Final Report-City Gas Distribution (CGD) _Daxit Akbari

A Study Report On City Gas Distribution Business Page 1

Vocational Training Report

A Study on CGD Business

Prepared

by

Daxit Akbari

2nd year Petroleum Engineering

PDPU


Index

Content Page No.

About Gujarat Gas Ltd. 4

CGD Business Overview 6

CGD Network 7

Steel Department 14

C & M Department 24

PE-PNG Department 30

CNG Department 42

O & M Department 48

HSE Department 56


ACKNOWLEDGEMENT

I express my gratitude to GUJARAT GAS LIMITED, for giving me this opportunity to

explore functions and activities concerned to CGD, understand equipment& relinquishing me

with delightful experience in the city gas distribution.

I extend my sincere thanks to Mr. Raju Kadam, Technical Manager for being my mentor

during the training and Mr. Chirag Bhanvadia, Deputy Manager for making me realise the

importance of academia in industry and helping me face every cumbersome task. Genuinely I

would like to thank Mr. Shiju Thomas for giving me this outstanding opportunity & helping

me make this experience a fantastic & memorable one.

I whole heartily thank Mr. Piyush Patel, Mr.KamleshJadeja, Mr.Dadhich Bhatt, and many

others of this company who guided me, thus strengthening my concepts of CGD and helping

me successfully completing this training.


G U J A R A T G A S L T D .

Natural gas is the fuel of 21st century. As a progressive company, Gujarat gas ltd. has tried

and identify new trend & prepare itself for future. Gujarat gas group is laying the ground

work and preparing themselves for the future.

The Pathway

Gujarat Gas Ltd (GGL)always works towards a principal aim to supply natural gas to retail

customers, i.e. Domestic,Commercial/Non-Commercial, Industrial and CNG. GGL is playing

a vital role to cater tothe natural gas demand up to the last mile of the retail network. GGL is

envisioned to becomplementary to Gujarat State Petronet Ltd. (GSPL), which is evident from

the presence of GGL retail network starting at every point and location that the GSPL

network ends.

Core Philosophy

Gujarat Gas core philosophy is to be 'A Complete Energy Company'.

Main Segments (Status on 30th June, 2016)

Gujarat Gas has charged network of over 16,000 km-long gas pipeline& providing 5.5

MMSCMD of Natural Gas to more than 10,80,000 domestic households, 11,900

commercial and non-commercial segments and 2,835 industrial customers. Gujarat Gas also

supplies natural gas in the form of Compressed Natural Gas (CNG) through 230 CNG

stations across the state.

PNG Domestic PNG Industrial PNG Commercial CNG


Natural Gas: It’s Characteristics & Composition

Naturally gas is composed primarily of Methane with minor quantities of Ethane,

Propane, Carbon Dioxide, Nitrogen and Traces of Higher Hydrocarbon and Oxygen. It is

a vital component of the world's supply of energy.

It is one of the cleanest, safest, and most useful of all energy sources.

It is a Non- Poisonous, Non- Toxic, Colorless, tasteless combustible source of Energy.

It has no odor of its own; however, for City Gas Distribution Ethyl Mercaptan is added

for distinct colour so that layman can identify the leak if any nearby and report to the

authorities for necessary corrective option.

Composition of Natural Gas

Component Chemical Formulae Percentage

Methane CH4 70%-90%

Ethane C2H6

0%-20% Propane C3H8

Butane C4H10

Carbon Dioxide C02 0%-8%

Oxygen 02 0%-0.2%

Nitrogen N2 0%-5%

Hydrogen Sulphide H2S 0%-5%

Rare Gases He, Ne, Ar, Xe Traces

Properties of Natural Gas

Specific Gravity (Air 1.0) 0.56 to 0.67

Boiling Point -161 °C

Melting Point -182 °C

Flash Point -161 °C

Auto Ignition Temperature 560 °C

Flammable Limit 5% to 15% by volume in air

Critical Pressure 45.99 Bar

Critical Temperature -82.59 °C


O V E R V I E W O F C G D B U S I N E S S

A City gas distribution means a distribution system in which CNG & PNG sold to

various segments by interconnecting gas pipeline & related equipments.

Currently the CGD segment constitutes 12 percent of the total gas consumption in

India. It is worth noting that this has been achieved in the past five years itself. It is

expected to reach a share of 20 percent by FY20.

The supply of natural gas for CGD is around 13 mmscmd in FY11 against the demand

of 15.83 mmscmd in the country.

Increasing demand from commercial and small industrial customers within the city

limits, in addition to the automotive and residential demand, are the key drivers of

growth in this segment.

Much of the demand in future will continue to be as a result of customers finding

natural gas to be more competitive than other fuels coupled with ease of handling and

lower pollution.

On the supply side expectation of large volumes of gas being made available within

the next few years, though both new domestic finds and imports, has created greater

compulsions for developing the CGD market. With an estimated demand of

45mmscmd by FY 20, CGD market is expected to grow by leaps and bounds.

CGD demand of natural gas from 2012-13 to 2029-10 of India.

MMSCMD 2012-13 2016-17 2021-22 2026-27

2029-30

CGD- City

Gas

Distribution

15.30 22.32 46.25 67.96 85.61

C I T Y G A S D I S T R I B U T I O N N E T W O R K

The selection of design for CGD Network is based on the gas properties, required flow rates, operating pressures and the environment.

A typical CGD Network shall comprise of one or more or all of the following:

1. City Gas Station (CGS)

2. Pipeline Network – Steel Pipeline, Polyethylene Pipelines, GI/Cu Pipes

3. Regulating Stations – District Regulating Stations (DRS), Service Regulators,

Domestic/ Commercial/ Industrial Regulators

4. Metering Stations/ Metering & Regulating Stations (MRS)

5. CNG Stations


CGD Value Chain

City Gas Station (CGS)

It is established at a tap-off point of high pressure transmission pipeline; from where

we get gas inside the city via pipelines.

Custody Transfer from Transmission Company to Distribution Company

The gas delivered at this point is at higher pressure i.e. greater than 50 bar. Once gas

enters to CGS unit its pressure is reduced to in between 24-30 bar. Rajkot - GA CGS is located at Gauridad Village which comes under GSPL Scope.


City Gas Station

The main Components of City Gas Station and their function is as follows –

1. Filtration Skid: Dust particle and liquid coming with the gas stream are separated

byhigh efficient filters in KOD.

Gas is maintaining same pressure from the inlet to the filtration skid.

After the filtration two streams are dividing from the main line using a header. Line

which is in function is known as active line where another one is called passive line

.

2. Pressure Reduction Unit: A pressure reduction valve is installed for the reductionof

the gas stream pressure from 60-65 bars to 25-30 bars.

Creep relief valve and Slam Shut off valve is being installed in this skid for the safety

purpose.


3. Metering Skid: Metering skid is installed for the gas flow measurement. Orifice

meteris used in this metering skid; because of the large pressure drop requirement.

