Linepipe

(G.S.R.
612 E)
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Click to edit Master title style
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STEEL PIPELINE

PNGRB
Regulations
SAFETY
PIPELINE
INTEGRITY
Patroling
Cathodic
protection
Operation
and
maintenance

Construction

Material

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MATERIAL
Steel Pipe
(API 5L
PSL2)
BALL AND
GLOBE
Valves(API
6D)
Fittings
(ASME B16.9,
ASME B16.25)
Insulation joints
( ANSI 150 TO
ANSI 2500)
GASKETS(ASME
B16.20)
Flanges
(ASME B16.5)
STEEL PIPELINE
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Steel Pipe :Pipeline is all parts of physical facilities through which fuel moves in transport
including pipe, valves, fittings, flanges, pressures vessels, metering stations, compressor
units etc., attached to the pipe.
Steel pipe are the main component of steel pipeline which accounts approx. 95% of the
capital expenditure. IGL is using 3 layer polyethylene pipes of various diameter as
detailed below:

Specification of line pipe is done based on API 5L ,ASTM A 106 HTCS.
For impact loads PSL2 standard is used.

STEEL PIPELINE
Sr. no. GRADE Thickness
(mm)
Strength
1. API 5L
X60(12,16,18)
6.4 60,000lb/psi
2. API 5L
Gr.B(4,6,8)
6.4 42000lb/psi
3. A106
SCHEDULE
80(2)
6.4 42000lb/psi
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There are total 28 types of valves. BALL and
GLOBE Valves are manufactured as per API 6D.
Ball/globe
Valves
Manually
operated
Underground Aboveground
Actuated
Aboveground Underground
Ball/globe
Valves can
also be
classified as
FE/BW and
Fixed
bore/Reduced
bore valves.

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Ball Valves These are used
for isolation.
Since the pipelines in CGD is
of non piggable line, RB
valves are used and RB
valves are less expensive
than the FB valves.
In reduced bore ball valve,
the port of the valve will be
one pipe size lesser than
the OD of pipe.

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Globe Valves Globe valves are used for throttling .Main functions of globe
valves are-
Regulating the flow while charging the gas , venting the gas in pipeline .
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Insulation Joint: The Pipeline
Insulating Joint (PIJ) is a high-
resistance fitting used to
electrically isolate sections of a
pipeline to improve the
effectiveness of cathodic
protection systems and to
reduce ground-loop currents.
Thus, I.J. are used to separate
above ground pipeline to
underground(cathodically
protected) pipeline.
Insulating joints are monolithic
type and allows smooth passage
of pigs.
PRESSURE RATING of I.J is done
according to ANSI 150 TO ANSI 2500.
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Fittings: These are designed as per ASME B16.9, ASME
B16.25.

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Flanges are designed as per ASME B16.5

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GASKETS are designed as per ASME B16.20 .
Spiral Wound gaskets
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PIPELINE LAYING DONE AS PER ASME B31.8
Pole Markers and RCC Markers Installation
Backfilling
Warning mat & HDPE duct laying
Padding of lowered section
Lowering
Coating repairs after Holiday Check and trenching
of graded land
Holiday testing for lowering section
Coating of pipe joints
NON DESTRUCTIVE TESTING
Welding of joints
Stringing(spreading) of pipes
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 10,SCHEDULE 1B :
QUALIFICATION OF PROCEDURES AND WELDERS
Welding procedures and welders for welding of gas pipelines shall be
qualified as per API 1104 and shall include toughness testing
requirements as applicable for the line pipe.

SMAW- Shielded Metal Arc Welding
Electrodes Used- 6010, 7010

INSPECTION OF WELDS
All Non Destructive Testing (NDT) including radiographic examination
shall be performed in accordance with the requirements of API 1104.

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G.S.R 612(E)
REQUIREMENT:PAGE NO. 23, SCHEDULE 1D
Casing Requirements under Railroads,
Highways, Roads or Streets
Steel casing at road/railway crossings, when
provided to meet statutory requirements, shall
be designed in accordance with API 1102.

