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GSPC Gas Company Limited

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Title: GSPC Gas Company Limited


1
Basic Concepts of Design Construction of Gas
Distribution Network
  • GSPC Gas Company Limited
  • December, 2009
  • Gandhinagar

2
City Gas Distribution An Overview
3
WHAT IS CITY GAS DISTRIBUTION?
  • CGD is the last component of the Natural Gas
    value chain delivering Natural Gas to end users
    in town and cities to meet the demand for a
    cleaner, more efficient, economical and
    environmentally-friendly energy source.

4
CITY GAS DISTRIBUTION CONCEPT
  • Development of Pipeline Network in a pre-defined
    geographical spread
  • Maintaining Different Levels of Gas Pressure to
    meet the Demand of various segments of gas users
    - Domestic, Commercial, Industrial and
    Automobiles.
  • Designing high pressure and medium pressure
    network such that supply to any consumer is
    possible from either side.
  • Design gas storage / Gas sourcing for maximum
    survival period
  • Consider Health, Safety Environment at all
    stages

5
Steps in the design of Gas Distribution System
  • Market demand estimated based on comprehensive
    field survey of units covering domestic,
    commercial, industrial and transport sectors.
  • Demand forecast projection is carried out for
    20-25 years.
  • Peak hour consumption estimated for network
    design.
  • The system is to be designed based on 20-25th
    year projected demand at peak load in a phased
    manner.
  • Reconnaissance Route Survey within the town to
    identify suitable routes for laying pipelines,
    locations for City Gate Station, District
    Regulating Station CNG Station

6
Steps in the design of Gas Distribution System
  • Network design and optimization with available
    software
  • Design of Mother Station and Daughter / Daughter
    booster station for CNG supply to automobiles
  • National / International standards adopted for
    design.
  • Project implementation done subsequently.

7
Battery Limits
Transmission
Distribution
8
CGD SYSTEM BASIC CONCEPT
9
CGD PRESSURE REGIMES
10
City Gas Distribution Applicable Codes
Standards
11
European Standard
12
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)
13
BS/DIN/ISO AND OTHER STANDARDS
14
OIL INDUSTRY SAFETY DIRECTORATE (OISD STANDARDS)
15
AMERICAN PETROLEUM INSTITUTE (API)
16
AMERICAN GAS ASSOCIATION (AGA)
17
City Gas Distribution System Components
18
CGD - Infrastructure
  • Major Constituents of CGD are
  • City Gate station
  • Pipeline Network
  • Steel Pipelines
  • Poly Ethylene Pipelines
  • GI / Cu Pipes
  • Regulating Stations
  • District Regulating Stations
  • Service Regulators
  • Domestic / Commercial / Industrial Regulators
  • Metering Stations / Metering Regulating
    Stations
  • CNG Stations

19
CITY GATE STATION (CGS)
  • CGS is the location of Custody Transfer from
    Transmission Company to Distribution Company.

20
CITY GATE STATION (CGS)
  • Inlet Outlet isolation valves
  • Knock Out Drum (KOD), If required
  • Filter
  • Metering Unit (Turbine / Orifice / Ultrasonic)
  • Gas Chromatograph (GC), If required
  • Pre-heater (if required)
  • Pressure reduction skid comprising
  • Active monitor Regulators
  • Stream discrimination arrangement
  • Slam shut valve for over under pressure
    protection
  • Creep relief valves.
  • Odorising Unit

21
STEEL PIPELINE
  • The Steel Grid pipeline sizes is 12NB 8NB
    whereas, spur lines shall be of 6NB 4NB.
  • Steel pipelines used in the distribution system
    is fully coated. The coating is extruded
    polyethylene, with each weld joint coated with
    either heat shrink sleeves or field applied tape.
  • Prior to the pipeline being put into service, the
    distribution pipeline to be non-destructively
    tested by two methods. Firstly, welds would be
    radio graphed and, secondly, the completed
    pipeline extension would be hydro-statically
    tested at a higher pressure than its operating
    pressure.
  • After hydrostatic testing, the pipeline to be
    dried, purged and filled with natural gas. The
    testing and commissioning procedures will be
    detailed during the detailed design phase of the
    project.