The various parameters such as temperature in the various sections of the line

pressure at the inlet & outlet joints, flow inlet & outlet are monitor by the SCADA

systems in the control room.

Odorization Unit

An Odorization unit is installed for addition of ethyl Mercaptan inthe gas stream.

Gauridad&MotiMoldiodorisation units are come under Gujarat Gas scope.

VericonneCompany is service provider of both of these odorisation units.

The dozing unit of the ethyl Mercaptan is in between 10 - 20 mg/𝑚3 as per

requirement.

This unit consists of mainly two cylinders of capacity of 200 litres, expansion tank

pneumatic panel, level indicator and a filter.

Ethyl Mercaptan boils at 35℃. In order to stable its liquid state, high pressure gas

blanket is provided above it in storage tank. During pumping, doping rate is

calculated in liquid state.

During maintenance all ethyl Mercaptan in the pumps stored in expansion tank.

Odorizationunit is directly connected to the main line.


District Regulating Station (DRS)

DRS are the device used to reduce the pressure from 25 bars to 4 bars.

It is the interface between the steel grid network and medium pressure network. It is

located at various demand centers for domestic /commercial users and typically

consists of:

1. Gas Filter

2. Heater, if required

3. Pressure reduction (active / monitor combination) skid with minimum 50%

redundancy including slam shut valve for over pressure protection.

4. Inlet and outlet isolation valves.

The flow capacity of DRS is in range of 5000-10000 SCMH.

DRS regulate gas pressure from 20-25 to 4 bar.

The inlet line of DRS is steel pipeline and outlet is polyethylene pipeline.

Components of DRS

Gas Filters

Pressure reduction:

• Active regulator

• Monitor regulator

• Slam Shut off Valve for over pressure

protection

• Creep Relief Valve.

Pressure Gauges


Heaters (if required)

Pilot regulators

NRV: Non- Return Valve

Inlet/outlet isolation valves

Filters & PSV

Monitor Regulator & Active Regulator

SSV & CRV


Equipment Set Pressure (bar)

PSV 42.0

SSV 5.2

CRV 5.0

Monitor Regulator 4.5

Active Regulator 4.0

DRS (Twin Stream Model)

Service Regulator (SR)

Installed before tertiary PE lines

Reduces the pressure from 4 bar to 110 mbar to the service device.

Located at customer premises for maintaining safe conditions in the event of rupture in

the regulating downstream section.

Maintains the required maximum and minimum pressure with shut off device.


SR 200 SR 50


STEEL DEPARTMENT

ROLES & RESPONSIBILITY

Engineer In charge

Site In Charge:- Look Forward to ongoing projects currently at Khotariya,Rajkot.

Contractor: - Execution of Pipeline Laying & Associated Work

Construction Supervision Engineer: - Supervision of Project

Third Party Inceptor: - Quality Assurance

Support Service: - Local Liasioning& Coordination with Concern Authority

Engineer In Charge

CotractorConstruction Supervision

Engineer

Third Party Inceptor

Support Service

Site In Charge


CURRENT STATUS

Steel Pipeline Network in Rajkot-GA

i. Commission/Charged Network Length : 90.614 Km

ii. No. of Steel Valve Chamber : 56

iii. No. District Regulator Station (DRS): 20

Steel Line (12") Network - GGL Scope Start FromGauridad GSPL CGS Station

Network Statistics of Rajkot - GA

Steel Line Steel Valve Chamber

Type Length Type Nos.

12" 44.2 12" 12

8" 14.3 8" 11

6" 15.8 6" 07

4" 14.2 4" 25


ON GOING PROJECTS

Steel Pipeline on Going Project in Rajkot-GA

Site Length (Km)

Kothariya 4

Ghanteshwar 3.5

Ambadi to MotaBhadra 15.5

Jamkandorana 7.8

Jetpur 23

Total 53.8

From Above all project only Ambadi to MotaBhadra is cross country pipeline.

METHODOLOGY

Stages of Steel Pipeline Project

Conceptualization

Market surveys for deriving basic assumptions on demand

Initiation of Feasibility Study for Commercial / Technical viability

Feasibility Report

Route Selection & Surveys

Hydraulics / Simulations

Estimation of Project Cost

Market Demand Assessment

Project Approval

Engineering & Planning

Design & Sizing

Specifications & Tender Document preparation

Material Procurement / Release of Work Orders & Contracts

Acquire RoU / Permissions

Project Execution & Commissioning

Considerations / Detailing Required

Pipeline Length

Type of Terrain

No of Crossings / Type of Crossings

No of Valves (Section/Tap off/Future Extension)


Obstructions / Limitations

Identification of Authorities for permissions

Type of Surveys

Topographical

Population Density Index (Location Class)

Soil Resistivity

Design / Hydraulics / SimulationProcess

Simulation for Network Hydraulics is done in the SYNERGEE software

This is basically required to derive diameter of pipeline in such a way that required

pressure at all locations can be achieved and future load projections can be

ascertained.

Construction Stages

Pre-constructional Activities

Construction Activities

Testing and Commissioning

Handover to Operations& Maintenance Department

Pre-constructional Activities

Activity Description / Steps

Planning • Resource &Equipments

Scheduling • Scheduling of activities & milestones

• Material Ordering / Delivery schedule

Mobilization • Mobilization of Manpower & Equipment

Procedures / Qualifications • Approval of procedures for various

activities

• Welding Preparedness (WPS/PQT,

EQT, Welders Qualification)

• Insulators’ qualification

Training • Safety Trainings

• Site Briefing


Construction Activities

1. Grading: RoU clearance, Marking and cleaning

Several possible pipeline routes are surveyed by surface mapping. The final route is selected

to optimize its economic design, construction and cost effective operation with minimal

environmental impact.

The strip of land along the pipeline route, where construction operations are performed and

the pipeline is allowed to remain is called right-of-way (ROW).

ROW width is kept as 5 m on left of Pipeline for storing the excavated soil and 15 m on right

side for movement of equipments.

Right-of-way agreement also permits free and uninterrupted access to the pipeline for regular

maintenance, repairs or periodic inspection during the operating life of the pipeline.

Cleaning the Route

2. Trenching : At Correct depth

: With the help of Machines or Labors as per site requirement

Pipelines are normally buried in a trench. The excavated soil from trench is neatly piled to the

side of the trench to facilitate rapid backfilling after the pipe is laid.


Typical Trenching

3. Pipe stringing and bending

Line pipe is ordered from the mill, transported to the coating yard for coating and then

delivered to a storage location near the construction site. Delivering and aligning the pipe

joints along the pipeline route is called pipe stringing.

GGL use 12 meter steel pipe line for Gas transmission.

The Pipeline route may not be straight, nor is the terrain flat. For these reasons the pipeline

must be bent in the field to fit the three dimensional profile of the trench. Pipe joints are bent

prior to welding

4. Welding

After the pipes are strung along the right-of-way and bent as required, welding can begin.