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Method of Crossing : Push Boring method
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 31, SCHEDULE 1D:
High Pressure Distribution System: Based on operation and
maintenance flexibility requirements,
-In steel distribution mains valve spacing should normally not
be more than 3 km

OISD 226,PAGE NO. 48, CLAUSE 5.2.3:
STRATEGIC VALVES
Such 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 3 KM for steel pipelines.

IGL is following the same.
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G.S.R 612(E)
REQUIREMENT: PAGE NO.16, SCHEDULE
1D:Buried piping inside the CGS area shall
have a minimum depth of cover of 1.2 m.
Where buried pipes come out of the ground,
the underground coating on the pipe will
continue for a length of at least 300 mm
above ground.
IGL IS FOLLOWING THE SAME.
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G.S.R 612(E)
REQUIREMENT:PAGE NO.22,SCHEDULE 1D:
Clearance between Pipelines or Mains and other
underground structures
(a) When a buried steel pipeline or main has to cross
any existing underground pipeline, cable, drain or
other services, the pipeline shall be laid at least 300
mm below from such services.
IN IGL THE PIPELINE IS LAID AT LEAST 500 mm BELOW
OTHER UTILITIES
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G.S.R 612(E)
(b) When laid parallel to any existing underground cable,
drain or other utilities, the pipeline or main shall be laid
with a clear distance of at least 300 mm from existing
utility.
IN IGL THE PIPELINE IS LAID AT LEAST 1M PARALLEL TO
EXISTING UTILITIES
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G.S.R 612(E)
(c) As far as practical, a minimum separation
of three (3) meter should be maintained
between the steel pipeline or main and
footing of transmission tower.
IGL FOLLOWING THE SAME
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G.S.R 612(E)
(f) While laying more than one new hydrocarbon
pipelines or mains in the same trench, clear separation
of minimum 500 mm shall be maintained between
adjacent pipelines.
IN IGL THE CLEAR SEPARATION OF AT LEAST 1M IS
MAINTAINED BETWEEN ADJACENT PIPELINES
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REQUIREMENT:
OISD 226 clause no.5.5, page No. 49
PIPELINE MARKERS
Route markers shall be placed on the entire
pipeline at a distance not exceeding 50 meter
and also at bends in the city.

G.S.R 612(E)
PAGE NO. 38 ,SCHEDULE 1E :
DISTRIBUTION PIPING MAINTENANCE.
Markers: Markers shall be positioned along
entire network at a maximum spacing of 100
meters in urban area and 200 meters within
industrial parks for steel mains.
IN IGL ,RCC MARKERS ARE PLACED AT EVERY 50M
and POLE MARKERS ARE PLACEDB AT EVERY 150M.
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Protection from Hazards
A warning tape of Yellow colour shall be laid 500 mm above the pipe.
IGL PRACTISING THE SAME.
OISD 226,PAGE NO. 51, CLAUSE 6: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.

Figure 1 (a) Concrete Slab

Figure 1 (b) Slab with support for
Impact protection of pipelines

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OISD 226,PAGE NO. 49,CLAUSE 5.7 PNG
ODOURISATION
Natural gas supplied through PNG distribution shall
have a distinct odour, strong enough to detect its
presence. In case ethyl mercapton is used as odorant,
the concentration range shall be 7 to 12.5 PPM.

G.S.R 612(E)
REQUIREMENT:PAGE NO.44,Schedule 1G:MISCELLANEOUS
ODOURISATION
A pre - determined quantity, equivalent to a max 12.5 ppm
Ethyl Mercaptan, or any other odorant shall be dosed into
the gas stream.
IN IGL ODOURANT LEVEL KEPT TO 10 PPM ON AN AVERAGE.
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 31 SCHEDULE 1D:
GAS SERVICE LINES
General Provisions Applicable to Steel, Copper and Plastic Service
Lines
Service lines shall be sized for a maximum flow velocity of 15 m / sec.

