are not achieved the
contractor will be required to replace the defective reinstatement work.

pg. 48
5.0.0 CNG PROJECTS
i. The CNG Stations are of following types:
ii. Mother Station - CNG facility connected to natural gas pipeline and having a compressor
meant primarily to fill mobile cascades. Mother station can also fill stationary cascades
for CNG dispensing into vehicles.
iii. Online Station - CNG facility connected with natural gas pipeline and having a compressor
primarily to fill stationary cascades for dispensing CNG to vehicles.
iv. DB Station - Storage cylinders mounted on vehicle are filled at the mother stations and
then transported to the daughter booster station for dispensing gas to vehicles through
booster compressors.
v. Daughter Stations - Filling at these stations is directly being done by mobile cascade,
which are being filled at mother station and there is no provision of any
booster/compressor.

The Delivery pressure at the CNG Station is 200Bar.

The main components for the CNG Station works are as:
1. Compressor
2. Storage Cascade
3. Dispenser.
4. Related Civil, Mechanical and Electrical Works.

We would cover the following details for the above components:

Types
Capacities
Usages
Codes followed

5.1.0 COMPRESSORS:

In the CGD Setup the types of Compressors are divided as;

As per Purpose of Use
DB Compressor
Online Compressor.
Variable Input Pressure.
Integrated Unit Compressor.

As per Source of Power:

Electric Driven
Engine Driven.

As per Capacity :
250SCMH / 450SCMH / 600SCMH / 1200SCMH / 2000SCMH / 2400SCMH

Suction pressure range for the different types of compressors varies from 3Bar to 200Bar. Online
compressors are typically designed to handle inlet pressure of 14-49 Bar and compressed to 250
Bar for filling of vehicles and to cascade storage.

pg. 49
5.2.0 CASCADES:

Cascades types as per usage:

Stationary / Mobile.

The Capacity (Normally used in India) varies from:

3000WL / 4500WL / 6600WL / 8800WL / 9360WL

The Cascades as per construction :

Type 1 / Type 2 / Type 3 / Type 4

STATIONARY CASCADES : These are used to Store the CNG in the Station and deliver to the
vehicles as per requirement either directly or through the compressors.
CNG Storage fulfils following functions.
1. Cascade is the storage equipment for the compressed gas as received from the mobile cascade
/ compressor.
2.It prevents the compressor from stopping and starting too often .

The Main Components of the Cascade are as :

Components
 Seamless Cylinders
 Cylinder isolation valves
 Tubing
 Safety Burst disc assembly
 Safety Valves
 Pressure Gauges
 Common venting arrangement
 Cascade frame

 Stationary Cascade is divided in three banks based on pressure viz. High bank, Medium
bank, & Low bank.
 Priority panels are installed for determining the sequencing & priority of flow of CNG from
the compressor to the cascade banks.
 When no vehicles is in the refueling stand, natural gas is passed to high bank, which is
getting the number one priority but next to the vehicle filling. Whenever any vehicle
comes for filling it has to fill the gas to the vehicle first and then to high bank.
 When the high bank is filled, then the priority goes to the medium bank.
 When the medium bank gets filled, it goes to the lower bank.
 When all the banks are filled, gas will be diverted into the light commercial vehicle called
as LCV in general.
 For filling from cascade, The order for vehicle filling is reverse , i.e. First, the gas is filled
from the low bank into the vehicle cylinder, on near equalization of pressure, , the
medium bank starts filling the cylinder, and again at the equalization of pressure, HP bank
starts filling the vehicle cylinder till pressure equalizes.

pg. 50
• BENEFITS : OPTIMUMIZATION OF UTILISATION OF COMPRESSOR, ELECTRICAL
CONSUMPTION AND O&M COST.

BASED ON CONSTRUCTION THE TYPES OF CASCADES ARE AS :

Type I: Seamless Metal Cylinders -Heavy, Constructions Lowest Cost

Type III : Aluminum Composite cylinder with carbon Lining
Aluminium or steel liner, fully wrapped with a composite material.
Liner takes small amount of the stress
75% lighter than type one.

Type iv: Seamless cylinders with plastic liners and non metallic shield
Plastic liner, fully wrapped with a composite material
Entire strength of tank is composite reinforcement
80% lighter than type one.

 Operating Pressure 255 Bar

 Hydro Test Pressure 435 Bar
 Periodic testing Every 3 Years

MOBILE CASCADES :
For Daughter & Daughter booster stations, where connectivity thru gas pipeline is not possible
or otherwise, are catered thru mobile cascades filled from Mother Stations
Mobile cascades are filled up to 230 Bar and used till 30 Bar at Daughter booster, & to 90-100
Bar at Daughter Stations

pg. 51
5.3.0 DISPENSERS :

The Dispenser gets the compressed gas either directly from the compressor or through the
storage cascade and meters it into the vehicle cylinder, regulating the final pressure to 200 bar

The CNG Dispensers are of following types :

Car Auto Dispensers – Flow Rate 15kg/min
Bus Dispensers – Flow Rate 75Kg/Min
Combo – Car / Bus Dispensers.

5.4.0 SS TUBING

i. All the High Pressure Tubing at CNG stations is made of Stainless Steel, which does not
corrode.
ii. All tubing are be of high quality, fully annealed, seamless type. Austenitic stainless steel
316 hydraulic tubing as per ASTM A 269, ASTM A 450 & ANSI B 31.3
iii. All tubing & fittings are procured from internationally reputed vendors.
iv. Reputed makes of the piping are:
i. Sandvik
ii. Parker
iii. FAE
iv. Tubacex
v. Ratnamani

5.5.0 ELECTRICAL WORKS.

 Assess power availability at ROs in a day for the past 1 year so that accordingly indent
of compressors (NG or Motor Driven) can be given.
 For DBS CNG Compressor (250 / 450 SCMH), motor power is 22.5 / 37 KW.
 For Online CNG Compressor (600/650 SCMH), motor power is approx. 95 KW.
 For Online CNG station (1200 SCMH), motor power consumption is approx. 160 KW.

5.6.0 Mother Station

CNG Compressor Type : Three stage Reciprocating

: 1200 SCMH (one or multiple of same capacity
or higher capacity e.g. 2400 SCMH based on demand)
Suction Pressure : 14 -22 barg
Discharge Pressure : 255 barg (max)
Driver : Gas Engine driven/ Electric motor driven
No of CNG Compressors : 2 (1 Gas Driver +1 Electric motor Driven)
However electricity tariff to be considered

pg. 52
Cascade filling bay : Minimum one bay
Dispensers (based on plot size) : Minimum 2

Mother station should be closer to demand centre in BPCL RO. However in case steel pipeline
connectivity upto demand centre takes time, Mother Station should be planned along with
CGS.

5.7.0 Construction of CNG Stations

5.7.1 SAFETY DISTANCES & OTHER REQUIREMENTS

i) For CNG Mother Station, the corresponding safety distances shall be taken into account:

Sr. Distance from (in CNG CNG Storage Outer

No. Meters) Compressor Dispenser Cascade Boundary
wall/ CLF
1 CNG Compressor - 3 2 3
2 CNG Dispenser 3 - 2 4
3 Storage Cascade 2 2 - Refer Table 2
4 Outer Boundary wall/ 3 4 Refer Table 2 -
CLF
Table-1 (Safe Interdistances as per OISD-179)

Total Capacity of Gas Storage units (In liters) Min. Distances from building & boundaries
(In Meters)
Upto 4500 2.5
4500 to 10000 4.0
10000 to 100000 10
Table-2 (Interdistances as per OISD-179)

ii) Basements & Multi story buildings should be avoided for safety purpose.
iii)) Boundary wall of Mother Station shall be minimum 2.0 m high industrial type wall.
iv) If the Mother Station is located on any National Highway then following guidelines issued by
MORTH shall be followed:

Sr. Terrain Frontage(In m) Depth (In m)

No.
1 Plain & Rolling Terrain on Rural Min. 35 Min. 35
stretch
2 Plain & Rolling Terrain on Urban Min. 30 Min. 30
stretch
3 Hilly & Mountainous Terrain Min. 20 Min. 20
Table-3 (Minimum Size of Plot as per MORTH Guidelines)

pg. 53
 Sr. Item Norms for Rural Norms for Urban/
No. Stretch (In Meter) hilly/ Mountainous
Stretch (In Meter)
1 Acceleration Lane Min. 100 NA
2 Deceleration Lane Min. 70 NA
3 Dist. From intersection Min. 300 Min. 100
4 Dist. From Toll Plaza/ Railway Min. 1000 Min. 1000
Crossing
5 Dist. From Approach road of ROB Min. 200 Min. 200
6 Dist. From flyover Min. 300 Min. 300
Table-4

5.7.2 STATUTORY REQUIREMENTS

Following statutory permissions are required before the start of construction:
i) DM NOC
ii) CCOE Initial Approval
iii) Change of Land Use
iv) Department of Pollution Control’s NOC in case Odourization unit is also present at Mother
Station.