22
STEEL PIPELINE
  • To protect the pipeline from corrosion, a
    cathodic protection (CP) system of impressed
    current is proposed. During the detailed design
    phase, the CP capability of the existing
    transmission system will be investigated to
    establish if it has the capacity to provide CP to
    the extension. If it is found that the existing
    system does not have the capacity, additional CP
    facilities will be designed.
  • The steel grid is installed at a minimum depth of
    1.0 meter cover, and in accordance with Indian
    requirements.

23
MDPE PIPELINE
  • The distribution pipe is with Standard Dimension
    Ratio (SDR 9) for 20 mm, (SDR) 11 from 32 mm up
    to 63 mm (SDR) 17.6 for above 63 mm. The term
    SDR is defined as the normal outside diameter
    (DN) divided by the minimum wall thickness.
  • It is standard practice in India to have a
    minimum 1.0 meter cover. This additional depth in
    a densely populated area would be recommended.
  • All MDPE pipe back filled with sand around it to
    protect the plastic material.

24
MDPE PIPELINE
25
Medium Density PolyEthylene (MDPE) Pipes
  • Tech Spec IS 148852001 ISO 4437
  • Material Grade Color Internationally approved
    resins of PE 100 grade of Orange color
  • Minimum Required Strength (MRS) of PE 100 grade
    pipe 10 MPa
  • Pressure Class SDR 9 (dia 20 mm), SDR 11 (dia 32
    63 mm) and SDR 17.6 (dia 90, 110, 125 and 160
    mm).
  • Operating pressure 4 bar (g).
  • Operating temperature range - 10 0 C to 40 0
    C.

26
Advantages of PE pipes
  • High performance (Globally proven leak free
    system)
  • More Flexibility, coil ability, ductility, High
    elasticity
  • Low density (low weight, high strength to weight
    ratio)
  • High resistance to corrosion
  • Low heat conductivity (small thermal loss)
  • Smooth surfaces (low pressure losses due to low
    pipe friction)
  • Easy to transport, handle and lay
  • Longer life

27
Advantages of PE pipes
  • Easier and speedier joining techniques to ensure
    leak tight joints by employing electro fusion
    techniques
  • Higher productivity, i.e., reduction in
    installation time (15 minutes in case of PE
    against 4 hours in case of steel), thereby lesser
    inconvenience to public
  • Reduced number of joints, hence safer and leak
    free system
  • Less time is consumed to repair PE damages as
    compared to steel damages
  • Good squeeze off properties

28
Advantages of PE pipes
  • Longer design life of PE pipes (50 years) as
    compared to steel pipeline (30 years)
  • Avoidance of NDT techniques in building premises,
    which is very critical
  • Size of trench is less in case of laying of PE
    pipe as compared to steel

29
MDPE Fittings
  • Tech Spec ISO 8085-3 or EN 1555-3
  • Material Grade PE 100
  • Terminal pin size 4 or 4.7 mm
  • Voltage 39 40 Volts.
  • Color Black.

30
PE Stop Off Valves (Typical)
  • Standard ASME B 16.40, EN 1555-4
  • Pressure Class SDR 11.
  • Design Pressure 5.5 bar (g).
  • Design Temperature 45 0 C.
  • Operating Temperature 10 0 C to 45 0 C
  • End Connections PE Material (Spigot Type)
  • Stem Extension Integral stem extension required
    (Minimum 690 mm from the Top of Pipe)
  • Valve Design One piece construction.
  • Ball position Indicator Open / Close limits
    required.

