KM Bulletin Tech Papers On CNG and CGD and HDD Article

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Edition 4
A Quarterly Publication
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Edition 5
MECON Limited
Knowledge
Management
Committee:
Chairman
Mr. J. Mathew
ED (Power) & MR
MECON-Ranchi
Members
Mr. A.K.
Prabhakara
DGM (Electrical) &
HRD LPC
MECON-Bangalore
Mr. T.K. Saha
DGM & Convenor,
KMS Core
Committee
MECON-Delhi
Mr. T.K. Biswas

DGM I/c
(IT Services)
MECON-Ranchi
Mr. A.K.
Agarwal
AGM, IM
MECON-Ranchi
Mr. R. K. Panda
AGM, PP&EE
MECON-Ranchi
Convenor
Mr. Sanjeev
Kumar
AGM I/c (HRD)
MECON-Ranchi
Edited by:
Ms. Meenakshi
Malviya
APO (HRD)
MECON-Ranchi
A Quarterly Publication
August -2009
December -2009
Sharing knowledge is not about giving people something, or getting

something from them. That is only valid for information sharing. Sharing
knowledge occurs when people are genuinely interested in helping one
another develop new capacities for action; it is about creating learning
processes. Peter M. Senge, The Fifth Discipline
Director (Commercial) and Director (Engineering) superannuated in the months of
August and November 2009 respectively. In addition to their priceless contribution to
the organization, they have set examples by their conduct of promoting such
learning processes to foster the knowledge management venture in MECON.
Encouraged by the response towards the previous two competitions, we are coming
up with our third attempt in the series of KM Article writing competition. We are
thankful to all the MECONIANS for their motivating and perpetual contribution
towards this step of sharing the knowledge residing within MECON.
Whats Inside?
Content
Topic, Rules & Guidelines for the next KM Article writing
Competition
Status of Intra/ Inter section lecture sessions in last quarter &
Document count growth in e-archive
KM News: International, India & At MECON Ltd.
Articles of the Best KM Contributors December 2009
Page No.
2
3
4
6-61
KM Article Writing Competition

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KM Bulletin (Edition 5) - December 2009
Page - 1
TOPIC: Journey of MECON in Rolling Mills & other services related to

Metals
Last date for entry: 30th January 2010
That gives you over a month to put your valuable experience in the form of an
article, so get busy!
Why enter the contest?

Winner's Prize: The Management of MECON LIMITED will award the winners
with a memento and a certificate.
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Publicity: The best articles will be printed in our next KM Bulletin along with
photograph of the contributors.
Knowledge: The main reason for entering the contest is propagation of your
knowledge. Writing down your intellectual inputs is one of the most essential
components of the learning process. This is a great opportunity for you to show
that you are an individual with lots of information and you are willing to promote
the knowledge sharing culture at MECON.
Respect: Together with this you have bright prospect to get respect and
feedback on your work from others interested in your work. This will be an
incredibly valuable experience.
Rules of the Contest
It's simple. You have to write an article in English covering not more than 4
pages (written on one side) with a font size of 12 for Body text and 14 for
Headings in Arial.
Only one (1) entry per person and group efforts will not be considered.
The articles will be judged by the panel comprising of the senior officials of
concerned sections of MECON.
Entries (in MS-Word format) are to be sent in hard copy to HRD Section, MECON,
Ranchi and a soft copy of the article with a scanned passport sized photograph of
the author is to posted at KM@meconlimited.co.in
Please ensure that your Name, Personal No., Designation & Section is mentioned
in the article.
Please submit the article within the time stipulated and any article received after
that will not be accepted.
Guidelines for Articles content
Strength, Experience and innovative practices belonging exclusively to MECON in

Rolling Mills & other services related to Metals
Comparison of the Processes and standards followed by MECON with other
competitors in the same domain, i.e. Analyzing MECONs stand in the market
The comparison may lead to finding of certain areas of improvement for MECON
and the individual may help in doing so by suggesting some practices based on
his knowledge and observation of the market
The article should be reflection of the individuals own experience and learning
about the above mentioned points
Intra/Inter-section Sessions @MECON, Ranchi
Page - 2
S.No
Title of the Session
1.
Basic Terminology
Relevant to Thermal
Power Plant
Instruments Transformer
2.
Section
Date
Presenter
PP & EE
07.09.09
Shri V. Trivedi & Shri Arun Minz

(PP & EE)
Electrical
23.09.09
Shri M.K. Jaiswara, ADE (PT&D)
3.
Performance Evaluation of
System Generator
PP & EE
09.10.09
Shri D. Bose, ADE (PP & EE)
4.
Blast Furnace
IM
16.10.09
Shri S. Sengupta, AGM (IM)
Intra/Inter-section Sessions @MECON, Bangalore
K
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S.No.
Section
1.
Awareness Programme on
ISO 9001:2008 QMS
2.
Training Programme on
"ISO 9001:2008 Version
of QMS"
Interactive Training
Programme
Quality
Steering
Committee
Quality
Steering
Committee
Vigilance
3.
Date
Presenter
07.08.09
14.08.09
21.08.09
14.09.09
Mr. G.V Aruna,Mr.Supriya Ray

& Mr.G.Krishna Kumar
27.09.09
Mr. Solomon Yash Kumar Minz,

IPS & CVO
Quality Steering Committee
Intra/Inter-section Sessions @MECON, Delhi
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S.No.
Section
Date
Presenter
1.
Solar system
Electrical
07.10.09
Mr. Aashis Moyal, ADE
2.
Pipeline Construction - I
Oil & Gas
26.10.09
Mr. A. K. Jha, Sr. Manager

(Projects)
Based on data mentioned above, Quality Steering Committee from Bangalore is

declared to be the Brightest Performer for this quarter.
CONGRATULATIONS!!!
Document Count Growth in e-archive (as on 4th December 2009)
Page - 3
LATEST KM NEWS
KM @International level
* KM World Announces Finalists for 2009 Promise and Reality Awards
The winner is chosen from a list of Knowledge Management companies that
provides innovative solutions for best knowledge management practices into
their business processes.
Some of the KM Promise finalists are:
Alfresco : It is an open source enterprise content management system
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Autonomy : It provides technologies for computers to understand electronic data

Cabinet NG : It is a provider of document management and workflow software
Cormine Intelligent Data : It integrates sources of data to produce query results
Expert System: It is a semantic indexing, search and analysis tool
KM @ National level
* 2009 Indian Most Admired
Enterprise
Bharti Airtel
eClerx
Eureka Forbes
HCL Technologies
ICICI Bank
Infosys Technologies
Larsen & Toubro, E&C Division
MindTree Ltd.
Patni Computer Systems
Reliance Industries
Tata Consultancy Services
Tata Steel
Tech Mahindra
Wipro Technologies
Knowledge Enterprise (MAKE) Finalists

Sector
Telecommunications
Services Information & technology services
Consumer products
Information & technology services
Financial services
Engineering & construction
Diversified industrials
Metal fabrication
Note: A total of 14 organizations were selected as 2009 Indian MAKE Finalists
* Workshop on Measuring KM in Projects: Why, What and How (30th

October, 2009) held at Bangalore:
Many enterprises have been successful in instilling the culture and practice of KM
across their organizations. In the initial years of KM, however, in spite of having
made deep inroads into the organization, it continues to possess the character of an
undifferentiated corporate. This is largely due to the nature of KM during this time
where, in responding to its appeal for bridging islands of knowledge across the
organization, the innate impulse of KM teams is to facilitate greater flows of
relatively generic and more widely applicable knowledge than of highly contextbound and locally relevant knowledge. While the former significantly caters to long
term knowledge needs of employees, the latter types of knowledge critical to the
immediate needs of business - are not well developed in the supply chain thereby
leading to a weakened perception of the value of KM. It may be recognized therefore
that for a KM solution to be enduring, it inevitably has to draw its sustenance from
the creative interplay between the local and the global, the specific and the generic,
and the immediate and the long-term applicable forms of knowledge in the
organization.
The current focus of KM in many organizations is on two primary issues: how do we
derive concrete business benefits from KM and how do we measure and demonstrate
the benefits as returns on investment made in KM? The workshop addressed both of
Page - 4
these issues by presenting a framework for adapting and fine-tuning generic KM

practices in particular projects to generate concrete business benefits, as well as for
measuring, analyzing and benchmarking critical KM parameters in projects.
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KM @MECON
* KM Article writing Competition- August 2009:
The articles published in the 4th edition of KM Bulletin- August 2009 were ranked
and Director (Engineering) awarded the winners with certificate of appreciation
and a memento.
We gladly announce the Best KM Contributors of August 2009:
First Rank:
Shri. S. K. Verma, AGM (Iron Making), MECON, Ranchi
Second Rank: Shri. S. K. Bhattacharjee, AGM (Iron Making), MECON, Ranchi
Third Rank:
Shri. A. K. Agarwal, AGM (Iron Making), MECON, Ranchi
Fourth Rank: Shri. Bikas Pandey, SDE (SMS), MECON, Ranchi
CONGRATULATIONS TO ALL THE WINNERS!!!

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In response to the second competition in series of KM Article Writing

Competitions, we received four articles on the topic of Journey of MECON in
Oil & Gas Sector from MECON, Delhi.
We are presenting the enriched articles of the following KM Contributors:
1. Shri. K. K. De, GM (Oil & Gas) (Page 6-31)
2. Shri. H. Chandnani, DGM (Civil) & Project Coordinator (Page 32-40)
3. Ms. Shalini singh, ADE (Iron Making) (Page 41-52)
4. Shri. R. K. Narayan, DGM (Oil & Gas) (Page 53-61)
Wish you a valuable plunge into the ocean of knowledge presented in the
form of articleshave a great reading time!!!
Page - 5
CNG AND CGD PROJECTS

K. K. De, GM (Oil & Gas)
MECON, Delhi
Background:
Rapid growth of Delhi after 60s resulted in significant increase in environmental pollution.
During the 70s and 80s, the national capital, saw an unprecedented growth in population,
vehicles and small-scale industries, which caused serious ecological imbalance and
environmental degradation.
This rapid growth of population along with an increase in vehicular population as well as
industrialization and has resulted in an increase in the levels of various air pollutants, namely
(1) Oxides of Sulphur, (2) Oxides of Nitrogen, (3) Suspended Particulate Matter, (4) Respirable
Suspended Particulate Matter, (5) Carbon Monoxide, (6) Lead, (7) Ozone, (8) Benzene, (9) and
Hydrocarbons.
Based on the ambient air quality monitored by the Central Pollution Control Board in 1998, it
was found that the contribution from vehicles to the ambient air pollution of Delhi is about 72%
of the total pollution from other industries including thermal power plants and domestic
sources. It was also noticed that there was a rising trend in sulphur-dioxide and Nox of about
25% per annum. Table- 1.1 and 1.2 indicates the contributions from various sectors to ambient
air pollution. The contribution from the vehicular sector increased from 23% in the year 1970/
71 to as much as 72% by the year 2001.
Sources of Air Pollution
Table : 1.1
Source
Industrial
1970-71
56%
1980-81
40%
1990-91
29%
2000-01
20%
Vehicular
Domestic
23%
21%
42%
18%
64%
7%
72%
8%
About 72 % Of Total Air Pollution Comes From Transport Sector

