Lusail Gas Design Regulation

LUSAIL DEVELOPMENT
Gas Distribution System

Design Guidelines for Mega-development
and Sub-development
Document No.: LUS-CPALL-MAQ-SPE-UT-0005
REASON ISSUED PREPARED CHECKED APPROVED

REV.
FOR DOCUMENT HISTORY STATUS
NO DATE BY BY BY
ISSUE
Muhamad Abdullah D. Reed

0 IFI 12-04-2012 A
Kamal Abushaikha Phillips
1 IFI 10-05-2012 Lusail comments incorporated A
Kamal Abushaikha Phillips
Muhamad Vinod D. Reed

2 IFI 30-10-2014 A
Kamal Kesavannair Phillips
REASON FOR ISSUE: STATUS

IFR Issued for Review/Comment(s) PFC Preliminary for Comment
IFI Issued for Information A Approved
IFA Issued for Approval SS Superseded
IFT Issued for Tender
IFC Issued for Construction
Project Name: Lusail Development Gas Distribution System

Design Guidelines for Mega-development and Sub-development Rev.02
LUSAIL DEVELOPMENT
CONTENTS
1 INTRODUCTION 7
2 SCOPE 7
2.1 Gas distribution systems 7
2.2 Gas utilization systems: 7
3 DEFINITIONS 7
4 COMPETENCY 8
5 OBJECTIVE 8
6 DESIGN PRINCIPLES 8
7 DESIGN CRITERIA 9
8 DESIGN PARAMETER 10
9 CODES, STANDARD AND SPECIFICATIONS 11
9.1 Institution of Gas Engineers & Managers (IGEM): 11
9.2 British Standards Institute: 11
9.3 European Standards Institute: 11
9.4 National Fire Protection Association: 12
9.5 American Society of Mechanical Engineers 12
9.6 Gas Industry Services, UK 12
9.7 Local Authority Regulations: 12
10 DISTRIBUTION MAINS (MOP UP TO 4 BAR) 12
10.1 Design Standards 12
10.2 Design Criteria 12
10.3 Feeder Mains 13
10.4 Sector Mains 13

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10.5 Mains Valves 13
10.6 Feeder Mains Valves 13
10.7 Sector Mains Valves 13
10.8 Design Parameters 14
11 GAS SERVICES DESIGN BASIS 14
11.1 Design Standards 14
11.2 Design Criteria 14
11.3 Design Parameters 15
12 PRESSURE REDUCING STATION (CUSTOMER PRIMARY METER) 16
13 RISK ASSESSMENT 16
14 PRODUCTS (HDPE PIPES, VALVES AND ACCESSORIES) 16
14.1 HDPE High-density polyethylene pipe (Black Colour with Yellow Stripes) 16
14.2 HDPE Fittings (Black Colour) 16
14.3 HDPE Transition Fittings 16
14.4 Sleeves 16
14.5 PE Ball Valves 16
15 JOINTING OF PIPES, FITTINGS AND VALVES 17
15.1 General 17
15.2 Electro-fusion Jointing 17
15.3 Butt-Fusion Jointing 19
15.4 PE Welder Qualifications 20
16 STEEL PIPE, FITTINGS AND VALVES 20
16.1 Pipe and Fittings Codes and Standards: 21
16.2 Steel Pipe 22
16.2.1 Technical Details 22

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16.2.2 Marking 22
16.3 Steel Fittings 23
16.3.2 Marking 23
16.3.3 Gasket, Bolt & Nuts 23
16.4 Steel Valves 23
16.4.1 Valve Codes and Standards: 23
16.5 Cathodic Protection: 25
16.6 Welding Qualification Record: 25
16.7 Steel Pipeline Welding Inspector Qualifications 25
16.8 Inspection & Testing 26
16.9 Cost for NDT inspections and tests 26
17 MATERIAL HANDLING AND STORAGE 26
18 PIPE INSTALLATION 26
19 VALVE INSTALLATION 28
19.1 General 28
19.2 Valve Locations 28
19.3 Pre-Installation 28
19.4 Valve Installation Details 28
20 LABELING AND IDENTIFYING 29
20.1 Warning Tape 29
20.2 Tracer wire 29
20.3 Marker Posts 29
20.4 Stone marker 29
21 TESTING AND COMMISSIONING OF PIPING 29

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21.1 Scope 29
21.2 Test pressure for Pneumatic Testing 30
21.3 Procedure for Testing 30
21.4 Test Equipment 30
21.5 The criteria for testing are 31
21.6 Safety Precautions 31
21.7 Testing Procedure 31
21.8 Test Failure 32
21.9 Pressure Test Certificate 33
21.10 Commissioning 33
22 CIVIL WORKS FOR PIPE LAYING 34
22.1 Design 34
22.2 Existing Services, Utilities, etc. 34
22.3 Trial Hole, Route survey, Excavation and Trenching 34
22.4 Crossing 35
22.5 Proximity to other Services, Utilities, etc. 35
22.6 Backfilling and Reinstatement 35
22.6.1 Surface Enclosure for Valves 35
22.7 Route Marking 36
22.8 Reinforced Valve Chamber 36
23 CONSTRUCTION RECORDS 36
24 DOCUMENTS TO SUBMIT PRIOR TO WORK 36
25 QUALITY CONTROL 38
APPENDIX 1 39
APPENDIX 2 40

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APPENDIX 3 41
APPENDIX 4 42
APPENDIX 5 43
APPENDIX 6 44

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1 INTRODUCTION
The purpose of this document is to describe the works related to the supply, installation, testing, pre
commissioning and commissioning of the buried gas pipelines for the gas distribution network at Lusail
Development.
This guideline is applicable for the Mega-development and Sub-development.
2 SCOPE
Due to non-availability of Natural Gas the network shall be designed base on Synthetic Natural Gas
with similar Wobbe index. Later in future when Natural Gas became available, the system will be
converted to use Natural Gas without any major modification.
Marafeq is providing the guidelines for mega-development and sub-development whom undertaking the
design and construction of synthetic natural gas distribution systems which will be connected to
Marafeq’s gas piping system within its supply areas which include:
2.1 Gas distribution systems

 Feeder Mains
 Distribution Pipelines
 Distribution Mains (MOP up to 4 bar)

 Gas Services (Gas Service Line)
2.2 Gas utilization systems:

 Pressure Reducing Station (Customer Primary Meter) Installations
The scope of this Design Guidelines is the design basis of Marafeq’s synthetic natural gas distribution
and associated utilization systems within its gas supply areas.
3 DEFINITIONS
 Client – The master developer Lusail Real Estate Development Company (LREDC) or its
appointed representative.
 Contractor – The organization or its appointed representative, responsible for execution of the
works
 Competency - The possession of a minimum level of knowledge, experience and proficiency
required to collect appropriate information, make informed decisions, and physically take the
needed actions to deliver the high-quality service of gas piping system installation.

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 Customer – The owner/ sub-developer in-charge of the building.
 Engineer – Marafeq’s supervision engineer or its appointed representative.
 Marafeq – The utility company which provides District Cooling, Gas supply and Waste
Management services.
 Mega-developer – The owner of the district.
 Sub-developer – The owner of the building.

 Vendor – Any invited companies being fully eligible to submit the tender. The successful vendor
will be the contractor or supplier.
 Supervising Consultant – Customer appointed representative.
4 COMPETENCY
Any contractor or person engaged in the design, construction, commissioning, inspection, operation,
maintenance or alteration of a pipeline should be competent to carry out such work. This may achieved
by an appropriate combination of education, training and practical experience.
5 OBJECTIVE
The Design Guidelines forms a part of a suite of technical documents and provides a platform for:
 Engineering instructions
 Management procedures
 Work Procedures
 Method statements
 Minimum functional specifications
 Material specifications
The objective of the Design Guidelines is to define the basis for the design of synthetic natural gas
distribution and utilization systems.
6 DESIGN PRINCIPLES
The key design principles that shall be adhered to are:
 In all matters, the overriding goal is safety
 Adoption of the best international practices utilizing appropriate modern technology.

 In addition the design principles shall include:
 Protection of customers, public, property and environment from injury, damage or harm.
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 Assurance of a safe, reliable, effective, efficient and secure supply of natural gas to
consumers.
 Achievement of a financially viable investment.
These principles shall be achieved by:
 Making provisions to reasonably mitigate the risk and consequences of system failure,
naturally occurring hazards or third party interference.
 Optimizing the use of the entire synthetic natural gas system during its operating life cycle.
 Ensuring that any design is appropriate to serve current demands yet is flexible enough to
serve markets which are identified as being available during the design period.
 Ensuring that the scope of impact of failure of one or more components on the gas supply to
consumers can be controlled and localized.
 Minimizing the complexity of the system from both the construction and operational stand
points.
 Providing synthetic natural gas measurement data for gas system management and fiscal
purposes.
7 DESIGN CRITERIA
The key design criteria that shall be adopted to are:
 The upstream synthetic natural gas supply shall be considered to be suitable, constant and
adequate to supply the peak demand as stipulated in the gas purchase contract.
 To improve security of supply multiple sources shall be considered. Where possible, designs
should allow for routine operation and maintenance without interruption of supply to consumers.
 Provision shall be made to incorporate means of control of synthetic natural gas flow within the
distribution system including isolation of damaged facilities or components.
 The gas supply source pressure considered in design shall be determined based on the
synthetic natural gas supply contract and upstream design conditions.
 The distribution system shall be designed without compression.
 The distribution system shall be adequate for the design load at each stage of its development.
 Distribution system shall be designed to supply a forecast hourly peak demand.
 Distribution system design shall be based on the predicted peak hour flows anticipated twenty
five (25) years ahead.
 The load that shall be applied during design should be diversified. Considerations in
determining the load diversity should include the nature of the facility being designed, the type
of load and the number of consumers.

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 The load diversities for pipelines, pressure reducing stations and mains shall be the same.
However this load diversity is different from that used for gas services, meter sets and
utilization piping systems.
 Designs should minimize the types and size range of materials and use only material items for
which approved Material Specifications exist. All materials should be suitable for local climatic
conditions.
 All materials, assemblies and installations shall assure correct functionality and full operability
taking due account of ambient conditions of the location.
 The design shall allow construction to be undertaken using existing and/or reasonably
available methods, tools and equipment. Where appropriate industry best practices shall be
utilized.
 The design shall be prepared considering the location of other utilities plant or obstructions,
where known.
 The design shall include provision for Gas Services to be installed to every plot and/or building.
8 DESIGN PARAMETER
The following design parameters have been adopted by MARAFEQ due to the nature of the specific
local environment in which the synthetic natural gas distribution systems must be constructed.
Synthetic Natural Gas specification shall be based on the table below:-

In the assumption that the gas specification as given below:-
1. Propane Calorific Value at 2514 Btu/cf and Specific Gravity at 1.5

2. Butane Calorific Value at 3280 Btu/cf and Specific Gravity at 2.01
3. Natural Gas Calorific Value ranging from 960 Btu/cf to 1105 Btu/cf and Specific Gravity of
0.56 to 0.66
Maximum
Calorific SNG Calorific SNG Specific
No. LPG Source Wobbe Index Operating
Value Value Gravity
Pressure
Net 2887
1 *LPG 1518 Btu/cf 1283 1.399 2 Bar
Btu/cf
Gross
2 *LPG 1545 Btu/cf 1283 1.449 2 Bar
3129 Btu/cf
**Natural 960 to
3 1283 – 1385 0.55 to 0.66 4 Bar
Gas 1050 Btu/cf
Notes: *LPG information from WOQOD LPG chemical composition table Appendix 2
** Natural Gas information for gas specification Appendix 3
 Distribution and service line Maximum Operating Pressure (MOP) design shall be 2 bar and
minimum operating pressure shall be at 1.2 Bar for SNG system.

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 Distribution and service line Maximum Design Pressure shall be at 7 bar.
 Natural Gas Maximum Operating Pressure shall be at 4 bar.
9 CODES, STANDARD AND SPECIFICATIONS
The Gas Distribution Network to be installed at a minimum, to comply with the recommended standards
and codes of practice listed below.
9.1 Institution of Gas Engineers & Managers (IGEM):

 IGE/TD/3 Edition 4; 2005 “Steel and PE pipelines for gas distribution”
 IGE/TD/4 Edition 4: PE and Steel gas services and service pipe work.
 IGE/TD/3 Edition 4 Supp1: Handling, transport and storage PE pipes and fittings
 IGE/GL/9: Guidance for large consumers in dealing with Natural gas supply emergencies
 IGE/SR/24: Risk assessment techniques
 IGE/SR/25: Hazardous area classification of Natural gas installations.
 IGEM/TD/13 Ed 2: Pressure regulating installations for Natural Gas, Liquefied Petroleum Gas
and Liquefied Petroleum Gas/Air
 IGE/SR/22: Gas Purging and Commissioning Method.
 IGE/SR/23 2nd Imp: Venting of Natural Gas.
 IGE/GL/1; edition 2; 2005 “Planning of gas distribution systems of MOP not exceeding 16 bars”.
 IGE/GL/5; edition 2; 2005 “Procedures for managing new works, modifications and repairs”.
 IGE/GM/8 Part 1 Non domestic gas meter installation
 GBE/PL2 Technical Specification for Polyethylene Pipes and Fittings
 All IGE related Amendments and updates in September 2011.
9.2 British Standards Institute:

 BS EN 1555; Suite of European specifications for polyethylene pipe and fittings.
 BS EN 1295-1; Structural design of buried pipelines under various conditions of loading.
9.3 European Standards Institute:

 PrEN 1555-2: Plastics piping systems for the supply of gaseous fuels – Polyethylene (PE) –
Part 2: Pipes.
 ISO 12007-2:2000; ”Gas supply systems – Pipelines for maximum operating pressure up to and
including 16 bar – Part 2; Specific Functional recommendations for polyethylene (MOP up to
and including 10 bar).