31
Crimping Fitting (Typical specification)
  • Used to connect u/g PE pipes with a/g GI pipes
  • Operating Pressure up to 4 bar (g)
  • Operating Temperature 40 0 C
  • Hydrostatic Test Pressure Minimum hold Pressure
    of 10 bar (g), for 1 hour duration
  • Pneumatic Test Pressure Minimum pressure of 6
    bar (g), for 1 hour duration
  • Pull out Test
  • Shall not fracture within the jointed assembly
  • Shall withstand the Pneumatic pressure leak test
  • Shall not leak

32
District Regulating Stations
33

District Regulating Station
34

District Regulating Station
35
Service Regulators
36
Typical requirements of Pressure Regulators used
for domestic and small IC customers
  • Maximum Inlet Pressure Maximum 4 bar (g)
  • Nominal Outlet Pressure 100 mbar (g)
  • Flow capacities 50, 150, 200, 250 scmh
  • End connections Threaded ( Tapered) as per BS
    21
  • Operating ambient temperature up to 45 0C
  • Lockup Maximum pressure, under no-flow
    condition, up to 125 mbar (g)
  • Creep relief valve To protect against downstream
    over pressure at low flows or in the event of
    valve seat malfunction, preset to 140 mbar (g)
  • Over Pressure Shut Off (OPSO) Device to protect
    against downstream over pressure, preset to 160
    mbar (g)
  • Under Pressure Shut Off (UPSO) Device to protect
    against downstream under pressure with a
    pressure setting range 40 mbar (g) to 65 mbar (g)

37
Regulator Selection
  • Information required to select a regulator
  • Maximum and Minimum inlet pressure
  • Required outlet pressure
  • Maximum flow rate
  • Tolerance on outlet pressure
  • Size of pipework
  • Type of gas
  • Safety features required
  • Size of orifice
  • OPSS, UPSS Relief settings
  • Installation indoors of outdoors
  • Orientation of regulator

38
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39
Gas Meters
  • The most common types of meters used are
  • Diaphragm
  • Rotary Positive Displacement (RPD)
  • Turbine

40
Diaphragm Gas Meters (Domestic)
  • Tech Spec EN 1359
  • Capacity 2.5 m3/hr
  • Rangeability or TD ratio 1150 or better
  • Nominal Working Pressure 21 mbar (g)
  • End Connections ¾, as per BS 746 (Male)
  • Center to Center distance 110 mm between inlet
    and outlet connections

41
Diaphragm Gas Meters (Commercial)
  • Tech Spec EN 1359
  • Capacity 10, 25, 40, 65 scmh
  • Rangeability or Turn Down ratio (ratio of Qmax
    and Qmin) 1150 or better
  • Nominal working Pressure 100 mbar (g)
  • Pressure rating Suitable to withstand maximum
    working pressure of 200 mbar (g)

42
Rotary Positive Displacement (RPD) meters
  • Tech Spec EN 12480
  • Volumetric meter
  • Appropriate for medium size load
  • Typical Turndown 351 to 501
  • Accuracy 1
  • Large measuring range
  • Not sensitive against disturbances
  • Not sensitive against fast changes in flow rate
  • Needs lubrication

43
Rotary Positive Displacement (RPD) meters
44
Rotary Positive Displacement (RPD) meters
45
Industrial Metering Station (IMS)
  • IMS are used to measure gas supplied to
    Industrial consumers
  • Main component in IMS is filter, Isolation
    Valves, RPD Meters with EVC Modem, Regulators
    (If low pressure requirement) and Non return
    Valve
  • Inlet pressure range 1.5 Barg to 4 Barg
  • Outlet pressure As required by customer

46
MRS components
  • Inlet Outlet isolation valves
  • Filter
  • Pressure regulator with a built in slam shut
    device
  • Relief valve
  • Strainer
  • Flow Meter (RPD, Turbine, etc.)