Welding is done in several passes. Usually a minimum of three welding passes is required. In

usual welding, lead welders carry out a first pass after the pipe ends are properly aligned and

held with line-up clamps.


Inception through Non-Destructive Test (NDT)

After a weld is made, it is examined to ensure integrity of the weld. For inspection a number

of non-destructive techniques are used,

I. Radiographic Test (RT): It is used to test welded joint. From RT we can find out

inadequate penetration without high-low, inadequate penetration with high-low,

inadequate cross penetration, incomplete fusion, and incomplete fusion due to cold

lap, internal concavity, burnt through, slag inclusion, porosity, cracks, undercutting,

accumulation of imperfection and pipe or fitting imperfection.

II. Dye Penetration Test (DPT): It is used to test root weld joint surface. It gives

indications of imperfection in root weld. Not all indications shown in DPT are

imperfection. Machining marks, scratches and surface condition may produce

indications similar to the imperfection. They are accepted according to API 1104.

III. Magnetic Particle Test (MPT): It is used to test welded joint surface. It gives

indications of imperfections but not all indications are imperfection. Sometimes

magnetic and metallurgical variations may produce indications similar to imperfection

but they are not relevant to acceptability. They are accepted according to API 1104.


IV. Ultrasonic Test (UT): It uses ultrasonic waves to identify defects in weld joint.

Indications produced by ultrasonic testing are not necessarily defects. Changes in the

weld geometry due to alignment offset of abutting pipe ends, changes in weld

reinforcement profile of I.D. root and O.D. capping passes, internal chamfering, and

ultrasonic wave mode conversion due to such conditions may cause geometric

indications that are similar to those caused by weld imperfections. Such indications

are accepted according to API 1104.

5. Lowering in

Upon completion of welding, inspection of the welds, and a final holiday check of the

coating, the pipe is ready to be buried.

The pipeline is lifted by side boom tractors and is carefully lowered to the bottom of the

trench. It is necessary, especially in rocky areas, to put a pad of fine soil on the trench bottom

to protect the pipe coating from damage.

Types of Markers

Warning marker

Above ground marker

ROU marker

Direction marker

Kilo meter marker

Route marker

6. Hydro Test: The purpose of hydraulic test is to test strength of pipe line laid and to

find out any leakage in the steel pipeline. The liquid is filled in the pipe and

pressurised to 1.5 times its maximum allowable working pressure i.e. 75 bar, as our

maximum allowable working pressure is 49 bar. The test pressure is held for 24 hours,


if no pressure drop found during this period the line is successful to do

commissioning.

Pressure Data for Class 300 pipe

Type Testing Design Operating Normal

Working

Class 300 75 bar 49 bar 29 bar 22 bar

7. Backfilling: the final operations in pipeline construction are backfilling and clean up

of the right-of-way. Immediately after lowering the pipeline, the trench is backfilled

with the soil that was excavated from the trench and carefully compacted all around

the pipe

REGULATORY REQUIREMENT

Governing Standard:

ASME B 31.8 Gas Transmissions and Distribution Piping Systems

PNGRB Guideline Technical standard specification including safety standards for

Natural Gas Pipeline

• API 1104 Standard for Welding Pipelines and Related Facilities

• API 1109 Specification for Pipeline Marker

• API RP1102 Liquid Petroleum Pipelines Crossing Rail Roads & Highways

• ASTM E 94, recommended practice for Radiographic Testing.


• ASTM E 142, Standard Method for Controlling Quality of Radiographic Testing.

• The American Society for Non-destructive Testing. Recommended Practice No. SNT-

TC-1A supplement A.

• ASME BPV – Boiler and Pressure Vessel Code – Section IX

• BARC rules for radioactive isotopes handling.

Reference Standard:

• ASME Sec. II, Part - C Specification for welding Electrodes and Filler Materials

• ASME Sec. V. Non Destructive examinassions

MAJOR CHALLENGES

i. Rocky Soil Strata: Trenching consume more time because of hard rocks below 1

meter at current construction sites and bit failure in case of HDD.

ii. Utility Unconformity: Because of displace warning belt or absence of warning

belt, chances of utility damage increase which disrupt the laying of steel network.

iii. Local Influence: In most of the cases farmers disagree to give permission to use

their lands for pipeline lay down.

iv. Permission Issues of Protect Forest

v. Contractor Issues: Lack of a) Resources

b) Knowledge

c) Machinery

d) Inconsistency of work


C & M D E P A R T M E N T

CURRENT STATUS

Type of Customer Total No. of Customers Avg. Gas Consumption

(SCM/Day)

Industrial 373 90,000

Commercial 774 6400

Domestic 1,50,179 67,500

CNG - 1,36,000

Type of Connection Basic Retail Selling

Price (Rs./SCM)

Pressure

(Bar)

Billing Period

(Days)

Industrial 29.50 0.110 to 5 15

Commercial 40.00 0.110 to 1.5 30

Non-Commercial 30.00 0.110 to 1.5 30

Domestic 20.50 0.22 60

CUSTOMER CARE

Types of forms to avail post conversion services:

i. Modification of PNG Connection

ii. Extra Point requirement

iii. Cancellation of PNG Connection

iv. Name/ownership transfer

Classification of Customer’s complaints:

There are basically 2 types of classification of customer’s complaints as below:

1. Function wise


2. Category wise

Function wise Classification:

I. O&M

a. Meter not working

b. Modification of connection is pending

c. No Gas

d. Meter fast

e. Gas tap/rubber tube pending

f. Flow problem

g. Modification job card entry pending

h. Extra point pending- geyser/extra kitchen point

i. Gas leakage

II. PE-PNG Project

a. No-work done for delay in PNG Connection

b. Ground Connection (GC) is pending

c. Burner conversion pending

d. GC pit open

e. Site visit pending for route clear

f. Job card pending

g. Utility Damage

III. F&A - Only Requests

a. Approval note for credit

b. Refund related

c. Check revalidation

d. Wrong payment transfer in other customer’s account

IV. C&M - Only Request

a. Name transfer


b. Waiver of meter replacement charge

c. Approval Note

d. Duplicate bill- A4 size

V. Billing

a. Advanced bill generation

b. Bill not received

c. Bill not generated

d. Wrong meter reading

Category wise Classification:

I. P8 : Complaints

a. SLA of 90 days has been allotted to this types of complaints. Priority

II. R8: Requests

a. For < 90 day from registration

III. I8: Internal

IV. E8: Enquiry

a. For < 30 days from registration

Source of Complaints

i. Walk-in: At GGL Rajkot office

ii. Tele calling

iii. Written

iv. Website

v. Head office –Gandhinagar

vi. RTI

DOMESTIC

Basic function of Domestic Department

1. Registration of New Customer : Comma Separate Value (CSV)


2. Service Order Generation

3. Contractor Allotment by PE-PNG Department

4. Billing of Direct Marketing Agency (DMA)

INDUSTRIAL

Basic function of Industrial Department

1. "Gas Sales Aggrement - GSA" signed by customer & Gujarat Gas

2. Document submission by customer

3. Selection of meter as per flow requirements

4. Meter connection cost, check payment

5. Customer create in System

6. Notification generation: PE- PNG department work on it

7. After commission - move in process

8. Collection of security deposit: Deposit check/bank security. Gujarat Gas gives 6%

annual interest on check deposit money.