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9.4 National Fire Protection Association:

 NFPA 58: Liquefied Petroleum Gas Code, 2011 Edition.
 NFPA 54: National Fuel Gas Code. 2011 Edition.
9.5 American Society of Mechanical Engineers

 ASME 31.8 Transmission and Distribution Piping System
 ASME 31.3 Process Piping
 ASME B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch
Standard
9.6 Gas Industry Services, UK

 GIS V7 Specification for distribution valves - Part 1: Metal-bodied line valves for use at
pressures up to 16 bar and construction valves for use at pressures up to 7 bar.
 GIS V7 Distribution valves Part 2: Plastics bodied valves of sizes up to and including 180 mm
suitable for operation at pressures not exceeding 5.5 bar
9.7 Local Authority Regulations:

 WOQOD Gas Department Regulations.
 Qatar Construction Specification
 Qatar Civil Defense
10 DISTRIBUTION MAINS (MOP UP TO 4 BAR)
10.1 Design Standards

 IGE/TD/3 Edition 4 Steel and PE pipelines for gas distribution
 IGE/GL/1 Planning of Gas Distribution Systems Operating at Pressures not Exceeding 7 bar
10.2 Design Criteria

 Shall be buried.
 May be either polyethylene or steel.

 Within a contiguous network, one MOP pressure shall be utilized.
 Minimum pipe size for a main shall be 63mm for PE and 50mm for steel.
 75mm, 200mm and 355mm PE are non-preferred pipe sizes.

 Maximum velocity as per IGE TD 3 requirement.
 Mains distribution pipe proximity limit shall be referred to IGE/TD/3 Table 5 (latest edition)

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10.3 Feeder Mains

 Normally installed outside of sectors but may be installed through sectors.
 Supply small networks of mains installed within each sector.
 Extend from the outlet of a Primary Pressure Reducing Station (PPRS).
 If the gas distribution system is supplied by more than one Primary Pressure Reducing
Station (PPRS) the feeder mains shall interconnect those Primary Pressure Reducing Station
(PPRS). Where a gas distribution system is not back fed from another source then it should be
looped
 May have branches
 Branches should be looped but may be single fed.

 Gas services should not be connected to feeder mains.
10.4 Sector Mains

 A sector should be served by one or more small networks of distribution mains installed within
the sector.
 Gas services should be connected to sector mains in the network installed within the sector.
 The network shall allow for gas services to be installed to every residential and commercial
premise in the sector.
 The network should be looped when serving more than 200 consumers.
 Looped networks may have single fed branches.
 Looped networks should have a dual supply from feeder mains outside the sector.
10.5 Mains Valves

 Strategic valves shall be installed per IGE/TD/3.
 Where expansion of the gas system is envisaged, provision for tie-ins shall be made. If the tie-
in provision is a valve it shall be a strategic valve:
10.6 Feeder Mains Valves

 spacing should typically not exceed 800m
 should be installed on either side of special crossings and major river or estuary crossings
 should be installed at branch connections
10.7 Sector Mains Valves

 Not normally installed within a sector other than at the connection to feeder mains
 Strategic valves should be double block and bleed type and be installed with body bleed
extended to a point near the ground surface to allow safe venting.

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10.8 Design Parameters

 Network Maximum Incidental Pressure (MIP) shall be determined considering:
 Material selection.
 Proximity distances.
 Site conditions.
 Minimum design operating pressures for pipelines within the distribution network should be 1.2
bar.
11 GAS SERVICES DESIGN BASIS
The primary function of a gas service is to transport synthetic natural gas from a distribution main to
service isolation valve (SIV). Each gas service shall be sized to deliver the quantity of synthetic natural
gas that meets the connected customer requirements. A gas service is the takeoff from distribution line
to each individual plot.

 IGE/TD/3 Steel and PE pipelines for gas distribution
 IGE/TD/4 Gas Services

 IGE/GL/1 Planning of Gas Distribution Systems Operating at Pressures not Exceeding 7 bar
11.2 Design Criteria

Functionality of a gas service shall include:
 For some installations, a flow limiting device (FLV) shall be installed near the main for
automatic restriction of gas flow in situations where excessive quantities of gas flow through the
pipe as a result of damage to the gas service.
 For some customers, multi-occupancy buildings and commercial or industrial installations, an
underground service isolation valve (SIV) shall be installed for manually isolating the supply of
synthetic natural gas from the connected customers.
 For all installations and customers, a riser shall be from below ground to above ground.
 For all installations and customers, above ground pipe shall be that is thermally stable at
ambient temperatures.
 For all installations and customers, an above ground ECV for manually isolating the supply of
synthetic natural gas from connected customers.
Considering the required functionality gas services:
 Shall consist of both buried and above ground components from the main to the outlet of the
Service Isolation Valve (SIV) and Emergency Control Valve (ECV).

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 Should install only one gas service to a plot. Conversely, a single gas service should not serve
multiple plots.
 May be dual (i.e. two services from a single service tee).
 Above ground service pipe shall be designed to take into account local climatic conditions.
 Services should be external to buildings.
 Minimum pipe size shall be 25mm HDPE.

 Service tee from main line shall be reducing tee or equal tee with reducer, no tapping/ saddle
tee is allowed.
Considerations in the gas service configuration are:
 Underground Routing - The gas service shall extend underground from a connection to a
distribution main. The gas service should be routed perpendicular to the main directly towards
the plot boundary, building or plot external wall where synthetic natural gas is to be provided.
Also underground gas service piping shall not:
 directly entering a building
 be routed through cellars, car parks and unventilated voids

 Services to Vacant Plots - Where services are to be installed to vacant plots they shall
terminate at a safe location.
 Above Ground Routing - Above ground section of the service shall be installed along a route
external to the building. Piping shall not pass through unventilated voids.
11.3 Design Parameters

 Gas service size will be determined in accordance with the appropriate sections of IGEITD/4-
Gas Services.
 Gas service sizing should be based on the diversified load, service length and minimum
pressure at the inlet to the gas service:
 Design Load - The gas service shall deliver synthetic natural gas equivalent to the design load
where the design load is the diversified load for all consumers receiving gas from the gas
service.
 Diversity Factors - Diversity factors used in calculating the design load should be
determined based on the type of consumer, the nature of gas utilization and the total connected
load.
 For sizing the gas service length shall include the equivalent length of all valves and fittings,
including the service tee and flow limiting device, that comprise the service.
 The maximum gas velocity within the gas service pipe shall be 15 m/s.
 The maximum pressure drop over the gas service length shall be limited to 20% of the
minimum gas service inlet pressure.

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12 PRESSURE REDUCING STATION (CUSTOMER PRIMARY METER)
It shall be referred to MARAFEQ Document for Pressure Reducing Station Guidelines No:
LUS-CPALL-MAQ-SPE-UT-0006.
13 RISK ASSESSMENT
Mega-developments shall comply with Marafeq requirements set out in the document no: LUS-CPALL-
MAQ-SPE-UT-0007, all Risk Assessment shall be finalized with compliance statement to this Design
Guidelines.
14 PRODUCTS (HDPE PIPES, VALVES AND ACCESSORIES)
14.1 HDPE High-density polyethylene pipe (Black Colour with Yellow Stripes)
All underground pipes are high density Polyethylene pipe of type PE 100, SDR 11 constructed
according to code prEN 1555-2 or ASTM D 2513.
14.2 HDPE Fittings (Black Colour)

ASTM D 2683, socket-fusion type or ASTM D 3261, or UNI EN 1555-9:2004, Bar coded butt-fusion type
with dimensions matching PE pipe.
14.3 HDPE Transition Fittings

Factory fabricated fittings with PE pipe complying with ASTM D 2513, or EN 1555, SDR 11 and steel
pipe complying with ASTM A 53/A 53M, black steel, Schedule 40, Type E or S, Grade B or ASTM A106
Grade B Schedule 40 or API 5 L Grade B Schedule 40.
14.4 Sleeves
For HDPE Pipe crossing under railway lines and sewage water lines) Steel Pipe Sleeves:
ASTM A 53/A 53M, Type E, Grade B, Schedule 40, galvanized steel, plain ends.
Cast-Iron Pipe Sleeves: Cast or fabricated "wall pipe," equivalent to ductile-iron pressure pipe, with
plain ends and integral water stop, unless otherwise indicated.
UPVC / GRP schedule 40 sleeves with 200mm concrete in casement as per normal practices.
14.5 PE Ball Valves

Polyethylene ball valve, with control bar constructed according to code UNI EN 1555-4:2004 or
ASME B16.40.
Direct welding into PE pipe, by using socket fusion (125mm and below) or butt welding180mm and

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above.
Full straight bore, no pressure loss
Ball polyethylene
Operating temperature -29º C to 60º
Operating pressure 7 bar
a. Body: PE.
b. Ball: PE.
c. Stem: Acetal / Galvanized Steel.
d. Seats and Seals: Nitrile.
e. Ends: Plain or fusible to match piping.
f. Operator: Nut or flat head for key operation.
g. Include plastic valve extension and or extension spindle for steel valve
h. Include tamperproof locking feature for valves.
15 JOINTING OF PIPES, FITTINGS AND VALVES
15.1 General
Only certified PE jointers shall be permitted to perform PE fusion jointing. Contractor shall provide
original certificates of certified PE jointer from the issuing body to Supervising Consultant for approval.
A method statement of construction for PE fusion joints shall be submitted by Contractor for Supervising
Consultant approval. Final approval shall be by Marafeq or its representative. This method statement of
construction shall ensure that all fusion joints are of high integrity, and shall include, but not limited to:
a) Procedures for the operation, maintenance, periodic inspection and testing of fusion tooling
and equipment.
b) A programme of update training for PE jointers, including the certification / re-certification of

personnel to ensure their competency.
15.2 Electro-fusion Jointing

Electro-fusion in accordance with IGE/TD/3 standards shall be used for all PE jointing. Fully automatic
butt fusion may be accepted by the Supervising Consultant and or Marafeq for use on special mains
laying techniques e.g. directional drilling and large diameter pipes.

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Barcode labeled or auto recognition electro-fusion jointing shall be used and all fittings shall incorporate
fusion indicators.
The equipment used for joint construction shall provide fusion data in the form of a print out specific to
each joint and shall in addition, include the operator identification reference. These print outs shall form
part of the as laid records.
The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion fitting. A
power generator shall provide the power requirements of the control box, taking into account the
electrical characteristics of the control box.
Alignment clamps shall be used for all types of electro-fusion systems to minimize misalignment and
movement during electro-fusion of the joint.
1) Pre-Joint Checks
a. Ensure that the correct jointing parameters for the machine and pipe being welded are
checked with manufacturer’s specifications.
b. Check the generator for sufficient fuel to complete the operation.
c. Check all welding equipment, in particular:
 The welding control box.
 The welding cables.
 The cable connectors.
 The fitting connections.
d. Pipe must be supported and well alignment.
e. Ensure pipe and fittings to be jointed are compatible with each other.
f. Fully scrapes pipe and/or spigot surfaces.
g. Clean equipment to ensure foreign particles do not contact pipe surfaces.
h. To control dust contamination, when possible welding will be carried out in a simple
protective shelter. The floor or ditch should be covered by tarpaulin (or similar).
2) Jointing Process
a. Ensure correct fusion and cooling times are observed and adhere too.
b. Ensure all fusion indicators have raised. If not, cut out and make new weld.
c. Do not remove clamps from fittings until cooling time has elapsed.
d. Always ensure mark the completed joints with the numbers issued from the electro fusion

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control box along with date, time, jointer number and machine number.
15.3 Butt-Fusion Jointing

Fully automatic butt fusion will be utilized only for 90mm pipes and larger. The butt fusion equipment
provides an electronic record that will be printed and retained as part of the construction records and
made available to Marafeq through Supervising Consultant for review.
Each butt fusion will be assigned a number that is recorded on the fusion as-built drawing. The
number and date will also be marked using an appropriate marker, on the external surface of the pipe
adjacent to the fusion.
Cleaning of the heater faces will be undertaken by aborting a joint after heating as required but, at
minimum, will be done on the first joint of the day and for each change of diameter.
During fusing the alignment of the pipe will be checked and monitored. Additionally the joint will be
protected from contaminants (e.g. water, oil, dust, blowing sand.)
Manufactures recommended joint cooling time will be extended depending on the ambient temperature.
Completed Fusions will be subjected to an external visual inspection assessment. In addition to visual
inspection, the external fusion bead will be removed and some internal fusion beads may also be
removed. The removal beads will be subjected to testing (Refer IGE/TD/3 Edition 4 Appendix 7).
Removed beads shall be numbered and all pieces retained in storage.
Pre-Joint Checks
a. Ensure that the correct jointing parameters for the machine and pipe being welded are
checked with manufacturer’s specifications.
b. Check the generator for sufficient fuel to complete the operation.
c. Check all welding equipment. In particular:
 The clamps must be effective in holding pipe square.
 The trimmer blades must be clean and sharp and the trimmer must be square
with power in reverse to ensure a clean cut.
 The heater plate must have a control system capable of maintaining a uniform
temperature over the area in contact with the pipe.
 The hydraulic system must be effective and a gauge must be attached which
can accurately resolve pressures to be used.
d. Pipe must be supported and well alignment.
e. Clean equipment to ensure oil and grease do not contact pipe surfaces.
f. To control dust contamination, welding is carried out in a simple protective shelter. The
floor should be covered by tarpaulin (or similar).

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g. To ensure that heater plate is fully clean a dummy weld every time the plate has been
allowed to cool will be completed.
h. Dummy Welding: To ensure that contamination does not affect welds in installed pipes, it is
necessary to make a dummy weld at the start of any welding session after the plate has
been allowed to cool. It is only necessary to follow the welding cycle to the point where the
pipe is snapped from the plate. Following cooling, the surfaces may be retimed to allow
production welding to begin. Alternatively a scrap piece of pipe may be used and then
discarded.
i. Do not remove clamps from fittings until cooling time has elapsed.
j. Always ensure mark the completed joints with the numbers issued from the electrofusion
control box along with date, time, jointer number and machine number.
15.4 PE Welder Qualifications

The PE Welder shall have a test certificate including the following:
 Welder name, photo and nationality.
 Employer name.
 The third party name/ qualification.

 Welder qualification record number.
 Pipe material specifications.
 Date of test.
 Validity for the certificate.
 Type of qualification tests.

 Weld form.
 Welding position.
 Code/testing standards.
 Qualifying criteria/rating points.