Sector-Wise Emissions In Delhi (Metric Tonnes Per Day)
(Statistics of 2000-01) Table : 1.2
Pollutants
UHC
SPM
Nitrogen Oxides
Sulphur Dioxide
Carbon Monoxide
Total
Transport
Power
Industry
Domestic
Total
310
320
13
50
60
12
135
157
143
20
323
11
121
35
12
179
810
128
117
1063
1301
324
249
146
2020
About 72 % of total air pollution comes from transport sector (SOURCE : CPCB)
Page - 6
On July 28, 1998, while hearing a Public Interest Litigation the Honble Supreme Court directed
among other things, the replacement of all pre-1990 Auto rickashaws and retrofitting all the
post 1990 auto rickshaws and taxis with devices running on clean fuels. In addition to this, the
Honble Court also directed the withdrawal of buses which were more than eight years old and
conversion of the rest of the citys bus fleet to CNG based vehicles and setting up of more CNG
filling station. This was based on the recommendations of Environment Pollution (Prevention &
Control) Authority (EPCA), also known as Bhure Lal Committee, set up by the Ministry of
Environment & Forests.
In late 2001, the Delhi Govt. prepared a phase out plan for diesel buses, which was approved
by the Honble Supreme Court. Under this plan, 800 diesel buses per month were to be phased
out every month between April, 2002 and November 2002. Following this plan, the entire public
city bus fleet was converted to CNG for which, Govt. of Delhi provided adequate funds. Apart
from buses, all pre 1990 auto rickshaws were also to be replaced with new auto rickshaws and
post 1990 auto rickshaws were to be retrofitted with CNG kits.
Worldwide, there are more than 10.5 million NGVs on the roads as of August 2009, with the
largest number of NGVs in Pakistan, Argentina, Brazil, India, Italy and China, with South
America leading with a global market share of 48%. At present there are about 3,00,000 CNG
vehicles in NCT of Delhi, including about 13,000 CNG buses, about 4,000 CNG RTVs, about
1,70,000 CNG private cars, 30,000 CNG taxis and about 90,000 CNG autos (3-wheelers).
With CNG accepted as an alternative clean fuel, another 16 states including the bordering
states of Delhi were set for making CNG network as per the recommendation of Bhure lal
Committee. CNG is also the cheapest of auto fuels, as per prevailing prices on date.
MECON in CNG and CGD Projects:
In July 1999, M/s Indraprastha Gas Limited, (a Joint venture company of GAIL, BPCL and
Delhi Govt.) appointed MECON as their Project Management consultant (PMC) to set up CNG
and City gas distribution network in NCT of Delhi for Phase I (to meet the deadline set by the
Honble Supreme Court) and later (in 2001), for expansion of CNG and City gas distribution
network further in NCT of Delhi under Phase II.
After successful completion of expansion programme of CNG and City gas distribution network
in Delhi, MECON has also completed CNG distribution network in another 7 cities (namely,
Ahmedabad, Vijayawada, Agartala, Lucknow, Agra, Grearer Noida and Pune) as PMC. Presently,
MECON is executing fresh PMC contracts for CNG and City gas distribution (CGD) project
(including expansion programme) for six cities, namely, Pune, Lucknow, Agra, Hyderabad,
Kakinada and Agartala.
In this article, a brief overview of CNG and CGD project has been presented.
About CNG and its advantages over other available fuels :
CNG is nothing but the natural gas in compressed form. Natural Gas is basically a
mixture of hydrocarbons consisting of approximately 80 to 90 percent methane in gaseous
form. Due to its low energy density, it is compressed to a pressure of 200 to 250 Kg/cm2 (to
enhance the vehicle on-board storage in a cylinder) and hence the name Compressed Natural
Gas. It is stored and distributed in Steel (now Aluminium/Composite/Metal-composite also)
cylinders at a normal pressure of 200220 bar (29003200 psi). CNG's volumetric energy
density is estimated to be 42% of LNG's (liquefied natural gas), and 25% of diesel's. Natural
Gas is colourless, odourless, non-toxic but inflammable and lighter than air. CNG is not a liquid
fuel and is not the same as LPG (liquefied Petroleum Gas), which consists of propane and
butane in liquid form. Natural gas is normally transported from the source upto the users by
pipelines. The typical composition and physical properties of CNG (i.e. Compressed Natural Gas)
is as follows:
Typical Composition of CNG: Table : 1.3
Methane
88%
Page - 7
Ethane
5%
Propane
1%
CO
5%
Others
1%
Total
100%
Note: As per the notification of Central Pollution Control Board (CPCB), Methane content in
Compressed Natural Gas to be used shall not be less than 87%.
Physical Properties of CNG:
Non-toxic Natural gas being lead/sulphur free, its use substantially reduces harmful engine
emissions. When natural gas burns completely, it gives out carbon dioxide and water vapour the very components we give out while breathing!
Lighter than air Natural gas being lighter than air, will rise above ground level and disperse
in the atmosphere, in the case of a leakage.
Colourless Natural Gas is available in the gaseous state, and is colourless.
Odourless The gas in its natural form is odourless, however, ethyl mercaptan is later added
as odorant so as to detect its leakage.
Technology in CNG cars:
Any existing petrol vehicle can be converted to a bi-fuel (petrol/CNG) vehicle. Authorized shops
can do the retrofitting. This involves installing a CNG cylinder in the trunk/boot, installing a
CNG injection system and the electronics. CNG cylinders can be made of steel or aluminum.
The equipment required for CNG to be delivered to an Otto-cycle engine includes a pressure
regulator (a device that converts the natural gas from storage pressure to metering pressure)
and a gas mixer or gas injectors (fuel metering devices). Earlier-generation CNG conversion
kits featured venturi-type gas mixers that metered fuel using the Venturi effect. Often assisting
the gas mixer was a metering valve actuated by a stepper motor relying on feedback from an
exhaust gas oxygen sensor. Newer CNG conversion kits feature electronic multi-point gas
injection, similar to petrol injection systems found in present generation cars. However, a
suitably designed natural gas engine may have a higher output compared with a petrol engine
because the octane number of natural gas is higher than that of petrol as this would allow for
an engine design with a higher compression ratio.
CNG compared to LNG:
CNG is often confused with liquefied natural gas (LNG). While both are stored forms of natural
gas, the key difference is that CNG is in compressed form, while LNG is in liquefied form. CNG
has a lower cost of production and storage compared to LNG as it does not require an
expensive cooling process and cryogenic tanks. However, CNG requires a much larger volume
to store the same mass of gasoline or petrol and the use of very high pressures (3200 to 3600
psi, or 220 to 250 bar).
Comparative Study of CNG Properties w.r.t. other automotive fuel and its Safety Aspect:
The properties of unleaded petrol, diesel, LPG and CNG are as mentioned in the table-1.4
Comparative Properties of available Fuels
Table : 1.4
Page - 8
PROPERTIES
UNIT
PETROL
DIESEL
LPG
CNG
Relative Density
WATER=1
0.74
0.84
0.55
Relative Density
AIR=1
1.285
0.64
Auto Ignition temperature
360
280
374
580
1-8
0.6-5.5
2.2-9.0
5-15
Flammability Range
% IN AIR
Flame Temperature
2030
1780
1983
1900
Octane No.
87
93
127
Conclusion : CNG is a safe fuel with better combustion quality

The data indicates that CNG is less likely to auto-ignite on hot surface than gasoline or diesel
and requires high energy for ignition. In case of spillage of liquid fuel (LPG), which is heavier
than air, the liquid tends to spread at ground level and burn at the surface, if catches fire.
Natural gas is lighter than air, so in case of leakage, the gas will not accumulate at the ground
but will disperse in the atmosphere. In case of fire, the gas will burn above ground level if
combustible/explosive mixture (which contains natural gas in the range of 5-15% only by
volume) is formed.
CNG Emissions:
A comparative table of emission measurements made by the apex institutes of India viz
Automotive Research Association of India (ARAI), Vehicle Research & Development
Establishment (VRDE) and Indian Institute of Petroleum (IIP) are as reproduced below.
Reduction in Mass Emission with CNG retrofitted kits in Petrol Vehicles as Certified by
ARAI/ VRDE in Gm/Km
Table : 1.5
Type of Vehicle
Pollutant
Petrol
CNG
Maruti Omni
CO
19.79
0.55
97
HC
1.14
1.02
11
CO
4.94
0.59
88
HC
1.86
1.42
24
CO
18.38
0.94
95
HC
2.83
2.03
28
CO
15.60
2.04
87
HC
2.57
1.92
25
CO
52.16
0.78
98
HC
6.37
4.33
32
HC
3.26
1.26
63.19
CO
5.48
1.57
71.35
CO
47.44
27.60
41.82
Nox
0.25
0.20
20.00
Maruti Gypsy
Premier Padmini
Premier 118 NE
Ambassador
Bajaj three wheeler
% Reduction
Conclusion : CNG is the cleanest fuel operating today

*
As per the notification of Ministry of Surface Transport (MoST), Methane content in
Compressed Natural Gas to be used shall not be less than 80%.
Page - 9
Advantages of CNG over other alternative fuels:

i)
CNG is the cleanest burning fuel operating today
The vehicles converted to CNG produce little or no emissions.

CNG Yields compared to Petrol
99% less CO; 52% less hydrocarbons;
36% less NOx; 100% less SOx; 100% less particles
CNG is the safest fuel operating today.
CNG is less likely to auto-ignite on hot surfaces, since it has a high auto-ignition temperature
(540 degrees centigrade) and a narrow range (5%-15%) of inflammability. It means that if
CNG concentration in the air is below 5% or above 15%, it will not burn. This high ignition
temperature and limited flammability range makes it an inherently safe fuel. In the event of a
spill, it poses no threat to land or water. CNG also disperse rapidly, minimising the ignition risk
compared to petrol or diesel.
iii)
CNG has better combustion quality than any other motor fuel.
CNG has much higher octane number which makes it a good alternative for spark ignition
engine. CNG driven vehicles' acceleration speed is greater than that of petrol or diesel vehicles.
Moreover due to cleaner burning characteristic of natural gas, CNG vehicle engines will run
more efficiently, thereby enhancing the life of the vehicle.
iv)
CNG is the most economical fuel operating today
On energy equivalent basis, CNG cost approximately 1/3 the cost of gasoline in India. This
means that the operational cost of vehicles running on CNG, as compared to those running on
other fuels, is significantly low at the prevailing price of fuel in India. Operational cost of CNG
vehicles in India is 68% lower than petrol and 36% lower than diesel.
v)
CNG mixes evenly in air
Being a gaseous fuel CNG mixes in the air easily and evenly. Being non-corrosive, it enhances
the longevity of spark plugs.
Methodology Adopted for CNG Distribution:
As already stated earlier that CNG (Compressed Natural Gas) is nothing but the natural gas in
compressed form. Due to low energy density of Natural gas, it is compressed to around 250
Bars for automobile use so as to facilitate increased onboard storage in the vehicles. Presently,
CNG dispensing in Delhi is done through four types of CNG stations namely, Mother stations,
On-line stations, Daughter station and Daughter Booster station. A brief technical
description of each type of station is presented below. The choice of different types of CNG
station at a location is primarily guided by cost of laying the steel pipeline upto the station
connecting the natural gas supply source, the requirement of CNG quantity and the types of
vehicles (ie, no.of buses /cars/3 wheelers to be filled.
Page - 10
Fig : 1.1
Schematic Diagram of Methodology Adopted for CNG Distribution
Mother Stations: Mother stations are installed on the pipeline route and are connected to the
natural gas pipeline for its continuous supply. On these stations, reciprocating compressors of
capacity 1200 SCM/hr. at suction (inlet) pressure 17-19 kg/cm2(g) and discharge (outlet)
pressure of 250 kg/cm2(g) are installed taking gas from pipeline. The Prime movers of these
compressors are either a Gas Engine or an Electric motor. However, except in Mumbai, most of
the these compressors are normally Gas Engine driven. Stationary storage cascades (as many
as the number of compressors) are installed for smooth functioning of station. They also act as
buffer for CNG supply as well as for the purpose of banking as per need. Exact number and
capacity of compressors, cascades and dispensers depends upon the requirement and demand
of CNG at these stations. Direct retailing/ dispensing are done to different types of vehicles
both car/autos and buses as per requirement. As the name suggests, a mother station also
feeds the daughter stations by way of supplying CNG through mobile cascades (usually of 2200
water litre capacity each). Normally each mother station has at least one filling point for filling
of mobile cascades.
Page - 11
Fig : 1.2
Schematic Diagram of a CNG Mother Station
On-line Stations - Online stations are also installed on the pipeline route and are connected to
the natural gas pipeline for its continuous supply. These stations are similar to the Mother
stations except that the facility of Mobile cascade filling is not provided at these stations. On
these stations, generally compressors with capacity of 550/600/750 SCM/hour and discharge
pressure of around 255 kg/cm2g are installed taking gas from pipeline. These compressors are
normally Electric Motor driven (because of comparatively low power consumption), although
gas engine driven on line compressors also exist. Number and capacity of compressor, cascade
and dispenser depends upon the available suction pressure and requirement/demand of CNG at
the on line station.
Fig :
1.3
Sche
mati
c
Diag
ram
of a
CNG
On
Line
stati
on
Daughter Station - These are the stations where natural gas pipeline is not available, At these
stations, CNG is transported through cascades (Bundle of Cylinders) normally of 2200 water
litre capacity fixed on light commercial vehicles (LCV). These cascades are called mobile
cascades which are filled at Mother Stations. At daughter stations, CNG is dispensed to vehicles
on pressure equilibrium principle. After few fills of the CNG vehicles, the pressure in the
cascade placed at daughter station gets reduced resulting in lesser quantity of CNG fills to the
subsequent CNG consumers due to low pressure in the cascade leading to general customer
dissatisfaction. It may be noted that at a daughter station, the CNG supply is made available
only through mobile cascades. Dispensing CNG from a daughter station generally incurs higher
cost but is the only option where there is no pipeline connectivity to source Natural Gas.
Daughter Booster Station - These are also the stations, where natural gas pipeline is not
available like daughter stations. The only difference between daughter station and daughter
booster station is that, a Booster Compressor is installed in-between the mobile cascade and
the dispenser. The function of the Booster Compressor is to draw the gas from the mobile
cascade right from 180 kg/cm2 pressures to as low as 30 kg/cm2 pressure and boost it to 200220 kg/cm2 before it is fed to CNG vehicles . Installation of booster compressor helps in higher
cascade capacity utilization and increased customer satisfaction. This also helps in evacuating
the mobile to a larger extent resulting in less cascade movement on road.
Page - 12
Schematic Diagram of a CNG Daughter Booster Station

Mega CNG Stations: Mega CNG stations have been conceptualised to cater to a large fleet of
vehicles, particularly the buses. The objective is to provide comfortable filling experience to the
consumers when they come to the station for refueling. Mega CNG stations are constructed on
much larger plot of land than that of conventional CNG Mother stations, as a result of which
more number of Compressors and Dispensers are installed and more number of vehicles are
simultaneously refuelled at such stations. A number of Mega CNG stations have been
commissioned in Delhi (at Rohini, Sector 23, Patparganj and Sarai Kale Khan in 2003). The
Mega CNG station at Patpargang, East Delhi, can simultaneously refuel five buses and eight
other vehicles (cars, autos, mini buses etc.). Built on a plot of size 75 m X 40 m, it has the
capacity to comfortably refuel CNG to 800 buses and over 1500 other vehicles daily. A Mega
CNG station at Chinchwad, Pune, (built in 2007) can simultaneously refuel four buses and
sixteen other vehicles (cars, autos, mini buses etc.). It has the capacity to comfortably refuel
CNG to 600 buses and over 3000 other vehicles daily.
Components of CNG Network:
Main Pipeline/Gridline (underground) network from CGS (City Gate Station) including Spur lines
(branch lines from Main Gridline through tap offs) upto the CNG stations. These are 3 layer PE
coated CS pipes
Odorising system
Sectionalizing Valve Stations,
CS Ball/Globe/Gate Valves as per requirement & other piping components, regulating
station equipment, etc.
Station Piping & SS Tubing for high pressure gas at CNG stations.
CNG Compressors, Cascades & Dispensers
CNG Stations.
All the above components are briefly discussed below:
About City Gate Station (CGS) :
It is the entry point of Natural Gas from a sub-transmission high-pressure gas pipeline to a
City, hence the name
Components of City Gate Station (CGS) :
Inlet & Outlet isolation valves
Knock Out Drum (KOD)
Filter (Cartritge)
Metering Unit (Turbine / Orifice / Ultrasonic)
Gas Chromatograph (GC)
Page - 13
Pre-heater (if required)