5.7.3 GENERAL ASPECTS

i) CNG Compressor & storage cascades shall be installed in fenced area away from Traffic
movement following interdistances mentioned in Table- 1 & 2.

ii) CNG storage Cascades shall be capable of operating at a working pressure of 250 bar and shall
comply with the requirements of Gas Cylinder Rules 2004.

iii) CNG Dispensing Island shall be adequately protected from maneuvering traffic by providing
bollards. They shall be designed to withstand impacts at a speed of up to 30 km/h. Their height
shall not be lower than the user’s vehicle bumpers.

iv) Care shall be taken while designing layouts that when vehicles are parked for refueling, they
shall not hinder the entry or exit of other vehicles free maneuvers, nor occupy public streets.

v) For refueling, vehicles shall preferably be parked parallel to the dispensing island & vehicles
shall not be allowed to drive in reverse for approaching or exiting the refueling position.

vi) If two or more dispensing islands are to be installed, they shall preferably be parallel, as this
distribution is the best one for a faster evacuation in case of emergency.

pg. 54
vii) Safety devices and fire extinguishers:

viii) In premises for filling and storing of NG, all electric meters, distribution boards, switches,
fuses, plugs and sockets, all electric fittings, fixed lamps, portable hand lamps and motors, shall
be of flame proof construction conforming to IS:2148.

5.7.4 EQUIPMENT DESCRIPTION

i) Online Compressor: CNG Compressor Type- Three stage Reciprocating

Capacity: 600/1200 SCMH
Suction Pressure: 14 -22 bar
Discharge Pressure: 255 bar (max)
Driver: Electric motor driven

ii) Cascades: Cascades are used to store the CNG at high pressure, to absorb the surge of
reciprocating compressor, frequent start and stop of compressor and to supply additional gas
when dispensing rate is more than compressor capacity. Cascade will be a group of cylinders and
provided with structural frame having facility of lifting and placement. The design of cylinder
shall be as per IS 7285 - 1988 and approved by Chief Controller of Explosives (CCOE), Government
of India for use in India for specified conditions. Cylinder neck threading shall be as per IS 3224-
2002 or as per design approved by Chief Controller of Explosive (CCOE) Government of India. The
cylinder shut-off valve shall be with combination Bursting Disc and Fusible Plug conforming to
requirements of IS 3224: 2002 or as per design approved by Chief Controller of Explosives (CCOE),
Government of India.

Storage Capacity: 9000/4500/3000 Water litre

Operating Pressure: 255 bar (max.)
Cylinder Material: Depends upon Type, Refer Table no. 5.
Tubing Material: SS 316

Particulars TYPE I TYPE III TYPE IV

Material Steel Aluminium lined carbon Plastic lined carbon
fibre wrapped fibre wrapped
Weight to Water 0.81 Kg /L 0.41Kg/L 0.31 Kg/L
capacity ratio
Corrosion Prone Immune Immune
Safety Fragmentation Leak before burst Leak before burst
Fatigue Yes Yes No
Service Life 20 Years 20 Years 20 Years
Maximum Capacity Water Capacity 4500 Water Capacity 8800 Water Capacity 8976
based on 9 ton payload Litre Litre Litre
vehicle

pg. 55
iii) SS Tubing: SS tubes are used for supply of natural gas in underground concrete/ masonry
trenches from compressor to dispenser, stationary cascade to dispenser & from compressor to
Mobile cascade. Area classification will be class-1, division-1; Group-D as per NEC or Zone-1
Group IIA/ IIB as per IS/IEC specification or equivalent specifications.

iv) Dispensers: Dispensers are used to feed the compressed natural gas from
compressor/cascade to the natural gas-based vehicles like buses, cars, three wheelers, etc.
Dispensing Pressure- Max. 250 bar
For Car: Capacity- 15 kg/min (Min.)
For Bus: Capacity- 75 kg/min (Min.)

5.7.5 DESIGN BASIS

Civil- In most (more than 90%) cases, CNG stations are in BPCL Retail outlet or in other CNG
stations. For Civil work Retail BU manual and T4S regulation of PNGRB for construction of Retail
outlet amy be refered.

Mechanical

 The design of High-pressure mains (steel grid) shall be for Location Class 4 (ASME B 31.8).
 Wall thickness shall be according to ASME B31.8 – Section 841.11 with Design factor of
0.4. However, a minimum wall thickness shall be 6.4 mm. Corrosion allowance shall be
0.5 mm.
 Buried parts of the pipeline shall be coated by means of 3LPE system.
 Buried gas pipelines shall be duly protected against corrosion by cathodic protection.
Pipelines shall be protected by Impressed Current system and Design life shall be 40
years.
 Design Criteria for Steel Pipelines shall be as follows:
Operating pressure: Max 49 bar
Minimum Operating Pressure: 16 bar
Maximum allowable velocity in network: 30 m /sec.
Efficiency: 1%
Roughness: 45 microns

6.0.0 Guidelines for Selection of Site for City Gate Station

The objective of these guidelines is to identify & select technically & financially viable land for
setting up of:
i) City Gate Station
ii) Odourization Unit
iii) Mother Station

pg. 56
6.1.0 SITE SELECTION
Identification of site for CGS, MS shall be the first activity of Project team after deployment at
site. Utmost importance shall be given to this as it is the most critical activity of any CGD Project.
During the identification of site, first preference shall be given to government or PSU land.
Government/PSU generally have clear Title & are free from any encumbrances which facilitates
early possession & expedites all construction activities. Identification of any Government/PSU
land takes maximum of 4 Months. If suitable government land is not found within 4 Months of
start of identification, an EOI shall immediately be floated for acquisition of Private land at
suitable location.
6.2.0 LOCATION OF SITE
Selection of available sites is often restricted to limited zones, e.g. land reserved for Industrial
development. A choice may have to be made regardless of site shape or quality. Proximity to
road Highways and strategic considerations affecting distribution of Natural Gas influence
selection of all sites. However sites requiring expensive filling and levelling or other major works
should be avoided as far as possible. Due consideration should be given to environmental factors
such as vegetation, ponds, nallahs hill etc. alteration to which is likely to affect ecological balance
in the area. Operational viability of any installation depends to a large extent upon suitable
approach and communication to the location. Sites should therefore be situated as close as
possible to the main road and public transport systems. It is advantageous for sites to be served
by public utilities like Electric power, water, drainage and telephone facilities. Hence, we should
consider availability of public utilities also, while finalizing the site.

6.2.1 LOCATION OF CGS

For the selection of CGS land, Tap off location for supply of NG supply shall be identified. Location
of Tap off is generally mentioned in the DFR of Project. In case of availability of multiple Tap off
locations, preference shall be given to Tap off location which will provide shortest & easiest Steel
pipeline route having minimum rivers & major Canal crossings, least Contour variation etc. upto
the major industrial & residential area of GA.
First Preference shall be given to identify the land within 200 m of distance from Tap off location.
Increase in the distance of land from Tap off location increases the cost of Project as Higher
Grade steel pipeline (Class 600) is required to be laid due to high pressure of NG. Moreover it
raises safety concerns. If no Suitable land is available within 200 m of radius from tap off location,
preference shall be given to identify the land along the route of proposed Steel pipeline.

6.2.2 LOCATION OF ODOURIZATION UNIT

Odourization unit shall be installed preferably in the same plot as that of CGS. In case it is not
feasible to install Odourization unit in the same plot due to space constraints, location of land
for Odourization unit shall be along the route of proposed Steel pipeline. However in any case it
shall be installed before entering into any major urban settlement area.

pg. 57
6.2.3 LOCATION OF MOTHER STATION UNIT

Mother Station shall be located as close as possible to CGS as it will minimize the laying of steel
Pipeline network & will facilitate the early commissioning of HCV filling facility which will further
facilitate the commissioning of DB CNG Stations of the GA. Also preference shall be given to
locate the Mother Station on/near to the major National Highway or State highway which will
increase the financial viability of station.

6.3.0 LAND REQUIREMENTS

A rectangular site with ample room for expansion and good load bearing capacity is most suitable
from the point of view of design and construction. Swamp land and other sites with a low bearing
capacity should be avoided, as these necessitate high initial expenditure to provide special
foundation. On reclaimed land special attention should be paid in establishing the nature of
original bottom and the material used for filling. Sites which have been reclaimed by dumping
town refuse should be avoided due to the indeterminable nature of filling and poor
consolidation.
Standard area required for setting up of CGS, Odourization unit & MS is given below:
a) CGS Comprising of Pressure Reduction Skid, metering Facility, heater (if required),
Filters along with Check metering & Odourization unit- 30 m x 40 m
b) CGS Comprising of Pressure Reduction Skid, metering Facility, heater (if required),
Filters without Check metering & Odourization unit- 25 m x 30 m.
c) Check metering & Odourization unit- 15 m x 15 m
d) Mother Station- 45 mx 50 m

6.4.0 CHECKLIST FOR TECHNICAL SUITABILITY

• Survey No. of plot.
• Survey plan available
• Temporary demarcation done in presence of revenue deptt official.
• Rough sketch of plot area.
• Clear title of land clear.
• INil Encumbrance certificate
• Key plan showing :-
1. Plot-North direction marked

pg. 58
 2. Road
3. Highway

4. Culvert/Causeway/Bridge
5. Trees inside the plot (Trees owned by Forest Deptt.)
6. Power transmission line (HT or LT)
7. Telephone lines
8. Tubewell, open channels
9. Any temple/mosque/grave yard
10. Industries, residential area within 500 M radius of plot
• Information regarding ownership of plot whether private or public and its type –Agricultural,
Industrial or combination
• Availability of Power Transmission line and its type Rural or Urban (Feeder)
• If Power Transmission line is not available in nearby area, the possibility of extending it to our
plot consideringrailway line, highway if required to be crossed
• Plot levelled or undulated/plain
• Data on high flood level
• MSL w.r.t permanent reduced level
• Rype of soil : alluvial, black cotton, hard sandy, rocky
• Availability of drainage and its catchment area –proposed plan for drainage in our plot viz-a-viz
existing drainage, also the annual rainfall in the area
• Approach road to our plot, its ownership, width and possibility of widening it
• Water availability, its source, quantity and whether potable, suitable for construction work, fire
fighter work

• Data from local people & meteorological deptt

i. Duration of rainfall and intensity of rainfall.
ii. Maximum rainfall during last 10 years.
iii. Highest and lowest temperatures recorded.
iv. Normal direction of prevailing wind & maximum wind velocity
v. Seismic details.
vi. Wind rose diagram if available.