 Pipe size of welding process.
16 STEEL PIPE, FITTINGS AND VALVES
There are some special cases where it is needed to use steel piping instead of the HDPE piping, some
of these cases are the above ground crossings (Bridges) and in special cases were the use of steel is
recommended by the standards and Marafeq. The use of steel material shall be Sch 40 minimum and
all pipes, fittings and valves should be designed and installed as per the standards and installation
requirements below:

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16.1 Pipe and Fittings Codes and Standards:

The used steel pipe material and fittings shall be Schedule 40 minimum. Pipes and fittings such as
elbows, tees & flanges shall comply with the following specifications
 ASTM A106 Standard Specification for Seamless Carbon Steel Pipe for High-Temperature
Service
 API 5 L Grade B Specification for Line Pipe
 A105/A105M- Standard Specification for Carbon Steel Forgings for Piping Applications
 ASTM A 234 WPB - Standard Specification for Piping Fittings

 ASME/ANSI B 16.5 - - Pipe Flanges & Flanged Fittings
 ASME/ANSI B 16.9 - Factory made wrought steel butt welded fittings

 ASME/ANSI B 16.25 - Butt welded ends
 ASME/ANSI B16.11 Forged Steel Fittings, Socket-Welding and Threaded

 ASME B31.3 :Main Reference Code - Process Piping
 ASME II Part A :Ferrous Material Specifications
 ASME II Part C :Specifications for Welding Rods, Electrodes, and Filler Metals
 ASME II Part D Properties (Customary) MATERIALS
 ASME V :Non-destructive Examination

 ASME IX :Welding and Brazing Qualifications
 ASTM A370 Rev A: Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
 API 1104 Welding of Pipelines and Related Facilities
 ASTM: All ASTM relevant materials standards.
 AWS D10.11M/ANSI D10.11 Guide for Root Pass Welding of Pipe without Backing Strip.
 AWS A2.4 :Standard Symbols for Welding, Brazing, and Non-destructive Examination
 AWS A3.0: Standard Welding Terms and Definitions.
 AWS A5.1/A5.1M :Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
 AWS A5.5 :Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
 AWS A5.17/A5.17M:Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding
 AWS A5.18/A5.18M :Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding
 NACE MR 0175- 2001: Petroleum and natural gas industries — Materials for use in H2S-
containing environments in oil and gas production
 AWS QC1: Standard for AWS Certification of Welding Inspectors (2007)
 AWS QC15: "Specification for the Certification of Radiographic Interpreters" (2008)

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 API RP 2201: Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries.
 API 570: Piping Inspection Code.
 ISO 3690: Welding and Allied Processes - Determination of Hydrogen Content in Ferrite Steel
Arc Weld Metal.
 ISO 21809-2:2007, Petroleum and natural gas industries – External coatings for buried or
submerged pipelines used in pipeline transportation systems - Part 2: Fusion-bonded epoxy
coatings.
16.2 Steel Pipe

There are some special cases where it is needed to use steel piping instead of the HDPE piping, some
of these cases are the above ground crossings (Bridges) and in special cases were the use of steel is
recommended by the standards and the consultant. 3 mm corrosion allowance shall be considered
when determining the pipe thickness.
Suitable 3 Layer Fusion Bonded Epoxy or Polyethylene coating shall be used for protection of pipe from
corrosion. The details procedure of application the coatings to be submit by contractor.
16.2.1 Technical Details
Carbon steel pipes shall be either seamless or electric resistance weld.
The pipes shall be provided with mill certificates and shall contain at minimum all mechanical and
chemical properties, heat number and production test results.
The wall thickness of the fittings shall match that of the pipe to which they will be welded.
Pipes with greater wall thickness will be acceptable provided the ends are counter bored to produce a
wall thickness matching that of the fittings.
Pipe ends will be beveled for welding in accordance with ANSI B16.25.
Pipe shall be minimum ASTM A106 Grade B Schedule 40 or API 5L Grade B Schedule 40
Pipes ends shall be fitted with a protective dust cap prior to shipping.
16.2.2 Marking
Pipes shall be clearly and permanently marked with the following information:
 Manufacturer's name or trademark

 Size and wall thickness
 Schedule number or weight

 Material type number
 Heat number

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16.3 Steel Fittings

Fittings such as elbows, tees, pipe support, bolt & nuts, gasket, flanges, hangers and expansion to be
used shall be matching the material being used for steel pipes.
Fittings shall be manufactured from material with strength equal to or greater than that of the pipe and
shall be suitable for welding to the line pipe. The wall thickness of the fittings shall match that of the
pipe to which they will be welded.
Fittings with greater wall thickness will be acceptable provided the ends are counter bored to produce a
wall thickness matching that of the pipe. Ends will be beveled for welding in accordance with ANSI
B16.25. Flanges shall be welding neck with 1/16" raised face for Class 150 flanges. The material shall
be of carbon steel.
16.3.2 Marking
Fittings and flanges shall be clearly and permanently marked with the following information:
 Manufacturer's name or trademark
 Size and wall thickness

 Schedule number or weight
 Material type number
16.3.3 Gasket, Bolt & Nuts
Gasket bolt & nuts shall comply with following specification:
 BS3381 – British Standard for gasket spiral wound

 ASTM A193 – American Society for Testing Materials Stud Bolts
 ASTM A194 – American Society for Testing Materials Nuts
 ASME/ANSI B16.21 – Non Metallic Flat Washers
16.4 Steel Valves

This specification details the minimum requirement for metallic ball valve or gate valve to be used for
distribution mains and service line including aboveground valve suitable for maximum operating
pressure (MOP) 4 bars.
16.4.1 Valve Codes and Standards:
 API 6D Specification for Pipeline Valves

 BS21 Pipe Threads for Tubes and Fittings Where Pressure - Tight Joints are Made on
the Threads

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 ANSI B16.34 Valves - Flanged, Threaded, and Welding End
 IGE/TD/3 Edition 4 2005 “Steel and PE pipelines for gas distribution”
 IGE/TD/4 Edition 4 PE and Steel gas services and service pipe work.
 API 607 Fire Test for Soft-Seated Quarter Turn Valves
 BS 5351 Specification for steel ball valves for the petroleum petrochemical and
allied industries.
 ANSI B16.5 Pipe Flanges and Flanged Fittings
 API 6FA Speciﬁcation for Fire Test for Valves
 API 598 Valve Inspection and Testing
 BS 6755 Part 1 Testing of valve, specification for production pressure testing requirement
 ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
 GIS V7 Part 1 Specification for Distribution Valves Part 1: Metal-bodied line valves for use
at pressures up to 16 bar and construction valves for use at pressures up to 7 bar
All valves shall be non-lubricated type
All valves shall be turn clockwise to close, full bore and stop when fully open or close
All valves shall be metallic and manufactured with corrosion coated material
Valve shall be able to withstand 4 bar operating pressure and 7 bar test pressure
All valves shall have open and close indicators.
Valve shall be full bore type
Steel valve shall be used pipe size 200mm and above
Valve shall have feature of block and bleed facilities
Threaded purge valve shall be tapered according to BS21 standard
Flange end valve shall be according to ANSI B16.34 standard
Valve 50mm and below shall be lever operated and shall be capable being remove
Belowground valve material shall be off ductile iron material with corrosion coating
Belowground valve shall have downpipe adapter and or extension spindle for steel valve
Operating temperature from -29°C to 60°C
a. Body: Steel or Ductile Iron

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b. Ball / Gate: Steel
c. Stem: Steel
d. Seats and Seals: Nitrile, NBR, for Secondary seat: Metal
e. Ends connection: Flange end to ASME B16.5 or PE pulp to GIS V7
f. Operator: Nut or flat head for key operation.
g. Include valve extension or street access down pipe adapter
h. Include tamperproof locking feature.
i. Specification for external painting and corrosion protection for belowground

installation shall be incorporated
16.5 Cathodic Protection:

Cathodic protection is required for all underground steel piping and steel valves, the cathodic protection
shall be installed as per the standards and the detailed drawings.
 NACE SP0169:2007 - Control of External Corrosion on Underground Metallic Piping Systems
 NACE TM 0497 - Measurement Techniques Related to Criteria for Cathodic Protection on

Underground Metallic Piping Systems
 BS 7361-1:1991 - Cathodic Protection.
Cathodic Protection design shall have design life of 25 years as minimum.
16.6 Welding Qualification Record:

 The Procedure Qualification Record (PQR) sheets.
 The production Welder Procedure Specification (WPS).
 The WPS used for the qualification test.
 The procedure qualification data sheet, including dates & welders names, of the actual welding
parameters applied to weld the test joint.
 The mechanical test results.
 The inspection and Non Destructive Test (NDT) results.
 The parent material test certificates indicating the chemical analysis and mechanical properties.
 Calibration certificates for the used equipment such as; thermometer, volt and ampere meters.
 Welder’s certificates.
16.7 Steel Pipeline Welding Inspector Qualifications

 AWS QC1: Standard for AWS Certification of Welding Inspectors (2007).

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 AWS QC15: "Specification for the Certification of Radiographic Interpreters" (2008).
 British Institute of Non-Destructive Testing (PCN) PCN Level 2 Weld Inspection.
 CSWIP-WI-6-92: Requirements for the Certification of Visual Welding Inspectors (Level 1),
Welding Inspectors (Level 2) and Senior Welding Inspectors (Level 3) (fusion welding) in
accordance with the requirements of BS EN ISO 17637:2011 (2011).
16.8 Inspection & Testing

Visual inspection will be done for fit-up, during welding and after welding.
The detail Non-Destructive Test (NDT) shall follow:
a. Production, field weld & repair weld - IGE/TD/3 (Operating pressure equal and more than 2
bar) – 100% Visual Inspection, Min 10% NDT of total weld joint and 100% for bridge
crossing.
b. Production, field weld & repair weld - IGE/UP/1B (Operating pressure less than 2 bar) –
100% Visual inspection
Acceptance criteria for all welds shall be as per API 1104 - Welding of Pipelines and Related Facilities
or as per the project specification and appropriately repaired and re-inspected. The results of the
inspection shall be used to control the quality of welds.
The NDT for production welding will be done after the weld has cooled down to ambient temperature.
Welding requirement of pipeline shall also be referred to ASME B31.8 Transmission and Distribution
Piping System.
16.9 Cost for NDT inspections and tests

The cost for welder qualifications and weld inspections shall be paid by the Contractor.
All costs for additional testing, or weld failure shall be paid by the Contractor. This includes costs for the
testing firm and the Contractor’s own costs.
17 MATERIAL HANDLING AND STORAGE
The material transportation handling and storage is to be carried based on the IGE/TD/3 Edition 4.
18 PIPE INSTALLATION
Mains pipe shall be laid to a minimum top cover of 1.00 m at all locations other than Special Crossings.
Marker tape and Tracer Wire shall be laid 400 mm above the pipe along the entire length of the mains.
Minimum clearance of the mains shall be 600 mm from electric cables, 500mm from sewage water
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pipes, 250 mm from other utilities and 1200mm under roadway, railway lines in case of crossing and
1000mm in parallel with railway accessories. Where these minimum separation distances cannot be
achieved, sleeve with concrete encasement or concrete slabs shall be installed between the mains and
the cables utilities in question as per approved details.
The crossing on the railway groups with total width more than 20 meters is not allowed
The laying of the pipe and the making of connections shall be in accordance with IGE/TD/3.
During pipe laying operations the ends of pipes shall remain temporarily sealed with suitable stoppers.
The angle of intersection between a pipe crossing and the highway shall be as near to 90 degrees as
practicable. In no case shall this be less than 30 degrees.
The minimum bend radius for the installation of PE pipe shall be 15D (D) = outside diameter of pipe).
When a joint falls within the pipe bend section, then the minimum radius shall be 25 D.
The introduction of stresses shall be avoided during pipe installation, both in the polyethylene pipe or at
joints.
During laying of pipes, the Contractor shall:
 Prevent the PE pipe from being damaged by contact with sharp materials during its installation.
 Ensure that the PE pipe is uniformly supported.
 Ensure that no rock or sharp object/stone impingement exists at the pipe soil interface.
 Ensure that when the pipe is laid within a sleeve, the sleeve ends to install pipe spacer in such
a way that no stress or cutting effect can be transmitted to the HDPE pipe.

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19 VALVE INSTALLATION
19.1 General
Full bore polyethylene ball valves / Ductile Iron Gate valves or Steel Ball valve shall be installed in the
distribution mains system for the purpose of sectorisation and isolation where design requirements
dictate and a service ball valve before each plot boundary. The installation of these valves shall comply
with the following requirements:
19.2 Valve Locations

Valves incorporated into the HDPE distribution mains system shall be installed in compliance with
IGE/TD/3 and as per approved shop drawings.
19.3 Pre-Installation
Prior to installation, all valves shall be checked for defects or damage.
All valves shall be thoroughly cleaned internally immediately prior to installation and all ends shall be
kept closed with protective coverings when the valve is not being worked upon.
Following installation, and prior to commissioning, all valves shall be operated from open to closed and
closed to open positions, respectively.
All parts or accessories shall be installed according to manufacturers’ technical recommendations of

this requirement.
19.4 Valve Installation Details

Valves shall be positioned so as to ensure unrestricted access and maintenance at all times. All valves
should be installed as per the manufacturer’s recommendations.
Purge points shall be installed either side of all main valves and these pressure points shall be 32 mm
diameter reducing to 20 mm.
For valves of 200 mm diameter and above the valve shall include a gear assembly and for such valves
a precast concrete blocks (PCC) or reinforcement cement concrete (RCC) chamber shall be provided
so as to allow access to and operation of the valve/gear assembly. Valve size 200mm and above shall
use Ductile Iron Gate valve with block and bleed capability.
For all service valves a surface box shall be provided 300 mm clear opening ductile iron cover while
main valves shall have double triangular 600mm clear opening and also ductile iron cover. The surface
boxes shall be installed flush with the ground surface and the valve spindle and pressure points shall
terminate 100 mm below the underside of the cover. All ductile iron cover shall have client logo, “gas”
marking and material standard stamp on it, refer to the Typical Manhole Cover Details drawing number
LUS-CPALL-MAQ-DWG-UT-30306 in Appendix 4.
Security devices with valve identification markings shall be fitted to the spindle of valves to prevent un-
authorized operation.