Pressure reduction skid comprising
Active & monitor combination with a minimum 50% redundancy
Stream discrimination arrangement
Slam shut valve for over & under pressure protection
Creep relief valves.
Odorising Unit
A City Gate Station (CGS)

About Steel Pipeline:
Steel Pipeline Design Parameters :
Max. Op. Pressure, kg/cm2(g)
by client)
Op. Temperature, C
Design Temperature
19 kg/cm2 (g) or 24 kg/cm2 (g) (as desired
:
:
5-50
Buried 45C
Above Ground 65C
Population Density Factor
:
0.4 (Class IV)
Design Life
:
30 Years
Corrosion Allowance :
0.5 mm for buried pipeline; 1.5 mm for A/G station
Pipeline Efficiency/ Roughness
:
0.9 / 45 micron.
piping
The sizes of pipes are finalized after carrying out simulations and sizing calculations based on
peak load as per market survey data. A minimum thickness of 6.4 mm is kept as per guideline
of PNGRB.
Selection of Steel Pipes :

Pipe size
Standards & Codes
Table : 1.6
Grade
Wall Thickness (mm) for 300#
Manufacturing Process
Page - 14
ASTM A106
API 5L
6
8
10
12
16
18
Grade B
Sch 80, 5.5
Seamless
Grade B
6.4
ERW / Seamless
API 5L
Grade B
6.4
ERW / Seamless
API 5L
Grade B
6.4
ERW / Seamless
API 5L
Grade B
As per calculation, but min. 6.4
ERW / Seamless
API 5L
Grade B
ERW / Seamless
LSAW / HSAW
LSAW / HSAW
Grade
X42
Grade
X52
API 5L
API 5L
B/
X42/
Insulation Joints :
Insulating joints are provided at transition point of aboveground & underground portion of
pipeline and at tap-off points for electrical isolation. These will be mono-block type suitable for
both above/ underground installation.
Pipeline External Corrosion Protection :
Three-layers of PE Coating are provided for the pipeline.
Temporary Cathodic Protection are provided to take care during construction period.
Impressed Current based Permanent Cathodic Protection System are provided.
Anode bed is designed for a service life of 35 years.
About Odorising system :
Natural gas is odorless. For safety reasons, odorant must be added to natural gas in order to
detect leaks in natural gas systems. Typically, odorant is transferred from an odorant storage
chamber to natural gas flowing in a gas line. The odorant commonly used is Ethyl Mercaptan.
Operating Principle: Programmable Pressure Injection System / Automatic dozing system with
solenoid operated pumps and Pneumatic Panel with Cabinet & Electronic Control unit. For the
Odorizer auto mode operation, flow signal is provided in form of analogue 4-20 mA serial
communication data inputs/ pulse from flow computer/ metering device. Therefore, the
Electronic Control unit of Automatic dozing system should be able to accept two nos. of 4-20
mA signals/serial inputs corresponding to flow rates of of each flow computers of dual stream
metering system.
About Sectionalizing Valve Stations :
Sectionalising valve stations are installed at approximately every 2.5-3 km (to stop the supply
of gas through these valves in case of any accident and also to facilitate tap offs, both hot and
cold). Venting provision are kept at approximately every 5-6 Km by way of providing a vent
pipe of min. 3m height above ground and located at a safe distance from the valve assembly.
All Main line sectionalising valves are full bore ball valve with extended stem. 4 dia. Tap-offs
are also provided at these locations for city gas distribution.
About Ball Valves :

Selection criteria of Ball Valves: Summarised in table 1.7
Size
Code
End Connections
Table : 1.7
Mounting type
Page - 15
Less than 2
BS 5351
Butt Welded / Flanged Ends
Floating
2 to 6(150#)
API 6D
Butt Welded Ends / Flanged Ends
Floating
8
and
API 6D
above(150#)
Trunnion
2 to 4(300#)
API 6D
Floating
6
and
API 6D
above(300#)
Trunnion
Both 150 and 300 class ball valve is used based upon the operating pressure class.
The maximum distance between two isolation valves is restricted to 3 km.
Important Features of Ball valves:
Fire Safe design: As per API 607/ 6FA. If soft seal is used in design / construction.
Double Block and Bleed: To facilitate complete flush, drain and venting of the valve body
cavity
Anti static design:
Anti Blow-out Design: The stem is designed with integral T-type shoulder to provide blow-out
proof effectively.
Selection Criteria of CNG Compressors and Dispensers in CNG Stations:
The major equipment (i.e. compressors and dispensers) in CNG Mother and On Line stations
are selected based on dispensing capacities and corresponding compression capacities of these
stations at peak load. The dispensing capacities of these stations at peak load are generally
considered as per market survey data or as given by client. The basis of selection of
compressors and dispensers is explained in the following table.
Table : 1.8
Selection of CNG Compressors and Dispensers in Mega Station at Chinchwad at peak load
No.
of
dispensers
Dispensing capacity at peak load

No.
of
vehicles
200
Buses/ day @
80 kg/ bus
500
Cars/ day @
5 kg/ car
500
Autos/ day @
2 kg/ auto
30
LCVs
(2200
WL) @ 350
kg/ LCV
Total
Load
= 16000
Uni
t
kg/
day
Compression capacity: 1:1.5

Gas Density : 0.8 Kg/SCM
Compression capacity : 45000 Kg/day
: 56250 SCMD
= 2500
kg/
day
= 1000
kg/
day
10500
(Equivalen
= t to 5250
autos)
= 30000
3 Bus + 3
Car
kg/
day
kg
/
day
Capacity of 2x1200
SCMH (with 18 hrs.
running) =
Capacity
of
1x750
SCMH (with 18 hrs.
running) =
Capacity
(2x1200+1x750)
SCMH =
of
4320
0
SCMD
1350
0
SCMD
5670
0
No.
of
Compre
ssors
2x1200
+
1x750
SCMH
SCMD
Note: Compression capacity is met.
About CNG Compressor packages:

Components of CNG Compressor packages:
Gas compressor
Prime mover
Drive assembly
Page - 16
Pressure vessel
Piping (sizes and routine), Valves and fitting
Air exchanger (Heat exchanger)
Common base frame
Acoustic enclosure
Electric control panel with PLC
Internal Electrical devices
Safety features.
Gas compressors: These are reciprocating compressors (due to low/medium volume and high
pressure). Number of stages is decided on the basis of compression ratio (Discharge pressure/
Suction pressure) & rise in temperature in each stage.
Prime mover: It may either be a Gas engine or an Electric motor whose power is decided
based on the BKW of compressor at design condition plus auxiliary power (of heat exchanger)
with 10% extra.
Drive assembly: It may either be direct drive coupling or Belt drive. However, if the driver
speed is more than 1500 rpm, direct drive is preferable (due to less transmission loss).
Pressure vessel: Sizing as per API after conducting Pulsation analysis as per API-618
approach-3. Mechanical design as per ASME Sec VIII.
Internal Piping (Mechanical design):. Sizing as as per Pulsation analysis. Mechanical design
as per ASME Sec VIII.
Acoustic enclosure: The adequacy of size of enclosure and thickness of mineral wool shall be
so decided as to reduce the overall noise level to 70 dbA at 1 meter distance from the
enclosure.
Electric control panel with PLC: The control panel shall be flame proof with area
classification mentioned in the Technical specification. The most important in the PLC is that the
flow chart, the logic write up and the operation philosophy shall be so created that the software
is operator friendly and suitable for smooth operation of the entire package.
Electrical devices: All Electrical devices shall meet the requirement for the area classification
specified in the Technical Specification.
Safety Features for Compressor package:
Emergency shut down (ESD) system in control room
Fail safe system incorporated to stop compressor, isolate cascade, dispenser & compressor
suction line, ground ignition and cut off fuel gas supply to engine on activation of ESD switch
Anti-static anti-fire type drive belt
Two L.E.L detectors and two Ultra Violet (UV) flame detectors for compressor enclosure
Instrumentation to prevent air-ingress in the system during start up, operation and shut down
PSV, NRV, IV, solenoid valves, probes for sensing temperature and pressure
Proper earthing of Compressor and Prime mover
Twin cylinder configuration, automatic CO2 flooding system to effectively cover the entire
enclosure (one CO2 cylinder inline and second standby)
Hoses, junction boxes, tubes made of plastic / rubber prohibited inside enclosure
Maximum vibration level at cylinder limited to 7.5 mm/s
Acoustic enclosure to restrict noise level below 70 dB(A) with flame proof lighting with proper
ventilation
Alarms and Trips for Compressors:
Low lubricating oil pressure
Low lubricating oil level
Lubrication failure
High discharge temperature at each stage
Page - 17
High discharge Pressure at each stage

Low suction pressure
High suction pressure
High BDV pressure
High vibration
Alarms and Trips for Gas engine:
Low oil pressure
Low oil level
High oil temperature
No coolant flow
High coolant temperature
Low coolant level
Engine over speed
Engine over load
High vibration
Gas detection (LEL)
Flame detection (UV)
ESD
Failure of forced ventilation system
About CNG Dispensers:
Type and basic features of CNG Dispensers
Type
of
Dispenser
Type of Flow
Hi / Low flow
Flow rate
Kgs/min
Bus
Hi
75
Car
Hi/Low
15
Components of CNG Dispensers
Mass Flow Meter
Coalescent filter
Solenoid Sequencing Valves
Dispenser Cabinet
Fill Hose & Fill Nozzle
Snap-tite Break-away (coupling)
Electronics and Display unit
Fill
Pressure
kg/cm2
(g)
200
Fill Hoses
Nos. per Dispenser
Remarks
1(Single)
200
2 (Two)
Inlet Pressure
250 Kg / cm2(g)
Mass Flow Meter : Coriollis Type Mass Flow Meter with Integral Display Unit should be
provided to ensure accuracy and direct Mass Flow measurement which shall conform to AGA 11
standard and approved for custody transfer metering of CNG at each of the refueling
hose.
Coalescent filter : Coalescent filter is provided at inlet of bank supply line with manual drain
valve to ensure that the oil carryover in the CNG being filled to Vehicle is < 5 PPM.
Solenoid Sequencing Valves : 1 Solenoid Valve for single arm bus dispensers (Single Bank
fill system) and 6 Solenoid Valves for twin arm car dispensers (for 3 Bank Sequencing System
for Car). Solenoid Valves are air actuated and not gas actuated.
Dispenser Cabinet: Complete cabinet shall be of Stainless Steel (SS-304) with tamper proof
locking arrangement. However, powder coated cold rolled steel cabinets are also being used in
this industry.
Fill Hose & Fill Nozzle : Fill hose should be electrically conductive hose meeting the
requirement of NFPA-52 and NGV 4.2. Fill hose shall have Sherex CT-5000 Nozzle or equivalent
suitable to fill bus or NGV 1 Type 2 Class A suitable to fill Car.
Page - 18
Dispenser Electronics and Display unit : The Dispenser Electronics shall be Microprocessor
based and inbuilt with the dispenser. All the electronic cards shall be located in flameproof
boxes inside the dispenser cabinet. The display unit shall be electronic type and display the
following key information on the dispenser with liquid crystal back-lit display for night viewing
showing:
Quantities of gas dispensed in kg (4 digits in 2 decimal points i.e., 00.00) in one row.
Unit cost of gas dispensed in Rupees, Rs/kg (4 digits in 2 decimal points i.e., 00.00)
Complete transaction value in Rs (6 digits in 2 decimal points i.e., 0000.00) in one row.
There should be 4 displays, two on each side of the car dispenser.
There should be 2 displays, one on each side of the bus dispenser.
Displays must remains active for at least 15 minutes after power failure.
Data Recorder : The dispenser shall have an inbuilt Automatic Refueling Data Recorder unit
for the each independent refueling line. The dispenser system should be capable of storing up
to 1,250 refueling transactions data with date & time which can be downloaded frequently into
another portable computer with compatible Microsoft software.
Safety Features for Dispensers:
Designed for hazardous area : Class-1, Division-1, Group-D
Break-away coupling
Dispenser automatically and immediately shuts-off CNG supply to fill individually in case of
power failure, loss of display, failure of metering low flow, overfill
Overfill protection through electronically programmed hose to terminate the fill after 200
kg/cm2(g). Pressure relief valve provided to avoid overfilling
About CNG Cascades:
Type and configuration of CNG Cascades generally used in India:
Type/Nomenclat
ure of Cascade
Flow
Sequencing
System
Configuration
Cascades
4500
WL
Stationary
for
Bus
(WL- Water Liter)
3000
WL
Stationary
for
bus
Single Bank fill

system
3000
WL
Stationary for car
or bus and car
combined
2200
WL
Stationary for car
(in
Daughter
Booster station)
3 Bank
(Hi/Medium/Lo
w) sequencing
fill system
3 Bank
(Hi/Medium/Lo
w) sequencing
fill system
2200 WL Mobile
for car
2 Bank
(Hi/Low)
sequencing
system
47 nos. cylinders 100