 Particulars and addresses of various authorities –

pg. 59
 i. District magistrate- For No Objection certificate
ii. PWD for approach roads
iii. Other landlords – for way leave for pipeline trench
iv. Municipality or corporation-for water and sanitary trench
v. Factory Inspector
vi. Fire Brigade
vii. Elect. Power supply authority
viii. Defence establishment
ix. Any other Govt. or semi Govt. Authority such as pollution control boards etc.

7.0.0 STATUTORY APPROVALS IN CGD

DESCRIPTION ACTION BY

1 Forest BPCL GAS / Survey agency

2 DM’s NOC GAS / Retail

3 Railway Crossings BPCL GAS / Survey agency

4 Licence from Labour Commissioner BPCL GAS / Contractor

5 Municipal approval BPCL GAS / Survey agency

6 NHAI / NH PWD BPCL GAS / Survey agency

7 River / canal / nala BPCL GAS / Survey agency

8 Municipal Council / Corporation BPCL GAS / Survey agency

9 Approval for DG set BPCL GAS

Electricity connection / water connection
10 BPCL GAS / Contractor
approval
11 PESO approval & license BPCL GAS / Retail

pg. 60
CENTRAL LEVEL CLEARANCES

ACT UNDER WHICH

TYPE AUTHORITY
REQUIRED.
Forest Clearance for State Forest Department/ The Forest (Conservation)
1
diversion of forest land MOEF Act,1980
2 Explosive License PESO The Explosives Act,1884
Rehabilitation and
3 State Government/ MOEF
Resettlement Plan

State /Central Pollution The Water (Prevention and

Control Board (SPCB/CPCB) Control of
4 Pollution Clearance Pollution)Act,1974 &The
Air(Prevention and Control
of Pollution)Act,1981

Registration as Principal
5 ALC Central
Employer
6 NHAI Project Director NHAI

STATE LEVEL CLERANCES

Sr.
Type Authority Act Under which required.
No
1 Allotment of land
Allotment of land/ Concerned Industrial
A shed in industrial Development
Areas Authority
Allotment of District Collector/ State Land Revenue
B Government Land Revenue Act
Department
District Collector/ The Land Acquisition
C Acquisition of land
State Government Act, 1894
2 Change in land use
Conversion of Land District Collector/ State Land Revenue
A use to Non Revenue Act
agriculture purposes Department
Change in land use Town Planning State Urban
B in urban areas Department Improvement/
Municipal Act
3 Approval of building plan
Approval of building plans Concerned Industrial
A
in Industrial areas Development Authority

pg. 61
 Approval of building plans
B Local Authorities # Municipal Byelaws
in other areas
‘No Objection’ from Fire
4 Fire Services Department
Department
Release of power State Electricity Board or its
5
connection successor entities
Consent for setting up
State Electricity Board or its The Electricity Supply Act,
6 captive power Plant - DG
successor entities 1948
sets
Site Clearance Certificate –
required in case of
7 State Government The Factories Act, 1948
identified highly polluting
Industries
8 Release of water connection
Release of water
Industrial Development
A connection in Industrial
Authority
Areas

Release of water State Water Supply

B
connection in other Areas Department

9 Boiler Certification Chief Inspector of Boilers The Indian Boilers Act, 1923
10 Registration as a Factory Chief Inspector of Factories The Factories Act, 1948
11 Approval for the Bore well State Ground Water Board
12 DM NOC DM and concerned offices

pg. 62
STATUTORY ACTS & REGULATIONS APPLICABLE TO PETROLEUM

7 • The Motor Vehicles (Central) Rules, 1989 under the Motor Vehicles Act - 1988

• Environmental Regulations under the Environment (Protection) Act–

8 1986/ amended in 2006.

• Water (Prevention & Control of Pollution) Act, 1974 and Rules made
9 there under

• Air (Prevention & Control of Pollution) Act- 1981 and Rules made
10 there under

• Manufacture, Storage & Import of Hazardous Chemicals Rules –

11 1989 (latest edition)

• Hazardous Waste (Management and Handling )Rules 2009

12

pg. 63
 • Disaster Management Act, 2005
13
• The Chemical Accidents (Emergency Planning, Preparedness and
14 Response) Rules, 1996.

• Environmental Protection Rules, 1986.

15

• Environmental Impact Assessment Notification-2006

16
• Manufacture, Storage & Import of Hazardous Chemicals Rules –
17 1989 (latest edition)

FOREST CONSERVATION ACT

 Contractor shall strictly comply with all the provisions of Forest Conservation Act 1980.
 Under no circumstances any trees will be cut or destroyed in and around the vicinity of
the project area.
 Adequate fuel (wood / coal / kerosene / LPG) will be supplied by the Contractor to the
laborers so as to prevent them from damaging the forest. Fuel wood shall be sourced
from the State Forest Department and record of procurement and distribution for use
will be maintained by the contractor.
 In case any damage to forest property / trees or environment is reported, the contract
will be terminated by the Company . Any penalty imposed by the Department of
Forests, shall be levied form the Contractor and legal action as deemed necessary will
be initiated against the Contractor.

 No trapping and hunting shall be allowed. If some one is found hunting, trapping and
otherwise disturbing the wild life and vegetation in the project area then he/ she shall
be fined heavily and/or handed over to the police. The contract is also liable to be

pg. 64
 terminated if the contractor’s labours are found to be violating the above provisions of
the contract.

FOREST CLEARANCES (PROACTIVE ACTION TO BE TAKEN 10 MONTHS IN ADVANCE)

pg. 65
HIGHWAY CLEARANCES (PROACTIVE ACTION TO BE TAKEN 9 MONTHS IN ADVANCE)

RAILWAY CLEARNACES (PROACTIVE ACTION TO BE TAKEN 9 MONTHS IN ADVANCE)

pg. 66
GROUND WATER CLERANCE

• For the water requirement we are required to apply to the

Industrial development Body for the water line in case the plant is
located in an Industrial Area. Or with the State Ground water
board in case the agricultural land is taken over.

• On receipt of the application the Ground Water board verifies the

location of the proposed Terminal.

• As per the All India mapping the land is earmarked as Red,

Yellow and Green Category.

 In case of the Red i.e. notified DRY AREA the approval for the
boring is selectively given for a particular type of Industry only that
too as per the recommendation from the District level committee as
headed by Collector.

 We are required to apply to the Ground Water Board and then

make a presentation to the District Committee and then the
clearance is given by collector to Ground water board for allowing
the Co to make the boring.

 Subsequent to the boring the approval for the extraction of the

water is also required to be taken from the Ground water board.

pg. 67
PESO APPROVAL

• Separate layout should be prepared showing Plot Boundary in

Red and Fire fighting facilities with HVLR, Monitors and
Hydrants in Red colour and balance facilities in Black colour.

• Fire Break wall, with tank dyke capacity and OWS should also be
shown.

• Product Pipeline connections like, strainers, valves, reducers etc.

should be shown in separate drawings ( P&ID)

• Draft for the fees as per guidelines to be attached.

The Proposal is to be signed by the Competent person as
authorized by PESO for the same.

While preparing the drawings following points need to be ensured :

• Plot Boundary to be shown in Red Colour and Balance facilities

in Black Colour.

• There Are Standard Four Colour Coding in CCOE:

Black for exisiting facilities.
Red for proposed facilities.
Yellow for facilities to be dismantled.
Green for already approved facilities but not erected

• In the drawing the distances from Plot Boundary wall to all

facilities and distances between all proposed facilities to be shown.

pg. 68
STATUTORY APPROVALS FOR CONTRACTOR

The Contractor shall comply with all provisions of applicable

Labour Acts, such as

• The Minimum Wages Act 1948

• The Factories Act 1948
• The Contract Labour (Regulations & Abolition) Act 1970
• The Building & other Construction Workers Act 1996
• The Employees State Insurance Act 1948
• The Employees Provident Funds & Miscellaneous Provisions Act
1952

pg. 69
 CGD Projects

Introductory Presentation
(part of CGD Projects Hand Book

70
 OVERVIEW OF CITY GAS DISTRIBUTION

CGD is the last component of the Natural Gas value chain delivering Natural Gas to end
users in towns and cities to meet the demand for cleaner, more efficient, economical &
environmental friendly energy source.