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Aluminum or Stainless Steel marker plates shall be installed on either buildings or securely fixed posts
adjacent to the location of all valves. The plates shall be coated with an epoxy type coating (colour
white) and the required lettering shall be silk screened (colour black). The layout of the marker plate
lettering and fixing arrangements shall be agreed with the Marafeq.
20 LABELING AND IDENTIFYING
20.1 Warning Tape

Acid and alkali-resistant PE film warning tape manufactured for marking and identifying underground
utilities, a minimum of 6 inches (150 mm) wide and 4 mils (0.1 mm) thick, continuously inscribed with a
description of utility, coloured yellow at 400 mm above the top of the pipe a warning tape shall be laid
along the length of the pipe.
20.2 Tracer wire

Metallic core encased in a protective jacket for corrosion protection detectable by metal detector.
Contractor shall identify and supply suitable tracer wire metal detector. Minimum size for copper type
tracer cable shall be 10 AWG. Warning tape could be incorporated with tracer wire or separated at 400
mm above the top of the pipe. A tracer wire shall be laid along the length of the pipe.
Completed installation of tracer wire should conduct a traceability and continuity test. The suitable
machine shall be used to doing the test. Contractor to ensure all connection and tracer wire are in good
condition and not damaged. If found any damage during testing, contractor to repair accordingly.
20.3 Marker Posts

Route marker posts complete with identification plates shall be installed each side of Special Crossings
and at such other locations or where practicable, at changes in direction or as directed by Marafeq or its
representative, for details refer to Typical Sign Board drawing no. LUS-CPALL-MAQ-DWG-UT-30302
and Typical Sign Board Details drawing no. LUS-CPALL-MAQ-DWG-UT-30303 in Appendix 5.
20.4 Stone marker

Stone marker for underground HDPE Pipe shall be installed for every 25 meter on any unmade areas,
marker plate shall be installed on hardscape areas, marker pins for road crossing and where
practicable, at any change of direction or as directed by Marafeq or its representative, for details refer to
Typical Marking Pin drawing no. LUS-CPALL-MAQ-DWG-UT-30304 and Typical Stone Marker drawing
no. LUS-CPALL-MAQ-DWG-UT-30304 and in Appendix 6.
21 TESTING AND COMMISSIONING OF PIPING
21.1 Scope
This specifies the minimum criteria to be adopted for pressure testing and commissioning of
polyethylene and steel gas distribution mains and services operating at pressures up to 4 bar. Testing
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and commissioning shall be in line with the requirement specify in IGE/TD/3, IGE/SR/22, IGE /TD/1.
21.2 Test pressure for Pneumatic Testing

The test pressure shall be 1.5 times the operating pressure of the system which is 4bar.
Prior to testing and commissioning, the pipes must be cleaned from any debris by carrying out pigging.
Pigging procedure must be provided by Contractors doing the pipe installation for supervision
consultant approval.
Intermediate pressure and low pressure testing criteria have been included in this specification to cover
situations where the normal operating pressure of isolated sections of main must be reduced due to
safety constraints.
The objective of the pneumatic test of polyethylene mains system and steel pipes is to prove the
integrity of the system before commissioning.
The pneumatic test sets out to ensure that any leakage is within permissible limits (Permissible
Pressure Loss).
The test shall take into account the fact that HDPE pipe creeps during the test, contributing towards any
measured pressure loss.
21.3 Procedure for Testing

All Polyethylene mains and steel piping with a maximum operating pressure (MOP) of 4bar, shall be
pressure tested in accordance with above mentioned codes but not less 1.5 MOP
Any part of the supply network which is constructed, diverted, altered or renewed and cannot be
included in a sectional or overall pressure test i.e. a tie-in, shall be tested at the system Maximum
Operating Pressure (MOP) using leak detection fluid. Such occurrences shall be minimized and shall
be approved by the Supervising Consultant and final approval be by Marafeq or its representative.
Following a successful test, commissioning shall commence immediately or pressure to remain at

certain level as directed by Marafeq or it representative.
21.4 Test Equipment

The minimum equipment shall be as given below:
 Suitable pressure instruments.

 Temperature thermometer.
 Pressure Gauges.
 Ball Valves.
 Barometer.
 Pressure & temperature recorder.

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21.5 The criteria for testing are

a. That there will be a soak or stabilization period of at least 48 hours for the mains, before
testing takes place,
b. The test duration shall be 24 hours or according to the volume calculations.
c. Pipe is SDR 11, PE 100 (HDPE) or carbon steel pipes Schedule 40 as minimum.
d. The reference test temperature is taken as 20ºC. (The temperature is likely to be higher than
20ºC in which case the creep allowance provided will be higher. Refer to IGE/TD/3 table
A4.4).
The method of calculating the permissible pressure loss for a 24 hour test shall comply with section
A4.2 of IGE/TD/3.
21.6 Safety Precautions

The precautions detailed below, shall be taken during the preparation and application of pneumatic
tests.
 The piping system should be clean and free from any debris, dirt, waste particle and mud prior
testing works. Suitable procedure to be taken consideration by contractor to implement the
cleaning works.
 All caps, plugs, bends, tees and other fittings on mains incorporating flexible joints shall be
restrained against any movement during the test.
 The trench shall be backfilled up to 200mm at least to secure the pipes in position before
pneumatic pressure is applied.
 All temporary pipe, fittings and equipment fitted to the section of main under test shall be
appropriately pressure rated.
 The stand pipe used for the purpose of pressurizing the main shall be fitted with a pressure
relief valve to ensure over-pressurization of the main does not take place.
 Consideration shall be given to means of minimizing noise during pressurization and de-
pressurization.
 Where the main is exposed and accessible to the public, notices warning that pressure testing
is in progress shall be prominently displayed and the area securely cordoned off.
 Before final pressurisation commences a visual check shall be made to ensure that the test
section is secure for pressurization.
 No person shall enter any excavation whilst the test pressure is being raised, the main is under
test or the main is being depressurized.
 Throughout the duration of the test, the system shall be examined at regular intervals to ensure
that all anchorage points are secure and that no hazards exist.
21.7 Testing Procedure

Testing and commissioning shall be carried out by competent person, and be
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 Certified or approved by local authorities.
 Prior to pressure testing, the completed pipe work section shall be cleaned and free from
construction debris and foreign matter.
 Mains to be tested shall generally be isolated into sections of and each section shall be tested
individually unless there is no intermediate valve in between.
 Immediately upon satisfactory completion of the sectional tests, the whole of the main shall be
subjected to a pneumatic soundness test at maximum working pressure 1.5 MOP.
 Following the satisfactory completion of the final tests, the main shall be purged and connected
to the live main in accordance with IGE/TD/3 and the tie-in joints tested under operating
conditions with leakage detection fluid.
 Mains which are not commissioned immediately following testing shall be de-pressurized and
replaced with nitrogen at 2 bar for monitored appropriately. This pressure will maintain until
commissioning works.
 Test instruments shall be fitted so that they can be read and operated without entering the
trench or standing in line with the end of the main.
 Closed valves shall not be used as end caps. All valves shall be tested in their open position.
Where a valve is fitted at the extremities of the main under test the valve shall be securely
blanked and anchored against movement.
 Dry air shall be introduced under controlled conditions into the main or service until the
appropriate test pressure is reached. Care shall be taken to ensure that the pipe-work is not
subject to over pressurization.
 No person shall enter the trench whilst the test pressure is being raised, during the test or whilst
the main is being depressurized.
 Before the start of the test period the temperature of the air in the pipe shall be allowed to
stabilize before the test period is commenced. This shall be indicated by a stable pressure
reading.
 When the test has been completed to the satisfaction of the Supervising Consultant and
submitted to Marafeq or Engineer for final acceptance, the air pressure shall be released
through suitable vents in a controlled manner until the whole of the main is at atmospheric
pressure.
 The Supervising Consultant and or Marafeq or Engineer shall confirm by checking the gauges
installed at all extremities that the pressure within the whole of the main has been reduced to
atmospheric pressure. The Consultant shall record this information on the test certificate before
authorizing further work to proceed.
21.8 Test Failure

Where the instrument reading after correction for barometric pressure and temperature readings shows
a pressure loss greater than the calculated allowable pressure loss, investigations shall be carried out
to find the leakage. All connections plugs and external fittings shall be re-examined for possible leakage
by leak detection fluid.
If the leakage still happen after rectified all the visible connection and fittings, contractor to use other
suitable method to find the leakages.
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Any leakage on a HDPE fusion joint should not be repaired and the joint should be cut away and
remade.
21.9 Pressure Test Certificate

Gas Contractor has to provide a Pressure test certificate as in appendix 1. The test certificates shall be
certified or approved by Supervising Consultant and or Marafeq.
21.10 Commissioning
The purpose of commissioning is to gasifying the pipeline with fuel gas (SNG, NG or LPG). Therefore it
is necessary to remove or purge the air, inert gas or nitrogen gas in the existing or new pipeline using
the fuel gas. Two basic methods can be employed for the purging operation
a. Ram Purging- purge gas is fed continuously at one end of the pipe work and the gas mixture
being vented off/flared at the other end under a steady and continuous condition until the
total content of the pipe work is replaced by the purge gas
b. Cycle Purging (pressure and vent) – the content inside the closed pipe work system is
diluted by introducing inert gas with minimum at 10% (Nitrogen) of the total pipe volume and
then introduce the fuel gas into the pipeline. Once the pipeline is full with the inert gas and
fuel gas, the mixture shall be vented off until gas percentage is 48 - 50% (SNG Gas) from
the vented content (it shall be more than 95% for Natural Gas). This process is repeated
until the required dilution off fuel gas/air is achieved or the replacement of the purge gas is
completed.
The Gas contractor through their Supervising Consultant shall submit a detailed procedure with
accompanying sketch(s) for all commissioning operations, 48 hours prior to the planned commissioning
date. The procedures shall be subjected to the Marafeq approval.
The planning and execution of the commissioning of mains must avoid large networks and excessive
lengths of feeder mains being commissioned at any one time.
The following criteria shall apply when planning and preparing a commissioning procedure:
 Looped sections of main shall be minimized and where the purge section contains a loop, it
shall be physically isolated by closure of a valve
 Branch sections shall be purged simultaneously or sequentially.
 Flow stopping on live mains shall be by a double block and bleed system.
 Purge velocities shall not exceed 20 m/s
 All vent pipes shall be manned during purging operations and equipped with flame arrestors.
 Communications shall be set up to ensure safe co-ordination of activities.

 Pressures at all points shall be monitored throughout the commissioning operation and the
minimum system requirements maintained.
 Tie in to existing gas pipes shall consider:
a. Gasified system

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b. Empty not in use system
c. Contractor to take consideration for tie-in works and submit the detailed procedure prior
the activity.
22 CIVIL WORKS FOR PIPE LAYING
22.1 Design
Civil works for below ground service piping will be in accordance with:
 IGE/TD/3
 Project specifications
 The International codes, project requirements and requirements of the local approving
authorities.
22.2 Existing Services, Utilities, etc.

Before commencement of any section of below ground works the Contractor shall identify the position
of services, utilities, etc. on the proposed route. Utility location plans issued to the Contractor shall be
studied carefully before digging operations are commenced. If necessary upon as directed by Marafeq,
no objection certificates shall be acquired by the contractor from other utility services.
22.3 Trial Hole, Route survey, Excavation and Trenching

Trial hole by hand dig method shall be performed to verify the existing utilities and the below ground
conditions.
Route survey should be conducted prior to the commencement of the construction.
Trench depths shall be sufficient to provide 1000 mm of cover to mains piping and service piping.
Cover shall be measured to the top of the pipe. Trench widths shall be a minimum of 400 mm or pipe
diameter plus 150 mm on each side of the pipe, whichever is the greater. However, where rapid
trenching techniques are used the trench need only be of sufficient width to allow fine filling material to
surround the pipe completely. The mains shall be protected against mechanical damage by means of
concrete slabs or steel plates at a height of 150 mm above the gas pipes, be embedded in sand or soil
and be compacted with backfill material firmly and evenly before making good of the road surface.
Excavation shall be by means of hand and/ or machine as expedient and it shall be the Contractor’s
responsibility to locate and protect all services, utilities, etc. encountered during excavation.
The width of the trench shall be maintained until commencement of backfilling and the Contractor shall
be responsible for providing any necessary shoring and supports for such purpose, if required, and for
ensuring the safety of workmen and other persons who may enter the excavated trench.
Excavations shall be kept free from water at all times and before commencement of excavation the

34 | P a g e
LUSAIL DEVELOPMENT
Contractor shall determine the water table level and, if considered necessary, install a well point
dewatering system.
Trench bottoms shall be uniformly graded to provide a firm base for the pipe along its length. The bed
and sides of the trench shall be free from loose stones and other sharp objects which may damage the
pipe during or after installation. Pipe bedding should be free from stones minimum distance of stones
away from pipe should be 150mm
22.4 Crossing
Sleeves and carrier pipes below roadway and railway shall be installed in accordance with the
Authorities’ requirements and shall have a minimum cover of 1,200 mm measured from the top of the
pipe to the ground level.
Installation of road crossings by open cut methods shall be so scheduled to minimize interruption to site
traffic and the Contractor shall co-ordinate such activities with the Supervising Consultant, Marafeq and
other third party contractors.
Pipe crossing the road not meeting the minimum depth requirement shall be installed in sleeve with
concrete encasement.
22.5 Proximity to other Services, Utilities, etc.

Minimum distances/spacing of 600 mm, 500mm and 250 mm shall be maintained between the mains
and electric power cables, sewage water and other utilities/services/obstructions respectively and the
Contractor shall be responsible for all additional excavation to ensure such distances/spacing are
maintained. At locations where such separation distances are not physically achievable the Contractor
shall provide and install precast concrete slabs between the mains and the cable(s) and the
services/utilities in question, or sleeves with concrete encasement subject to the approval of the
consultant. No other utilities are allowed to be laid in the Gas Corridor.
22.6 Backfilling and Reinstatement

Pipes shall be installed in a bedding, with consolidated stone free material (dune or wash sand), either
selected from excavated materials or imported. The bedding shall be of 150 mm thickness.
The pipe surround shall apply 150mm on top of pipe by using stone free material. The sample of
material shall submit in detail for Engineer’s approval.
The trench shall be further backfilled and hand tampered, with stone free material (dune/wash) to a
level 400 mm above the top of the pipe.
At this level a warning tape shall be laid along the length of the pipe. The tape shall be supplied in
accordance with Warning Tape with tracer wire or as specified by the Marafeq. The trench shall be
further backfilled to the finished level with the excavated material and compacted with a mechanical
hand compactor. Backfill material should be well compacted to avoid trench settlement.
22.6.1 Surface Enclosure for Valves
The surface box should be constructed with either solid blocks or precast concrete. Blinding concrete
35 | P a g e
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should be provided prior to installation of the pre-cast concrete/solid block. Bitumen coating should be
provided on the surface of the plaster where it comes in contact with the soil.
22.7 Route Marking

Marker posts shall be installed at each side of Special Crossings and at other locations, specified by the
Marafeq, where it is felt that the main could be susceptible to interference damage.
22.8 Reinforced Valve Chamber

The valve chamber shall be reinforcement cement concrete (RCC) type if falling under asphalt. Others
than the road area precast concrete blocks (PCC) can be used. The standard chamber details shall be
given by contractor to Marafeq for approval.
23 CONSTRUCTION RECORDS
The construction records shall include the following:
 Type and specifications of materials and fittings used with certifications.