OISD 226, PAGE NO. 16,CLAUSE NO. 7.2.2 : Pressure limiting devices
Pipe size shall be such that gas velocities in the piping shall not be
more than 20 mtr / sec for unfiltered gas and 40 mtr/ sec for filtered
gas at peak condition. Sound pressure level shall be the maximum
limit prescribed by environment dept.

IGL PRACTICING THE SAME

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Hydrostatic Testing is carried out by following API 1110 (RP)
Hydrostatic Test is carried out to ensure the integrity of the
pipeline.

G.S.R 612(E)
REQUIREMENT:PAGE NO. 24, SCHEDULE 1D:Testing after
Construction General Provisions
Hold-up time for the pressure testing shall be minimum 24
hours for underground and four hour aboveground pipeline.
IGL FOLLOWING THE SAME

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Activities carried out in Hydrostatic testing
Volume Calculation for water filling
Thermal Stabilization
Thermo couple installation
Test Pressure = 1.4 X Design Pressure
Pressure Cycling 50%, 75% and 100% pressure cycles
(Air Volume Calculation)
Hold Pressure- After getting the clearance for Air
Volume Calculation, the pressure will be kept hold for
24 Hours
Recording of Pressure and Temperatures in graphs

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PNGRB requirement:-
G.S.R 612(E)
PAGE NO. 39, Schedule 1E:Leakage Surveys
Highly congested areas shall be surveyed using
gas detectors at least once in three months.
Other less congested areas shall be surveyed at
least once a year.
In ,IGL implementation of the same is in
process.

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Sectionalizing Valve Stations:
Sectionalizing Valve(s) shall be provided with blow down or vent line connection to
isolate the pipeline section and evacuate the pipeline section in case of an emergency
and repair.

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Functional check of all SVs and functional check of all
Under Ground Isolation Valves should be done at least
quarterly but IGL doing it monthly.
Monitoring of valve chambers are carried out once in
every month and draining of water & cleaning of mud,
painting of rusted portion, replacement of damaged
man hole caps are carried out on regular basis.

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Checking of PASSING VALVES/SV's is being
done QUARTERLY.
LEAKAGE FROM VALVES/S.V.'s/ FLANGES is
being done MONTHLY.
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Depth Survey is being done AS AND WHEN REQUIRED.

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According to standards min. 3 m gap should be
maintained from power cable ( >=66 kv). IGL is
maintaining the same ,otherwise installing P CELLS
Polarization cell
A device inserted in the earth connection of a
structure that drains only a small current from the
source used to provide cathodic protection for the
structure, but provides a low resistance path to
currents from high d.c. voltages and all a.c. voltages
carried by the structure.
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IMP-PNGRB ACT,REQUIREMENT:PAGE NO. 9,
Schedule 5
Thickness assessment and periodic review against
baseline values
Periodic thickness assessment for all CGD network
skids and pressure vessels and comparison to
baseline values shall be done once a year.
IGL is planning to carry out the thickness survey.
Thickness gauges are to be purchased.

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OISD 226,PAGE NO. 19, CLAUSE 9.2.5 :Cathodic Protection
System:
In addition to protective coating, buried pipelines shall also be
provided with cathodic protection system. CP system shall be
designed in accordance with NACE-RP-0169.
During construction period pipeline shall be protected by temporary
sacrificial anode based cathodic protection system. This may not be
provided in case Permanent Cathodic Protection system is provided
within 6 months of start of pipeline construction.
Permanent Cathodic protection system i.e. Sacrificial anode or
impressed current shall be brought into operation as soon as possible
following pipeline construction.
For Impressed Current Cathodic Protection System, it shall be
ensured that continuous power supply is maintained in cathodic
protection system.
Test leads points (TLPs) shall be installed at 1 km interval and at all
crossings on pipeline for taking electrical measurements to ensure
adequacy of the CP system.
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Potential Gradient Associated with a Cathodically-Protected pipeline
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CATHODIC PROTECTION (CP) is an electrical
method of preventing corrosion.
Initially pipeline will be protected by
providing Temporary Cathodic Protection
for a period of 2 years and converting it into
Permanent Cathodic Protection.