9. Industrial Department handover the customer connection to billing department.

Substitute fuels of Natural Gas

Type of Fuel Gross Calorific Value (KCal/Kg)

CBFS- Carbon Based Feed Stock 11,000

FO- Furnace Oil 10,500

LPG-Liquefied Natural Gas 11,900

Coal 8,350

Wood 3,000

LDO – Light Diesel Oil 10,500

Electricity 860 KCal/kWh


RECOVERY DEPARTMENT

1. Function: To Recover GGL pending money from the customers those haven't paid the

gas bills in time.

2. Bill period: From 1st January to 28th February. (Same for all months)

3. Last day of Bill payment: 21st March

4. Gujarat Gas has 8 recovery team in Rajkot - GA. Each team consists of 2 members.

5. Gujarat Gas has divided whole Rajkot into different pockets for easy working.

6. Following Action are taken sequentially by recovery department to those customer

who hasn't paid last 2 bills/ Due is >1000 Rs.

Tele-calling

Payment Reminder Notice

Field-Visit

Forced Disconnection(FD)

FD with Police Protection

Legal Notice

MAJOR CHALLENGES

i. Industrial Customer

PNG is Costlier compare other replacement fuels (largely solid fuels and furnace oils)

for same energy equivalent

Industrial units are far from the existing CGD network. Economically not viable to

build large infrastructure PE line for few customer.

High & Non-refundable installation cost of PNG connection is unfavourable for new

customer.

ii. Commercial Customer

High rate of gas restrict new registration of commercial customer

High & Non-refundable installation cost of PNG connection is unfavourable for new

customer.

iii. Domestic Customer


Delay in connection due to

i. Rajkot Municipal Corporation (RMC) permission

ii. Monsoon Season

iii. Contractor Issues

iv. Customer Care

Handling the customer during interruption in gas supply due to third party damage of

PE line.

Dependency on external factors like excavation permission for city area

Recovery Team Salary is not linked with its performance which decreases the quality

work of individual team member.


P E - P N G P R O J E C T D E P A R T M E N T


Achieve the New Commission Customer Target Annually Given by PNGRB.

Target of 20,000 new customers during financial year 2016-17 in Rajkot - GA.

Ensuring a huge profit to Gujarat Gas by increasing customer base of all kind

(Domestic, Commercial, Non-Commercial and Industrial).

Expanding the GGL CGD network by penetrating in rural areas of Rajkot -

GA.

Avoid accidents by giving HSE training to labours & contractors.

Improving quality work through high quality PE-PNG training programmes

organized by Gujarat Gas - Rajkot.

Provide clean & high flow capacity fuel till every end customers of rajkot.

Ensure quality surveillance of PE-PNG installation being installed by Gujarat

Gas.

CURRENT STATUS

PE Pipeline Network in Rajkot-GA

Commission/Charged Network Length: 1695.67 Km

No. of PE Valve Chamber: 733

No. of Service Regulator (SR): 830

No. District Regulator Station (DRS): 20


PE Network near Nana Mava Village

PE Line Specification

Symbol Size of PE Line (mm) Type

125 MDPE

90 MDPE

63 MDPE

32 MDPE

Service Regulator (SR)

Type Flow Capacity(SCMH) Max. No of Customer

B50 50 150

B100 100 300

B150 150 500

B200 200 650


ON GOING PROJECTS

PE laying is going on at below sites

i. JetpurTaluka Villages

ii. Jamkandorana

iii. GondalTaluka Villages

iv. Rajkot Central

METHODOLOGY

Steps followed by PE - PNG Department

1. Route Selection Survey: It is done by HO- Team of Gandhinagar. Different

routes are proposed by this team.

2. Final route selection: Simulation for Network Hydraulics is done in the

SYNERGEE software. This is basically required to derive diameter of pipeline in

such a way that required pressure at all locations can be achieved. Gas supply

requirements & Pressure drops are taken into consideration for best route.

3. Right of Use (ROU): Permission from concerned authorities (Municipal

Corporation, Gram Panchayat, State highway authority, etc.) are taken by ROU

department.

4. Route Survey: Marking is done on final route by PE-PNG project team of

individual GA. Pipe size selection is also determined during survey. Numbers

and locations of SR are also decided by team.

5. PE Laying

PE Network is divided into two part

A. MP Network

1. The MP PE network starts from downstream of DRS/CPRS and distributes the

Natural Gas till the different Service Regulator located nearby a cluster of domestic

customers or a main commercial customer or Industrial Customers upto MRS/IMS.

2. The PE mains are subdivided into sections by means of adequately located manually

operated valves (Note: As per PNGRB in MP network minimum one at every 1 Km).


B. LP Network

The LP Network in PE starts from the downstream of Service Regulator (SR) and brings the

natural Gas to domestic customers.

A. PE Laying Process for Open Cut Excavation:

i.Trench depth to maintain 1.0 meter cover.

ii.To check underground utilities with a minimum clearance of 25cm. from PE pipe. If not

maintain min clearance distance to cover pipe by using RCC half round / PVC sheet.

iii.When two PE pipeline (MP & LP) to be laid in same trench then min. 300mm distance to be

maintained between two pipes. Also MP pipeline is to be laid at Road side and LP pipeline to

be laid at extreme side of the road.

iv.Pipe laying at the center of the trench for proper sand padding surrounding PE pipes.

v.75mm sand bedding below pipe in case of normal soil and 150mm in case of rocky terrain

and 75mm sand padding above pipe.

vi.Stone free soil backfilling above sand padding upto 0.5 mtr. Of PE pipes.

vii.Laying of Warning tape at 0.5 mtr. Depth from ground level

viii.Backfilling entire Trench, Watering and Compaction, Excess soil scrapping.

Trench Dimension for PE Pipeline: Size–32mm. Similar for other Pipe Sizes


Safe distance for Excavated soils storage/ Barricades

B. PE Laying Process for Crossing of River/Water Canal/ National Highway / Four-

lane state Highway and Railway

1. No EF joints shall be allowed in PE pipes in major crossings as mentioned above. If

the pipe dia. requirement is higher than 90mm then steel pipeline shall be used in

major crossings by providing Transition Fittings at both ends.

2. 90 mm dia. PE pipes can be used without any EF joint in between if the crossing

length is less than 100 mtr.