 Test certification package.
 As-built drawings including details of surface construction, depth of cover, pipe protection, etc.
 Ground conditions (soil).

 Construction methods, including trenchless techniques.
 Welding procedure specification.
 Welder qualifications.
 NDT records.
 Quality control procedures and documentation.
 Inspection records.
 Pneumatic Pressure test records

 Soil compaction test results.
 Commissioning certificates.
 Handover documents.
24 DOCUMENTS TO SUBMIT PRIOR TO WORK
In order to assess the Contractor’s proposal through Supervising Consultant , Marafeq, the Engineer’s
has the right to request the complete list of material, apparatus and various fittings that the Contractor
envisages using for the execution of the work with the detailed manufacturers details associated with
the selected materials and equipment.

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During the work preparation period of 30 days, the Contractor, through its Supervising
Consultant shall submit to the Marafeq or Engineer’s:
 A detailed program for the work per construction phase. The work shall be in a multi-utility
environment. The construction program should take into consideration the other utilities and
adapt to this situation.
 Full set of shop drawings including layout plans and combined profiles.
 One set of complete detailed construction drawings for the work; these drawings shall provide
all information necessary for their comprehension and verification.
 The design calculation notes, which may be supplied in different files for restitution to the
Contractor after examination.
 If necessary, within a period of 15 (fifteen) days after return of the draft construction drawings
accompanied by all observations by the Engineer, the drawing up of a new rectified drawing to
take the observations into account.
 Detailed list of suppliers and specification of materials and equipment showing particularly the
compliance with the Engineer specification.
 Method of statement including:
- Description of the project.
- Objectives-Execution of Work.
- Scope and Major Activities needs to be completed before work start.
- Reference Documents.
- Personnel Responsibilities Matrix.
- Material.
- Material Storage, Transportation and Handling.
- Instrument and Measurement Devices.
- Methodology for Installation of Polyethylene Gas Pipe Network.
- Objective, Pre Installation Check and Installation Works of the Network.
- Health Safety and Environmental Plan.
- Commissioning procedure included testing, cleaning, swabbing and or drying
- Risk Assessment for the gas development work
This list is not exhaustive; the Engineer may ask the Contractor at any time for any specific construction
or technical drawing.

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25 QUALITY CONTROL
The Contractor should be able to document and demonstrate that all the activities relating to quality
throughout the process from confirmation of order to design/development, purchasing, manufacturing
and delivery to the customer have been carried out in a properly monitored and well organized fashion.
As a minimum, the Contractor should provide a quality manual in which the quality system is described.
The areas of responsibility and authority with regard to quality should be clearly defined such that the
performance of the system and the authority of the quality system manager can be assessed.
The quality system should be based on the requirements laid down in the international standard for
quality systems, ISO 9001.

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APPENDIX 1
TYPICAL PRESSURE TEST CERTIFICATES FORM IN: IGE/TD/3 Edition 4:

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APPENDIX 2
WOQOD LPG Gas Quality Report

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APPENDIX 3
Natural Gas Quality Report

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APPENDIX 4
Typical Gas Manhole Cover drawing no. LUS-CPALL-MAQ-DWG-UT-30306

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KEYPLAN:
NOTES
1. ALL DIMENSION ARE IN MILLIMETERS AND LEVELS

ARE IN METERS UNLESS OTHERWISE NOTED.
2. MARKING ON COVER AS PER COSTOMER'S

REQUIREMENT
SPECIFICATIONS:-
TYPE: CLASS 'B' 125
LOADING - 125 KN
MATERIAL - DUCTILE IRON (500/7)
STANDARD - EN 124 D-400
PAINTING - 200 MICRON EPOXY COATING
PLAN ISOMETRIC TOP VIEW

FEATURES:-
NON-ROCK SEATING
CLOSED KEYHOLES
HEAVY DUTY FOR TRAFFIC LOADING
NON-SKID CHECKER DESIGN
PRY BAR SLOTS
SECTION A-A
SECTION A-A
CLEAR OVER DEPTH (C)

OPENING (A) BASE (B)
300 X 300 450 X450 75
0 09.04.12 ISSUED FOR INFORMATION

REV DATE DESCRIPTION
DRAWING TYPE:
DETAILED DESIGN
CLIENT:
ISOMETRIC UTILITIES PROVIDER:
PROJECT :
LUSAIL DEVELOPMENT
CLEAR OVER DEPTH (C) DRAWING NAME:
OPENING (A) BASE (B)
TYPICAL GAS MANHOLE COVER

600 X 600 750 X750 100MM
DETAILS
DRAWN BY: P.K.S DATE: 09.04.2012
CHECKED BY: M.K.Y DATE: 09.04.2012
REVIEWED BY: A.ABUSHAIKHA DATE: 09.04.2012
APPROVED BY: D.R.PHILIPS DATE: 09.04.2012
DRAWING NUMBER: REV
LUS-CPALL-MAQ-DWG-UT-30306 0
DRAWING SCALE:
LUSAIL DEVELOPMENT
APPENDIX 5
Typical Sign Board drawing no. LUS-CPALL-MAQ-DWG-UT-30302
Typical Sign Board Details drawing no. LUS-CPALL-MAQ-DWG-UT-30303

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KEYPLAN:
NOTES
ENLARGED ELEVATION ENLARGED ELEVATION

SCALE 1:1 (DETAIL C)
SCALE 1:2 (DETAIL A)
1 09.04.12 ISSUED FOR APPROVAL
ELEVATION SIDE VIEW 0

REV
30.04.12 ISSUED FOR COMMENTS
DATE DESCRIPTION
SCALE 1:5 SCALE 1:5 DRAWING TYPE:
DETAILED DESIGN
CLIENT:
UTILITIES PROVIDER:
PROJECT :
LUSAIL DEVELOPMENT
ENLARGED PLAN GAS DISTRIBUTION NETWORK
PLAN VIEW ENLARGED PLAN SCALE 1:1 (DETAIL D)
DRAWING NAME:
SCALE 1:5 SCALE 1:2 (DETAIL B)

GAS PIPE LINE
TYPICAL SIGN BOARD DETAILS
CHECKED BY: H. K DATE: 30.04.2012
DRAWING NUMBER: REV
DRAWING SCALE: AS SHOWN @A1
LUSAIL DEVELOPMENT
APPENDIX 6
Typical Pin Marker drawing no. LUS-CPALL-MAQ-DWG-UT-30304
Typical Sign Board drawing no. LUS-CPALL-MAQ-DWG-UT-30305

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KEYPLAN:
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE
STATED.
LEGEND
STRAIGHT PIPE LINE
T - CONNECTION
TURN (CHANGE IN DIRECTION)
GAS GAS GAS

PLAN VIEW PLAN VIEW PLAN VIEW
STRAIGHT PIPE LINE TURN (CHANGE IN DIRECTION) T - CONNECTION
ASPHALT ROAD
ASPHALT ROAD
UNMADE
UNMADE
I L QA I L QA I L QA I L QA
A A A A
T
S
S
S
T
T
S
LU
LU
AR
AR
LU
LU
AR
AR
G A S G A S
PAVING TILE
G A S G A S
EDGE OF ASPHALT
EDGE OF ASPHALT
EDGE OF KERB
PAVING TILE
EDGE OF KERB
0 30.04.12 ISSUED FOR COMMENTS

DRAWING TYPE:
DETAILED DESIGN
PLAN VIEW PLAN VIEW CLIENT:
UTILITIES PROVIDER:
PROJECT :
LUSAIL DEVELOPMENT
GAS DISTRIBUTION NETWORK
DRAWING NAME:
GAS PIPE LINE
SECTION VIEW SECTION VIEW SECTION VIEW SURFACE MARKER

(TYPICAL MARKING PIN)
DETAILS MARKING PIN POSITION OF MARKERS IN ROAD REVIEWED BY:
APPROVED BY:
A.ABUSHAIKHA DATE:
DATE:
30.04.2012
D.R.PHILIPS 30.04.2012
DRAWING NUMBER: REV
DRAWING SCALE: NTS @A1
KEYPLAN:
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE
STATED.
LEGEND
STRAIGHT PIPE LINE
T - CONNECTION
TURN (CHANGE IN DIRECTION)
GAS GAS GAS
PLAN VIEW PLAN VIEW PLAN VIEW

STRAIGHT PIPE LINE TURN (CHANGE IN DIRECTION) T - CONNECTION
ASPHALT ROAD
LUSAIL QATAR LUSAIL QATAR
GAS GAS
PAVING TILE
PAVING TILE
EDGE OF KERB
EDGE OF KERB
0 30.04.12 ISSUED FOR COMMENTS

DRAWING TYPE:
DETAILED DESIGN
PLAN VIEW CLIENT:
ISOMETRIC VIEW
STONE MARKER FOR
UTILITIES PROVIDER:
HARDSCAPE AREAS
PROJECT :
LUSAIL DEVELOPMENT
ISOMETRIC VIEW DRAWING NAME:

GAS DISTRIBUTION NETWORK
STONE MARKER FOR GAS PIPE LINE

SURFACE MARKER
LANDSCAPE AREAS SECTION VIEW (TYPICAL MARKING STONE)
POSITION ON MARKERS IN ROAD

DRAWING NUMBER: REV
DRAWING SCALE: NTS @A1
LUSAIL DEVELOPMENT
Gas System
Building Internal Gas Piping
Design and Installation Guidelines
REASON
REV. ISSUED PREPARED CHECKED APPROVED
FOR DOCUMENT HISTORY STATUS
NO DATE BY BY BY
ISSUE
0 IFR 14-April-2013 PFC
Kamal Yaacob Abushaikha Phillips
Muhamad
08-September- Vinod K. D. Reed
1 IFR PFC Kamal Yaacob,
2014 Kesavannair Phillips
Ali Hashim
Note is added: This guideline is
subject to change or to be Muhamad D. Reed
2 IFI 28-April- 2015 PFC Vinod K.
superseded by Civil Defense at Kamal Yaacob Phillips
Kesavannair
any time without notice

IFR Issued for Review/Comment(s) PFC Preliminary for Comment
IFI Issued for Information SS Superseded
IFA Issued for Approval A Approved
LUSAIL DEVELOPMENT
1 INTRODUCTION ...................................................................................................... 4
2 SCOPE..................................................................................................................... 4
3 DEFINITIONS........................................................................................................... 4
4 COMPETENCY LEVEL ........................................................................................... 6
5 DESIGN PRINCIPLES ............................................................................................. 7
6 DESIGN CRITERIA.................................................................................................. 7
7 DESIGN PARAMETERS ......................................................................................... 7
7.1 Local Environmental Conditions ............................................................................. 7
8 DESIGN STANDARDS AND REGULATIONS ........................................................ 8
8.1 Design Standards ..................................................................................................... 8
9 PIPING MATERIAL .................................................................................................. 9
10 PIPE SIZING ....................................................................................................... 10
11 CUSTOMER PRIMARY METER ......................................................................... 10
12 JOINTING ........................................................................................................... 10
13 BUILDING INSTALLATION PIPEWORK ........................................................... 11
13.1 General ................................................................................................................ 11
13.2 Residential - Villas .............................................................................................. 12
13.3 Residential And Residential/Commercial Multi-Story Buildings ..................... 12
13.4 Risers................................................................................................................... 13
13.5 Ducts and Shafts................................................................................................. 13
13.6 Pipe in Pipe Systems .......................................................................................... 13
13.7 Gas detection and safety shut off Equipment................................................... 14
13.8 Installation Pipework .......................................................................................... 14
13.9 Secondary Pressure Regulation and Isolation Valve ....................................... 14
13.10 Gas meter in high rise building .......................................................................... 14
13.11 Pipe support and hangers .................................................................................. 15
14 SMALL COMMERCIAL INSTALLATIONS ......................................................... 15
15 MEDIUM/LARGE COMMERCIAL ....................................................................... 15
16 PAINTING AND COLOR CODES ....................................................................... 15
16.1 General ................................................................................................................ 15
16.2 Technical Details................................................................................................. 16
16.3 Pipe Marking ....................................................................................................... 16
17 RISK ASSESSMENT .......................................................................................... 16
18 TESTING ............................................................................................................. 17
18.1 Pressure and Leak Test ...................................................................................... 18
18.2 Safety ................................................................................................................... 18
19 COMISSIONING ................................................................................................. 18
20 APPENDICES ..................................................................................................... 19
Project Name: Lusail Development Internal Gas Piping Design and Installation Guidelines Rev.2
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LUSAIL DEVELOPMENT
Appendix A – Single Riser Multiple Dropper & Multiple riser ……………………………..20