• Under the Petroleum and Natural Gas Regulatory Board (PNGRB) Act 2006, PNGRB
grants the authorization to the entities for developing a City Gas Distribution (CGD)
network (including PNG network) in a specified Geographical Area (GA) of the country.
• The push for city gas expansion is part of the government plan for raising the share of
natural gas in the country's energy basket to 15% by 2030 from the current 6.3%

71
There are four segments of customers in CGD:
• Domestic Consumers- Households for cooking
• Commercial Consumers-Hotels, Restaurants, Hospitals, Malls, Bakeries,
Schools etc.
• Industrial Consumers - Medium & Small Industries using fuels like LPG,
HSD, LDO, Furnace Oil, coal etc. ( UP to 50,000 SCMD)
• Automobile Customers- City and school buses, private cars, taxis, auto-
rickshaws, vans etc.

72
73
Project Planning 1. Demand
Survey

2.
5. Financial
Infrastructure
Feasibility
requirement

DFR

4. Time & 3. Statutory

cost estimate Clearances

74
STEPS IN THE DESIGN OF GAS DISTRIBUTION SYSTEM

 Estimation of Market demand based on comprehensive field survey of

POTENTIAL CONSUMERS in domestic, commercial, industrial &
transport sectors.
 TO CARRY OUT Demand forecast for 25 years.
 Reconnaissance Route Survey to identify suitable routes for laying
pipelines, locations for City Gate Station, District Regulating Station &
CNG Station
 Peak hour consumption estimated for network design.
 The system is designed based on 25th year demand at peak load in a
phased manner.

CONT…
75
 STEPS IN THE DESIGN OF GAS DISTRIBUTION SYSTEM (CONT…)

 Network design and optimization of pipeline size in software like

Pipeline Studio / Gas Works / Synergy etc.
 Design of Mother Station, On Line Station & Daughter Booster
Station for CNG supply to automobiles.
 National / International standards adopted for design.
 Project implementation done subsequently.

76
Major Constituents of CGD INFRASTRUCTURE:

City Gate station located at outskirts of the City with Odorization

system
Primary Network
 Steel Pipeline Network operating between 49 – 7 bar
Secondary Network
 Polyethylene Pipelines operating between 7 bar to 100 mbar
Tertiary Network
 GI / Cu Pipes operating at less than 100 mbar

77
 Major Constituents of CGD (Cont..):

 District Regulating Stations (DRS)

 Meter Regulating Stations (MRS)
 Service Regulators
 Domestic and Commercial Regulators and Meters
 CNG Stations

78
 DETAILS OF STANDARD EQUIPMENTS/ MATERIALS USED IN CGD
Sl No. Main Equipment/ Material Description

1 PE Coated Steel Pipeline API 5L Grade B, X-42, X-60, X-70 etc.

2 CNG Compressor – 1200 SCMH Gas Engine Driven/ Electric Motor Driven

3 CNG Compressor – 650 SCMH Gas Engine Driven/ Electric Motor Driven

4 CNG Compressor – 450/250 SCMH Electric Motor Driven

5 CNG Cascades 9360 WL, 8800 WL, 4500 WL, 3000WL, 2200 WL

6 CNG Dispenser Car/ Auto & Bus Dispenser

7 MDPE Pipe dia. 180mm to 20mm, PE 80/100,

8. District Regulatory System (DRS) 600 SCMH, 1000 SCMH, 2000 SCMH & 5000 SCMH.
79
 49 Bar

7 Bar

100 Mbar

80
81
 CGD PRESSURE REGIMES
SR. NETWORK INLET
INLET FROM OUTLET PRESSURE OUTLET TO
NO. COMPONENT PRESSURE
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 6/4 – 1 BARG MP MDPE PIPELINE

INDL. MRS & COMM.
4 MDPE PIPELINE DRS 6 / 4 BARG 6 / 4 – 1 BARG
CONNECTIONS
SERVICE
5 MDPE PIPELINE 6 / 4 – 1 BARG 100 MBARG LP MDPE PIPELINE
REGULATORS (SR)
1.5 BARG OR CUSTOMER
MDPE PIPELINE 6 / 4 – 1.5 BARG
6 INDUSTRIAL MRS SPECIFIC PRESS. WITHIN INDUSTRIAL PIPELINE
STEEL PIPELINE 26 – 14 BARG
THE SUPPLY RANGE
REGULATOR OF
PE /GI / CU
7 SR 100 MBARG DOMESTIC / COMM.
PIPELINE 100 – 50 MBARG
CONNECTIONS
DOMESTIC MDPE / GI / CU
8 100 – 50 MBARG 21 M BARG METER & GAS STOVE
CONNECTIONS PIPELINE
ONLINE/ MOTHER
9 STEEL PIPELINE 26 - 14 BARG 250 BARG VEHICLE AT 200 BARG
CNG STATION
MDPE / GI / CU 110 – 75 MBARG 75 MBARG OR CUSTOMER
COMMERCIAL
10 PIPELINE 6 / 4 – 500 SPECIFIC PRESS. WITHIN METER & GAS STOVE
CONNECTIONS
MDPE PIPELINE MBARG THE SUPPLY RANGE 82
 CITY GATE STATION (CGS)

 CGS is the location of Custody

Transfer from Transmission
Company to Distribution Company.
 It is the entry point of Natural Gas
from a sub-transmission high-
pressure gas pipeline to a City /
Geographical Area

83
TYPICAL CITY GAS STATION

84
85
 PRIMARY NETWORK ( underground Steel Pipeline )

Design Parameters :

Design Pressure : 49 Kg/cm2(g)

Max. Op. Pressure, kg/cm2(g) : 17 - 32 kg/cm2

Design Temperature : – 29°C to 60 °C

Joint Factor : 1

Population Density Factor : 0.4 (Class IV)

Design Life : 30 Years

Corrosion Allowance : 0.5 mm

Pipeline Efficiency/ Roughness : 0.9 / 45 micron.

Depth of pipeline laid : 1.0 M below ground level

SV STATIONS : AT EVERY 3 KM

86
87
 STEEL PIPELINE LAYING PROCEDURE
Sl. No. Procedure Description
1 Route Survey
2 Clearing and Grading of ROW
3 Electrode Qualification Test
4 WPS (Mainline)
5 Welder Performance Qualification
Receipt, Handling, Storage & Stringing of Line Pipes,
6
Material and Equipment
7 Incoming Material Inspection
8 Mainline Welding &Tie-in Joint Welding
9 Stringing of Line Pipes
10 Weld Joint Numbering

88
 STEEL PIPELINE LAYING PROCEDURE

Sl. No. Procedure Description

11 Radiography
12 Blasting
13 Field Joint Coating & Repair
14 Repair of Arc Strike
15 Trench Excavation
16 Lowering & Backfilling of pipe section
17 Pipe Book Handling
18 Mainline Hydrostatic Testing
19 Dewatering, Swabbing & Drying of Pipeline

89
 STEEL PIPELINE LAYING PROCEDURE
Sl. No. Procedure Description
Pipeline Markers, Fabrication & installation
20
Cased Crossing by Boring/ Opencut & Minor Water CrossingPre-
21 commissioning

SV Installation
22
Pre-commissioning & commissioning
23

24 Restoration

90
91
PESO

92
93
 TECHNICAL DETAILS OF DRS
SL. TECHNICAL DETAILS PARAMETERS
NO.
1 Standard Capacity 500, 1000, 2500 & 5000 SCMH
 Design pressure 49 barg
 Upstream pressure 17 - 32 barg

2 Downstream pressure 6 / 4 barg

3 Design temp (min / max) 0 oC / +60 oC

4 No. of streams 1 + 1 or 2+1

5 Redundancy Minimum 50 %

6 Installation Above Ground / Under Ground

94
DISTRICT REGULATING STATION (DRS)

EXTERIOR VIEW

INTERIOR VIEW

95
96
MRS (METER REGULATING SKID) FOR INDUSTRIES

97
METER REGULATING SKID

98
PIPED NATURAL GAS (DOMESTIC)

99
 MDPE PIPELINE LAYING PROCEDURE

Sl. No. Procedure Description

1 Route Survey

2 Gas supply requirements & Pressure drops are taken into consideration for the best route.

Permission from concerned authorities is taken for RoU

3
4 Excavation: Trench depth to maintain 1.0-meter cover

5 Clear distance from other utilities maintained

6 Proper sand padding surrounding PE pipes.

Laying of Warning tape at 0.5 meters depth from ground level.
7
8 Earth Back filling

9 Isolation valve to be installed at every 1.0 km on secondary (MP) PE pipeline

10 Pipeline marker at every 200 meters distance

11 Connection required to a joint additional piece of PE pipe : Electrofusion joint.

12 Transition Fitting Joint: From here Galvanized Iron/ Copper Pipe is jointed with PE Line.
100
 MEDIUM DENSITY POLYETHYLENE (MDPE) PIPES
 Material Grade & Color: Internationally
approved resins of PE 100 grade of Orange
color (PE 80 of yellow colour)
 Minimum Required Strength (MRS) of PE
100 grade pipe: 10 MPa
 Pipe thickness – SDR 11
 Operating pressure: 6 bar (g).
 Operating temperature range: - 10 0 C to +
40 0 C.
 Not to be installed in above ground piping

101
ADVANTAGES OF PE PIPES
 Higher productivity, i.e., reduction in installation time (15 min.
FOR PE against 4 hrs. FOR steel), thereby lesser inconvenience
to public
 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 press. losses due to low pipe friction)

CONT…
102
 Easy to transport, handle and lay
 Longer life
 Easier and speedier joining techniques to ensure leak tight joints by
employing electro fusion techniques
 Reduced number of joints, hence safer and leak free system
 Less time is consumed to repair PE damages as compared to steel
damages
 Good squeeze off properties
 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
critical
 Size of trench is less in case of laying of PE pipe as compared to steel
103
 MDPE FITTING

 TRANSITION FITTING -Used to connect u/g PE pipes with a/g GI pipes

104
SERVICE REGULATORS

105
GI ERW PIPES
 Types used : Medium Class and Heavy Class
 Pipes shall be screwed with Taper threads
 Threads: Tapered and conforming to BS 21
 Galvanizing : Mass of coating is 400 gms / m2
 Powder Coating :Pure Polyester, Electrostatic spraying

FORGED FITTINGS OF WROUGHT STEEL IRON

 Coating requirements: Mass of

coating is 700 gms / m2.