3. Installation of PE Valve

a. Isolation valve to be installed at every 1.0 km on 90mm dia. and above PE

pipeline Medium Pressure network. Where tapping of 90mm and above on

Medium Pressure PE network, PE isolation valve to be provided immediate

after tapping.

b. Isolation valve to be installed before 2.0 meter of end cap for 125mm and

higher dia. Medium Pressure PE pipeline.

4. PE Pipeline Marker

a. Pipe line marker shall be installed at every 200 mtr. distance on sizes of 63mm

and above PE pipelines. Also pipe line marker shall be installed at both sides

of Main road crossing, river crossing, railway crossing and any other locations

as specified by Gujarat Gas.

5. Ground Connection


Ground Connection required to joint additional piece of PE pipe as per individual connection.

Two part of PE pipe are jointed together through Electro fusion joint.

Electro Fusion Joint

The pipes ends to be welded must be cut at right angle by using proper pipe cutters.

Mark the scraping area with an indelible marker pen. The scraping area must be

10mm larger than the insertion depth of the fittings.

Oxidized surface is removed from the pipe, by scraping it

The scraped surface is cleaned using isopropyl alcohol.

Coupler is inserted up to the location mark and the pipe is fasten into the aligning

clamp.

The plugs are connected to the control unit to the terminals on the fittings and proceed

with the set-up of the welding parameters, strictly following the instructions of the

welding unit

When the fusion cycle is completed, fusion indicators are verified

Cooling the joint, in order to avoid possible stresses on the jointing

Ground Connection

1. Transition Fitting Joint: From here Galvanized Iron/ Copper Pipe is jointed with PE

Line. RCC Guard is placed on it to protect this joint from external faactors.

2. Industrial Metering Station (IMS)/MRS


A. They are used to measure the gas supplies to Industrial customers. The main

components in IMS is filter, Isolation Valves, RPD Meters, Regulators (if low pressure

requirement) and Non Return Valve.

B. Inlet Pressure Range – 1.5 Bar to 4 Bar, Outlet Pressure – As required by customer.

Main Components of IMS

i.Filter -It is also a cartridge type filter with pore size of 5 microns.

ii.Gas meter -Volumetric gas meter is used here mostly RPD meter.

iii.NRV -It allows one way flow as discussed above.

iv.CRV -It is used here to relief excess pressure in line in case of over pressure.

v.PRV in customer premises -Same as PRV in CGS skid, it reducespressure as required. It

operates without pilot valve.

1. Domestic and Commercial / Non-Commercial PNG Connection

The connection between consumer meter set assembly and gas appliance may be made by GI

Pipes or Copper Tubing or Steel Rubber Hose.

Commercial Connection has same components as domestic connection but some customers

may have larger diameter GI Pipeline and higher pressure meter.

The quantity of gas consumed by an average domestic consumer will remain almost same for

all customers.

Design of vertical risers:

Apartment connections can be classified into the following category:


- ½‟‟GI pipe riser up to 7 floors for one connection on each floor.

- ½” GI pipe riser up to 3 floors for two connections on each floor.

1” GI pipe riser for connecting more than seven floors and up to sixteenth floor from single

riser & single connection on each floor.

Riser Installation (Labour wear petzlSet for Safety)

Following Steps are followed by Gujarat Gas for Installation of Domestic/Commercial

Connection

1) Route Selection

2) Positioning of Valves, Regulator & Meter

3) Appliance Valve

4) 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.

British Standard Pitch Thread (BSPT) are done on both side of each pine.

5) G.I. Pipe Installation & Clamping

Teflon tapes of approved make shall be wrapped on threaded portion of the

pipe with minimum three overlaps.


The pipeline portion containing the Regulator and Meter, either horizontal or vertical, shall

have clamps on both side of the regulator and meter. Distance between two clamp should be

≤ 1 meter.

6) Testing of Installed Piping Connection

Pneumatic Pressure Test medium is inert nitrogen/air

1) Conversion of Burner: Gas flow rate & pressure are different for LPG &

PNG so nozzle sizes are set according to PNG requirement.Jet diameter of 110

mm / 125 mm should be used in PNG.

2) Meter Job Card: Meter Job card to be prepared duly signed by Contractor,

Customer & Third Party Inspector and to be submitted to GSPC Gas

immediately on completion of conversion.

Schematic Diagram of a Domestic PNG Connection

Sr. Type of Testing Test Pressure Test Duration

1 Pneumatic Pressure Test (PPT) 3.5 Kg/𝐶𝑚2 30 minutes

2 Mano-Metric Test (MMT) Gas Pressure 15 minutes

3 Riser PPT 7 Kg/𝐶𝑚2 1.0 Hrs.


Commercial Connection

REGULATORY REQUIREMENT

Plastic Pipe and Components:

Polyethylene (PE) pipes conforming to IS 14885 or ISO 4437, and PE fittings conforming to

ISO 8085 Part 3 shall be acceptable.

Pipes and tubing for above ground service lines up to meter:

After meter, GI pipes or Copper tubing shall be used up to gas tap.

After Gas tap, Steel reinforced rubber hose shall be used to connect customer

appliance which shall conform to IS: 9573 Type IV.

Fittings in PE Network

Thermoplastic / thermosetting fittings shall not be used in above ground piping system.

Thermoplastic fittings conforming to ISO 8085 Part 3 shall be acceptable and shall meet

following requirements:

a. 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.

c. Colour of fittings shall be yellow or black.

d. Electro-fusion fittings complying with ISO 8085 Part 3 / EN- 1555 -3 shall be used for all

sizes of PE pipes.

f. 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.


g. The fusion jointing shall be carried out as per the procedure outlined in the standard DVS

2202 or equivalent.

h. Carbon steel part of transition fittings used for connecting PE system with Carbon Steel

system may have butt weld/plain/flanged ends.

Velocity Requirements

The maximum velocity in the pipeline network should be limited to 100 ft / sec (30 m/sec)

immediately after pressure regulating instrument.

Network Design Requirements

- Supply of gas at constant volume into a system, which fluctuates in pressure between pre-

determined upper and lower limits in the distribution network.

- Supply of gas at a constant pressure at consumer end.

Facilities forming part of CGD networks shall be designed considering

- Range of flow rates and pressures required in various sections of the network.

- Quality of gas, including cleanliness in respect of both solid and liquid particles.

- Metering requirements.

- Noise control

- Corrosion Protection

SDR= 𝑁𝑜𝑚𝑖𝑛𝑎𝑙𝑂𝑢𝑡𝑒𝑟𝐷𝑖𝑎.