47
GI ERW Pipes
  • Tech Spec IS 1239 (Part 1)
  • Types used Medium Class and Heavy Class
  • Material IS 1387
  • Pipes shall be screwed with Taper threads
  • Threads Tapered and conforming to BS 21
  • Galvanizing IS 4736
  • Coating requirements Mass of coating is 400 gms
    / m2
  • Test Pressure 5 MPa
  • Powder Coating
  • Powder Material Pure Polyester
  • Application Electrostatic spraying (40 90 KV,
    Manual / Automatic)

48
GI Fittings (Malleable Cast Iron)
  • Tech Spec IS 1879
  • Material IS 2108 Grade BM 290
  • Dimensions IS 1879
  • Threads IS 554
  • All Internal External Threads shall be tapered
  • Chamfer shall have included angle of 900 /- 50
    for Internal threads 700 /- 100 for external
    threads
  • Galvanizing IS 4759
  • Coating requirements Mass of coating is 700 gms
    / m2.

49
Forged Fittings (Wrought Steel Iron)
  • Tech Spec IS 1239 Part 2
  • Material IS 1387
  • Dimensions Tolerances IS 1239 Part 2
  • Threads IS 554
  • All Internal External Threads shall be tapered
  • Chamfer shall have included angle of 900 /- 50
    for Internal threads 700 /- 100 for external
    threads
  • Galvanizing IS 4759
  • Coating requirements Mass of coating is 700 gms
    / m2.

50
Brass Valves(Meter Control Valves, Riser
Isolation Valves Appliance Valves)
  • Tech Spec EN 331
  • Pipe Nominal Diameter - ¼ to 2 NB.
  • Operating Pressure 4 bar (g).
  • Operating Temperature 10 60 0 C.
  • Material Nickel Plated Forged Brass.
  • Pattern Full Bore, Quarter Turn Ball Valve.
  • Handle Suitable Metallic Handle, Lever / Knob /
    Cap Type with yellow coating (Powder / Plastic)
    on Surface marked as GAS
  • End connection Screwed, As per BS EN 10226-1,
    Tapered Threaded, Female

51
Meter Regulator
  • Gas flow rate 2.5 m3/h
  • Nominal Inlet Pressure 100 mbar (g)
  • Maximum Inlet Pressure 160 mbar (g)
  • Nominal Outlet pressure 21 mbar (g)
  • Lock-up pressure Shall not exceed 30 mbar (g)
  • Low pressure Cut-Off at inlet pressure of 11.5
    mbar to 15 mbar (g).
  • Re-pressurization safety device is fitted which
    prevents the regulator from re-opening when the
    inlet pressure is restored unless there is a
    downstream backpressure, i.e., all connected
    appliances have been turned off.
  • End connections Right angled inlet and outlet
    connections of ¾x ¾ BSPT (Female)

52
Rubber Hose (flexible and steel wire braided)
  • Used to connect the appliance, inside the house
    of domestic customer
  • Tech Spec Type IV of IS 9573
  • Size 8 mm NB
  • Material It consists of
  • Lining Synthetic rubber like Nitrile Butadiene
    Rubber (NBR) or Chloroprene Rubber (CR)
  • Reinforcement Wire reinforced in braided form in
    between the lining and the cover
  • Cover Consolidated by wrapping, and uniformly
    vulcanized to give good adhesion

53
Rubber Hose (flexible and steel wire braided)
  • Mechanical Properties
  • Tensile strength Minimum 10 MPa for lining and
    cover
  • Elongation at break Minimum 200 for lining and
    250 for cover
  • Salient features
  • Strong (Steel wire reinforced) hence rats can't
    bite through steel wire Flame resistant
  • Abrasion, ozone and weather resistant, hence no
    cracks
  • Low temperature flexibility
  • Minimum burst pressure of 0.5 MPa
  • Long life (5 years)
  • Grip strength (to nozzle of appliance)