106
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 pipe work
• Safety features required
• Installation indoors of outdoors
• Orientation of regulator

107
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)
End connections: Right angled inlet and outlet connections of ¾”x
¾” npt (Female)

108
GAS METERS
THE MOST COMMON TYPES OF METERS USED ARE:

 Diaphragm
 Rotary Positive Displacement (RPD)
 Turbine

A TYPICAL DOMESTIC GAS

METER (DIAPHRAGM TYPE)

109
RUBBER HOSE (FLEXIBLE AND STEEL WIRE BRAIDED)
 Properties:
 Tensile strength: Min.10 MPa for lining and cover
 Strong (Steel wire reinforced) hence rats can't bite
through steel wire Flame resistant
 Minimum burst press. of 0.5 MPa
 Long life (5 years)
 Grip strength (to nozzle of appliance)

• Conversion of Burner:
Gas flow rate & pressure are different for LPG & PNG so
nozzle sizes are set according to PNG requirement. The jet
diameter of 110 mm / 125 mm should be used in PNG.
110
VIRTUAL PIPING

111
 CNG STATIONS
IN
CITY GAS DISTRIBUTION

112
CNG ADVANTAGES
PROPERTIES UNIT PEROL DIESEL LPG CNG
RELATIVE DENSITY WATER = 0.74 0.84 0.55 -
1
RELATIVE DENSITY AIR = 1 - - 1.285 0.64
AUTO IGNITION 0C 360 280 374 540
TEMP.
FLAMMABILITY % IN AIR 1-8 0.6 – 5.5 2.2 – 5 - 15
RANGE 9.0
FLAME TEMP. 0C 2030 1780 1983 1900

OCTANE NO. - 87 - 93 127

113
CNG ADVANTAGES
 Safer fuel
 narrow flammability range
 no threat to land or water on spillage
 Disperses rapidly, minimizing ignition risk
 Better combustion quality
 higher octane number makes it suitable for spark
ignition engine
 CNG engines run more efficiently, enhancing vehicle life
 Cheaper than Petrol

CONT…
114
 CNG STATIONS
STEEL PIPELINE – NATURAL GAS CARRIER

Mother station Online station

*Not connected directly by pipe

line

Daughter booster
Daughter
station *
station * 115
116
MOTHER STATION - SCHEMATIC

STORAGE CASCADE

MOTHER
COMPRESSOR

CNG VEHICLE

CNG
CNG
Dispenser

Gas Supply

LCV - MOUNTED
CASCADES
117
 CNG - Mother Station
The units envisaged in Mother Station are :
• Electric / Gas Engine Driven Reciprocating Compressor Capacity :
1200 SCMH along with auxiliaries
• Electric Power Consumption of Compressor : 180 KW
• Dispensers for buses - 75 Kg/min
• Dispensers for cars and three-wheelers – 15 Kg/min
• Loading Facility for Mobile Cascades – 3000/4500 WL Capacity
• Stationary Cascades - 3000/4500 WL Capacity
• Electrical Control Panel
• Instrument Air and Water Facilities
• Fire Fighting equipment and safety sign
• Office-cum-Control Room and other facilities
118
CNG ON-LINE STATION - SCHEMATIC

Storage
Cascade

On-line
Compressor

CN Vehicle

CNG
CNG

Dispenser

Gas Supply

119
50
 CNG - ON-LINE STATION

The units envisaged in On-line stations are:

 Electric / Gas Engine Driven Reciprocating Compressor
Capacity : 1200 / 750 SCMH along with auxiliaries.
 Electric Consumption of Compressor : 180 / 120 KW
 Dispensers for buses (as required) - 75 Kg/min
 Dispensers for cars and three-wheelers – 15 Kg/min
 Stationary Cascades of 3000WL.
 Electrical Control Panel
 Instrument Air and Water Facilities
 Fire Fighting equipment and safety sign.
 Office-cum-Control Room and other facilities
120
CNG DAUGHTER BOOSTER STATIONS

121
DAUGHTER BOOSTER STATION

The units envisaged in daughter booster stations are:

 Booster compressor of 250 SCMH Capacity along with
auxiliaries
 Electric Consumption of Compressor : 22 KW
 Dispensers for cars and three-wheelers : 15 Kg/min
 Stationary Cascades – 3000 WL
 Electrical Control Panel
 Instrument Air and Water Facilities
 Fire Fighting equipment and safety sign
 Unloading facility from mobile cascades
 Office-cum-Control Room if reqd.
122
CNG DAUGHTER STATIONS

123
 CNG COMPRESSOR – MOTOR/ENGINE DRIVEN

• Cost varies from Rs 1 to 1.5 Cr

• Cost varies from Rs 50 to 60 L

124
GAS (% LEL)/FLAME (UV-IR) DETECTOR INSIDE THE CNG COMPRESSOR

125
 CNG DISPENSER

• The dispenser is available in the single hose,

double hose & four hose.

• There are car/ bus/car cum bus dispensers

• The dispensing pressure is always less than 220

bar

• Cost varies from Rs 12-15 L

126
 CNG CASCADE

TATA LPT 1412g / EICHER PRO 2114 XP

Truck Model --->
Type 1 Type 3 Type 4
Cascade
4500 8800 9360
Capacity (WLC)
Cascade
5300 x 1875 x 2991 x 2438 x 5800 x 2100 x
Dimensions
1670 2594 2480
(mm)
Payload
9700 7250 7250
Required (Kg)

Type-III/IV cascade can carry more CNG and also weight is less because it is made of lighter material

127
 What is MWP target &
importance of achieving it

In the perspective of 9th , 10th & 11TH CGD Bid

Round

128
 Bid parameter of
Commitment
PNGRB
M...Minimum Quoted by CGD Entity

1.PNG-D connection
CGD
W…Work Infrastructure
2.CNG Station no.
3.Inch-Km Steel
Pipeline*

Time
P...Program Schedule
8 Contract Years*

(with target for each year)

* For GA of Bilaspur, Hamirpur & Una,

there is no MWP of steel inch-km

10 contract years available for MWP 129

 Origin of MWP…the Bidding process…the composite
score
Bidding Bid Evaluation Weightage
Parameters
LOI is given to CGD entity with highest
Lowness in Network score
tariff for CGD (in 10%, floor is set @
Rs 30 per MMBTU (after negotiation in case abnormal bid)
Rs./MMBTU)
Lowness in
Compression Charge
On submission of PBG Authorization is
for CNG (in Rs./kg) 10%, floor is set @Rs granted.
2 per Kg (PBG/performance bond depend on
population of the GA and shall be encashed
Highness in No. of PNG in case of shortfall of MWP)
Domestic connections 50% (55% for Una)
(no ceiling, becomes MWP) Each Authorization letter consists Schedule-
Highness in No. of CNG D
20% (25% for Una)
stations
(no ceiling, becomes MWP)
Work-Program mentioned in Schedule-D
becomes MWP
10% (NA for Una)
Highness in Inch-km (no ceiling, becomes MWP) 130
 MWP is limited to three parameters
Qualifier Completion Marker of MWP

1. Domestic connections • Registration

PNG • Piping upto kitchen
connections • Installation of meter

2. Online and Daughter Installation of facilities & PESO license

CNG stations Booster stations

3. Steel pipeline Laying (lowering)

Inch-Km
(Including post-
authorization STPL)

Beyond MWP
• CGS commissioning is very critical for profitable operation of CNG stations.
• Also profitable work-program like CNG stations can be more than the MWP which is planned in DFR. 131
 P: Program …. The Schedule

For GA of Bilaspur, 120%

Progress Profile

For all GAs Hamirpur & Una

Yr
Inch-
PNG-D CNG PNG CNG 100%
Km
Cumulative percentage target of MWP
80%

1 -- -- 5
-- --
2 10 15 20 10 10 60%

3 20 30 40 20 20
4 30 45 60 30 30 40%

5 40 60 70 40 40
6 60 75 80 50 50 20%

7 80 90 90 60 60
8 100 100 100 70 70 0%
1 2 3 4 5 6 7 8 9 10
9 80 80 PNG CNG Inch-Km PNG/CNG (Una)

10 100 100
132
 Salient points of time scale

• MWP target is provided for each year, e.g. Contract Year

• Contract year starts from 1st day of subsequent quarter after grant of
authorization
• There is provision of time extension in case of Force majeure
occurrence
• Force majeure is to be reported to PNGRB within 15 days of occurrence
• Within 15 days of end of the event, PNGRB is to be requested for Time
Extension considering Force majeure
• Force Majeure can be considered in part of the CGD Geographical Area,
which may be a district, tehsil or smaller administrative unit. 133
 Managing the Schedule