𝑀𝑖𝑛.𝑊𝑎𝑙𝑙𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠

Testing Plastic Piping after Construction

Test Requirements

For test pressure higher than 100 psig, water shall be used as test medium. Test duration shall

be minimum 24 hours for plastic distribution mains of length greater than 1 km and minimum

4 hours for length shorter than 1 km. In case water is used as test medium, test duration shall

start after achieving thermal stabilization

Wall Thickness and Standard Dimension Ratio for Thermoplastic pipes

Nominal Outside

Diameter in mm

Minimum wall thickness in mm for Standard Dimension Ratio

(SDR)

D 17.6 13.6 11 9

63 3.6 4.7 5.8 7.1

90 5.2 6.6 8.2 10.1

125 7.1 9.2 11.4 14


VALVES

Based on operation and maintenance flexibility requirements, valves may be provided on:

- Either side of water body crossings.

- In plastic distribution mains valve spacing should normally not be more than 1 km.

Markers

A marker shall be marked in bold and legible local language and Hindi / English with at least

the following:

• Name of CGD Network Operating Company - Gujarat Gas Ltd.

• Contact Telephone Number to Report emergency

• Location Area Code

• Warning - “High Pressure Gas Line, Dial before Digging” etc.

Markers may not be installed for service pipeline within consumer premises, however, the

GGL shall maintain such service pipeline routing drawings for easy reference.

MAJOR CHALLENGES

Rajkot Municipal Corporation (RMC) permission issues

Labor issues

Difficulty in providing connection within timeline because new registration inflow

is more compare to work done

Manufacture faults in Service regulator

Lack of quality in manpower

Increase challenges Due to direct customer engagement with PE-PNG department

Individual Contractor give more priority to more profitable work from PE

laying/PNG installation

Lack of Interlink between project department & marketing department increase in

SBNC (Signed But Not Commission) numbers.


C N G D E P A R T M E N T


1. CNG Refuelling Station is a facility set-up for supplying CNG mainly as a fuel to

vehicles. The system receives odorized gas at certain pressure (19 Bar), through

transmission line and supplies the same to the customers/vehicles after filtration,

compression (upto 250 Bar) and check metering.

2. CNG is stored at compression stations which are directly connected with the gas

pipeline. Here the gas is compressed to a required pressure and aids fuelling. CNG

can also be transported to other retail outlets by cylinder trucks. These trucks carry a

number of cylinders which provide CNG to fuel stations which are not connected by

pipelines.

3. The system has major assets like, Odoriser Unit, CNG Compressor, Storage facility,

Dispenser, LCV/HCV Filing Point, Mobile cascade vehicle, Electrical Installations,

DG set and Air Compressor. The size, rating and type of the major and sub assets are

selected based on the pressure rating, capacity and other applicable criteria considered

for refuelling station for meeting the current and future customer potential, health and

safety of employees, customers and public at large, environmental protection and

complying the statutory, legal requirements, national and international technical and

safety standards/ practices.

4. Various operation and maintenance activities, as per annual operation and

maintenance plan is carried out for ensuring safe and uninterrupted gas supply.

CNG Station


CURRENT STATUS

There are currently 25 working CNG station in Rajkot - GA.

Type Number

Mother Station 4

Online Station 14

Daughter Booster Station 1

Daughter Station 6

Total 21 compressors are operating at various CNG stations.

Compressor

Flow Capacity (SCMH) Number

1200 6

650 13

250 1

375 1

Average CNG Gas Selling in RAJKOT - GA: 90,000 Kg/day

CNG Retail Price: 44.75 Rs./KG (as on 07/07/2016)

ON GOING PROJECT

Two CNG station are under construction phase.

Santram near Gondal - Daughter station

Gayu farm near Jetpur - Mother staion


METHODOLOGY

Types of CNG Refuelling Stations

1.Mother Station: A CNG station provided with whole set up (compressors, dispensers,

cascade etc.) along with a LCV filling point is known as a mother a CNG station.

2.Online Station: This CNG station has same set up as a mother station but LCV connection

is not provided for filling.

3.Daughter Booster Station: Daughter station provided with the compressor (known as

boosters) to compress the gas we are getting from the mother station are known as daughter

booster station.

4.Daughter Station: Daughter stations are established in those areas where laying a pipeline

is not possible. In that case gas is delivered from mother station to daughter station; via

mobile cascade van. The gas from mother station is filled in mobile cascade by a LCV filling

point.

Types of CNG Station


Working of CNG Station:

CNG Compressor

Steel line of 2 inches dia. coming to compressor as a suction line (25 bars). Suction

line is provided with isolation valve followed by a strainer for removing of foreign

particles.

After strainer comes the suction filter of size 5 micron. From here the suction line is

divided into two lines, one is inlet to 1st stage of compressor and another one is

instrument line for operating actuator valves in the compressor.

Instrument line having a pressure of 25 bar it goes to a PRV which reduces pressure

upto 6-8 bars for the SOV which provide functioning of actuator.

Now the main suction line goes in Non Returning Valve (NRV) which provides only

forward movement of gas. From NRV it goes into Blow down Vessel. We have two

interconnected Blow down vessels. In these, gas is stored which is mainly used during

startup of compressor.

Now from NRV it comes to main PRV & then first Suction volume bottle. From here

it enters to compressor.

Valve and Piston means in other compressors valve and piston are provided separately

but here valve is provided in the piston so function of both is performed by piston

only.

The first stage is double acting stage; here compression is affected from both the ends

of the cylinder of the compressor. Then gas is sent to the intercooler for the cooling of

the gas.

Now gas from intercooler enters to second stage for the compression. Second stage is

single acting means one suction and one discharge. After compression it goes to

intercooler for air cooling of the compressed gas.

Finally it reaches to third stage (single acting) for final compression from intercooler

for the desired final pressure of gas.

At every stage, the gas pressure and temperature is:


After third stage compression from intercooler it comes in discharge line.

Lubrication oil is provided for piston and crank case separately.

Oil SS220 for lubrication

Oil SS150 for Crank Case

Final discharge line goes to separator first and then filter of size of 1 micron. Now gas

enters to mass flow meter for measurement. Water cooling is provided for the cooling

of the oil used in compressor. From mass flow meter gas

comes to priority panel.

Safety Units in Compressor

Flame detectors and Gas detectors

CO2 flooding system

Safety Relief Valve (SRV)

Priority Panel

Priority panel is designed to fulfil the priority requirement of gas

to different consuming ends according to pressure availability. It

gives first priority to dispenser (fore court area), LCV/HCV

filling point and then stationary cascade. It operated by PLC panel. Logical working of

priority panel is as below.

When High bank pressure of cascade decreased to set point, PLC will give command

to start compressor.

When compressor starts priority panel will decide the priority either to Dispenser

(Fore court) or Cascade through High bank/direct line.

If there is no any load / Vehicles at dispensing area, Priority panel will start filling gas

in Stationary cascade.

Cascade fill in a sequence of High, Medium & Low bank respectively and dispenser

will dispense the gas to vehicles in a sequence of Low, Medium & High.

When High bank pressure reaches up to set point (215 bar), priority panel will open

medium Bank and gas will starts fill in both Medium bank and high bank

simultaneously.