54
City Gas Distribution Network Design
55
System Basics
  • System of units
  • The International System of Units (SI), also
    known as the "Metric System" to be used. The
    International Gas Union (IGU) has also
    recommended to generalize the use of the SI
    system in all matters relating to Gas and Gas
    facilities. The SI system shall be in compliance
    with ISO 1 000. The SI system shall be of general
    use with exception to the following
  • Gas Volumes and Flow,
  • Pressure,
  • Temperature,
  • Heating Value
  • Pipeline and Piping Nominal Diameters shall be
    expressed under either one or both systems where
    "Common Practice" of Pipeline and Piping
    Engineers so suggests

56
System Basics
  • Data relating to equipment shall use that system
    of unit that is most common in the relations with
    suppliers.
  • Where advisable for good understanding, the
    corresponding value in the other System of Units
    shall be mentioned between brackets.
  • Results of technical calculation and related
    figures issued from specific software shall
    remain expressed in that system of units that is
    used by the relevant software.

57
Steel Pipelines
  • Steel mains
  • Notwithstanding the major advantages of
    polyethylene (PE), steel pipelines remain
    necessary as follows
  • High-Pressure Mains
  • Location class the design of High pressure mains
    shall consider requirements as for Location Class
    4 (ASME 31.8) to allow timelessness should the
    environment change in the future.
  • Wall thickness according to ASME B31.8 Section
    841.11 with Design factor of 0.4. In addition,
    wall thickness shall, in no way, be lower than
    the values below in function of Nominal Diameter
    (ND)

58
Steel Pipelines
  • 4 in. and below - 3.9 mm
  • 6 in. - 4.5 mm
  • 8 in. - 5.0 mm
  • 10 in. - 5.6 mm
  • 20 in. - 6.3 mm
  • GSPC Gas is using 6.4 MM Wall thickness.
  • Steel Grade The Design Concept considers API
    Grade X 52 Steel quality to offer maximum
    flexibility for line pipes procurement.
  • Bend Radius to allow pigging under special
    circumstances

59
Steel Pipelines
  • Steel Pipes
  • API 5 L - Line Pipes
  • ASTM A 106 - Seamless Pipes
  • ASTM A 333 - Seamless Welded Pipes for low
    temperature services
  • Location Class
  • Location Class I - 10 or fewer buildings in 1
    mile section
  • Location Class I I - 10 46 buildings in 1 mile
    section
  • Location Class III - 46 or more buildings in 1
    mile section
  • Location Class IV - Areas where multi story
    building heavy traffic plus other
    underground utilities
  • Steel Pipe Design Formulae
  • P (2 St/D) FET As per ASME B 31.8, 841.11
    (a)
  • t PD / 20fs

60
Steel Pipelines
  • Above Ground Mains
  • Polyethylene being forbidden for above ground
    crossings, if any, steel mains sections are
    needed at the crossing with PE/steel transition
    fitting to be buried with the adjacent PE mains.

61
Steel Pipelines
  • Process Design
  • Wey-mouth Formulae
  • Q 0.0813 (d)2.6667 (p12-p22)1/2 / (S
    L)1/2
  • Velocity
  • V Q / A
  • Velocity for filtered gas to be 40 m/s
    unfiltered gas to be 20 m/s maximum.

62
Example
  • P 1 15 Barg, P2 10 Barg (Min.)
  • Q 2,00,000 SCMD
  • L 32,000 m

1
2
63
Example
  • Q 2,00,000 SCMD i.e. 9,166.66 SCMH
  • Using Wey Mouth Formulae Q 0.0813 (d)2.6667
    (p12-p22)1/2 / (S L)1/2
  • 9166.66 0.0816 x (d)2.6667 (16.0132-10.0132)1
    /2/(S L)1/2
  • d 198.52 mm Calculated Diameter.
  • We have to select diameter from the available
    range e.g. 200.1 mm from API 5 L
  • Now, P1V1 P2V2
  • 1.013 9,166.66 (9.321.013) V2
  • V2 898.8 M3 / Hr 0.2497 M3 / Sec.
  • Now, for Velocity, Q A v
  • 0.2497 (3.14/4) (200.1 10-3)2 v
  • V 7.94 m/s
  • Now, for Wall Thickness, t (PD) / 20fs
  • t (16.013 219.1) / (20 0.29 241)
  • t 2.5099 mm