WL each
Or 62 nos. cylinders
75 WL each
WL each
75 WL each
WL each
75 WL each
WL each
75 WL each
50 WL each
WL each
50 WL each
Single Bank fill

system
of
Fill
Pressure
kg/cm2
(g)
approx
weight of
CNG
contained in
each type of
cascade
250
580 Kg
Overall
dimension of
cascade frame (B
x H x L) in mm
and approx
empty weight of
cascade.(Refer
note below)
1800x1600x 5600
8800 kg
250
380 Kg
1800x1600x 3800
5400 kg
250
380 Kg
1800x1600x 3800
5400 kg
220-250
280 Kg
1200x1600x 2800
4300 kg
220-250
280 Kg
1200x1600x 2800
4300 kg
Page - 19
Note: Dimensions B & H are fixed as per technical specification, while, only L shall may vary
depending on the configuration of cascade as well as the design of manufacturer/supplier of
cascade.
Components of CNG Cascades:
Cascade Frame: Structure are designed for 4G impact test.
CNG cylinders: Approved by Chief Controller of Explosives (CCoE)
Piping manifold with flow components: All SS tubes, fittings, Inter connecting valves,
safety relief valves and check valves shall be of approved make.
Safety Features for Cascades :
Cylinder material is seamless alloy steel (Cr-Mo) and approved by Chief Controller of Explosives
(CCoE)
Fusible burst disc (IS:3224) will rupture at 280 kg/cm2 pressure
Cascade frame structure designed for 4G impact test.
About CNG Stations:
Design aspects of CNG station :

Position / Location of CNG compressors: This is guided by OISD 179 (Safety requirements for
compression, storage, handling and refueling of CNG for use in automotive sector). However,
the inter distance between two successive compressors is generally kept as 3.0 m for safe
operation of doors.
Position / Location of CNG Dispenser island: Guided by OISD 179; however, the requirement of
local (state) authorities (like Municipal corporation, PWD etc.) are also taken care of.
Position / Location of Stationary cascades: Guided by OISD 179; however, these are also
placed over roof of Utility building to save costly ground space.
Location of LCV filling stand (ie, Mobile cascade): Guided by OISD 179; however, it shall be so
decided as to minimize interference with regular traffic. LCV stand shall also be designed in
such a way that the LCV does not take a reverse turn after filling (for safety reason).
Page - 20
Position / Location of Utility building, Sales building and Transformer room (substation): The
edge of Utility building cum Sales building (or, both Utility building and Sales building if they
are separate) should be at least 6.0m away from the dispenser. The Transformer room / Dipole structure shall be at least 12.0 m away from the compressor as well as dispenser (for
safety reason).
Canopy for dispensers: Height is generally 5.5 m from finished forecourt although, canopies of
height 3.5 m exclusively for 3- wheelers also exist. Projection of canopy shall be 4.0 m
(minimum) all around from the dispenser for canopy height 5.5 m (from forecourt level) and
3.0 m all around from dispenser for canopy height 3.5 m (from forecourt level). The structural
design of canopy shall meet the 3-S criteria (ie, strength, stability and serviceability) for most
adverse loading combination.
High pressure SS tubing trench: Route of tubing trench shall be so selected as to minimize the
length of trench and tubes. Proper slope and provision for storm water drainage system inside
the trench shall be kept while designing the trench. This is also to be ensured during
construction.
Station piping (above ground): While designing the piping manifold, including hook up of
compressors, aesthetics shall also be taken into consideration apart from technical requirement.
Clear and safe passages for vehicles from ingress and egress to dispenser
Safe turning radius for vehicles and parking during filling.
Safety fencing to equipment area and safety guards around dispenser island; proper slopes, oil
catch pits and quick drainage system.
Proper slope and adequate drainage system for forecourt.
Electrical installations: Shall be designed as per provisions of OISD 179. Care shall be taken to
ensure that the area lighting fixtures in the vicinity (within 6.0 m) of CNG equipment and LCV
filling area are flameproof. Canopy lighting fixtures and electrical installations within the canopy
ceiling need not be flame proof provided there is air tight false ceiling all around the canopy u/s
including the canopy facia. In case the u/s of canopy is not covered with false ceiling, (as in the
case of some MS/OLS constructed within the Bus depot with existing canopy) the existing
lighting fixtures and all electrical installations must be replaced with flame proof installations.
Earthing pits: Shall be designed as per provisions of OISD 179. Number and location of
Earthing pits (both Electrical and Instrumentation) shall be so selected that they meet the
safety requirement of the equipment and the electrical installations within the station (as per
guidelines of Chief Controller of Explosive).There shall be minimum two electrical earthings for
each compressor, one electrical & one instrumentation earthing for each dispenser, one
electrical earthing for each cascade and LCV stand apart from earthing of other electrical
installations.
Position / Location of Fire Safety Equipment: Shall be installed as per guidelines of Chief
Controller of Explosive for CNG equipment.
Traffic signs for CNG vehicles: Also called as direction signs are mandatory before
commissioning.
Safety signs: Following safety signs (minimum) are mandatory in each CNG station before
commissioning.
i)
NO SMOKING sign.
Ii)
STOP VEHICLE sign.
NO OPEN FLAME PERMITTED sign.
Page - 21
iv)
v)
FLAMABLE GAS sign.

Sign showing DETAILED PRECAUTIONS & PROCEDURE DURING REFUELLING
Environment friendly design with adequate green turfing

Rain water harvesting system
Aesthetics- the last but not the least.
Components of CGD (City Gas Distribution) / PNG (Piped Natural Gas) Network:
Main Pipeline/Gridline (underground) network from CGS (City Gate Station) including Spur lines
(branch lines from Main Gridline through tap offs) upto the DRS.
Odorising Unit (in CGS or immediately after CGS (before entering DRS).
District Regulating Station (DRS)
Medium pressure (upto 6 bar (g)) MDPE pipeline network after DRS to connect Domestic,
Commercial and Industrial consumers.
Metering and Regulating Station (MRS) for Industrial consumers.
Pressure Regulators at downstream of Medium pressure MDPE pipeline (at 4 - 6 bar (g)) to low
pressure (300 mbar for commercials & 100 mbar for domestic) PE pipes before entering
Domestic and Commercial consumers premises.
Installation of low pressure underground PE pipes outside the premises and above ground GI
pipes along the outer walls of premises (for both Commercials and Domestic consumers)
Diaphragm type Gas Meters for both Domestic and medium/ small Commercial consumers.
i) Copper tubing (at 21 mbar pressure) within kitchen of premises.
Except for (a) & (b) which have already been discussed earlier, the rest of the
components are briefly discussed below.
19 Bar Steel Network
CNG Station
City Gate Station
21 mbar
(Copper
pipe)
Domestic Kitchen
DRS
6 Bar (PE pipe)
100 mbar
(PE pipe)
GI Installation
Service Regulator
Page - 22
Typical site installation of a DRS

About District Regulating Station (DRS) :
DRSs are installed at various strategic locations in the network to supply PNG to domestic,
commercial and industrial consumers
Twin stream regulating system with hot stand-by stream
Regulating from inlet pressure of 19 kg/cm2 (g) pressure to outlet pressure range 1.5 - 6
kg/cm2 (g)
Downstream Distribution via PE pipeline
DRS components:
Filter
Active and Monitor Pressure regulators with a built in slam - shut device
Independent slam shut valve
Relief valve
About Metering and Regulating Station (MRS) :
MRS are used to supply gas to Industrial & large Commercial consumers requiring gas at 1-2
bar(g).
Designed for Single Stream / Twin stream regulating and metering system as per requirement
of client.
Inlet pressure range : So as to ensure differential pressure of 1 bar (g) between inlet & outlet.
Outlet pressure : 0.5 2.0 bar(g), depending on the requirement of customer.
MRS components:
Filter
Pressure regulator with a built in slam shut device
Relief valve
Strainer
Page - 23
Flow Meter (RPD/ Turbine, etc.)
Single Stream MRS
Dual Stream MRS
About Pressure Regulators :
Technical requirement of Pressure Regulators used for domestic and medium/ small
commercial customers:
Maximum Inlet Pressure: Maximum upto 4- 6 bar (g) as per design of Network.
Nominal Outlet Pressure: 100 mbar (g) for domestic & 300 mbar (g) for commercials.
Flow capacities: 10, 25, 40, 65 SCMH.
End connections: Threaded (& Tapered) as per BS 21
Operating ambient temperature: up to 45 0C
Lockup: Maximum pressure under no-flow condition.
Creep relief valve: To protect against downstream over pressure at low flows or in the event of
valve seat malfunction.
Over Pressure Shut Off (OPSO): Device to protect against downstream over pressure.
Under Pressure Shut Off (UPSO): Device to protect against downstream under pressure.
Information required to select a regulator:
Maximum and Minimum inlet pressure
Required outlet pressure
Maximum flow rate
Tolerance on outlet pressure
Size of pipe network at downstream of regulator.
Type of gas
Safety features required
Size of orifice
OPSO, UPSO & Relief settings
Installation of indoors & outdoors
Orientation of regulator
About Gas Meters:
Page - 24
The most commonly used Gas Meters in CGD (or PNG) include
Diaphragm Meters
Rotary Positive Displacement (RPD) Meters
Turbine Meters
Diaphragm Gas Meters (for Domestic consumers)
Tech Spec: EN 1359
Capacity: 2.5 m3/hr
Rangeability or TD ratio: 1:150 or better
Nominal Working Pressure: 21 mbar (g)
End Connections: , as per BS 746 (Male)
Diaphragm Gas Meters (for medium and small Commercial consumers)
Tech Spec: EN 1359
Capacity: 10, 25, 40, 65 scmh
Rangeability or Turn Down ratio (ratio of Qmax and Qmin): 1:150 or better
Nominal working Pressure: 100 mbar (g)/ 300 mbar (g)
Rotary Positive Displacement (RPD) meters (for large Commercial and small
industrial consumers)
Tech Spec: EN 12480
Volumetric metering
Appropriate for medium size load
Typical Turndown 35:1 to 50:1
Accuracy 1%
Large measuring range
Not sensitive against disturbances
Not sensitive against fast changes in flow rate
Needs lubrication
Turbine meter (For Industrial Consumers)
Tech Spec: EN 12261
Inferential meter
Sensitive to gas velocity rather than volume flow
High Pressure steady loads
Typical Turndown 15:1
2% Q min to Qt
1% Qt to Qmax
Sensitive against disturbances
Sensitive against fast load changes
About Medium Density Poly Ethylene (MDPE) Pipes:

Tech Spec: ISO 4437 / BIS 14885
Page - 25
Material Grade & Color:

Internationally approved resins of Yellow color for PE 80 grade & of Orange color for PE 100
grade
Minimum Required Strength (MRS): 8 MPa for PE 80 grade pipe & 10 MPa for PE 100 grade pipe
Pressure Class: SDR 11 (dia 20, 63, 90, 125 and 180 mm).
Operating pressure: 4 bar (g) for PE 80 grade pipe & 7 bar (g) for PE 100 grade pipe
Operating temperature range: - 10 0 C to + 40 0 C.
Density Range 930 to 940 kg / m3
Tensile strength at yield elongation: 15 MPa.
Elongation at break: More than 350% up to pipe size upto 125 mm, 500% for pipe sizes more
than 125 mm
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
Easier and speedier joining techniques to ensure leak tight joints by employing electro fusion
techniques
Higher productivity, i.e., reduction in installation time, 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
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
MDPE Fittings:
Tech Spec: ISO 8085-3 or EN 1555-3
Material Grade: PE 80 or PE 100
Terminal pin size: 4 or 4.7 mm
Voltage: 39 40 Volts.
Color: Yellow / Black.
PE Stop Off Valves (Typical):
Standard: ASME B 16.40, EN 1555-4
Pressure Class: SDR 11.
Operating Pressure: 4 / 7bar (g) for PE 80 / 100 Grade respectively
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.
Valve Design: One piece construction.
Ball position Indicator: Open / Close available.
Crimping Fitting (Typical specification):
Page - 26
Used to connect u/g PE pipes with a/g GI pipes

Operating Pressure: up to 4 / 7bar (g) for PE 80 / 100 Grade respectively.
Operating Temperature: 40 0 C
Hydrostatic Test Pressure: Minimum hold Pressure of 10 / 16 bar (g), for 1 hour duration for PE
80 / 100 Grade respectively.
Pneumatic Test Pressure: Minimum pressure of 6 / 9 bar (g), for 1 hour duration for PE 80 /
100 Grade respectively.
Pull out Test:
Shall not fracture within the jointed assembly
Shall withstand the Pneumatic pressure leak test
Shall not leak
GI ERW Pipes:
Tech Spec: IS 1239 (Part 1)
Types used: Heavy Class
Material: IS 1387
Pipes shall be screwed with Taper threads
Threads: Tapered and conforming to BS 21 / A1.20.1
Galvanizing: IS 4736
Coating requirements: Mass of coating is 400 gms / m2
Test Pressure: 5 MPa
GI Fittings (Malleable Cast Iron):
Tech Spec: IS 1879
Material: IS 2108 Grade BM 290
Dimensions: As per IS 1879
Threads: As per 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
Coating requirements: Mass of coating is 700 gms / m2.
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
Coating requirements: Mass of coating is 700 gms / m2.
Brass Valves (Meter Control Valves, Riser Isolation Valves & Appliance Valves):
Tech Spec: EN 331
Pipe Nominal Diameter :- to 2 NB.
Operating Pressure: 4 bar (g).
Operating Temperature: 10 60 0 C.
Material: Nickel Plated Forged Brass.
Pattern: Full Bore, Quarter Turn Ball Valve.
Page - 27
Handle: Suitable Metallic Handle, Lever / Knob / Cap Typed with

yellow coating (Powder / Plastic) on Surface marked as GAS
End connection: Screwed, As per BS EN 10226-1,
Tapered Threaded, Female
Meter Regulator:
Gas flow rate: 2.5 m3/h
Nominal Inlet Pressure: 100 mbar (g)
Maximum Inlet Pressure: 160 mbar (g)
Nominal Outlet pressure: 21 mbar (g)
Lock-up pressure: Shall not exceed 30 mbar (g)
Low pressure Cut-Off: at inlet pressure of 11.5 mbar to 15 mbar (g).
Re-pressurization safety device is fitted which prevents the regulator from re-opening when the
inlet pressure is restored unless there is a downstream backpressure, i.e., all connected
appliances have been turned off.
End connections: Right angled inlet and outlet connections of x BSPT (Female)
Copper Tube:
Used inside the kitchen of the domestic consumer
Tech Spec: BS EN 1057
Size: 12 mm OD X 0.6 mm wall thickness
Material: Grade Cu-DHP or CW024A
Mechanical Properties:
Ultimate Tensile strength: 235 MPa
Elongation: 30% (minimum)
Hardness: 53 to 80 on HV Scale
Test Pressure: 1 bar (g) for a period of 2 minutes
Bending Test: 900 & 1800
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
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)
Page - 28
Piped Natural Gas (PNG) Distribution Network:

Earlier (before inception of PNGRB) the PNG Distribution Networks (which originates from the
downstream of DRS) were/ used to be designed for a maximum operating pressure upto 4
Kg/cm2(g). However, consequent to publication of PNGRB guidelines, MECON has started
designing PNG Networks at a maximum operating pressure upto 7 Kg/cm2(g).
Piped Natural Gas (PNG) Distribution Network for Medium/ small commercial
consumers:
In medium and small commercial connections (which comprise the Hotels, Restaurants, Malls
etc.) the gas inlet pressure shall be regulated from 3- 4 Kg/cm2(g) or 6-7 Kg/cm2(g)
(depending on the network design) to 300 milli-bars (0.3 bar) through a service regulator at
the entry point to the Hotel / Restaurant/ Malls. It will be further supplied through MDPE and GI
pipes upto the Kitchen of Hotel / Restaurant with individual meter (normally with Diaphragm
Gas Meters) only.
Piped Natural Gas Distribution Network for Domestic consumers:
In Domestic connections (which comprises the large / medium housing complex) the gas inlet
pressure shall be regulated from 3- 4 Kg/cm2(g) or 6-7 Kg/cm2(g) (depending on the network
design) to 100 milli-bars (0.1 bar) through a service regulator at the entry point to the society /
housing complex. It will be further supplied through MDPE and GI pipes upto the Kitchen of
individual flats with individual meter and regulator assembly. In the Meter / regulator assembly
of the individual flats the inlet pressure of the PNG shall be reduced from 100 milli-bars (0.1
bar) to 21 milli-bars (0.021 bar).
Page - 29
Typical Piped Natural Gas Distribution Network

Codes & Standards for CNG Dispensers
NFPA 52
:
Standards for CNG Vehicular Fuel Systems
NGV 4.1/ AGA 2-92: Requirements for CNG Dispensing Equipment for Vehicles
NGV 4.2/ AGA 1-93: Requirement for Hoses for NGVs and Fuel Dispensers.
ANSI / NGV1 :
Compressed Natural Gas Fuelling Connection Devices.
Standard for Fuelling Nozzles and Receptacles.
NGV4 / AGA
:
Requirements for Breakaway Devices for CNG Vehicle
Fuelling Dispensers and Fuelling Hoses.
IS 5572
:
Classification of Hazardous areas (other than Mines) for
Electrical Installations
IS 5571
OISD 179
Guide for selection of Electrical Equipments for hazardous area

Safety requirements for Compression, Storage, Handling
and Refuelling of CNG for use in Automotive Sector.
Page - 30
OISD 113
:
Classification of areas
Processing and Handling facilities
for
Electrical
Installations
at
Hydrocarbon
NFPA-52: 1992, ANSI, ASTM, NEC, NEMA, ASNZ, OIML, Indian Electricity Rules, Indian
Explosives Act., Australian / New Zealand Refuelling Standard. AG901 / NZS 5425
The Standards of Weights and Measures Act 1976.
The Standards of Weights and Measures (Enforcement) Act, 1985.
The Consumer Protection Act, 1986.
Codes & Standards for CNG Compressors :
API-618 second edition
NFPA-37, NFPA-52:1992: -Standards for CNG vehicular fuel systems
NFPA-70:
-Standard for electric devices & wiring
OISD 179:
-Safety requirements for compression, storage, handling and refueling
for use in automotive sector
Indian Electricity Rules, Indian Explosives Act
of CNG
Codes & Standards for CNG Cascades:

NFPA 52
-Standards for CNG vehicular fuel systems
OISD 179
-Safety requirements for compression, storage, handling and refueling of CNG for
use in automotive sector
Gas cylinder rules : 1981-Standards for CNG storage and gas cylinder rules
Static and mobile pressure vessels (unfired ) rules, SMPV - 1981
CNG cylinder design code, IS : 7285 1988
IS:3224 1979 CNG cylinder valves (amendments 1983, 84,85,86,89,92,98)
IS:5844 1970Hydrostatic stretch test
IS:5903 -1970Safety devices of gas cylinders
Indian Explosives Act
Australian / New Zealand refueling standard - AG901 / NZS 5425
Page - 31
MECONS GAINT LEAP IN TRENCHLESS ENGINEERING

(A report on Indias longest HDD project)
Harish Chandnani,
DGM (Civil) & Project Coordinator
MECON Delhi
MECON Delhi successfully executed a 2008m long HDD (Horizontal Directional Drilling) to cross
MAHI River near Vadodara with a 12 NB carbon steel pipe string under restoration of natural
gas supply project of GAIL from Dabka to Dhuvaran. The HDD which was completed on 23rd
July 2008 was the longest ever Horizontal Directionally Drilled length undertaken by any HDD
agency in India as on the date of completion. The pipeline has since been charged and gas-in
has been successfully completed thereafter.
This report gives a brief on Guided Boring & Directional Drilling, which is also known as the
Horizontal Directional Drilling (HDD), which is ideal for the underground installation of gas,
electric, water, telecommunication or soil remediation lines - without excavation or trenching.
We shall subsequently give an insight on this unique HDD project which has been successfully
got executed by MECON Delhi.
A Brief on Horizontal Directional Drilling (HDD)
Introduction
Trenchless Engineering is a branch of construction engineering dealing with techniques and
related equipment used to develop, maintain and renew subsurface utility networks without
excavating continuous trenches. It is a branch of applied engineering, which is State-of-Art,
used to develop, manage, and renew continuous cabled and piped networks for transferring
signals and fluids respectively. Major applications of these techniques are for Water Supply,
Rainwater Disposal, Sewer Disposal, Natural Gas, Crude oil and Petroleum products, LPG,
Electrical and Telecom signals and other underground networks.
Following techniques are adopted in trenchless engineering viz:For Repairs & Renovation
Cleaning, Localized Repair Techniques, Lining Techniques
For Replacement
Pipe Bursting, Pipe Splitting, Pipe Eating, Lead Extraction & Replacement Systems
In New Installations
Impact Moling, Pipe Ramming, Auger Boring & Thrust Boring, Pipe Jacking, Micro Tunneling,
Guided Rod Pushing, Guided Boring & Directional Drilling (Horizontal Directional Drilling), Rock
Boring, Cable Pulling, Cable Blow In Systems
In this report we shall be speaking of Guided Boring & Directional Drilling, which is also known
as the Horizontal Directional Drilling which is ideal for the underground installation of Natural
gas, electric, water, telecommunication or soil remediation lines - without excavation or
trenching.
What is HDD?
HDD (Horizontal Directional Drilling) is a trenchless methodology that provides an installation
alternative for underground utilities like pipelines / cables that can offer a number of benefits
over traditional open-cut laying.
Why use HDD technique?
HDD is used in place of other techniques for the following reasons:
Little disruption to surface activities
Requires less working space
Can be performed more quickly than open-cut methods.
Page - 32
lower cost
deeper installation possible
longer installation possible
no access pit required
shorter completion times
fairly accurate directional capabilities
safer for the environment
Areas where HDD can be used?

HDD technique can be used to install new pipelines or replace existing ones
For installation of municipal underground infrastructure systems
Standards for HDD techniques?
Currently there are no national standards regarding HDD installations for any pipe material,
however in India, an apex autonomous body IndSTT (Indian Society of Trenchless
Technologies) has taken up various initiatives to develop and popularize the application of
Trenchless Technology in the nation. Certain guidelines and codes of practices for HDD have
also been developed by IndSTT.
Major elements for an HDD installation?
A rig, which provides the physical means thrust and torque, to open the hole and pull in the
product pipe.
A transmitter/receiver system for tracking the location of the bore
The down hole equipment - drill pipe, drill bits, and reamers, which converts the physical
properties of the rig to open the hole and pull in the product.
The drilling fluid, which serves to stabilize the hole, cools the down-hole equipment, and
removes the spoils from the hole.
The drilling fluid delivery and recovery system made up of tanks, mixing systems, pumps; and,
when recycling fluids, a system of screens, filters, shakers, cones, etc. To remove spoils
brought to the surface from the fluid.
Procedures involved in HDD?
PLANNING
It comprises of: Thoughtful Planning, Ascertaining Ground Conditions, Locating surrounding
utilities, Bore profile design, Survey and plotting on paper, Considering Safety and
Environmental issues and Selection of HDD machine of suitable capacity based on above
factors.
DRILLING A PILOT HOLE

Drilling is carried out by using a directional drill machine of required capacity, which pushes a
bore head connected to hollow pipe into the ground at an angle. As each joint of drill rod is
pushed into the ground a new one is added behind and the joints torqued tight using a
hydraulic vice.
Page - 33
REAMING
Upon reaching the exit point, the bit or bore head is detached and the end of the drill pipe is
attached to a reamer or hole opener (for rock) if the borehole must be enlarged. The reamer is
pulled back while rotating the drill rods with as many consecutive passes as required. Drill rods
are added from behind the reamer or hole opener so that there are always drill rods in the
borehole.
The pilot hole is enlarged (usually approximately 1.5 times the largest outside diameter of the
new pipe) by pulling back increasingly larger reamers, or reaming heads, from the pipe
insertion point to the rig side.
To achieve the appropriate bore path size it may be necessary to perform several reaming
operations. Generally, all reaming procedures prior to the actual product installation are
referred to as pre-reams, and the final ream to which the product pipe is attached is referred to
as the back ream.
Page - 34
PULL-BACK
When the borehole is 25 - 50% larger than the pipe to be installed, the end of the pipe is
connected to a packer/reamer or barrel reamer and then a swivel attached to the pipe to be
installed and pullback commences. For some telecommunications or power cable projects,
the drill pipe itself becomes the conduit and is left in the ground upon reaching the exit point.
This type of installation is known as "drill and leave".
After the pre-reams, the pulling head and connecting product pipe are attached to the reamer
using a swivel, a device that isolates the product pipe from the rotation of the HDD drill pipe.
The product pipe is then pulled behind the final reamer back through the horizontal directional
drill path towards the rig side.
The Mahi River HDD Project
Background
GAIL Vadodara awarded the work of Rehabilitating / Repairing of their existing 12 Dabka
Dhuvaran CS Gas pipeline to MECON Delhi as their Project Management Consultant for restoring
the supply of natural gas to GSEC, Dhuvaran. A section of the 12 CS pipeline passing under
Mahi River between Dabka Gajna section was swept away during the floods. This was due to
the bank erosion of Mahi River on Dabka Village side wherein the bank got washed away by
over 300 meters, exposing and breaking the existing 12 gas pipeline laid on the Dabka side of
Mahi River.
Page - 35
THE BROKEN & EXPOSED PIPE IN MAHI SAGAR
Rehabilitation Options Available

Since the damage of the pipeline was anticipated to be not within the earlier executed 1220 m
HDD part of the pipe length, the Rehabilitation / Repair of existing pipeline by Open Cut Method
was considered in the first instance. This method involved survey and detail investigation to
identify the location and extent of damage, construction of temporary Coffer Dam/ Dykes etc.
including installing well point system for creating working conditions suitable to carryout the
pipeline removal / re-laying works inside river bed from Dabka side bank and replacing the
existing broken pipeline with a new pipe string of approximately 750 m length which was to be
laid at a 3.0 m minimum depth from scouring depth which effectively worked out to be16 m
from deepest point of river bed.
The proposal of rehabilitation by Open Cut Method was not opted for economic reasons. Besides
shifting course of Mahi River was another deterrent and which further added to the issue of
methodology to be adopted.
MECON subsequently proposed restoring the pipeline by an all together new HDD by crossing
pipeline under Mahi River at the same location. Considering the eroding nature of the river bank
on Dabka side, an unusually long HDD of at least 2000 m length was proposed to cross the
1200 m wide Mahi river so as to punch out sufficiently away, about 500m from the unstable
river bank on Dabka Side.
Uncertainties and Challenges

The proposition of crossing Mahi river with a 2000m long HDD at nearly the same location was
extremely challenging due to following reasons:
no one could anticipate the types of problems that one would encounter while
undertaking such a big length crossing
there were very few agencies who in past had undertaken such long HDD crossings
there had been repeated failures in the past while undertaking HDD works at this
location in Mahi river due to the typical soil characteristics.
Page - 36
the As-built details, data and records of the HDD section earlier carried out by GAIL in
1997 were not elaborate with regard to design, piping calculations and the nature of
ground strata.
The sub-soil conditions for the proposed 2.0 km long HDD length at proposed location was
unknown and unpredictable.
Execution Plan
A drilling agencyM/s N R Patel & Co. had been appointed who had prior experience in HDD
works and had a drilling machine of 250 Tonne capacity.
Detailed site investigation works involving river and embankment survey work and geotechnical
investigation were carried out inside the river by the drilling agency on either sides of the river
bank on the proposed route to decide on the HDD drilling path parameters and profile. Apart
from mapping of the Riverbed along the proposed alignment, 13 numbers of boreholes were
drilled in and around the riverbed along the proposed alignment to study the geotechnical
features and the sub soil profile.
Based on the sub-soil condition, the maximum scour depth due to the highest flood levels were
worked out. Keeping into consideration the material specifications of the pipe, the depth of the
HDD hole with respect to the deepest point of riverbed, the drill hole path and profile were
worked out.
The pilot hole drilling work was the most difficult part of the project to complete. Right from the
beginning itself, there had been repeated hold ups in drilling the pilot hole along the proposed
path.
250 T HERRENKNECHT RIG IN OPERATION