According to NACE SP0169, PSP reading
should be taken quarterly.
IGL takes ON READING on monthly basis.

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OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection
of Cathodic Protection System

A. Pipe to Soil Potential (PSP) Readings shall be
taken as follows:
i) PSP readings at feeding points shall be
monitored fortnightly.
ii) The PSP reading ( ON potential) at the test lead
points for entire pipeline shall be taken once in a
quarter. The PSP survey results shall be plotted
graphically to identify and locate cathodic holidays.

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OFF READING: It is the potential reading when TR unit is
OFF. OFF reading is more important than ON reading as in
case of OFF reading, voltage drop in the earth is not
included.
OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection of
Cathodic Protection System
Instant pipe to soil OFF potential readings at test lead
points of entire pipeline shall be taken once in a year. For
the purpose of logging the instant OFF PSP, care shall be
taken to minimize the effect of polarization decay., by
logging the reading within the first 1 or 2 seconds of
simultaneous switching of all Cathodic protection station
affecting that section of the pipeline. The PSP survey results
shall be plotted graphically to identify and locate cathodic
holidays.

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Cathodic protection rectifiers shall be inspected
once in two months.

OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection of Cathodic
Protection System
TRANSFORMER RECTIFIER UNIT MONITORING
According to NACE SP0169 TR unit monitoring should be done fortnightly.
But IGL does it WEEKLY.
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CURRENT DENSITY: It is the current per unit
geometrical area of the protected structure,
coated and uncoated, in contact with the
electrolyte.
It require summation of current taken by
temporary as well as permanent CP and dividing
it by total area. Current Density is calculated to
know whether current is supplied as per initial set
requirement.
IGL has carried out survey for 200 km and
balance is under process.
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NATURAL POTENTIAL: IGL do it once in year.
Natural Potential reading is taken to ensure
that interference is not occuring because of
other stray current. Normally natural potential
is-.45V to -.75V .If natural potential reading in
TLP is coming -1.1,-1.2 etc.It means interference
is occurring.

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CORROSION SURVEY AS PER OISD NORMS:

OISD 226,PAGE NO. 30,12.3.6 :Coating Survey
Pearson Survey / Direct Current Voltage gradient
(DCVG) / Continuous Potential Logging (CPL) survey
/ Current Attenuation Test ( CAT) shall be carried
out once in 5 years. Insulating joints and couplings
shall be inspected once in a year.
IGL is doing the same.

DCVG Meter
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Inline DCVG
Survey
Technique
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According to ASME B 31.8S Closed Interval Potential
Logging Survey should be done once in 5 year .IGL is
doing the same.

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INTERFERENCE SURVEY:
Electrical Interference
Electrical interference due to following shall also be
considered in cathodic protection design:-
Fault Currents
Fault current resulting from lighting or upset conditions of
electrical facilities could result in serious damage to
coating and pipe wall and danger to personnel. These
adverse effects may occur where a pipeline or main is
close to the grounding facilities of electrical transmission
line structures, sub-stations, generating stations or other
facilities that have high short circuit current-carrying
grounding networks.

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Pipeline Integrity is-
Ability of a pipeline to contain the product in required circumstances

OISD 226 PAGE NO. 29 ,CLAUSE 12.3.3: Pigging
Pigging operation shall be carried out for all pigable pipelines at least
once in a year for wet gas and once in 3 years for dry gas. Records of
quantity and quality of deposits (pig residue) collected after pigging shall
be chemically examined. Depending upon the out come of the chemical
analysis and review pigging frequency shall be increased.
12.3.4 Intelligent Pigging
Intelligent pigging survey ( IPS) shall be carried out once in 10
years and this data shall be compared with the data collected during
electronic geometric pigging .