Appendix B – Pipe Riser (Ventilated Shaft) Detail……………………………………………21
Appendix C – Fire Stop Detail …………………………………………………………………...22
Appendix D – Typical Branch and Kitchen Gas Pipes Routing…………………………...23
Appendix E – Demarcation Point………………………………………………………………..24
Appendix F - Design Checklist…………………………………………………………………..25
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LUSAIL DEVELOPMENT
1 INTRODUCTION
The objective of this Building Internal Gas Piping Design and Installation Guidelines is to define
and implement a standard and identical design and installation approach for the SNG, NG and LPG
Gas System that to be interface between Lusail City Gas Network Distribution System and Gas
Utilization Systems (Building Internal Piping). This design and installation guideline is not to be used
to override any other international standard in use currently. The purpose of this document is also to
provide a clear direction to have safe and prudent gas piping installation.
Note: This guideline is subject to change or to be superseded by Qatar Civil Defense at any
time without notice
2 SCOPE
This guideline shall be utilized by Plot Developers for the Gas Utilization System design downstream
of the Gas Distribution System.
The work and responsibility of the installation designer and Plot Developers begins at the point of
delivery service isolation valve and continues up to and including all installation pipework and gas
consuming equipment.
Initially the system will operate using SNG provided via Gas Farm facilities that will blend the LPG
with air to produce Synthetic Natural Gas in proportions that match the same Wobbe index of Natural
Gas. It is anticipate that at a later stage the SNG fuel supply may be replaced with Natural Gas (NG)
supplies as they become available. For this reason the design shall incorporate measures for the use
of both LPG and NG downstream of the Gas Farm facilities.
The physical demarcation between the Gas Service Provider and Plot Developers design and build
responsibilities are shown in Appendix E and further detailed in these guidelines which consist of
Building Internal Gas Piping system.
Others reference for Plot developer shall be as follows:-
 Design Guidelines for Mega-development and Sub-development Gas Distribution System to

be referred to LUS-CPALL-MAQ-SPE-UT-0005
 Guidelines for Pressure Reducing Station (Primary Customer Meter) to be referred to LUS-
CPALL-MAQ-SPE-UT-0006
3 DEFINITIONS
The document use the terms “should”, “shall” and “must” as follows:
a) The term “should” identifies a requirement which, it is intended, will be complied with unless,
after prior consideration by a competent person, deviation is considered to be acceptable
b) The term “shall” identifies a requirement which, it is intended, will be complied with in full and
without deviation.
c) The term “must” identifies a requirement by law.
Other definitions applied within this document are provided below:
Consumer - Any person, agency or authority to whom gas is delivered either directly or indirectly.
Consumer (Secondary) Meter Installation - The gas utilization equipment that measures the
volume of gas delivered to a consumer.
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LUSAIL DEVELOPMENT
Customer - a property owner or any person, agency or authority operating under his consent to
whom Gas Service Provider sells gas.
Customer (Primary) Meter Installation – Pressure Reducing and Metering Station (PRMS) - A gas
utilization facility that measures the volume of gas delivered to a customer. A customer primary meter
installation may also filter the gas and/or reduce the pressure of gas to the customer’s delivery
pressure.
Delivery Pressure - The pressure at which gas is to be delivered to a customer at the inlet to the
utilization pipework.
Design Criteria - Design Criteria are established, but usually unquantifiable, inputs that shall be
applied in the design process.
Design Parameters - Design Parameters are quantifiable inputs that shall be used in completing a
design.
Distribution Main (MOP up to 4 bar) - A gas distribution facility consisting of pipe and other
components, used for gas distribution at operating pressures ≤ 4 bar.
Distribution Network - Interconnected group of pipes that are part of the Gas Distribution System.
Distribution Pipeline - (MOP) less than or equal but exceeding 4 bar. A gas distribution facilities
consisting of PE and/or steel pipes and other components.
Diversified Load The ratio of the maximum potential demand, typically hourly, to the maximum
actual demand.
Dropper Pipework that is part of the Gas Utilization System. The flow of gas through a dropper is
vertically downward.
Emergency Control Valve (ECV) A valve that is part of the Gas Distribution System. An ECV is
utilized in an emergency to shut off the supply of gas and shall also be deemed to be the customer
meter control valve immediately prior to the inlet of the Customer Primary Meter Installation.
Emergency Isolation Valve (EIV) A valve that is part of a Gas Utilization System. An EIV is to be
used to isolate a section of pipework such as a lateral or an entire area of a building.
Gas Distribution System A network consisting of pressure regulating stations, distribution

pipelines, distribution mains and gas services that distributes gas from the Tank Farm supply
system to the Gas Utilization Systems.
Gas Leak Detector gas leak detector is to provide a means for safely detecting any malfunction of a
pressurized gas system in order to prevent accumulation of combustible gases so that damage or
explosion due to such an accumulation of gases is prevented.
Gas Quality The chemical composition of the gas supplied to the gas distribution system.
Gas Service A gas distribution facility consisting of pipe and other components. A service may be
comprised of either steel and/or PE materials. It transports gas between a Distribution Main and a
Customer Primary Meter Installation. Gas Services may consist of both below and above ground
components.
Gas Service Provider (GSP) the company appointed by LREDC having the authority to supply gas to
5 | Page
LUSAIL DEVELOPMENT
customers in Lusail City.
Gas System The combined gas supply system, Gas Farm, Gas Distribution System and Gas
Utilization Systems that process, transport, measure, distribute and deliver gas for consumption.
Customer Internal Piping is a Gas Utilization (Building Internal Piping) small network consisting of
Customer Primary Meter Installations, installation pipework and utilization equipment that carry gas
from the Gas Distribution System to the utilization equipment for consumption.
Maximum Incidental Pressure (MIP) The maximum pressure to which the system may be
subjected under abnormal conditions.
Maximum Operating Pressure (MOP) The maximum pressure to which the system may be
subjected under normal conditions.
Overpressure Shut Off valve (OPSO) senses the pressure downstream of the regulator but
isolates the line pressure of the regulator should the pressure exceed a set value.
Plot A finite amount of property/land used for commercial or residential purposes. Plots may belong
to or be controlled by a specific individual, entity or authority. Plots may be vacant areas but may also
be occupied by buildings, facilities or equipment. Buildings are typically located fully within plots but in
some circumstances do extend beyond plot boundaries.
Polyethylene (PE) for the purpose of these guidelines means PE100 SDR 11.
Primary Pressure Regulating Station (PPRS) A facility that regulates the pressure of gas received
from a Transmission pipeline prior to the gas entering the Gas Distribution System. Depending on the
distribution network configuration, a PPRS may be connected to a Distribution Pipeline or Distribution
Main.
Gas Riser - Pipework that is part of either a Gas Service or the Gas Utilization System. The flow
of gas through a riser is vertically upward.
Secondary Pressure Regulating Station (SPRS) A facility that regulates the pressure of gas
received from a Primary Pressure Regulating Station (PPRS) prior to the gas entering a Distribution
Main.
Second Stage Regulator is a regulator to be use in the house or apartment after the Customer
Primary Meter installation or building Pressure Reducing Metering & Station (PRMS) to reduce the
gas pressure from 75mbar or 350 mbar to 21mbar for SNG and NG or 37 mbar for LPG in the
house. The second stage regulator must be use incorporated with under pressure shutoff device.
Solenoid valve is an electromechanical device used for controlling gas flow by turning on or off the
valve and normally connected to Gas Leak Detector, and Emergency switch. Solenoid valve is
considered as part of safety system.
Synthetic Natural Gas (SNG) A blended of LPG and air to produce a fuel gas mixture with Wobbe
index similar to those of natural gas.
Under Pressure Shut Off valve (UPSO) shuts off the gas flow should the inlet working pressure
be interrupted or a malfunction cause the regulator to fully open (low pressure). The UPSO will also
operate if the maximum capacity is exceeded.
4 COMPETENCY LEVEL
Intentionally left blank.
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LUSAIL DEVELOPMENT
5 DESIGN PRINCIPLES
The key design principles that shall be adhered to are:
 In all matters, the overriding goal designing and installing the utilization network is safety.
 Adoption of the best international practices utilizing appropriate modern technology.
 Ensure that gas piping system installed in Lusail City is identical for ease of operation &
maintenance and avoiding any complicated installation.
 Assurance of a safe, reliable, effective, efficient and secure of gas supply system install in all
building premises in Lusail City.
6 DESIGN CRITERIA
 Provision shall be made to incorporate means of controlling the gas flow within the building
gas piping system including isolation of damaged facilities or components.
 The gas supply source pressure considered in the design shall be determined based on the
upstream design conditions.
 System shall be designed to supply a forecast hourly peak demand
 The load that shall be applied during design shall be diversified. Considerations in
determining the load diversity shall include the nature of the facility being designed, the type
of load and the number of consumers.
 Designs shall minimize the types and size range of materials and use only material items for
which approved Material Specifications exist.
 All materials shall be suitable for local climatic conditions.
 All materials, assemblies and installations shall ensure correct functionality and full
operability taking into accounts the ambient conditions of the location.
 All piping and fittings as well as other components and accessories shall be suitable for both
LPG and NG usage.
 All gas shafts within a building preferred to be dedicated for gas with a minimum size suitable
for accessing the shaft for maintenance purposes.
 Gas pipes may run in the same shaft as most other services, including hot and cold water
services, electrical conduits, and pipes containing other fuels. However, there are some
restrictions when gas pipework is routed in combination with other services, such as services
containing oxidizing or corrosive fluids.
 All gas shafts must be open to sky, and have permanent access at each floor of the building.
Due to the possible future conversion from LPG to NG the following parameters shall be considered
during the design;
 Designs shall ensure specific considerations are taken to accommodate the significant
difference in specific gravity of LPG in SNG and future NG supplies; the value of 0.64
(relative to air) shall be assumed for NG.
 Selection of gas appliances shall be in accordance with BS 3156-11.0.2 and ISO13686:1998
Specification for Family 2 Type Gases and should be fitted with flame failure protection
devices.
7 DESIGN PARAMETERS
The following design parameters have been adopted:
7.1 Local Environmental Conditions
Site conditions must be assumed to be as follows:
• Maximum Ambient Temperature; 55°C
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LUSAIL DEVELOPMENT
• Minimum Ambient Temperature; 1°C

• Design Ambient Temperature; 55°C
• Max. Metal Temperature under Sun; 85°C
• Min Barometric Pressure; 998 Mbar
• Average Barometric Pressure; 1015 Mbar
• Max. Ambient Humidity; 100%
• Min Ambient Humidity; 20%
• Design Ambient Humidity; 100%
• Design Wind Velocity; 160km/Hr
• Yearly Rainfall; 80-150mm
• Seismic Co-Efficient; 0.07g
8 DESIGN STANDARDS AND REGULATIONS

All designs must comply with Qatar laws and regulations in addition to relevant national and
international standards relating to design of Gas Utilization Systems, in so far as they apply to the
work including;
Relevant International Standards such as;
1. ASME - American Society of Mechanical Engineers.

2. ASTM - American Society for Testing and Materials.
3. Institute of Gas Engineers and Managers (IGEM).
4. National Fire Protection Association (NFPA).
5. American Gas Association (AGA).
6. ANSI - American National Standards Institute.
7. BS - British Standards
8. EN – European Standards.
9. ISO - International Standardization Organization
Main Codes and Standards reference for Gas Piping Design and Installation
1. IGE/G/5 – Gas in flats and other multi dwelling buildings.
2. IGEM/UP/2 – installation pipework on industrial and commercial premises.
3. IGE/GM/8 Part 1 Meter Installations I & C – Design, MOP ≤ 38 bar.
4. IGE/GM/8 Part 2 Meter Installations I & C – Location and Housing, MOP ≤ 38 bar.
8 | Page
LUSAIL DEVELOPMENT
5. IGE/TD/4 – Gas Services.
6. BS EN 6400 –Specification for installation, exchange, relocation and removal of gas meters
with a maximum capacity not exceeding 6 m3/h Medium pressure (2nd family gases)
 Part 1: Low pressure (2nd family gases)
 Part 2: Medium pressure (2nd family gases)
 Part 3: Low and medium pressure (3rd family gases).
7. BS 6891 – Specification for installation of low pressure gas pipework of up to 28 mm (R1) in

domestic premises (2nd family gas).
8. NFPA 58 - Liquefied Petroleum Gas Code
9. NFPA 54 - National Fuel Gas Code
9 PIPING MATERIAL
Pipe fittings and component shall be designed and installed in accordance with relevant standards.
Material shall have the physical properties suitable to the proposed duty considering all surrounding
forces, operating temperature and pressure.
Steel pipe
Carbon steel or wrought iron pipe shall be at least of Schedule 40 Grade B, and shall comply with the
following standard.
1. ASME B36.10 M
2. ASTM A106
3. API 5 L
4. ASTM A53 M, black steel
5. BS EN 10208, BS EN 10216, BS EN 10217 – 1, BS EN 10255
Copper
Copper tube install in the building (inside kitchen only) shall be rigid type.
Annealed-Temper or Drawn-Temper Copper Tube shall comply with ASTM B 88, Type K (ASTM B
88M, Type A) / ASTM B 88, Type L (ASTM B 88M, Type B) /ASTM B 837, Type G.
Copper Fittings shall be to ASME B16.22, wrought copper and streamlined pattern.
Copper Pipe to BS EN 1057 shall be also be used and the maximum diameter shall be limited to 108
mm.
Fittings shall be in compliance to:
 BS 2051-1
 BS EN1254
Fittings shall be protected from mechanical damage
Polyethylene
Pipe shall be to BS EN 1555-1 and -2
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PE pipe shall be for buried used only.

PE pipe must not be used within building, for entry or exit sit shall be sleeved with special requirement.
Gas hose
Gas hose connection to the kitchen Equipment shall comply with BS 3212 or BS EN 1762 or
equivalent.
Gas hose connection to kitchen equipment and excess flow valve must use female or male NPT
threaded coupler.
The hose mechanical coupler shall be of factory manufactured fitting.
Hose shall have marking and steel braided is preferable.
Second stage regulator

It must reduce the pressure to 21mbar for SNG or NG and 37mbar for LPG
It must be incorporated with under pressure shutoff device (UPSO).
Regulator vent shall be piped to outdoor atmosphere.
Solenoid valve
Solenoid valve must be explosion proof type and suitable to be used for fuel gas.
Gas leak detector

The primary objective of the gas leak detector is to provide a means for safely detecting any
malfunction of a pressurized gas system in order to prevent accumulation of combustible gases so that
damage or explosion due to such an accumulation of gases is prevented.
The gas leak detector must be calibrated to the type of gas to be detected.
Installation shall be as per manufacturer recommendation.
The kitchen domestic gas detector shutoff switch shall be located outside the kitchen area (near to
kitchen entry).
The pipe in pipe, PRMS, Gas shafts gas detector must be explosion proof type.
10 PIPE SIZING
Pipework should be sized so that the pressure at the appliance input is safe and compatible with
optimum operation as per the manufacturer’s instructions.
11 CUSTOMER PRIMARY METER