While drilling frequent trip outs and trip ins of the drill rods had to be undertaken at numerous
instances due to various problems encountered while drilling viz: probe problem, sensor cable
problem, non return of bentonite in down hole, problem in drill bit, pilot not moving in desired
direction, high pushing torque and change in path of the HDD profile by making a fresh path.
Casing pipes of various sizes and lengths were provided at the entry point side to ensure that
the drilled hole remained intact, and to avoid undue thrust on drill rods / pipes due to high
Page - 37
pushing torque particularly at the bends, etc. Substantial time was lost in placing / replacement
of casing. The casing pipes were replaced by changing casing size and length to avoid rotation
of casing pipe inside the drilled hole and to arrest wobbling of drill rods.
The Failures
The first pilot hole, which started from the Gajna villages end, could not be drilled beyond
1739m from the entry point. The hole could not be advanced further from where the upward lift
of the pilot was to be started. Even after trying to drill along a deviated path, the forward
drilling length could be achieved beyond 1624 m from the Gajna end in the deviated hole. The
thrust of drill rig appeared to get dissipated in the surrounding ground beyond this length. This
was due to an unfavorable soil condition / unduly enlarged bore hole down below due to which
drilling rods were getting bent much inside the down hole and further drilling could not proceed
further. So, it was decided to drill a separate hole along the approved drill alignment from the
other side of the river bank i.e. Dabka village side by using a separate drilling rig and intersect
the new hole with the existing deviated hole of 1624 m length.
Considering that there may be boulders and adverse soil conditions, additional exploratory bore
holes were got conducted at certain locations, between the already drilled bore holes, to get a
more realistic and clear picture of the sub soil condition. Additional boreholes were drilled
beyond 1750 m point.
At this point a second drilling machine from Dabka end had also been deployed. Even after
drilling 390m from the Dabka end, the point of intersection with the hole from the Gajna end
could not be accomplished as the ends of the holes couldnt be properly guided into each other.
One of the reasons for not achieving this was non-deployment of specialized tracking tool,
Paratrack-2, required for making the precise meet of the two ends by the drilling agency.
Moreover in the event of making repeated attempts to intersect the two bore holes using the
Tensor tracking tool, the drill rods gave way and the bore hole tools viz. the drill bit, the Tensor
tracking tool and the non magnetic color and a few drill rods were lost inside the downhole
drilled from Dabka side. As a result the pilot hole drilled so far became redundant and had to be
abandoned all together.
Observations, Investigation & Suggestive

Measures adopted
The loss of 1739m+390m drilled length of pilot hole, from Gajna side and Dabka side
respectively over a period of over three months, along with loss of drill tools and drill pipes
called for an in depth analysis, introspection and detailed deliberations for ascertaining the
reasons of this failure. From the results of additional exploratory bore holes drilled, it was found
and noted that the depth at which the pilot hole was being laid on Dabka side (approx 1750 m
away from the entry point side) was having a layer of Sandy gravel and this layer was not over
the entire depth of the borehole. The layer above it was silty sand. Since the river portion was
already crossed without any hindrances with the pipeline laid at ~16m below the deepest bed
level, the executing agency was asked to change the drill path profile beyond the 1600 m
point and start lifting up the pilot hole avoiding the Sandy gravel layers.
The data of the pilot hole drilled upto 390m from Dabka side wherein problems were faced
while drilling pilot hole in the first attempt, was also used to collate the exact ground details.
Further, additional exploratory (survey) boreholes were got drilled and data collected on Dabka
side. The boreholes data and the pilot hole drilling data confirmed presence of gravel at
different locations. Based on this, the HDD profile was re-designed and customized to avoid the
gravelly layers on the exit side in the second attempt while drilling from Gajna side.
Page - 38
While making pilot hole from the Gajna end in the second attempt, a 300m long casing was
provided on the entry side right from the very start. This was so done to make the requisite
push force available at the pilot drill point even as the length of the drill string gradually
increased to over 2000m. This was also provided to avoid loss of torque from the rig on the
curved portion of the pilot hole where sticky clayey layers were present.
Success at Last
A new pilot hole of 2008m was drilled at a different location, about 2.0m away from the earlier
drilled hole, from Gajna side. Based on MECONs advise the Paratrack pilot tracking system was
used along with a single rig of 250 T capacity instead of the Tensor tool used earlier to
successfully punch out the hole on the other end at Dabka side in the second attempt. Other
activities which followed included cleaning the pilot hole using wiper sub, removal of 300 m long
casing pipe and widening the hole by reaming with 18 fly-cutter reamer, clean pass using 18
barrel reamer and pull through of the pre-fabricated, pre tested pipe string.
2017M LONG SINGLE PIECE PIPE STRING BEING PULLED THROUGH

The remarkable feat of completing the pulling of 12 NB pre-fabricated & pre-tested pipe string
of 2017m length inside a 2008 m drilled HDD hole was finally achieved using a 250 T capacity
rig of Harrenknecht make. The pulling of the pipe which started at 07.30 hours from
approximately 500m from the unstable bank of Dabka side was finally completed at 19.00
hours in a single go without any hiccups / hurdles when the pipe surfaced approximately 250m
away from the firm and stable river bank on Gajna side.
Page - 39
THE PROUD MOMENT WHEN THE END OF THE 2017M LONG PIPE STRING
SURFACED AT THE RIG SIDE END FROM 2008M LONG HDD HOLE.
The other activities of completing the associated piping works along with post hydrotesting of
the associated pipe string and HDD string, tie-in with existing pipeline on either sides of Mahi
River were subsequently taken up and the gas in was successfully completed. .
Conclusion
Though HDD is not a new technology, but the uncertainties of the ground conditions still remain
the root cause of hold ups in the project, which at times lead to total failure of the project. In
the Mahi river HDD, hold ups have been successfully overcome by taking crucial site decisions
to accomplish this unusual HDD, still a lot of study needs to be done to ascertain and analyze
the exact causes of hold ups which occurred at various stages for preventive pre-construction
measures to be resorted to and to avoid delays in completion of the project and ensure smooth
pull through of the pipe section in a single go.
The HDD undertaken for rehabilitating the damaged pipeline is the major milestone of this
project and is crucial due to the extraordinary length of the crossing which has not been
done till date in India. This project is of a unique nature since the 2008m pilot hole drilling
has been successfully completed by drilling from one end only using a single rig despite the
complexity of the ground condition of Mahi river which was very soft at certain places while
extremely clayey and gravelly at other locations which required detailed analysis of strata
and customized HDD profiling.
Page - 40
PIGGING OF PIPELINES
Shalini Singh, ADE
MECON Limited, Delhi
Pipelines affect daily lives in most parts of the world. Modern peoples lives are based on an
environment in which energy plays a dominant role. Oil and gas are major participants in the
supply of energy, and pipelines are the primary means by which they are transported.
To fulfill the gas demand for power generation, recovery processes and other uses, pipelines
are utilized to transport the supply from their source. These pipelines are mostly buried and
operate without disturbing normal pursuits.
PIPELINE CONSTRUCTION ACTIVITIES:
There are number of activities involved in Long distance pipeline construction. They can be
broadly enumerated as below:
Pipeline Route Survey and Land Acquisition
Right of Use (ROU) Clearing and Grading
Trenching
Stringing of Line Pipe
Bending of Line Pipe
Welding of Line Pipe
Field Joint Coating
Lowering of Line Pipe
Tie-ins of Pipe Sections
Backfilling of Trench
Crossing of Road / Rail / Water bodies etc.
Pigging of Pipe
Hydrotesting of Line Pipe Sections
Pipeline Markers Installation, Clean Up & Restoration Works
Station Works (Despatch / Receiving / Intermediate / Sectionalising Valves etc.).
Herein the following paragraphs, the pigging activity in a long distance pipeline project, is being
dealt with :
PIGGING
When a pipeline is being constructed, after it is constructed and before it is put into service
there are a number of key activities required in order to ensure that the pipe meets the
requirements of its owners or operators. These will vary to some extent depending on the
service for which the line is intended, but as a minimum they will be looking for verification that
the line has been laid without significant defects and is in a condition suitable to be filled with
the intended product.
Pipeline pigging has a significant role to play in meeting these conditions as it has become an
important part of the pipeline construction and maintenance program. Pigging is the process in
which a pipeline is cleaned, gauged, dewatered after hydrotesting, inspected, assessed for
Page - 41
pipeline health condition and made to transmit throughputs of one or several products using a
device generally known as PIG or Pipeline Inspection Gauge.
Pipeline pigs are the devices that are inserted into and travel through out the length of the
pipeline driven by the product flow. They were originally developed to remove deposits which
could obstruct or retard flow through a pipeline. Today pigs are used during all phases in the
life of a pipeline for many different reasons.
PIG DESIGN
Pigs are designed so that sealing elements provide a positive interference with the pipewall.
Once inserted into a line, pigs are driven through the line by applying pressure in the direction
of required movement. A pressure differential is created across the pig, resulting in movement
in the direction of the pressure drop. In operational lines, this pressure is applied by the line
product, whereas, in un-commissioned lines, the propelling medium can be chosen to suit the
task being carried out, e.g. water for flooding or dry air or nitrogen gas for dewatering.
Pig
Pipeline
Opposing Force
Sufficient flow is also required to ensure pig movement at a suitable velocity.
Once the force behind the pig becomes greater than the opposing force due to friction and
pressure maintained in the pipeline on the other side of pig, the pig will move in the direction of
the applied force (pressure).
The pressure at which the pig begins to move is known as the "break-out" or "stiction"
pressure. This tends to be greater than the pressure required to maintain movement and is
characterised by a pressure rise followed by a pressure drop to a plateau for the pig launching
operation.
(Cup-Type Seal)
(Cone-Type Seal)
(Bi-Directional Seal)
Pig Seal Design
Page - 42
Depending on the design of the sealing element, pigs can either be run in a single direction, or
run backwards or forward through a line. Pigs that can only be run in one direction are known
as unidirectional pigs, and have polyurethane sealing elements of the cone or cup design. These
types of pigs are generally used in established lines known to be piggable.
Sealing elements in the bidirectional pigs are flat, providing an identical seal in either direction,
and therefore, giving more adaptability in previously unpigged lines.
Additional sealing elements can be added to pigs, leading to better sealing properties along with
a higher pressure differential required to drive the pig.
Support for the pig to ensure it remains central in the line can be provided by either support
discs, or, for large diameter pigs, centralising wheels.
As a general guide, the following table summarises pig characteristics:
Component
Size
Sealing Disc Diameter

Support Disc Diameter
Pig Assembly Length
102% to 105% Pipeline ID

99% Pipeline ID
1.5 Pipeline ID
PIG SELECTION
The type of pig to be used and its optimum configuration for a particular task in a particular
pipeline should be based on several criteria, which include:
The purpose
Type, location and volume of the substance to be removed or displaced in
conventional pigging,
Type of information to be gathered from an intelligent pig run,
Objectives and goals for the pig run.
The line contents
The contents of the line while pigging,
Available vs. required driving pressure,
Velocity of the pig.
Characteristics of the pipeline
The minimum and maximum internal line sizes,
Maximum distance pig must travel,
Minimum bend radius, and bend angles,
Additional features such as valve types, branch connections, and the elevation
profile.
WHY PIGGING IS CARRIED OUT
A pipeline is pigged simply in order to remove any debris lying inside the pipeline and to obtain
a regular throughput from the pipeline. There are generally three main reasons for pigging a
pipeline. They consist of improving the line flow efficiency, improve or insure good data on
inspection tools runs, and to improve the results of chemical programs to increase the lifetime
of the pipeline.
A pipeline is pigged essentially during each phase of its life. Following are the main functions of
pigging :
Page - 43
To Batch or Separate Dissimilar Products

Pigs form a solid barrier between dissimilar fluids, e.g. liquid and gas. As such, pigs can
be utilised in a train to "batch" chemicals or other fluids to perform a function. A good
example of this would be the following pig train.
Nitrogen Gas Slug Glycol
Slug Glycol
Slug Fresh Water
Slug Fresh Water
The first two slugs of fresh water provide desalination for a line previously flooded with
seawater, while the glycol slugs aid in dehydration and hydrate inhibition upon the
introduction of product. The whole train is driven by nitrogen gas.
Displacement Purposes
As there is a solid interface formed between the pipe wall and the pig sealing element,
any fluid in the line (liquid or gas) is displaced from the line as in the pig train above.
Inevitably there is some bypass due to surface roughness, weld penetration, and seal
bypass.
Cleaning
Like the process for displacement, the positive interface between the pig and the pipe
wall imparts a cleaning action on the pipewall. This can be further enhanced by the
addition of brushes, scrapers, or even more aggressive tools to the pig. For lines where
ferrous debris is expected, magnets attached to the pigs can add a pick-up action for
removal of magnetic debris.
Discs
and
Brushes
Clean Pipe Wall
The turbulence
within the fluid
flow will hold any small, solid debris in suspension, effectively sweeping it out of the line.
The use of bypass ports through the pig can aid this sweeping effect.
Waxes and sludges tend to adhere to the pig brushes and scrapers and are generally
"ploughed" through the line.
Internal Inspection
Page - 44
Gauge Plate
In order to identify any major restriction in flow area through a line a simple metal plate
is attached to the pig to provide an internal line gauge. Generally sized to 95% of the
pipeline internal diameter (95% nominal or 95% minimum, dependant on specification
being used), the gauge plate tends to be made of a soft metal such as aluminium
(minimum thickness 10 mm) and is chamfered on the leading edge. It is common to
"petal" the gauge plate with short, radial cuts to minimise the risk of the pig becoming
stuck. These radial cuts through the gauge plate allow the plate to bend more easily if
an obstruction is encountered.
Gauging a New Pipeline