NON-PIGGABLE LINE
PIGGABLE LINE-
101 KM - Planning for carrying out pigging is under progress.
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Post Assessment
Reassessment Intervals, Remaining Life, DA effectiveness & Health assessment
Direct Examination
Dig site verification, Coating assessment, Corrosion assessment, NDE.
Indirect Inspection
The operator is required to conduct flow modeling to determine the critical angle for water
transport where forward motion is prevented by gravity and surface tension.
Pre Assessment
Gathering data and deciding if the data is sufficient to be able to conduct
Dry Gas-Internal Corrosion Direct Assessment.
As per standards DIRECT ASSESSMENT should be done once in 5 year.
IGL is planning to carry out the DA.
DA Model Process
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PATROLING
(PNGRB GSR612E-Schedule 1E)
Entire primary
network at least
once in three
months
Secondary
network-at least
once every
month
REQUIREMENT:PAGE NO.
39,GSR612E-Schedule 1E
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.
IGL IS DOING THE PATROLING
ROUND O CLOCK.

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Either onsite or offsite emergency plan should be approved yearly.
G.S.R.612(E) REQUIREMENT:
PAGE no. 37, schedule 1E:
Training shall include mock safety drills, at least twice a year.
The training program should cover following:
1.Hazardous characteristics of Gas.
2.Familiarization with commissioning, operation and maintenance
procedures.
3.Hands on experience on operation of emergency and manual shut
down systems.
4.Effective isolation of any gas leak.
5.Safety regulations and accident prevention.
6.Firefighting equipment operation and its upkeep.
7.First Aid and Housekeeping.

IGL does safety drills quarterly.

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IMP-PNGRB ACT,REQUIREMENT:PAGE NO.25
Schedule 9
Review of Internal Audit
Internal Audit as per the checklist for CGD
Networks provided by Petroleum and Natural
Gas Regulatory Board shall be carried out by
the CGD entity every year;
IGL IS PRACTICISING THE SAME.

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IMP-PNGRB ACT,REQUIREMENT:PAGE NO.25
Schedule 9
Review of External Audit:
External Audit (EA) by third party, approved by the
Board, as per the methodology specified by the
Petroleum and Natural Gas Regulatory Board once
every 3 years.
IGL IS PRACTICISING THE SAME.

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Sr.no Description Status
in IGL
Remarks
1 Design/ specification documents
2 Route maps, alignment sheets, crossings, drawings, Piping and
Instrumentation Diagrams, station layouts Pipe Book/ Installation
Records
3 Surveillance inspection and maintenance reports
4 Records and maps showing the location of CP facilities and piping
5 CP Monitoring report
6 Leak burst and repair records
7 History cards of equipment
8 Pipeline Pigging Report
9 Material certification including dimension, metallurgy, DT and
NDT, strength, tightness, performance and functional report .
10 Welding records
11 PQR, WPS & Welder qualification records
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Sr.no. Description Status
in IGL
Remarks
12 Third Party technical audit report of infrastructure before Gas-
IN
13 Commissioning reports
14 Non-conformance/ deviation reports
15 Calibration records of Inspection, Measuring & Metering and
Test equipment
16 Audit compliance reports
17 Statutory clearances
18 Approved drawings/documents
19 HAZOP/ Risk assessment studies/ compliance to
recommendations
20 All operation & maintenance manuals
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Sr.no.

Description

Status in
IGL

Remarks

1 Cathodic Protection Design documents.
2 Soil Resistivity Survey Report
3 Electrical Interference Report
4 Inspection and maintenance report
5 Material certification reports Material certication including
dimension, metallurgy,performance and functional
6 Material test reports
7 Approved drawings/documents
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Design/ specification documents
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Route maps, alignment sheets, crossings,
drawings, Piping and Instrumentation
Diagrams, station layouts Pipe Book/
Installation Records

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Surveillance inspection and maintenance
reports
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59

Records and maps showing the location of CP
facilities and piping
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60

CP Monitoring report
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61

Leak burst and repair records
62
62

History cards of equipment
63
63

Pipeline Pigging Report
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64

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65

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