Incentive
Penalty
If CGD entity timely achieves MWP in
each of the eight contract years, For shortfall in each PNG-D connection:
Marketing Exclusivity* shall be extended 750/-
by additional two years.
For shortfall in each Inch-km : 1,50,000/-
If the entity is not able to timely achieve For shortfall in each CNG Station:
the work programme in any of the eight 20,00,000/-
contract years but
is successful in timely achieving the
Penalty is applicable in each contract
cumulative work programme at the end
year from second year contract onwards
of the eighth contract year, then
Marketing Exclusivity shall be extended
by a period of one year.
3rd Year Check: Authorization
*Marketing Exclusivity is available for Cancellation in case cumulative weighted
eight years in absence of incentive. CGD achievement falls short of 30% of the
network will be considered as common work programme
or contract carrier after end of
marketing exclusivity. 134
 Relaxations w.r.t MWP
MWP is not restricted by Area
e.g. all CNG stations can be in a major/district town

However natural gas has to reach in all charge areas

MWP is not linked with Gas Charging or Sales, its emphasis on infrastructure

MWP check is always at the end of each contract year

135
136
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SINGLE LINE DIAGRAM FOR
MAIN DISTRIBUTION PANEL FOR CNG STATION (22-37.5KW)
250A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA

2A DIGITAL 2A DIGITAL 2A DIGITAL

ENERGY ENERGY ENERGY
METER METER METER

250A FP 200A FP 100A FP

MCCB, 35kA MCCB, 35kA MCCB, 35kA
2A 2A 2A
R Y B R Y B R Y B

FROM STATE TO CNG PANEL TO RETAIL PANEL

3.5c 95sqmm A2XFY 3.5c 35sqmm A2XFY
ELECTRICITY
BOARD
3.5c 120sqmm A2XFY

GENERAL ARRANGEMENT FOR

MAIN DISTRIBUTION PANEL FOR CNG STATION (22-37.5KW)

Mild Steel POLYCARBONATE

(Enclosure IP-42) (Enclosure IP-65)
750mm
1200mm
400mm 400mm 400mm
250A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA
25 x 6 mm Cu. (Electrical grade) x 4 No’s
250A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA
25 x 6 mm Cu. (Electrical grade) x 4 No’s

375 x 750mm

ENERGY ENERGY ENERGY ENERGY ENERGY ENERGY

METER METER METER METER METER METER

250A FP 200A FP 100A FP

MCCB MCCB MCCB
35kA 35kA 35kA 100A FP
250A FP 200A FP
MCCB MCCB MCCB
35kA 35kA 35kA

BUS LINKS BUS LINKS BUS LINKS BUS LINKS

INCOMER INCOMER OUTGOING OUTGOING

375 x 750mm

FRONT VIEW FRONT VIEW

FOUNDATION VIEW FOUNDATION VIEW

pg:179
SINGLE LINE DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (22-37.5KW)

3.5c 95sqmm A2XFY

200A FP MCCB 35kA 200A FP
with SHUNT RELEASE MCCB
35kA 60KVA, 3PH.
FROM PANEL - 1 /
STATE ELEC. BOARD SERVO VOLT
STABILISER
2A
3.5c 95sqmm A2XFY R Y B

200A, FP, ON LOAD

CHANGE OVER SWITCH RETAIL GENERATOR
≥ 15KVA, 3Ph.
2A
R Y B

200A, 3 Phase 4 Wire,

Copper Bus Bar, 35kA

160A, FP 100A, FP
MCCB, 35kA MCCB, 35kA
2A R
Y
3c 2.5sqmm 2XWY
2A R 2A R B
Y Y
B B
100A, FP, ON LOAD
ESD-1 CHANGE OVER SWITCH
CNG COMP.
(22-37.5kW) 30KVAR - 6 STEP 2A
3.5c 50sqmm A2XFY
(1+2+2+5+10+10) DVM
HRC
ESD-2 63A, FP MCB, 10kA
with SHUNT RELEASE

2A R
Y
B

16A DP MCB 32A 32A 32A 32A 10A 10A

DP MCB DP MCB FP FP DP DP
10kA with 10kA 10kA MCB MCB MCB MCB
SHUNT RELEASE 10kA 10kA 10kA 10kA
2A
DVM
6A DP MCB 10kA - 8Pcs 3c 2.5sqmm
(3c 2.5sqmm 2XWY) 25A DP MCB 2XWY
(Dispenser - 2, CNG comp. - 1, Change Over Sw.
Automation-1, Co2 flooding - 1, 3KVA 3KVA
CNG GAS Metering -1, )
2A R 2A R UPS-1- UPS-2-

3c 2.5sqmm 2XWY
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (22-37.5KW)
(Mild Steel Enclosure duly powder coated)
1350mm
450mm 450mm 450mm

MCB+K+CAP
From SEB
200A FP
MCCB

To Servo
200A FP 100A FP
MCCB MCCB APFC

From Servo
DPM
200A FP
COS
200A BUS BAR

25 x 6 mm Cu.
(Electrical grade)
x 4 No’s

From Retail
GEN. 15KVA 100A FP
COS

ESD CTRL
SPARE 63A FP
SPARE
MCB
SPARE 160A FP
To AIR COMP. MCCB
SPARE
To UPS-1
To UPS-2 MCB’s 10A DP x 2
32A FP x 2, 32A DP x 2
From UPS-1
From UPS-2
To Dispenser-1 16A DP MCB
To Dispenser-2
To Dispenser-3
To Automation To CNG Comp
To CNG comp.-1
To CNG comp.-1
To Metering
To Co2 Flooding MCB DP COS 25A
MCB DP 6A x 6

FRONT VIEW

FOUNDATION VIEW

pg:181
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (22-37.5KW)
(POLYCARBONATE Enclosure IP 65)

TOP VIEW
1500mm

MCB+K+CAP
To CNG Comp

APFC DPM

100A FP 200A BUS BAR

MCCB 250A FP
MCCB
25 x 6 mm Cu.
(Electrical grade)
x 4 No’s
MI0301 MI0301 MI0301

63A FP
MCB

200A FP 200A FP 200A FP

MCCB MCCB 100A FP
COS COS

MI0301 MI0301 MI0301 MI0301

TERMINALS

From SEB To Servo From Retail

From Servo
GEN. 15KVA
)HE
(C
T
W
A 01
L
E
S
N
7
.9

MI0201

FRONT VIEW

FOUNDATION VIEW
SINGLE LINE DIAGRAM FOR
MAIN DISTRIBUTION PANEL FOR CNG STATION (90KW)
400A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA

2A DIGITAL 2A DIGITAL 2A DIGITAL

ENERGY ENERGY ENERGY
METER METER METER

400A FP 320A FP 100A FP

MCCB, 35kA MCCB, 35kA MCCB, 35kA
2A 2A 2A
R Y B R Y B R Y B

FROM STATE TO CNG PANEL TO RETAIL PANEL

3.5c 240sqmm A2XFY 3.5c 35sqmm A2XFY
ELECTRICITY
BOARD
3.5c 300sqmm A2XFY

GENERAL ARRANGEMENT FOR

MAIN DISTRIBUTION PANEL FOR CNG STATION (90KW)
Mild Steel POLYCARBONATE
(Enclosure IP-42) (Enclosure IP-65)
1200mm 750mm
400mm 400mm 400mm

400A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA

400A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA 50 x 6 mm Cu. (Electrical grade) x 4 No’s
50 x 6 mm Cu. (Electrical grade) x 4 No’s

375 x 750mm

ENERGY ENERGY ENERGY

METER METER METER ENERGY ENERGY ENERGY
METER METER METER

400A FP 320A FP 100A FP

MCCB MCCB MCCB
35kA 35kA 35kA

400A FP 320A FP 100A FP

MCCB MCCB MCCB
35kA 35kA 35kA

BUS LINKS BUS LINKS BUS LINKS

INCOMER OUTGOING OUTGOING
BUS LINKS BUS LINKS BUS LINKS
INCOMER OUTGOING OUTGOING

FRONT VIEW 375 x 750mm

FRONT VIEW

FOUNDATION VIEW FOUNDATION VIEW

pg:183
SINGLE LINE DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (90KW)

3.5c 240sqmm A2XFY

320A FP MCCB 35kA 320A FP
with SHUNT RELEASE MCCB
35kA 160KVA, 3PH.
FROM PANEL - 1 /
STATE ELEC. BOARD SERVO VOLT
STABILISER
2A
3.5c 240sqmm A2XFY R Y B

315A, FP, ON LOAD

CHANGE OVER SWITCH RETAIL GENERATOR
≥ 15KVA, 3Ph.
2A
R Y B

2A
DPM
VAF

320A, 3 Phase 4 Wire,

Copper Bus Bar, 35kA

250A, FP 160A, FP
MCCB, 35kA MCCB, 35kA
2A R
Y
3c 2.5sqmm 2XWY
2A R 2A R B
Y Y
B B
100A, FP, ON LOAD
ESD-1 CHANGE OVER SWITCH
CNG COMP.
(90kW) 40KVAR - 6 STEP
3.5c 185sqmm A2XFY
(1+2+2+5+10+20)
ESD-2 63A, FP MCB, 10kA
with SHUNT RELEASE