TYPES OF PIGGING
Pigging is classified based on the stage in the life of a pipeline. It is required at various stages
of a pipelines life for a variety of reasons.
1.
Pigging During Construction of a Pipeline
When new pipelines are built they generally need to be cleaned of construction debris
and prepared for acceptance testing (hydrostatic testing) of the pipeline. It involves
-
Debris removal, Cleaning, Gauging, Hydrostatic Testing,

Swabbing, Drying for getting a continuous throughput.
Specially designed pigs are used for such operations.
Dewatering,
Page - 45
2.
During Commissioning of the Pipeline
As the product is introduced into the line, a pig can be used to separate the product
from the medium currently in the line.
3.
During operation
Once the pipeline is commissioned, there is a deposition on the pipe walls or

accumulation of condensates in the line. Pigging is used for its cleaning and removal and
hence operational pigging is an effective way of maintaining flow and minimizing back
pressure.
Besides, pigging helps to ensure that multiple products can be transmitted in a single
line by using specially designed batching pigs. This brings down the cost of erecting a
new pipeline.
4.
During Inspection of pipeline
Pigging is also carried out for gathering information and determining the condition of the
pipeline which includes:
Checking of any physical damage
To detect any metal loss/ corrosion, scaling or cracks inside the
pipeline
To detect any leakages in the pipeline

Measurement of diameter, geometry & curvature monitoring,
temperature, pressure, bend detection, deposition of wax and product sampling.
Provide a baseline information
In-Line inspection pigs / Electronic Geometry Pigs (EGP) are used.
5.
During repairing and maintenance of a pipeline
Prior to carrying out the repairs and maintenance of a pipeline, pigging is done to detect
leakages, dents or any damage to the pipeline. Pigging operation enables to isolate the
damaged section and thereafter carry out the repair and maintenance work.
Specialized pigging tools are used for this purpose.
6.
During Renovation and rehabilitation of a pipeline
For various situations like when a pig is stuck, or for removing difficult and enormous
amount of debris from a pipeline, for applying in situ coatings for preventing corrosions,
scale removal, decommissioning and re-commissioning.
Highly specialized Pigs are used.
7.
During Decommissioning of a pipeline
Decommissioning of a pipeline involves removal of a product, cleaning of pipe wall, and

for inerting/ laying off a pipeline.
TYPES OF PIGS
Based on specific requirements as referred above, there are many types of pigs:
Batching Pigs: Also known as Swabbing/ sealing pig, the batching pig is designed to
act as a simple barrier/ interface between dissimilar fluids or to provide a sweep of a
line.
Page - 46
Cleaning Pigs: Pigs can be configured with various tools to aid cleaning. Circular
brushes, spring mounted brushes, scrapers or plough blades for waxes and sludges, or
more aggressive tools such as carbide pins for removal of scales.
Gauging Pigs: The inclusion of simple gauge plate, made of a soft metal (generally
Aluminium) on batching pigs provide the function of confirming the integrity of the flow
area of pipe. Any major intrusion into the line will cause damage to the gauge plate,
highlighting there is a problem, though not highlighting where.
Magnetic Pigs: Inclusion of powerful rare earth magnets on the circumference of the
pig mandrel allows the pig not only to lift ferrous debris from the line, but can also
provide the secondary functions of activating pig signallers.
Geometry pigs: It is a configuration pig designed to record conditions, such as dents,

wrinkles, ovality, bend radius and angle and occasionally indications of a significant
internal corrosion by making measurements of the inside surface of the pipe.
Intelligent
Pigs:
Research
and
development into inline inspection tools began in the late 1960s. Advance in technology
have led to Intelligent / Smart Pigs that can carry out complex tasks, and data logging
as they traverse the line. Intelligent Pigs are highly sophisticated instruments. They are
basically a computer that collects various forms of data during the trip through the
pipeline.
The technology used to accomplish the service vary by the service required and the
design of the pig, each pigging service provider may have unique and proprietary
technologies to accomplish the service. Surface pitting and corrosion, as well as cracks
and weld defects in steel/ferrous pipelines are often detected using Magnetic Flux
Leakage (MFL) pigs. Other "smart" pigs use ultrasonics to detect pipe defects.
Page - 47
MFL INSPECTION TOOL
ULTRASONIC INSPECTION TOOL

Although the two most common requirements are for geometry/diameter measurement
and for metal- loss/ corrosion devices, the information which can be provided by these
intelligent pigs covers a much wider range of inspection and trouble shooting needs
which include:
Diameter/ geometry measurements;
Curvature monitoring;
Pipeline Profile;
Temperature/ Pressure recording;
Bend measurement;
Metal- loss/ corrosion detection;
Photographic inspection;
Crack detection;
Wax deposition measurement;
Leak detection;
Product sampling, and;
mapping
PIGGING MEDIUMS
Liquid
Page - 48
The preferred medium for propelling pigs is an incompressible liquid. Incompressible liquids
provide maximum control over pig speed as well as lubrication for the pig seals, minimizing
wear, and maximising seal effectiveness and life.
Liquids such as water, crude oils, or process products and chemicals can be used as propelling
mediums. Care is taken to ensure sealing element materials are compatible with fluid medium
and prevailing pressure and flow conditions.
Gas
As gasses are compressible, the amount of stored energy behind a pig propelled with gas is far
greater than that of a similar pig propelled with liquid. Appropriate consideration is given to
safety implications resulting from this stored energy. Pig movement can also be affected by
improper use of a compressible gas as a propulsion fluid. Failure to deliver adequate quantities
of gas required to maintain sufficient pressure behind the pig can result in a stop-start motion
of the pig. This effect can be minimised to some extent by sizing equipment properly and
maintaining a constant back pressure on the pig to minimise velocity changes.
When pigging with gas as a propelling medium, wear may be increased on the sealing discs.
This should be considered during pig selection.
Multiphase Fluid
When the pig propelling medium is multiphase, the same safety consideration is given to the
pigging operation as if the propelling medium were gas. Extra care is taken to consider the
effect of slugging and the associated forces at the receiving end. Any temporary pipework
should be secured and permanent facilities and equipment should be rated for multiphase flow.
PIG LAUNCHING AND RECEIVING
The most common method of getting pigs in and out of lines is through the use of pig traps.
The selection of pig traps and the method of launching and receiving of pigs depend on several
factors.
The number of pigs required to be launched or received in the pig train would have an effect on
the physical size of trap and associated pipework required, although space limitations may also
have an effect.
The pressure rating of the pig trap required to meet system design codes/standards and
function can also affect physical size and design of the trap.
Whether a trap is temporary or permanent can affect design. Construction material can be
affected, as can method of closure. Temporary traps may have simple flange closures, whereas,
permanent traps tend to have quick opening door-type closures.
Page - 49
Pig Signaller
Schematic of typical horizontal pig trap system

Pigging systems are designed so that the pig is loaded into the launcher, which is pressured up
to launch the pig into the pipeline through a kicker line. The pig is removed from the pipeline
via the receiver at the end of each run. All systems must allow for the receipt of pigs at the
launcher, as blockages in the pipeline may require the pigs to be pushed back to the launcher
(Refer the Schematic Diagram shown above). Some systems are designed to pig the pipeline in
either direction. Such systems require Bi-directional pig traps (Refer Sketch shown below).
Page - 50
BI-DIRECTIONAL PIG TRAP

(Typical General Arrangement Drawing)
There are inherent risks in opening the barrel to atmosphere and care must be taken to ensure
that the barrel is depressured prior to opening. If the barrel is not completely depressured, the
pig can be ejected from the barrel and operators can be severely injured when standing in front
of an open pig door. When the product is sour, the barrel should be evacuated to a flare system
where the sour gas is burnt. Operators should be wearing a self-contained breathing apparatus
when working on sour systems.
SUMMING-UP
We have seen how pigging is an indispensable activity in pipeline construction. It plays a
significant role in the various stages of a pipelines life cycle. As long as there are pipelines in
operation, there will be a need for pipeline pigging. As technology advances, the use of
intelligent pigs will increase as real-time communications allow pigs to record more information
while being more compact as data storage will no longer be an integral part of the pig. The
information obtained from the intelligent pigs tell the operator the location and type & size of
each defect by evaluating the rate of change of a particular defect over several years, proactive
plans can be made to repair the pipeline before any leakage or environmental damage occurs.
Page - 51
PIPELINE CONSTRUCTION
R.K. Narayan, DGM (O&G),
MECON Limited, Delhi
1.
Introduction
In the present age transportation of petroleum crude alongwith various refinery products
and natural gas through pipeline has become most techno-economically viable mode of
transportation. Whether it is required to be used as raw material for various refineries,
fertilizers plants or to be used as fuel in Gas based power plants. These plants are
located in far-flung areas much away from oil well heads or gas wells. Under these
condition laying of cross country pipelines has become of utmost importance for the
developing economy. Wherever these pipelines has crossed any state it has contributed
significantly in the development of that area. After Indias first Hazira Bijaipur
Jagdishpur (HBJ) pipeline lots of spurlines and branch lines have been laid for natural
gas. More than four thousand kilometer pipeline have been laid for natural gas and
many large dia meter mega natural gas projects are in the pipeline to complete the
national gas grid subsequently Reliance K.G. Basin gas from its D6 block.
Pipeline construction for cross country is really very challenging and is altogether
different than any construction confined within boundary of any plant as all activities are
to be carried out beyond walled area. The pipeline crosses beyond boundary of any
village, district and even states for bigger lines. The pipeline has to cross various
obstacles such as river, canals, creeks, national highway, state highway, railway lines,
ponds, express way, other roads etc.
Cross country pipeline laying involves extensive traveling along the pipeline route and
even camp facilities and temporary facilities to store the material are to be made along
the pipeline route in remote villages.
Apart from laying pipeline in cross country, nowadays, natural gas pipeline is being laid
in many cities also to cater the need of automotive sector as well as domestic and
commercial sector.
Challenges of laying CNG pipeline in cities are different than laying in cross country
areas due to extensive underground utilities, thick population demography, busy traffic
scenario, clearances from various authorities / agencies.
2.
Codes & Standards

Various codes and standards are to be followed for any pipeline construction. Some
important standard are enumerated below :
(i)
(ii)
ANSI B 31.8
ANSI B 31.4
(iii)
OISD 141
(iv)
OISD 226
(v)
(vi)
OISD 214
API 1104
Gas Transmission and Distribution Piping System

Liquid Transportation System for Hydrocarbon,
Liquid Petroleum Gas, Anhydrous Ammonia and
Alcohols.
Design & Construction requirement for cross country
liquid hydrocarbon pipeline.
Natural gas transmission pipeline and city gas
distribution network.
Cross Country LPG Pipelines.
Welding of pipelines and related facilities.
Page - 52
(vii)
API 1102
Steel pipeline crossings Railroads & highways.
Before construction of pipeline statutory clearances and permission are obtained from
authorities such as CCOE (Chief controller of explosive), MOEF (Ministry of Environment
& Forest), SPCB (State Pollution Control Board), Forest authorities, railways, irrigation,
national / state highways also.
In case of city gas laying permission has to be obtained from various concerned
authorities and underground utilities agencies.
3.
Laying in Different Terrain

A cross country pipeline encounters various type of terrain which may encompass
normal soft soil, sandy soil, rock, black cotton soil or marshy land. Suitable methodology
& equipment are to be used for pipe laying in specific terrain. If the area is hilly, where
normal trenching is not possible, rock cutting machines or controlled blasting is used.
Special considerations are required for laying in black cotton area due to its property of
water absorption.
4.
Documents required before start of construction.

The detailed survey report is required for pipeline. It mainly consists of
Pipeline Route Map,
Cadastral Map,
Alignment Sheets
Crossing Drawings
Soil Investigation Report
Hydrographic survey of major water bodies
The route map indicates the actual route on Geographic map of the area and alignment
sheets describes the actual surveyed length, deflection angle, contour, terrain and
obstacles.
5.
Pipeline Construction Activities :

There are number of activities involved in pipeline construction. They can be enumerated
as below :
i)
Route Survey, ROU Clearing and Grading

This is required to indicate the pipeline route of site including the ROU limits,
pipeline alignment, pipeline chainages, crossing limits, in-field IP and TPs Pillars,
identifying the existing pipeline in common ROU if any in accordance with the
route maps, cadastral map and crossing drawings for verification of alignment
and crossings.
The contractor is required to perform his construction activities within the width
of Right of Way (ROU) set aside for construction of pipeline, unless he has made
other arrangements with land owner for using extra land.
ROU boundary line is first stacked by the contractor and centre line of pipeline is
marked following alignment sheet stacking is done after clearing and grading of
ROU and making / identifying approach roads to ROU for movement of man and
machinery.
ii)
Handling, Hauling, Stringing and Storage of Material.