64
Example
  • P 1 26 Barg, P2 10 Barg (Min.)
  • Q 1 Q 9250
  • L 12000 m L 20000
  • Q 4000
  • L 7000

1
2
3
21
65
Polyethylene Pipelines
  • MRS (Minimum Required Strength)
  • The MRS value represents the long-term
    circumferential stress in the pipe under which
    the break may occur after 50 years at the
    earliest.
  • Stress MRS / C, where C is overall service
    coefficient
  • The minimum value of C for the material to be
    used for Gas application is 2.
  • MAOP (Max. allowable Operating Pressure)
  • MAOP (20 MRS) / C (SDR-1).
  • Standard Dimension Ratio
  • SDR Dn / En
  • SDR used in GSPC Gas is SDR 9, SDR 11 SDR 17.6
  • Standard followed by GSPC Gas
  • IS 14885 2001

66
Polyethylene Pipelines
  • Base resin
  • The PE resins of Third Generation (PE 100 or
    MRS 10) in full compliance with detailed
    specification is being used. First Generation is
    PE 63, second PE 80 Third generation is PE 100.
  • Wall thickness
  • The MDPE network designed and qualified for a MOP
    of 4 bar.
  • The Network analysis and resulting structure
    and behaviors are based on such design. PE line
    pipes wall thickness shall be in accordance with
    the following SDR
  • Gas mains (ND 90 mm) SDR 17.6
  • Gas mains and Service lines (ND 90 mm) SDR 11.
  • Service lines (ND 20 mm) SDR 9

67
Polyethylene Pipelines
  • Different Material used for PE Pipes
  • The following materials have been approved to
    date
  • Solvay Eltex TUB 121(Black) or Eltex TUB
    125(Orange) PE 100
  • Borealis HE 2490 PE 100
  • Fina Finathene XS 10 B PE 100
  • Dow BG 10050 PE 100
  • Elenac Hostalen CRP 100 PE 100
  • Codes
  • Manufacturer Commercial Brand Name Code()
  • SOLVAY ELTEX TUB 121/125 E3
  • BOREALIS HE 2490 N3
  • FINA FINATHENE XS 10 B F3
  • DOW BG 10050 D3
  • ELENAC HOSTALEN CRP 100 H7

68
Polyethylene Pipelines
  • Process Design
  • Wey-mouth Formulae
  • Q 0.11672 (d)2.664 (p12-p22)0.544 / (S
    L)1/2
  • Velocity
  • V Q / A
  • Velocity for filtered gas to be 40 m/s
    unfiltered gas to be 20 m/s.
  • Being a complex network, required specialized
    tools for Planning Designing the network. GSPC
    Gas use SynerGEE software for designing the PE
    Network.

69
PNG Domestic Commercial Connection
  • Process Design
  • Polyflow Formulae
  • Q 1.522786 10-3 (d)2.623 (h/L)0.541
  • Peak Gas flow is assumed _at_ 0.5 SCMH for one house
  • Being a standard PNG Connection, we have
    standardize the design of PNG Network as follows
  • ½ GI pipes up to G 4 apartments OR 5
    connections in case of raw house.
  • 1 GI Pipe above 5th Floor apartment OR above
    five connections in raw house.