2A R
Y
B

16A DP MCB 32A 32A 32A 32A 10A 10A

DP MCB DP MCB FP FP DP DP
10kA with 10kA 10kA MCB MCB MCB MCB
SHUNT RELEASE 10kA 10kA 10kA 10kA

6A DP MCB 10kA - 8Pcs 3c 2.5sqmm

(3c 2.5sqmm 2XWY) 25A DP MCB 2XWY
(Dispenser - 2, CNG comp. - 1, Change Over Sw.
Automation-1, Co2 flooding - 1, 3KVA 3KVA
CNG GAS Metering -1, )
2A R 2A R UPS-1- UPS-2-

3c 2.5sqmm 2XWY
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (90KW)
(Mild Steel Enclosure duly powder coated)
1500mm
500mm 500mm 500mm

MCB+K+CAP

From SEB
320A FP
MCCB

To Servo
320A FP 160A FP
MCCB MCCB
APFC

DPM
From Servo

315A FP
COS
320A BUS BAR

40 x 6 mm Cu.
(Electrical grade)
x 4 No’s

From Retail
GEN. 15KVA
100A FP
COS
ESD CTRL

SPARE
SPARE 63A FP
SPARE MCB
To AIR COMP.
SPARE
To UPS-1
To UPS-2 MCB’s 10A DP x 2
From UPS-1 32A FP x 2, 32A DP x 2
From UPS-2
To Dispenser-1 16A DP MCB
To Dispenser-2
To Dispenser-3
To Automation To CNG Comp
To CNG comp.-1
To CNG comp.-1
To Metering MCB DP COS 25A
To Co2 Flooding MCB DP 6A x 6

FRONT VIEW

FOUNDATION VIEW

pg:185
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (90KW)
(POLYCARBONATE Enclosure IP 65)

TOP VIEW
1800mm

MCB+K+CAP To CNG Comp

DPM
APFC
160A FP
MCCB 250A FP
320A BUS BAR MCCB
40 x 6 mm Cu.
(Electrical grade) x 4 No’s

MI0301 MI0301

63A FP
MCB

320A FP 320A FP
315A FP 100A FP
MCCB MCCB
COS COS

MI0301 MI0301 MI0301 MI0301

TERMINALS

From SEB To Servo From Retail

From Servo
GEN. 15KVA

MI0301 MI0301

FRONT VIEW

FOUNDATION VIEW
SINGLE LINE DIAGRAM FOR
MAIN DISTRIBUTION PANEL FOR CNG STATION (160KW)
630A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA

2A DIGITAL 2A DIGITAL 2A DIGITAL

ENERGY ENERGY ENERGY
METER METER METER

630A FP 500A FP 100A FP

MCCB, 35kA MCCB, 35kA MCCB, 35kA
2A 2A 2A
R Y B R Y B R Y B

FROM STATE TO CNG PANEL TO RETAIL PANEL

2X3.5c 185sqmm A2XFY 3.5c 35sqmm A2XFY
ELECTRICITY
BOARD
2X3.5c 240sqmm A2XFY

GENERAL ARRANGEMENT FOR

MAIN DISTRIBUTION PANEL FOR CNG STATION (160KW)

Mild Steel POLYCARBONATE

(Enclosure IP-42) (Enclosure IP-65)
1400mm 1000mm
500mm 500mm 400mm

630A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA

630A, 3 Phase 4 Wire, COPPER Bus Bar, 35kA
50 x 10 mm Cu. (Electrical grade) x 4 No’s
50 x 10 mm Cu. (Electrical grade) x 4 No’s

375 x 375mm 375 x 375mm

ENERGY ENERGY ENERGY ENERGY ENERGY ENERGY

METER METER METER METER METER METER

375 x 375mm 375 x 375mm

630A FP 500A FP 100A FP

MCCB MCCB MCCB
35kA 35kA 35kA
630A FP 500A FP 100A FP
MCCB MCCB MCCB
35kA 35kA 35kA
375 x 375mm 375 x 375mm

BUS LINKS BUS LINKS BUS LINKS

INCOMER OUTGOING OUTGOING BUS LINKS BUS LINKS BUS LINKS
INCOMER OUTGOING OUTGOING

FRONT VIEW
375 x 375mm 375 x 375mm

FRONT VIEW

FOUNDATION VIEW
FOUNDATION VIEW

pg:187
SINGLE LINE DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (160KW)

2X3.5c 185sqmm A2XFY

500A FP MCCB 35kA 500A FP
with SHUNT RELEASE MCCB
35kA 200KVA, 3PH.
FROM PANEL - 1 /
STATE ELEC. BOARD SERVO VOLT
STABILISER
2A
2X3.5c 185sqmm A2XFY R Y B

630A, FP, ON LOAD

CHANGE OVER SWITCH RETAIL GENERATOR
≥ 15KVA, 3Ph.
2A
R Y B

2A
DPM
VAF

500A, 3 Phase 4 Wire,

Copper Bus Bar, 35kA

400A, FP 200A, FP
MCCB, 35kA MCCB, 35kA
2A R
Y
3c 2.5sqmm 2XWY
2A R 2A R B
Y Y
B B
100A, FP, ON LOAD
ESD-1 CHANGE OVER SWITCH
CNG COMP.
(160kW) 50KVAR - 6 STEP
2 x 3c 150sqmm A2XFY
(1+2+2+5+10+30)
ESD-2 63A, FP MCB, 10kA
with SHUNT RELEASE

2A R
Y
B

16A DP MCB 32A 32A 32A 32A 10A 10A

DP MCB DP MCB FP FP DP DP
10kA with 10kA 10kA MCB MCB MCB MCB
SHUNT RELEASE 10kA 10kA 10kA 10kA

6A DP MCB 10kA - 8Pcs 3c 2.5sqmm

(3c 2.5sqmm 2XWY) 25A DP MCB 2XWY
(Dispenser - 2, CNG comp. - 1, Change Over Sw.
Automation-1, Co2 flooding - 1, 3KVA 3KVA
CNG GAS Metering -1, )
2A R 2A R UPS-1- UPS-2-

3c 2.5sqmm 2XWY
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (160KW)
(Mild Steel Enclosure duly powder coated)
1500mm
500mm 500mm 500mm

MCB+K+CAP

From SEB
500A FP
MCCB

To Servo
500A FP 200A FP
MCCB MCCB
APFC

DPM
From Servo

630A FP
COS
630A BUS BAR

50 x 10 mm Cu.
(Electrical grade)
x 4 No’s
From Retail
GEN. 15KVA
100A FP
COS
ESD CTRL

SPARE
SPARE 63A FP
SPARE MCB
To AIR COMP.
SPARE
To UPS-1
To UPS-2 MCB’s 10A DP x 2
From UPS-1 32A FP x 2, 32A DP x 2
From UPS-2
To Dispenser-1 16A DP MCB
To Dispenser-2
To Dispenser-3
To Automation To CNG Comp
To CNG comp.-1
To CNG comp.-1
To Metering MCB DP COS 25A
To Co2 Flooding MCB DP 6A x 6

FRONT VIEW

FOUNDATION VIEW

pg:189
GENERAL ARRANGMENT DIAGRAM FOR
MAIN LT PANEL - FOR CNG STATION (160KW)
(POLYCARBONATE Enclosure IP 65)

TOP VIEW
1800mm

MCB+K+CAP To CNG Comp

DPM
APFC
200A FP
MCCB 400A FP
630A BUS BAR MCCB
50 x 10 mm Cu.
(Electrical grade) x 4 No’s