All pipeline materials are stored in stores / dumpsites created at suitable
locations along the pipeline route so that movement is smooth and travel
Page - 53
distance is short. After grading, line pipe stringing is done on the ROU by the side
of trench centerline by suitable handling and lifting equipment.
iii)
Trenching
Pipeline trench is excavated on the cleared and graded Right of Way as per the
approval trench profile so that minimum cover of the pipeline is achieved after
backfilling. The trench profile should be tapered and wider at the top with
suitable angle to ensure trench wall stability against collapse. Trench shall be
excavated on surveyed routes as stacked in ROU. The centerline of the trench
shall be established from the TP stakes established after route survey. Trench
excavation is carried out by mechanised machinery.
In case of hard rocky terrain, trenching is done by controlled blasting.
iv)
Welding
Welding is most important activity of pipeline laying and integrity of entire
pipeline depends on soundness of weld joints. Welding is done as per approval
procedure and established WPS (Welding Procedure Specification) first with the
same line pipe of the project, welding procedure is established by test welding
and its NDT and destructive testing of the test weld is carried out for different
procedures of welding involved in mainline.
All pipe ends are visually checked, if any damage found the same is repaired. All
weld joint nos. are numbered as per standard specification. Before fit-up pipe
ends inside and outside shall be cleaned by wire mesh. Internal / external clamps
are used depending upon size of pipe for fitment.
Normally SMAW (Shielded Metal Arch Welding) method is used for pipeline
welding. For small dia line pipe manual welding method is adopted for root and
other passes.
For bigger dia pipe semi-automatic or automatic welding machine is used
depeding upon quantum of length of pipeline and progress requirement as per
completion schedule.
For inspection of weld, apart from visual inspection, various NDT techniques are
used. API 1104 code is generally used for welding of Mainline. Weld joints are
radiographed by X-ray using internal crawler for bigger size pipe. X-ray films are
examined for any defects on weld joints as per relevant code and specification.
For inspection other NDT technique such as ultrasonic examination is also used
for checking lamination wherever required as per approved procedure.
Page - 54
WELDING ACTIVITY
v)
Field Bending & Long Radius Bends

Elastic bends are preferred to be used for negotiating any angle as per alignment
sheet. However for sharp turning point normally factory made long radius bends
(R=6D) are used to allow smooth passage of pigs during testing, operation and
periodic inspection.
Cold field bends are also permitted in the field. These bends are made on site
with the help of pipe bending machine maintaining sufficiently high bend radius
recommended by the code for different diameter of the pipeline.
vi)
J
Joint Coating
For Line Pipe, normally 3 Layer PE Factory Coated pipe are used. For Coating on
all girth weld joints, heat shrink sleeves (compatible to property of parent pipe
coating material) are used as per approved recommended procedure of heat
shrink sleeve supplier.
Before applying sleeve weld joints are cleaned by sand blasting machine. Pipe
joints are heated and then sleeve is wrapped as per recommended procedure.
For Girth weld coating of pipe string to be pulled by HDD technique, high shear
strength material joint coating sleeves is used.
Integrity of coating sleeve and pipeline coating is checked by Holiday detector.
vii)
Lowering
Lowering follows as soon as possible, after the completion of the joint coating of
the pipeline. Before lowering in, complete check by full circle holiday detector for
pipe coating and field joint coating shall be carried out. If any defects in coating
is detected the same shall be repaired before lowering-in of the pipe.
Page - 55
The pipeline is lifted and laid using suitable equipment of non-abrasive material
having adequate width for fragility of the coating. Care shall be exercised while
removing slings from around the coated pipe after it has been lowered in the
trench. Suitable no. of pipe lowering equipments should be used and it should be
spaced at suitable inter distances to avoid pipe snaking i.e. the pipe is not
subjected to undue stress / strains / deflection beyond elastic limit.
viii)
Backfilling
Backfilling is done immediately after the pipeline has been laid in the trench.
Backfilling shall not be done until the pipe is following the ditch profile at the
required depth that will provide the required cover. Before backfill, pipe & HDPE
duct, if any, proper accommodation inside the trench and cover over the pipe is
checked.
ROU, gravel, lumps of hard soil or like material shall not be used for direct
backfilling unless suitable padding over the pipe by sand or special select backfill
soil has been provided.
ix)
Crossing (Cased Crossing)

Pipeline crossings for major State Highway / National Highway roads, rail road,
lined canals are executed by boring using casing pipe. The crossing string shall be
pre-tested before installation inside casing pipe.
Casing pipe is installed using auger / boring / jacking / ramming / HDD
technique.
The size of casing pipe is kept minimum 3 size higher than the carrier pipe.
Casing pipe thickness, in case of railway or highways, shall be checked as per API
1102 code. Casing insulators shall be installed between carrier pipe and casing
pipe. Electrical insulation between casing and carrier should be insured before
lowering.
The cover above the casing pipe shall be as per cover recommended by
concerned authority of concerned crossing.
BORING FOR CASED CROSSING
Page - 56
x)
Open Cut Crossing

Depending upon the width, traffic, volume water level, some crossings can be
possible by open cut method. After laying the pipeline in a road crossings by
open cut method, road is restored. It shall be ensured that traffic is not stopped
during execution of the work.
xi)
Concrete Coating
Concrete coating over the line pipe is done to avoid buoyancy of the pipeline
while laying. In some of the waterlogged area, if pipe has to be layed, to
maintain the cover over pipe, the mainline weight shall be increased so that pipe
shall not float in water / mud. Similarly while crossing any water body such as
pond, canal, river, etc. by open cut method, the pipe string has to be suitably
concrete coated to prevent floating of pipeline.
The pipeline is coated with cement mortar over steel wire mesh net using
gunniting work as per specification. Thickness of coating is decided to provide
negative buoyancy of pipeline.
xii)
Crossing by Horizontal Directional Drilling Technique

This technique is used for crossing highways, canals, and river by trench less
method. In this method crossing can be done without using casing pipe and
without damaging coating of carrier pipe. This is a very specialized and now
proven technology for crossing of obstacles by trench less method. The specific
crossing is designed and crossing profile is approved. The crossing string is
prepared and pre-hydrotested. Here first a pilot hole is drilled directionally on the
predetermined drill path by HDD machine located at one end of the crossing.
After the pilot hole, the reamer is attached to the pulling rod end and the hole is
reamed to the required size. After the reaming operation is completed, the string
kept at other side of the crossing is pulled inside the drilled hole by the machine.
xiii)
Tie-in
The unconnected sections of the pipeline at various locations have to be tied in
after the sections are coated lowered and backfilled. The sections to be connected
Page - 57
shall have at the ends, sections of over lapping, uncovered pipe of sufficient
length to absorb, without inducing excessive stresses in the steel, small
displacements necessary for perfect alignment and connection of the ends.
Tie-in should be done in such a way as to leave a minimum of strain in the pipe.
xiv)
Hydrostatic Testing The purpose of this testing is to check integrity of

the pipeline.
Hydrostatic testing shall be performed on the entire length of the pipeline.
Hydrostatic test shall commence only after mechanical and civil work completion
i.e. all welds have been accepted and the pipeline has been laid and backfilled.
Hydrostatic test shall also include those sections which have been previously
tested i.e. rail, road, major water crossings sections.
Hydrotesting shall be done as per approved procedure for each project and the
hydrotest pressure shall be as per specified minimum hydrotest pressure
specified in the job specification.
This hydrotesting shall be a cyclic pressurization and once the desired pressure is
obtained it shall be kept stabilized for minimum 24 hours duration.
xv)
For better accuracy of pressure measurement, dead weight tester is used for
measuring pressure, thermocouples are used for measuring continuous
temperature. Test pressure is accepted after pressure temperature correction
if it is within acceptable limit.
Dewatering, Swabbing and Drying
By dewatering operation the major quantity of hydrotest water shall be removed
from the main pipeline.
Swabbing operation is done to take out the remaining water in the pipeline to
bring the pipeline into touch dry condition as specified.
Dewatering operation consists of number of dewatering pig runs when air is used
as propellant for pig train. Bi-directional cup pigs, which are designed to prevent
damage to pipeline, shall be used for dewatering.
For swabbing air pigging headers is used for launching the foam pigs. Weighing
arrangement is available at launching & receiving ends. Remaining water if any
shall be removed by four cup batch pigs and high density foam pigs. The
swabbing operation shall involve the weighing of the pigs before launch &
immediately after their removal. The swabbing operation shall be considered to
be complete when it is established that there is no free water left in the pipeline
and the pipeline is ready for drying. Drying of the pipeline is done by absorption
of water into dry air blown through the pipeline. The air drying operation shall be
carried out continuously by blowing compressed air which will be free from oil &
dust. The blowing shall be continued until the desired due point (-20C) is
achieved.
xvi)
Restoration
Contractor has to restore ROU and all sites used for construction.
-
All surplus and defective material to be disposed.
ROW has to be cleared of all rubbish, broken, empty cans, card board,
sacks, leftover construction material.
Page - 58
xvii)
All auxiliary structures such as bridges, culvert, sheet piling posts, signs
etc. which were erected or installed as temporary measure are to be
removed.
Damages to roads, bridges, private properties, drainage, are to be

repaired and restored to original condition.
Slopes, water course sides or banks damaged during execution has to be

properly consolidated & restored.
Any temporary, markers, hutments, storage area, fencing, barricading

etc. made by the contractor during execution has to be removed and area
restored as original condition.
Pigging
When a pipeline is being constructed, after it is constructed and before it is put
into service there are a number of key activities required in order to ensure that
the pipe meets the requirements of its owners or operators. These will vary to
some extent depending on the service for which the line is intended, but as a
minimum they will be looking for verification that the line has been laid without
significant defects and is in a condition suitable to be filled with the intended
product.
Pipeline pigging has a significant role to play in meeting these conditions as it has
become an important part of the pipeline construction and maintenance program.
Pigging is the process in which a pipeline is cleaned, gauged, inspected and
made to transmit throughputs of one or several products using a device generally
known as PIG or Pipeline Inspection Gauge.
Pipeline pigs are the devices that are inserted into and travel through out the
length of the pipeline driven by the product flow. They were originally developed
to remove deposits which could obstruct or retard flow through a pipeline. Today
pigs are used during all phases in the life of a pipeline for many different reasons.
During pipelines construction caliper pigging is done which checks any damage of
pipeline occurring during laying. This caliper pig is used in conjunction with
various type of cleaning pig, magnetic pigs etc. which checks the ovality, any
dent on the through out total length of the pipeline.
xviii) Pipeline Markers

Various type of markers are installed throughout the pipeline length to facilitate
laying as well as to locate the pipeline after laying in the future. Following type of
markers are installed as per specification :
1.
2.
3.
4.
5.
ROU Boundary Marker To indicate ROU width.

KM Marker To indicate cumulative chainage.
Direction Marker To indicate direction at turning point.
Pipeline Warning Sign To indicate important crossing points.
Aerial Markers To indicates direction at every 5 Km interval.
6.
Inspection at site
For laying the pipeline, approved procedure for specific activity is to be followed. For
inspection, inspection tests plan (ITP) for each activity is to be followed. While laying,
safety has to be ensured, relevant HSE (Health, Safety & Environment) specification and
guidelines to be followed.
7.
Challenges
Pipeline construction is very challenging as most of the pipeline has to be completed in a
very tight time schedule. Construction is undertaken at several fronts simultaneously.
Page - 59
Working in different terrain and demography has its own problems. Obtaining permission
from various agencies has to be organized timely.
Since pipeline construction is an open field activity, some time law and order problem
also arises while acquiring or entering into ROU of the proposed pipeline corridor. In
some of areas, farmers / local villagers put up obstacles which also stop or slow down
the overall construction progress. Therefore, apart from technical problems, skill to
tackle problems arising due to socio-economic problem, local law & order problem, are
also required for successful completion of pipeline construction.
Hope you gained some valuable inputs after going through the
articles during this voyage of knowledge!!!
Suggestions and feedbacks are welcome from all readers to
ensure continuous improvement. Please send your views to
KM@meconlimited.co.in
In case of any query or suggestion related to the articles, the
owners of the articles may also be contacted.
For using Discussion Forum, please log in to
http://www.meconinfo.co.in
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KM Bulletin Tech Papers On CNG and CGD and HDD Article

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K

Mr. T.K. Biswas

Sharing knowledge is not about giving people something, or getting

KM Article Writing Competition

KM Bulletin (Edition 5) - December 2009

TOPIC: Journey of MECON in Rolling Mills & other services related to

Why enter the contest?

Rules of the Contest

Guidelines for Articles content

Strength, Experience and innovative practices belonging exclusively to MECON in

KM Bulletin (Edition 5) - December 2009

Title of the Session

Shri V. Trivedi & Shri Arun Minz

Shri M.K. Jaiswara, ADE (PT&D)

Shri D. Bose, ADE (PP & EE)

Shri S. Sengupta, AGM (IM)

Intra/Inter-section Sessions @MECON, Bangalore

Title of the Session

Mr. G.V Aruna,Mr.Supriya Ray

Mr. Solomon Yash Kumar Minz,

Quality Steering Committee

Intra/Inter-section Sessions @MECON, Delhi

Title of the Session

Mr. Aashis Moyal, ADE

Oil & Gas

Mr. A. K. Jha, Sr. Manager

Based on data mentioned above, Quality Steering Committee from Bangalore is

KM Bulletin (Edition 5) - December 2009

Autonomy : It provides technologies for computers to understand electronic data

Knowledge Enterprise (MAKE) Finalists

Note: A total of 14 organizations were selected as 2009 Indian MAKE Finalists

* Workshop on Measuring KM in Projects: Why, What and How (30th

KM Bulletin (Edition 5) - December 2009

these issues by presenting a framework for adapting and fine-tuning generic KM

CONGRATULATIONS TO ALL THE WINNERS!!!

In response to the second competition in series of KM Article Writing

KM Bulletin (Edition 5) - December 2009

CNG AND CGD PROJECTS

Sources of Air Pollution

About 72 % Of Total Air Pollution Comes From Transport Sector

KM Bulletin (Edition 5) - December 2009

KM Bulletin (Edition 5) - December 2009

Comparative Properties of available Fuels

KM Bulletin (Edition 5) - December 2009

Auto Ignition temperature

Conclusion : CNG is a safe fuel with better combustion quality

Bajaj three wheeler

Conclusion : CNG is the cleanest fuel operating today

KM Bulletin (Edition 5) - December 2009

Advantages of CNG over other alternative fuels:

CNG is the cleanest burning fuel operating today

The vehicles converted to CNG produce little or no emissions.

KM Bulletin (Edition 5) - December 2009

KM Bulletin (Edition 5) - December 2009

KM Bulletin (Edition 5) - December 2009

Schematic Diagram of a CNG Daughter Booster Station

KM Bulletin (Edition 5) - December 2009

Pre-heater (if required)