Customer meter design and installation shall be referred to LUS-CPALL-MAQ-SPE-UT-0006.
12 JOINTING
All joint shall be as per codes, standard and manufacturer requirements and recommendation.
Ream ends of pipes and tubes and remove burrs.
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Remove scale, slag, dirt, and debris from inside and outside of pipe and fittings before assembly.
Threaded Joints:
 Thread pipe with tapered pipe threads complying with ASME B1.20.1.
 Cut threads full and clean using sharp dies.
 Ream threaded pipe ends to remove burrs and restore full inside diameter of pipe.
 Apply appropriate tape or thread compound to external pipe threads unless dry-seal threading
is specified.
 Damaged Threads: Do not use pipe or pipe fittings with threads that are corroded or damaged.
Do not use pipe sections that have cracked or open welds.
Welded Joints:
All welding of metallic piping shall be in accordance with ASME Boiler and Pressure Vessel Code,
Section IX or API1104, using qualified processes and welding operators.
All welding end preparation shall be in accordance with ANSI B16.25
All joints to be welded unless otherwise required example the connection to threaded valves or
pressure gauge.
Steel pipe fitting shall be in accordance to ANSI ASME B16.9
Welded pipe joint shall be tested with Non Destructive Test, X –ray, Dye Penetration Test, Magnetic
particle Test or Ultra Sound Test. See Section 18.
Brazed Joints:
Construct joints according to AWS's "Brazing Handbook," "Pipe and Tube".
Brazing Filler Metals: Alloy with melting point greater than 540 Degree Celsius complying with AWS
A5.8/A5.8M.
Brazing alloys containing more than 0.05 percent phosphorus are prohibited.
Flanged Joints:
Flanged joint shall be to ASME B16.5
Install gasket material, size, type, and thickness appropriate for natural- gas service. Install gasket
concentrically positioned.
Flared Joints:
Cut tubing with roll cutting tool. Flare tube end with tool to result in flare dimensions complying with
SAE J513. Tighten finger tight, then use wrench. Do not over-tighten.
PE Piping Heat-Fusion Joints:
Pipe fittings shall be clean and dry joining surfaces by wiping with clean cloth or paper towels. Join shall
be according to ASTM D 2657.
Plain-End Pipe and Fittings: Use butt fusion.
Plain-End Pipe and Socket Fittings: Use socket fusion.
13 BUILDING INSTALLATION PIPEWORK
13.1 General
Designer shall ensure the gas pipes service to the plot is accurate.
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Customer Installation Pipework extends from the outlet valve of the Pressure Reducing &
Metering Station (Customer Primary Meter) to the consumer appliances.
At the initial stages of building design and planning the Designer/Installer needs to ensure that the
Customer Internal Piping connected to the meter outlet valve are adequately designed in order to
provide a safe supply of gas to the point of use.
Residential and unit apartment pipe work in the kitchen shall be installed with shutoff valve, solenoid
valve, low pressure regulator with under pressure shut off (UPSO), auto-shutoff valve, gas meter,
Emergency switch, and domestic gas leak detection system as minimum.
Gas regulator in the building shall be able to be operated with 75mbar incoming pressure from the main
Pressure Reducing and Metering Station.
13.2 Residential - Villas
Where the customer meter installation is located at the boundary wall downstream piping should be
extended to the villa below ground using PE pipe (with GRP sleeve) or above ground using Steel, PEX
(with GRP sleeve). The belowground pipe work shall not run in villa or conceal in cement. Below
ground pipework shall be in accordance with IGE/TD/4 – Gas Services.
 Pipework operating pressure shall depend on load and distance between Customer Primary
Meter Installation and point of entry to a building but shall not exceed 75 mbar.
 Maximum pipework operating pressure within the building should be 21mbar.
 Where the external installation pipework operates in excess of 21 mbar, secondary pressure
regulation should be installed prior to or immediately after pipework entry into a building.
Secondary pressure regulator installations shall incorporate UPSO and OPSO capabilities.
Gas regulator shall be vented to outdoor air.
 An OPSO device installed inside a building which is fitted with relief mechanisms shall
ensure that the gas is vented directly to the outside atmosphere.
 Pressure loss calculations and friction factor shall be in accordance with the relevant
standard. Equivalent lengths of valves and fittings shall be added to the pipe length.
 An isolation valve shall be installed and should be inside the building as close as practicable
and within 2m of the point of entry of the pipework into the building.
 The Building Internal Piping shall be designed to deliver at least the minimum operating
pressure of all connected appliances.
 LPG related safety equipment (i.e. solenoid valve, combustible gas detector, and separate
low pressure shut off) shall be installed to monitor leakage and isolate the gas supply.
 Natural Gas provisions shall be considered during design stage.
13.3 Residential And Residential/Commercial Multi-Story Buildings
 Pressure from the Gas Distribution System at the outlet of the Pressure Reducing &
Metering Station should not exceed 75 mbar.
 Pressures from the Gas Distribution System at the outlet valve of the Pressure Reducing &
Metering Station in excess of 75 mbar shall be in consultation on an individual basis with the
Gas Service Provider and only in cases where;
 Riser pipework is external to the building and secondary pressure regulation is deployed
to ensure pressures within the building do not exceeding 75 mbar.
 Commercial supplies require pressures in excess of 75 mbar.
 Diversity should be taken into account when determining pipe sizes.
 Pressure loss calculations and friction factor shall be in accordance with the above relevant
standard. Equivalent lengths of valves and fittings shall be added to the pipe length.
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 Expansion joints and flexible connections shall be considered to avoid unacceptable

stresses being inflicted on any steel riser, dropper or lateral pipework.
 Riser, dropper and lateral pipework should be a minimum of 400mm away from any
electrical line and a minimum 150mm away from any electrical instrument
 Pipework shall be supported adequately along its entire length
 Threaded steel pipework ≤2” shall be of schedule 80 and >2” schedule 40
 Provision of gas sensors in all confined space where the gas pipe is passing through, for
example in areas within false ceiling of the kitchen and corridor etc. as well as void spaces
which are confined or any pipe in pipe systems.
 Pipework above ceilings or in voids shall have pipe in pipe arrangements and gas detection
equipment linked to a safety shut off devices capable of monitoring and shutting off the
pipework supplying that area.
13.4 Risers
 Risers should be installed external to the building or in a duct or shaft designed in

accordance with IGEM/G/5 and the additional requirements for LPG pipework in
ducts/shafts. Refer to Appendix A to F.
 External risers may be operated at a higher pressure (e.g. 350mbar) than droppers,
secondary regulators shall be required to provide a lower pressure to droppers i.e. 75mbar.
Gas regulator shall be vented to outdoor air.
 Risers may be extended to form a rooftop distribution manifold fitted with isolation valve at
the top of each dropper. All riser and dropper shall be provided with ¼” valve with plug for
ease of purging and commissioning the pipeline.
13.5 Ducts and Shafts
Ducts or shafts used to convey gas pipework in buildings shall be dedicated for gas, and incorporating
the following requirements into the design;
 Ventilated by means of both an open to sky and base level opening that will direct any
leakage to outside the building.
 Sealed from the building such that gas leakage into any duct shall not be able to enter any
part of the building other than the duct/shaft.
 Fitted with sealable access panels to enable operation and maintenance activities to be
undertaken.
 Fitted with a gas detection system at suitable locations.
 Provision must be made for safe and adequate access for inspection of any riser, valve,
lateral, meter and other gas equipment.
13.6 Pipe in Pipe Systems
 Pipe in pipe systems shall be used to prevent gas leakage entering a building in the
exceptional cases where it is necessary for the gas pipe to run above false ceiling inside
kitchens.
 The system can be connected to the duct /shaft system described above to provide the
ventilation requirements to outside but shall be adequately sealed to ensure any gas
leakage shall not enter the kitchen.
 Pipe sleeve material shall be of similar type of the annular/carrier pipe with proper spacing
between the annular and sleeve pipes.
 Pipe sleeve shall be vented to outdoor atmosphere air.
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13.7 Gas detection and safety shut off Equipment
 Gas detection equipment shall be installed in pipe in pipe systems, PRMS, gas shafts,
kitchens, and any other areas where there is a potential for gas release inside the building.
 The gas detectors should be installed at regular intervals and connected to safety shut off
devices that are strategically placed to isolate the section of pipework that the gas detector
is monitoring.
 To avoid isolating areas not affected by fault conditions, consideration should be applied to
zoning gas detection and safety shut off systems.
 Combustible gas detector linked to a solenoid valve and separate low pressure shut off shall
be installed in areas where appliances are connected to monitor leakage and isolate the gas
supply to that particular area.
 Location of gas detector for LPG/SNG should be at low level 300mm from floor level
 Location of gas detector for NG should be at high level 150mm from false ceiling level,
provision for the same should be incorporated into the design.
 PRMS, shaft and gas detector must be explosion proof type.
 Gas detection equipment should be positioned per manufacturers’ instructions.
13.8 Installation Pipework
 Installation pipework in buildings, downstream of any regulator operating at a

maximum of 21 mbar could be carbon steel or copper. Maximum allowable copper length is
only 2 meter.
 Maximum pipework operating pressure within individual residential units is 21 mbar.
13.9 Secondary Pressure Regulation and Isolation Valve
 Where the external installation pipework operates in excess of 21 mbar, secondary pressure
regulation should be installed prior to or immediately after pipework entry into a building.
Where a secondary regulator is installed inside a building, it shall he installed within 2m of
the entry point. Secondary pressure regulator installations shall incorporate UPSO and
OPSO capabilities.
 An isolation valve is required for each consumer unit. The isolation valve shall be installed
inside the building as close as practicable and within 2m of the point of entry of the pipework
into the building.
 Where a secondary pressure regulator is installed for the consumer unit the isolation valve
shall be upstream of the regulator.
13.10 Gas meter in high rise building
 A meter installation shall be located in a cupboard or compartment, designed for the

purpose and ventilated to outdoor atmosphere.
 All meters should be located in well-ventilated areas and be easily accessible to allow them
to be read, maintained and isolated when necessary.
 Meters must not be exposed to extreme temperatures, excessive humidity, vibration,
corrosive substances, accidental damage, or ignition sources.
 Gas meter installed in individual apartment shall be located in individual compartment
designed for the purpose.
 Gas meter installed in high rise building (multi dwelling building) shall have smart metering
capability that should include for billing, monitoring and controlling. Gas smart meter reading
facilities shall be able to be connected using TCP/IP communication protocol to Lusail City
main control center.
 Gas meter shall be installed at minimum 3 meter away from any building opening and
source of ignition, and not installed above basement.
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13.11 Pipe support and hangers
Pipework can be subject to movement from thermal expansion, thermal contraction, structural
movement of the building, vibration and rotation or torsion.
 Pipework support should allow for pipe movement without damage being caused to
corrosion protection or pipework installation.
 When supporting pipework on a horizontal or near horizontal surface, the support brackets
should ensure that the pipework remains clear of the surface.
 The support brackets and screws should be of corrosion resistant materials.
 Ferrous materials e.g. screws and support brackets should not be in contact with copper
piping.
14 SMALL COMMERCIAL INSTALLATIONS
 Meter installation should connect into the Customer Internal Pipework as close as possible
to the entry point to the building.
 Isolation valves are required immediately downstream of the point of entry into any building.
 An isolation valve shall be installed in the pipework immediately after passing through
interior partition walls and shall be clearly tagged as such.
 Secondary pressure regulator installations installed within Customer Installation
 Pipework shall incorporate UPSO and OPSO capabilities.
 Pipework should be Carbon Steel Schedule 40 Grade B.
 The maximum allowable pressure drop is 10% of the delivery pressure.
 Diversity should not apply to the design of commercial piping systems
 Pressure loss calculations and friction factors shall be in accordance with IGE/UP/2.
 Equivalent lengths of valves and fittings will be added to the pipe length.
 LPG related safety equipment (i.e. solenoid valve, combustible gas detector, and separate
low pressure shut off) shall be installed to monitor leakage and isolate the gas supply.
15 MEDIUM/LARGE COMMERCIAL
 Medium and large commercial premises shall be treated on an individual basis.

 Meter installation should be located at or near the property boundary and any
downstream piping shall be extended below ground in PE and/or steel pipe to the point(s) of
entry into building.
 All above ground Customer Internal Piping should be welded steel.
 Delivery pressures shall depend on the requirements of the equipment.
 Delivery pressures in excess of 75mbar should be considered on an individual basis.
Regulator installations within installation pipework shall incorporate UPSO and OPSO capabilities.
 Pressure loss calculations and friction factors shall be in accordance with IGE/UP/2.
 Equivalent lengths of valves and fittings shall be added to the pipe length.
 Suitable isolation valves shall be installed in appropriate locations in the pipework
downstream of the Customer (Primary) Meter Installation and shall be clearly tagged as
such.
 Where the gas installation has multiple branches an isolation valve shall be installed on
each branch.
16 PAINTING AND COLOR CODES
16.1 General
The steel piping shall be protected from corrosion and to be provided with piping color for ease
of identification of the pipelines and their content. Pipeline color coding shall follow to
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international acceptable standard.
Copper piping shall be marked with yellow color band around the pipes internal every 2 meter.
16.2 Technical Details
 The material surface to be painted shall be cleaned from any welding slag, dust,
grease or debris.
 Various methods of surface preparation can be adopted e.g. degreasing, high pressure
fresh water hosing, hand tool cleaning, power tool cleaning, blast cleaning etc.
 Paint shall be in 3 layer coating system as given below:-
- Primer coating shall be 85% metallic zinc by weight, grey colour, matte finish
- Intermediate coating shall be Polyamide Epoxy, matte finish
- Finish coating shall be polyurethane, golden yellow, high gloss finish.
 Procedure for painting shall be submitted to Marafeq for approval.
 Color coding for SNG, LPG and NG steel piping shall be Golden Yellow color RAL
1007
 Material surface to be painted shall be dry
 Paint shall be fully cured before another layer to be applied.
 Paint application shall follow manufacturer specification or procedure.
16.3 Pipe Marking
 Pipe shall be provided with arrow marking direction of the gas.
 Arrow marking shall be black with word “GAS”.
 Copper piping can be marked with yellow color band around the pipes internal every 2
meter.
 All supply pipework in a multiple meter installation should be clearly marked to indicate
the premise number, floor number and/or section of building being supplied.
 The marking of pipework is essential for correct meter recording, safe operation,
maintenance and accurate billing of gas consumed.
17 RISK ASSESSMENT
The requirements of Risk Assessment are based on reducing risks “As Low as Reasonably
Practicable. Where there are established or standards design, this requirement can be met by
the application of standards and best practice. Where there are not, as with all multi-occupancy
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buildings, a risk assessment approach is required in addition to demonstrate the necessary risk
reduction.
A generic consideration of the hazards and risks from different supply options leads to a
number of general principles:
 Gas supplies should be as far as possible sited out of doors.
 Gas supplies should be sited in well-ventilated area
 Gas supplies should be excluded from poorly ventilated or strongly confined spaces
such as basements and cellars.
 Apparatus should be sited to avoid accidental damage or interference with the supply
wherever possible.
 Consideration shall be given to the location of the supply with respect to the ability of
the structure to withstand the consequence of an ignition in the event of a gas escape.
18 TESTING
 Any installation shall be subject to pneumatic strength test and tightness tests. Testing
shall be carried out prior to application of paint or other protective coatings and before
the installation is put into service.
 The Contractor shall submit the Testing & Commissioning procedures and shall be
approved by Marafeq. The submission shall be made at least one month before the
commencement of Testing & Commissioning.
 Before carrying out any test, the Contractor shall ensure that the installation fully
complies with the relevant statutory obligations and regulations.
 Upon completion of such Testing, the Contractor shall complete and sign a testing
certificate to the effect that agreed Testing procedures have been duly carried out.
 The installation shall generally comply with the requirements of the Local Authority
requirement and codes of practices.
 Meters, regulators and associate equipment shall not be subjected to on site
pneumatic or test. It shall be tested by manufacturer in factory.
 Minimum 10% (or as per authority requirement) x-ray to be applied to building steel
pipe installation to ensure the welding quality is met according to welding procedure.
The installation shall use API 1104 or ASME IX as welding standard and guidelines.
 Items to be buried underground shall be inspected and tested before protective
finishing is applied and the finished work is buried. The Contractor shall arrange Gas
Authority to inspect and witness the tests including pressure test and “Holiday test” for
the underground pipeline prior to cover up/back-filling.
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18.1 Pressure and Leak Test
 After the completion of internal gas piping installation, it shall be subjected to