MI0301 MI0301

63A FP
MCB

500A FP 500A FP
630A FP 100A FP
MCCB MCCB
COS COS

MI0301 MI0301 MI0301 MI0301

TERMINALS

From SEB To Servo From Retail

From Servo
GEN. 15KVA

MI0301 MI0301

FRONT VIEW

FOUNDATION VIEW
 GENERAL NOTES FOR ELECTRICAL PANELS:
A. FABRICATION OF SHEET METAL PANEL:
1. ALL DIMENSIONS ARE IN MM.
2. THE PANEL BOARD SHALL BE CUBICAL DESIGN, UNIFORM DEPTH, COMPARTMENTALIZED, DUST
AND VERMIN PROOF OR AS PER GA DRAWING
3. THE PANEL BOARD SHALL BE SUITABLE FOR FLOOR MOUNTING AS MENTIONED IN G.A.
DRAWING.
4. THE PANEL BOARD SHALL BE FABRICATED AS LOAD BEARING MEMBER SHALL BE 2.0 MM AND
NON LOAD BEARING MEMBERS SHALL BE 1.6MM THICK CRCA SHEET., MOUNTING PLATE SHALL
BE 2.0MM CRCA
5. FRONT DOOR AND REAR COVER SHALL BE HINGED TYPE.
6. THE BASE FRAME SHALL BE AS PER GA DRAWING.
7. ALL CABLE ENTRIES IN THE BOARD SHALL BE AS PER G.A. DRAWING. (TOP/BOTTOM)
8. THE DEGREE OF PROTECTION OF PANEL BOARDS SHALL BE IP-42
9. THE BOARD SHALL BE EPOXY POLYESTER POWDER COATED WITH STRUCTURE SIEMENS GREY
SHADE NO. RAL-7035
10. SHEET METAL WORKS SHALL BE PROCESSED WITH EIGHT TANK PROCESS.I.E. DEGREASING,
WATER RINSING, DERUSTNG, WATER RINSING, ACTIVATION, PHOSPHATING, WATER RINSING &
PASSIVATION
B. ASSEMBLY / SHROUDING
11. THE PANEL BOARD SHALL BE SUITABLE FOR 3PH., 4WIRE 415V±10%, 50HZ.±3%AC SUPPLY
SYSTEM.
12. BUS BAR SHALL BE AL./CU. OF ELECTROLYTIC GRADE & SHALL BE INSULATED WITH RED, YELLOW,
BLUE AND BLACK COLOUR HEAT SHRINKABLE PVC SLEEVES.
13. EARTH BUSBAR SHALL RUN THROUGHOUT THE LENGTH AT THE TOP/BOTTOM OF THE PANEL AS
PER GA DRAWING.
14. ALL BUS BAR SUPPORTS SHALL BE OF SMC/DMC CAST AND PROVIDED AT SUITABLE INTERVAL.
15. EACH FEEDER SHALL BE PROVIDED WITH INDIVIDUAL INSCRIPTION PLATE MADE OUT OF BLACK
ANODIZED AL./POLYCARBONATE SHEET WITH PRINTED LETTERS
16. SHROUDING SHALL BE DONE WITH PVC/POLYCARBONATE FR MATERIAL.
17. MCCB'S SHALL BE PROVIDED WITH DOOR OPERATING MECHANISM, DOOR INTERLOCK IN ON
POSITION AND PADLOCKING FEATURE IN OFF POSITION
18. ALL MCB'S SHALL BE MOUNTED IN SIDE THE PANEL WHICH CAN BE OPERATED AFTER OPENING
THE FRONT DOORS UNTIL UNLESS SPECIFIED OTHERWISE
19. PU/PE FOAM GASKET SHALL BE PROVIDED INSIDE THE DOOR TO MAKE IT DUST PROOFING
20. LOUVER/FILTER AND EXHAUST FAN SHALL BE PROVIDED ON 2500A & ABOVE ACB FEEDERS/
CAPACITOR FEEDERS ON REAR DOORS
21. HARDWARE DIRECTION/SIZE SHOULD BE SYMMETRICAL
22. ALL THE BACK DOORS OF ACB & CAPACITOR FEEDER SHALL HAVE LOUVER/FILTER UPTO IP42.
23. PERFORATED MS SHEET FOR INTERNAL SHROUDING IP2X MINIMUM
24. THE MINIMUM CLEARANCE IN MAIN BUS BAR (HORIZONTAL/VERTICAL) SHALL BE AS FOLLOWS :
a. BETWEEN PHASE TO PHASE : 25MM
b. BETWEEN PHASE TO NEUTRAL : 25MM
c. BETWEEN PHASE TO EARTH : 19MM
d. BETWEEN NEUTRAL TO EARTH : 19MM
25. ALL HARDWARE SHALL BE ZINC PLATED. ALL JOINTS AND CONNECTIONS SHALL BE MADE BY
GALVANIZED PASSIVATED OR CADMIUM PLATED HIGH TENSILE STRENGTH STEEL BOLTS NUTS
AND WASHERS.

pg:191
C. WIRING
26. ALL CONTROL WIRING SHALL BE DONE WITH PVC FLEXIBLE (FR) CABLE OF 1100/660V AS UNDER:-
a. AC CONTROL CIRCUIT : 1.5 SQ. MM CU. FLEXIBLE WIRE. (GREY COLOUR)
b. DC CONTROL CIRCUIT : 2.5 SQ. MM CU. FLEXIBLE WIRE. (BLACK COLOUR)
c. AC CURRENT CIRCUIT : MIN. 2.5 SQ. MM CU. FLEXIBLE WIRE (R-PHASE,Y-PHASE,B-PHASE
& NEUTRAL) (RED,YELLOW,BLUE & BLACK COLOUR) (METERING/PROTECTION)
d. AC VOLTAGE CIRCUIT : 1.5 SQ. MM CU. FLEXIBLE WIRE (R-PHASE,Y-PHASE,B-PHASE) &
NEUTRAL (RED,YELLOW,BLUE & BLACK COLOUR) RESPECTIVELY.
(METERING/PROTECTION)
e. EARTH WIRE CIRCUIT : 2.5 SQ. MM CU. FLEXIBLE WIRE. (GREEN WITH YELLOW LINE
COLOUR)
f. CONTROL TERMINAL - SCREW TYPE, SIZE-0-2.5SQ.MM FOR 1.5SQMM WIRE & 4 SQ. MM
FOR 2.5 SQ. MM WIRE
g. C.T. SHORTING LINKS TERMINAL TYPE
27. POWER WIRING
a. AC POWER CIRCUIT : MIN.4.0 SQ. MM CU. FLEXIBLE WIRE (RED,YELLOW,BLUE & BLACK
COLOUR) & ABOVE 6.0 SQ.MM CU. WIRE TO BE BLACK COLOUR WITH COLOUR
SLEEVE AT END.
b. DC POWER CIRCUIT : MIN. 4.0 SQ. MM CU. FLEXIBLE WIRE (+VE) RED COLOUR & (-VE)
BLUE COLOUR.
28. ALL DOOR SHALL BE EARTHED WITH 2.5 SQ.MM FR FLEXIBLE COPPER WIRE (GREEN WITH YELLOW
LINE COLOUR)
29. ALL CT'S CONNECTION FOR METER'S / RELAY SHALL BE THROUGH CT'S SHORTING TERMINALS
30. ALL CONTROL AND POWER TERMINAL MOUNTING CLAMP SHOULD BE VERTICAL IN CABLE ALLEY
31. TESTING FOLLOWING TEST SHALL BE CARRIED OUT ON COMPLETION OF PANEL:
a. MEGGER TEST
b. HIGH VOLTAGE TEST
c. C.T. SECONDARY CURRENT INJECTION TEST
d. OPERATIONAL TEST

NOTE:
1. ELECTRICAL PANEL MADE OUT OF POLYCARBONATE, FABRICATION DETAILS SHALL NOT BE APPLICABLE.
2. FOR POLYCARBONATE PANELS DIMENSION MAY VARY SLIGHTLY DEPENDING ON MAKE USED.
Ground Level MS Sheet Cover 500 x 500mm

Wire mesh funnel

100x75mm grove
for earth strip entry

Brick Work (9”)

Earth connection out
25 x 3mm Cu. Strip
Cu. Strip
25 x 3mm

Soil
25mm Dia
GI pipe with holes

Charcoal + Salt Layer

600 x 600 x 3mm Cu Plate

GI / BRASS Nut Bolt

TYPICAL COPPER PLATE EARTHING

pg:193
 Ground Level MS Sheet Cover 500 x 500mm

Wire mesh funnel

100x75mm grove
for earth strip entry

Brick Work (9”)

Earth connection out
50 x 6mm GI STRIP
Soil

100mm Dia GI pipe with holes

Charcoal + Salt Layer

Holes for water outflow

TYPICAL GALVANISED IRON PIPE EARTHING

 EARTHING PIT LABEL DESIGN

Dark Green - CMYK combination: C-90 & Y-100

Dark Green - RGB combination: R-0, G-153, B-61

Blue - CMYK combination : C-100 & M-40

Blue - RGB combination: R-0, G-103, B-172

Yellow - CMYK combination : M-10 & Y-100

Yellow - RGB combination: R-252, G-219, B-0
TEXT in BLUE : Font - Futura HV BT; size 89
TEXT in GREEN : Font - Futura HV BT; size 120

VINYL PASTED SUNBOARD -

305 x 450mm - 0.13725 sq mtr
1.0 ft x 1.5 ft - 1.5 sq ft

450mm

FRONT VIEW SIDE VIEW REAR VIEW

MS SHEET : 305 x 450mm

Thickness: 2.0mm

450mm
WELD JOINTS
PAINT: ENAMEL BLACK COLOUR
CMYK combination: K-100
RGB combination: R-0, G-0, B-0

HOLLOW PIPE : 25 X 25 mm
Wall Thickness: 2.0mm

MS SHEET WEIGHT - 0.305m x 0.450m x 2mm x 7.85Kg/sqmm-mm => 2.155 Kg

MS HOLLOW TUBE WEIGHT - 1.0m x 1.44 Kg/Mtr => 1.44 Kg
TOTAL WEIGHT => 3.595 Kg

pg:195
 60 OD PIPE
SUITAFLE FOR LIGHTING FIXTURE
1000mm

WELDED CAP
5 MM THICK

5.0 THK. SUPPORT PLATE WELDED

10 2 SCREWS WELDED 180 DEG. APART
BRACKET RESTS HERE ON POLE

78.0 I.D. BRACKET PIPE

3 BOLTS M10 TO FIX BKT ON POLE

3 NUTS M10-SWLDED OR TAPERED

HOLES ON 120 DEG. APART
POLE TOP DIA.
PLAN

`X` 114.3

76.1(0.D.)
3.25 THK.

88.9 (0.D.)
4.85THK.

114.3 (0.D.)
5.4 THK.
M10 NUT
WELDED 7M - TUBULAR POLE
`Y` M10 BOLT TO PIPE

EARTHING
STRIP 114.3 INDICATIVE GENERAL ARRANGEMENT
PIPE DRAWING FOR 7M TUBULAR POLE 22-06-2021

EARTHING DETAIL
pg:196
STP-7M-114