70
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71
PNG Domestic Commercial Connection
  • Route Selection for GI / Copper Pipe Installation
  • Route selection for GI pipe installation shall be
    carried out as per the guideline given below
  • Pipe shall not be installed on un-plastered wall
    or in the house under construction.
  • Pipe shall not be installed in an unventilated
    void space.
  • Route shall be selected that maximum length of
    the pipeline shall be installed outside.
  • Route of the pipeline shall be planned for the
    shortest possible length.
  • The gas pipeline shall be away (minimum distance
    of 200mm) from the electrical line.
  • There shall be minimum change of directions and
    minimum no of threaded joints.
  • Maximum two Point in the kitchen for gas stove
    only.
  • Compound gate or doors and windows inside the
    house shall not hit the Gas pipeline.
  • Copper installation should be a minimum 300mm
    away from heat source and Electrical
    installations. If it is not possible for copper
    installation then suitable protection should be
    given.
  • If the copper pipe installation is carried out
    inside cupboards, there should be a provision for
    adequate ventilation like louvers/holes in
    cupboard doors.

72
PNG Domestic Commercial Connection
  • Positioning of Valves, Regulator Meter
  • Riser Isolation Valve
  • For apartments, one riser isolation valve shall
    be provided at a height of 2 meter
  • From the ground and individual meter control
    valve shall be installed for each connection.
  • The riser isolation valve shall be installed at a
    convenient height so that it is easy to operate
    the valve in emergency.
  • Meter Regulator
  • Regulator shall be installed in such a way that
    it reduces the length of H.P. Line (Max. pressure
    0.1 Bar) to minimum possible.
  • Wherever possible meter Regulator shall always be
    installed outside residence and at a convenient
    height.

73
PNG Domestic Commercial Connection
  • Gas Meter
  • Gas Meter shall be installed in such a way that
    it shall be protected from direct rain or
    waterfall on the meter. Location of the Gas meter
    shall be decided during the route selection.
  • Meter shall be installed at convenient height so
    that it is easy for the meter reader to take
    correct readings.
  • The meter shall never be positioned very near to
    Electric Line. A minimum distance of 200 mm shall
    be maintained.
  • Appliance Valve
  • The position of the appliance valve shall be
    convenient to operate and it shall keep the
    rubber tube at a safe distance from the heat
    source.
  • The orientation and distance from cooking
    platform/ground shall be maintained in such a way
    that the Bending Radius of the Rubber Tube shall
    be more than 100mm.
  • Appliance valve shall be installed in ventilated
    space and the lever of appliance valve shall not
    foul with the wall during the on-off operation.

74
Clamping
75
GI Pipe cutting Threading
  • After site and route clearance, the measurements
    for pipe cutting shall be taken and pipes shall
    be cut accurately as per the required lengths.
  • If the length of pipes is not correct, the
    threaded joints come under heavy stresses, which
    may ultimately cause gas leakage.
  • Installed piping threaded connections / joints
    shall be tightened in such a way that all the
    joints shall be free from heavy stresses and
    misalignments due to incorrect pipe length.
  • The condition of thread die and pipe vice jaws
    shall be checked regularly and shall be free from
    defects.
  • Cutting fluids (oils) shall be used while thread
    cutting.
  • Threaded pipes shall be handled carefully so that
    the threaded oily portion shall be free from
    dust, mud, water and any damage due to impact of
    any object.
  • Cutting burrs on the pipe shall be removed from
    the edges. The edges shall be straight and free
    from Knife-edge formation.

76
G.I. Pipe Installation Clamping
  • Teflon tapes shall be wrapped on threaded portion
    of the pipe with minimum three overlaps. The
    Teflon tap should be of approved make and gauge.
  • The no of clamps shall be adequate. The pipeline
    portion containing the Regulator and Meter,
    either horizontal or vertical, shall have clamps
    on both side of the regulator and meter. Clamps
    shall be fitted in such a way that they do not
    create misalignment of pipes.
  • The clamp shall be installed by drilling 6 mm
    hole in plastered wall and screwed using rowel
    plug.
  • Distance between two clamps shall not be more
    than 2 meter the gap between riser and wall
    shall be minimum 25 mm.
  • Clamps shall be installed in a straight line and
    shall be parallel to each other.
  • The clamps shall be fixed properly on the walls
    and should grip pipe in position.
  • For wall crossing, drill the hole with the help
    of electrical drilling machine in such a way that
    plaster and tiles shall not be damaged. It shall
    be ensured that there is no concealed wiring or
    any other fitting on the opposite side of the
    wall for a particular location of drilling.