When Medium bank pressure reaches up to set point (225 bar), priority panel will

open low Bank and gas will starts fill in all three bank Low, medium and high

simultaneously.


When Low Bank pressure reached up to set point (240 bar), PLC gives command

compressor to stop.

Cascades

A bank of cylinders used for buffer stock of compressed natural gas is known as cascade.

Stationary cascade is used to store the gas when vehicle is not there at the dispenser then the

gas from compressor flows into a cascade.

Stationary Cascade: These are fixed cascades established on CNG station for the storage of

CNG. It has a direct inlet from compressor and outlet to line connected to dispenser.

Mobile Cascade: Cascade is mounted over an LCV and it carries CNG from Mother Station

to Daughter station or Daughter booster station as per the requirement.

Cylinders in a cascade are divided accordingly as:

- High Pressure Cylinders (HP) - 5 cylinders

- Medium Pressure Cylinders (MP) - 15 cylinders

- Low Pressure Cylinders (LP) - 20 cylinders

-

Stationary Cascade

Dispenser

Main components of a dispenser

High, Medium, low bank lines

Gas Filter

SOV

Actuator


Mother Board

Non Returning Valve (NRV), Ball Valve, Pressure Regulating Valve (PRV), SRV

Mass flow meter, Pressure Transmitter

Hose Pipe

Three Way Valve

Hex Nipple, Filling Probe

O-Ring

Working of a Dispenser:

A dispenser has three banks connection namely:-

- Low pressure Bank (LP)

- Medium pressure Bank (MP)

- High pressure Bank (HP)

Gas from dispenser will dispense in the sequence: - low bank, medium bank and high bank.

MAJOR CHALLENGES

Operation of Light Commercial Vehicle (LCV) & Heavy Commercial Equipment

(HCV) at remote location causes road accidents.

Equipment Breakdown and handling of customer complaints.

Coordination with Retail Outlets dealers through (Oil Marketing Company) OMC

officers.


O & M D E P A R T M E N T


The main operation area would be to handle & manage

i. Gas receipt

ii. Odorisation

iii. Pressure reduction (including heating the gas, if required)

iv. Underground Pipeline network

v. DRS (District Regulating Station)

vi. SR (Service Regulator)

vii. Field regulators

viii. Gas metering for all kind of customers such as domestic, commercial and industrial.

The safety, health and environment including compliance of regulatory measures shall be a

part of the responsibility of the operating group.

The maintenance activity shall cover the maintenance and upkeep of

i. City Gate Station

ii. District Regulating Stations

iii. Field Pressure regulating Stations

iv. End consumers facilities,

v. Sectionalising valves and other assets and facilities.

Major activities of O & M department includes regular maintenance, route patrolling to

contain third party damages and maintenance of safety provisions including offsite

emergency plan and onsite emergency plan, mutual aid and disaster management plan.

CURRENT STATUS

Type of Customer Total No. of Customers

Industrial 373


Commercial 774

Domestic 1,50,179

PE Network: 1695 km

PE Valve Chamber: 733

Steel line: 90.16 km

Steel Valve Chamber: 56

DRS: 20

SR: 830

Gas Consumption: 2, 81,880 SCMD

(All data are of Rajkot - GA)

ON GOING PROJECT

i. Testing of all SR 50 & SR 100.

Below listed instrument checked during testing

Instrument Operated Pressure range (mbar)

URSO- Under Shut Pre. Shut off Valve 40-60

CRV- Creep Relief Valve 130-140

OPSO- Over Pre. Shut off 145-175

Lock Up Test <122

Seat Tightness Test -

ii. Height Increase & Painting work of PE valve chamber

iii. GI Riser Maintenance :

Painting

Corrosion Control

Checking of proper Clamp

iv. Meter Box Installation of Commercial Connection


METHODOLOGY

1. Odourant System

Monitoring of Odorant level / Consumption v/v NG

Monitoring of odorant smell

Odorant transfer from barrel/SBC to tank

Thickness test of odorant tank / expansion tank

Leak checks of all joints

Monitoring of scrubber & neutralizing agent / Replacement of Neutralizing

drum

Checking of earth pits &earthing electrodes

Test and examination of odorant tank

NDT like ultrasonic flow detection (100% for all weld joint from outside)

2. Steel Distribution Network

Patrolling of steel distribution network ( Including railway crossing and

road crossing)

Leak detection inside & outside city area

Emergency patroling and third party coordination if work is going on or

near gas pipeline route

Maintenance of all type of markers

Repairing of pipeline coating

3. Cathodic protection system

Preventive maintenance of TR unit

Monitoring of insulating joints

Preventive maintenance of TLPs

4. DRS

Monitoring of pressure (Inlet / Outlet)

Checking the filter cartidge and cleaning


Functional test of PRV/SSV/SRV/CRV

5. PE Distribution network(MP &LP)

Patrolling of MPPE network and crossings

LDT/ LPT of PE network

Special leak survey during festival

6. Valve chambers (PE)

Maintenance of valves including greasing of valves, housekeeping of

chambers

Civil repair of valve chamber / sleeper, if any

Pest control for rat and snake repellent (Post monsoon)

7. Valve chambers (Steel)

Maintenance of valves including greasing of valves

Painting of valves and piping

Civil repair

Pest control for rat and snake

8. Service regulator(SR)

Monitoring of pressure (Inlet / Outlet)

Leak Detection Test

Testing of OPSO /UPSO regulators

General maintenance of whole installation including painting

9. Annual Maintenance of Domestic & Commercial Connection

Annual maintenance of each PNG Domestic connection

Replacement of flexible rubber hose for all points ( No cost to customer

for single kitchen point)

GI Riser maintenance

Annual maintenance of each PNG Commercial connection


REGULATORY REQUIREMENTS

1. PNGRB -T4S

2. OISD - Oil Industry Safety Directorate

3. PESO - Petroleum and Explosive Safety Organization

4. BOCW - The Building and Other Construction Work

5. Environmental Protection Act

6. Labour Law

7. EISC - Employee's State Insurance Corporation

8. WC - Workers' Compensation

9. SMPV - The Static and Mobile Pressure Vehicle

The CGD system has leak detection system in position and is operative. For pipeline

network it shall be ozonisation based and for enclosures such as CGS, above ground

DRS, it shall be gas leak detection based.

The CGD system has in position necessary pressure relief valves

There shall be protection of the system against third party damages both in respect to

steel pipe, PE pipe and copper tubing.

LIST OF CRITICAL ACTIVITIES

Sr. Critical infrastructure/ activity/ processes Time Period

For

Implementation

Implementation plan

1 On line odorisation equipment designed to minimize

fugitive emissions during loading, operation and

maintenance.

1 year Automated odorisation

systems to be used

2 Height of the vent shall be minimum 3 meters above

working level 6 months Increase height of vent

3

Gas detectors shall be installed at critical locations 1 year Install gas detectors in

the CGS and District

Pressure Regulating

Station.