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G.I. Pipe Installation Clamping
  • Self-adhesive anticorrosive tape shall be wrapped
    on the pipe with 50 overlap.
  • Casing sleeve shall be installed in wall for wall
    crossing.
  • Alignment of the pipeline shall be maintained.
  • Whenever compound gate, house door or window hits
    the G.I. pipe protection clamp shall be installed
    to protect the pipe.
  • Concealed piping shall not be done.
  • All the pipes shall run on walls with clamps.
    Pipe should not be overhung and shall not be
    installed without pipe clamp.
  • Wherever powder coating is peeled off during
    fitting and tightening of the pipe, touch up
    shall be done after the installation is completed
    by two coats of approved paint.
  • Prior to installation all pipes and fittings
    shall be checked internally to ensure that they
    are free from any obstruction.
  • PE to GI (transition fitting) joint shall be
    provided above ground.

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Installation of Valves, Regulator Meter
  • Union and testing T shall be installed before
    riser isolation valve.
  • Meter control valves, Meter regulator and Gas
    meter shall be protected from the over tightening
    of the thread.
  • Valves, Meter regulator and Gas meter shall be
    installed with the clamps on both sides. As far
    as possible hex nipple shall not be used for
    connecting. Both side threaded 3 to 8 long pipe
    nipple shall be used.
  • Gas meter, regulator and installed piping shall
    be aligned properly.
  • Flow direction of the gas meter shall be checked
    before installation.
  • Flat rubber washer shall be checked and ensure at
    inlet and out let of the adaptor joint to the
    meter.
  • Pipe nipple shall be installed between elbow and
    regulator to avoid direct load of line or riser
    on regulator and a clamp must be provided on the
    pipe nipple.

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Testing of Installed Piping Connection
  • Before carrying out the pneumatic test of the
    whole installation testing assembly, air foot
    pump with pressure gauge / manometer shall be
    checked its calibration and proper functioning.
  • Before pneumatic testing of the installed
    connection spacing between two clamps, tightening
    of the clamps thread joints, alignments of the
    whole piping shall be checked. Valve shall be
    kept in open position and the appliance valve
    shall be kept in close position.
  • Calibrated pressure gauge shall be used having
    the range of 0 1 Bar.
  • Position of the pointer of the pressure gauge
    shall not be marked with the marker pen on the
    glass. It should be recorded in the test records.
    Pneumatic testing pressure shall be kept 1.5
    times of the working pressure and should be
    maintained for 30 minutes.
  • After pressurization of the whole piping section
    shall be checked for the leakage with the help of
    soap solution.
  • During the testing, air should reach up to the
    appliance valve. After completion of testing,
    pressurized air shall be released from appliance
    valve only.

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Conversion of Burner
  • All the appliance valve and riser isolation valve
    shall be kept in closed position.
  • Ensure that meter and regulator adaptor shall be
    leak proof.
  • Open the burner knob and remove the plug from the
    hot plate.
  • Clean the simmer hole.
  • Make the simmer hole of 0.6 mm with the help of
    simmer drill.
  • At the time of drilling the hole, ensure that it
    should not be inclined.
  • Remove the dust from plug.
  • After greasing, plug and knob should be properly
    positioned at their original position.
  • Remove the burner from hot plate and clean it.
  • Open the existing jet (LPG) and replace it by 125
    no jet if it is big burner or 110 no jet if it is
    small burner.
  • Place the burner on its original position and
    connect the nozzle with appliance valve using
    flexible and braided rubber hose.
  • The length of rubber hose shall not exceed 1.5
    mtr.
  • Both the ends of the rubber hose shall be clamped
    by metallic clamps on the nozzle.
  • Check all the joints with soap solution and
    ensure that the flame color should be blue.

81
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