4 Pressure reduction for DRS (active / monitor combination)

skid with minimum 50% redundancy including two safety

devices at least one of them shall be a slam shut valve for

over pressure protection/under-pressure and inlet and

outlet isolation valves.

2 year Modification/

replacement


Layout of Station Facilities

The following aspects are to be considered in deciding layout of facilities at CGS, DPRS, SR,

etc.

Type and size of equipment.

P&IDs

Utility requirement.

Venting wherever required.

Operation and Maintenance philosophy.

Patrolling

Patrolling schedule shall be such that entire primary network is inspected at least once in

three (3) month and secondary network is inspected at least once every month to observe

surface conditions, construction activity, encroachments, soil wash outs and any other factors

that may affect the safety and operation of the network.

Leakage Surveys

GGL must have an effective method to identify and locate leakages in the system. Any one or

combination of methods described in ASME B 31.8, can be adopted based on their

effectiveness for the specific areas.

ODORISATION

Natural gas supplied through CGD Network shall have a distinct odour, strong enough to

detect its presence in case of leakage.

If odour level falls below the minimum acceptable level same shall have to be intimated to

the control room of the gas supplier and accordingly corrective actions are to be taken.

5 Steel reinforced rubber hose conforming to IS 9573 Type

IV 6 months Replacement of all

rubber hoses @ fifty

thousand per year

6 Pipeline test record and joint radiography and cover in the

form of pipe book 3 months Can be submitted in

stages

7 Emergency Response Plan, Disaster Management Plan

and written emergency procedures. Also, provide for an

Emergency Control Room, manned round the clock and

equipped with effective communication system and

emergency vehicles fitted with communication facilities,

first aid equipment, fire extinguishers, gas detectors,

repair kits and tools, maps, plans, material safety data

sheets etc. at its disposal

6 months To be implemented


The odorizing equipment shall be located in a separate area at CGS. There should be a clear

safety distance of 1.5 m.

The odorant unloading should be done in a safe way. Precautions for handling odorant shall

be prominently displayed.

Odourant absorber like activated carbon saw dust, dry sand and odorant neutralizer like

sodium hypochlorite for spillage handling of odorant shall be provided.

MAJOR CHALLENGES

i. Gas Interruption due to third party damages

ii. Emergency response to villages within time line is difficult due to large geographical

distance

iii. Common Contractor for all PNG and O&M activity.

iv. Expanded PNG network in Rajkot GA -Difficulty in providing service to end

customer within timeline as per PNGRB.

v. Difficulty in patrolling in large network.


H S E D E P A R T M E N T


In general execution/implementation of HSE system/ processes at locations/ sites.

Review of PTW work request & safety critical site compliance monitoring.

Mock drill exercise

local level HSE committee meeting

Field compliance monitoring-Work Place Inception/ HSE tour & Life Saver

monitoring

Contractor Engagement for HSE aspect

New Project HSE facilitation & compliances monitoring

Participation & facilitation HSE audits - internal

Locational "Safety & Technical Competency Training Management

Environmental Monitoring

Facilitating Incident fact finding & field investigation

Driving HSE Campaigns & Celebrations at locations.

Location HSE performance reporting to corporate and facilitation in mandatory

compliance.

METHODOLOGY

Following processes is prepared as part of HSE Management System

Emergency Management System to safely handle emergencies with minimal risk.

Disaster Management Plan encompassing offsite and onsite emergency response

plans and mutual aid system

Hazard Identification Processes such as HAZOP

Risk Analysis and Risk Assessment Process such as QRA

Safety and Technical Competency System


HSE Management System

Life Saver of Gujarat Gas: BE WEL CGDS

All employees, contractors and labours of Gujarat Gas have to follow this 8 life saver in field.

1. Boring

2. Excavation

3. Work at Height

4. Electrical - ELCB (Earth Leakage Circuit Breaker)

5. Lifting

6. Confined Space - Oxygen Level should be > 19%

7. Driving

8. Safe System

Continual Improvement

HSE Policy

SOP Work permit system/ PTW matrix PPE compliance as per PPE matrix Site Specific Risk assessment Safety talk before starting work Risk Register Life Saver

Organizational structure and responsibilities Training awareness and comptence Communication Document and its control Control of HSE critical operation i.e. NRO Emergency preparedness and response HSE Motivaion

Life Saver audit Work place inception Incident reporting and investigation

HSE Committee meeting/ review


REGULATORY REQUIREMENTS

Basic Requirements

The entity operating a CGD network shall have an effective Health, Safety and Environment

Management System (HSE Management System) and Management of Change System in

place to ensure overall safety during operation and emergencies.

HSE Regulatory requirements are taken from this following reference documents.

1. PNGRB -T4S

2. OISD - Oil Industry Safety Directorate

3. PESO - Petroleum and Explosive Safety Organization

4. Factory Rules

5. BOCW - The Building and Other Construction Work

6. Environmental Protection Act

7. Labour Law

8. EISC - Employee's State Insurance Corporation

9. WC - Workers' Compensation

10. SMPV - The Static and Mobile Pressure Vehicle

11. Gas Cylinder Rules

Essential Features of the Emergency Plan

Entities operating CGD Networks shall provide for an

i. Emergency Control Room, manned round the clock and equipped with effective

communication system and

ii. Emergency vehicles fitted with communication facilities

iii. First aid equipment

iv. Fire extinguishers

v. Gas detectors

vi. Repair kits and tools

vii. Maps

viii. Plans


ix. Material safety data sheets etc. at its disposal.

The CGD entity shall put in place an Emergency Response Plan, a Disaster Management Plan

and a Pandemic Plan. While preparing these plans the entity shall take into confidence the

various local authorities (i.e. The Fire authorities, Police authorities, Health authorities, local

administration, Disaster Management authorities, Mutual aid, Factory inspectorate etc) and

clearly elaborate on their role in case of an incident.

Accident / emergency reporting procedures

The entity shall put in place a documented in house accident reporting procedure and its

response plan for all kind of accidents/emergencies such as

(i) Near miss accidents

(ii) Accidents without loss of production, supply or human life

(iii) Accidents with loss of production, supply or human life

(iv) Fire

(v) Explosion or other emergencies leading to disaster effecting outside public.

The level of reporting shall also be mentioned in the procedure. The Board shall be informed

in respect of the accidents/emergencies under category (iii), (iv) and (v) above with remedial

measures


MAJOR CHALLENGES

Labours have lack of awareness about safety

Training Issues due to high person turnover ratio

underground Gas passage issue - Gas Ingress due to

i. Rat Bite

ii. Joint Failure

Work in Public

Inherent risk of gas

LCV/HCV vehicle accidents during transportation of CNG.

Two Wheeler Driving Accidents

Third Party Damage due to careless work/misplace warning belt.

Negligence by CNG vehicle owners for not testing the cylinder & maintenance

Working at height at buildings during riser installation

Underground boring work