pneumatic pressure test.
 The Pressure Test shall be witnessed by Local Authority, or Marafeq Qatar together
with customer. The Contractor is required to liaise with Local Authority on the
arrangement and should advise Marafeq Qatar the parties involve accordingly.
 In accordance with the standard requirement, installer /contractor is requested to

conduct pressure test the piping installation not less than 1.5 times maximum operating
pressure for not less than one hour depending on the volume of gas pipe to be tested.
 Marafeq will reserve the right not to connect / gasify the building internal piping if the
testing result is not satisfactory.
 Marafeq will commission the gas facilities with LPG, Synthetic Natural Gas or Natural
Gas only after customer/contractor obtaining No Objection Certificate (NOC) from
Authority on the internal piping installation.
18.2 Safety
The test procedure should not jeopardize the safety of persons or property. All testing operations
should comply with the following:
i) The task should be performed by competent persons;
ii) The person responsible for the test should ascertain the extent of the pipework to be tested;
iii) The person responsible for the test should be present during pressurising and
depressurising the pipework;
iv) The test should be carried out in site and where possible all joints should be easily
accessible and free from covering; Open ends of pipework and valve outlets should be sealed
with an appropriate fitting.
v) Any appliances or other components considered not capable of withstanding the test
pressure should be disconnected or isolated. E.g. regulators, meters, safety devices, etc.
vi) Only work related to the test is carried out on the pipework while the test is in progress;
vii) If the test is deemed to be potentially dangerous when the test is in progress, persons not
under the supervision of the person responsible for the test should be prohibited from the area
and warning signs should be displayed;
viii) During the test any pressure increase should be gradual;
ix) If the test is not immediately followed by commissioning, the pressure in the pipework tested
should be reduced to working pressure and the pipework sealed.
19 COMISSIONING
Prior to commissioning of the building internal gas piping, the building Owner or Consultant or
Gas Contractor is required to provide Test Certification, Pre-commissioning, and
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commissioning procedure, Local Authority approval and other details deem required for
commissioning.
20 APPENDICES
1. Appendix A – Single Riser Multiple Dropper & Multiple riser

2. Appendix B – Pipe Riser (Ventilated Shaft) Detail
3. Appendix C – Fire Stop Detail
4. Appendix D – Typical Branch and Kitchen Gas Pipes Routing
5. Appendix E – Demarcation Point
6. Appendix F - Design Checklist
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APPENDIX F
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DESIGN CHECKLIST
Section Check Item Compliance Notes

A Specific Guidelines, Safety & Integrity General Requirements
1 Gas pipe shall be designed at 75mbar pressure.
The maximum allowable Gas Pressure within the
Building is 75 mbar. In case more-than 75mbar is
2
required (eg 350 mbar) the pipe riser shall be
installed outside the building.
The design of the Gas System within the Building shall
include the Calculation, Pressures Drop, Piping
Location, Routing, Piping Construction, Gas Leak
Detection System, Piping Ventilations and Materials to
3
be used are in compliance with IGE/UP/2 & IGE/G/5
latest Edition and the Latest Marafeq Qatar Gas
Internal Piping Guidelines.
All kitchens and boilers rooms shall be properly and
4 safely ventilated to outdoor atmosphere.
All gas firing appliances in the apartment or house shall
5 be equipped with Safety Systems.
All Building Shafts, Ducts and Access Panels
dedicated for the Gas Riser and Droppers shall be
Fire Rated and comply with the Structural
6
Requirements of Building Regulation. Locations &
Routings shall comply with Local
Authorities’ Requirements.
All Building Shafts, Ducts and Access Panels shall
provide ease of access for Maintenance and
7
Inspection of the Gas Piping. The door shall be tight
proof type.
Piping design shall consider Building Shrinkage &
Movements and to be provided with necessary
8 expansion joints for the expansion and contraction of
the Pipe Work. Connections of the Laterals to the
Riser and/or Droppers should be with flexible joint.
Specific Guidelines, Safety & Integrity General Requirements

A
All Riser & Droppers shall be Steel Pipe and NDT
9
tested. (Minimum 10% X-ray and DPT)
All the Piping in confined space (e.g. above false
ceiling) shall be NDT (steel pipe) tested and inside an
10 adequate containment pipe (steel pipe) and
ventilated to a safe open air. Copper pipe shall be
pneumatically tested.
Necessary safe ventilations for all the Installations
11
Pipe Work within the Customer’s Premises.
All Materials, Pipes, Valves and Fittings shall comply
12
with codes and standard requirement and the
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Specifications shall be approved prior to installation.
The Construction, Testing & Commissioning of the
13 Gas Installations Pipe Work shall comply with the
latest version of t h e s e g u i d e l i n e s .
The Main Gas Leak Detection / Control Panel
System shall be interlinked with the Fire Alarm
14 and BMS System of the Buildings. Main Gas solenoid
valve shall be installed with manual emergency button.
Gas detector must be explosion proof type.
The Supervision, Inspection and Testing of the Gas
15 Installation Pipe Work shall be carried out by a
specialized contractor and third party inspector
Intentionally left blank

16
Gas piping in the kitchen shall be installed with manual
17 shutoff valve, solenoid valve, auto shut-off valve, gas
meter, FNPT-NPT hose connector to the appliances.
Domestic type gas leak detector installed in the
kitchen area must be connected to solenoid valve. The
18
emergency switch shall be located outside the kitchen
area.
B Prohibited Location for Gas Installation Pipe Work as per Requirements
Gas Installation Pipe Work in the following areas
and under the following circumstances shall not
be installed:
1 Gas pipe installed in basement shall be avoided.
No gas pipes installed under concrete flooring within
2
the Building.
3 No gas pipes installed under Building Foundation
No gas pipes installed in a Fire Isolated Stairway,
4
Passage way or Ramp.
No gas pipes shall be installed in a clothes or rubbish
5
chute.
No gas pipes installed in a Fire Hydrant or Reel
6
Cupboard.
No gas pipes installed in a Ventilation Duct and
Vacuum Pipes that operate at Sub-Atmospheric
7
Pressure and that are not Welded or Brazed
Construction.
No gas pipes installed in a Fire Control Room Fire
Fighting Lobbies and Rescue Command C e n t e r s ,
S m o k e Stop Lobbies, Fire Pump Room, Fire
8
Fighting Water Tank Rooms, Sprinkler Control Rooms,
Fire Fighting Riser Ducts, Areas of Refuge,
protected corridors.
No gas pipe to be installed in bedrooms, or chased in
9
common partition walls with Bedrooms. Where the
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Bedroom and Kitchen are located in a common area
such as Studio Apartments, Gas Installation Pipe
Work and Gas Appliances shall be separated b y a
f u l l height wall from the sleeping area.
10 No gas pipe to be installed attached to a fence.
No gas pipe to be installed any location defined as
11
“required exits.”
B Prohibited Location for Gas Installation Pipe Work as per Requirements
No gas pipe to be installed any voids within a cavity
12 in a partition wall unless specifically designed and
purpose built as ventilated ducts.
No gas pipe to be installed in a B u i l d i n g
13 S h a f t /Duct t h a t d o e s n o t comply within the
Structural Requirements of local Building Regulation.
No gas pipe to be installed in the same Building
14 Shaft/Duct with services containing Oxidizing or
Corrosive Fluids.
In a Ductwork that is used to distribute Air around
15
the Buildings.
Remarks:
……………………………………………………………………………………………………………….…….....
………………………………………………………………………………………………………………...………
Inspected by: Reviewed by:

Date: Date:
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Gas Distribution System Design

Guidelines for Pressure Reducing Station
(Primary Customer Meter)
REASON
REV DOCUMENT APPROVED
FOR DATE STATUS PREPARED BY CHECKED BY
NO. HISTORY BY
ISSUE
James Abdullah
0 IFR 22-12-2011 PFC D. Reed Phillips
Kenyon Abushaikha
WOQOD’s
James Abdullah
1 IFA 09-01-2012 comments A D. Reed Phillips
incorporated Kenyon Abushaikha
PRS detail for villas Abdullah
2 IFI 12-04-2012 included A Muhamad Kamal D. Reed Phillips
Abushaikha
Lusail comments Abdullah
3 IFI 10-05-2012 incorporated A Muhamad Kamal D. Reed Phillips
Abushaikha
Additional
Abdullah
4 IFI 12-11-2014 requirement on gas A Muhamad Kamal D. Reed Phillips
meter Abushaikha

IFR Issued for Review/Comment(s) PFC Preliminary for Comment A Approved
IFA Issued for Approval
LUSAIL DEVELOPMENT
CONTENTS
1 INTRODUCTION 4
2 SCOPE 4
3 OBJECTIVE 4
4 GENERAL 4
5 DESIGN STANDARDS 5
7 DESIGN CRITERIA 7
9 LOCATION OF PRESSURE REDUCING STATION (CUSTOMER

PRIMARY METER) SET 8
9.1 Gas Meter Room 10
10 COMPONENT OF PRESSURE REDUCING STATION (CUSTOMER

11 ELECTRICAL APPARATUS 11
11.1 Electrical apparatus near to a gas meter 11
11.2 Electrical Bonding 11
11.3 Smart Meter Reading 11
12 PAINTING AND COLOR CODES 12

12.1 General 12
12.2 Technical Details 12
12.3 Painting Standard and Codes of Practices 13

Design Guidelines for Pressure Reducing Station V.4
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LUSAIL DEVELOPMENT
13 FABRICATION/INSTALLATION 13
14 TESTING AND COMISSIONING OF PRESSURE REDUCING STATION14

14.1 General 14
14.2 Acceptance Test 15
14.3 Non-Destructive Test (NDT) 15
14.4 Pressure and Leak Test 16
14.6 Pressure Reducing Station Foundation and box/cabinet Preparation 16
14.7 Commissioning and Start-up 17
APPENDIX 1 18

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LUSAIL DEVELOPMENT
1 INTRODUCTION
The purpose of this document is to describe the works related to the supply and installation of
the gas service riser and pressure reducing station and metering (customer primary meter) for
Villas and Multi Storey Buildings in gas distribution network at Lusail City project development.
2 SCOPE
The design guidelines are the basis of Marafeq’s synthetic natural gas distribution and
associated utilization systems within its gas supply areas. The scope of these guidelines is
covering the work from gas service riser to the primary meter set for Villas and Multi Storey
Buildings.
Gas utilization systems:

 Gas service riser.
 Pressure Reducing Station (Customer Primary Meter) installations for Villas and
Multi Storey Buildings.
3 OBJECTIVE
The design guidelines form a part of technical documents and provide a platform for:
 Work procedures
The objective of the design guidelines is to define the basis for the design of synthetic natural
gas distribution and utilization systems.
4 GENERAL
Gas supplied to domestic or commercial customers shall be metered to enable the
Gas Utility Company to charge for energy consumed.

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LUSAIL DEVELOPMENT
The Pressure Reducing Station (Customer Primary Meter) installation is to be provided by the
gas plot developer and is used for billing purposes. All gas meter installed shall be calibrated to
International Organization of Legal Metrology (OIML) standard.
A Pressure Reducing Station (Customer Primary Meter) installation typically comprises of inlet
isolation valve which may be the ECV, a pressure regulator to control the delivery pressure and
a meter fitted with an outlet valve.
Customers requiring the measurement of gas usage for each of their consumers may install
Consumer (Secondary) Meter Installations at their discretion.
All installed gas meter shall be calibrated by approved third party.
5 DESIGN STANDARDS
Pressure Reducing Station (Customer Primary Meter) shall be designed and installed with
minimum requirement complying to the below listed reference standards and codes of practice.
 IGE/GM/6 – Diaphragm and RD Meter Installations, > 6m3/hr, MOP ≤ 75 mbar
 IGE/GM/8, Part 1 – Meter Installations I & C – Design, MOP ≤ 38 bar
 IGE/GM/8, Part 2 – Meter Installations I & C – Location & Housing, MOP ≤ 38 bar
 IGE/GM/5 – Electronic Gas Meter Volume Conversion Systems
 IGE/SR/25 – Hazardous Area Classification of Natural Gas Installations
 IGE/TD/13:2001 - Pressure regulating installations for transmission and distribution
systems
 BS EN 1359:1999 - Gas meters. Diaphragm gas meters
 BS EN 12480:2002 - Gas meters. Rotary Positive Displacement (RPD) gas meters
 BS EN 12261:2002 - Gas meters. Turbine gas meters
 BS EN 12405-1:2005 - Gas meters. Conversion devices. Volume conversion.
 BS 6400 – Specification for the Installation of domestic-sized gas meters maximum
rated capacity not exceeding 6 m3/h (2nd and 3rd family gases)
Part 1 Natural Gas (low pressure)
Part 2 Natural Gas (medium pressure)

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LUSAIL DEVELOPMENT
 IGE/UP/15- Gas In Flats: Gas Installations In Multi-Occupancy Buildings
 IGE/UP/2 - Gas installation pipe work, boosters and compressors on industrial
and commercial premises
 IGE/G/5 - Gas in flats and other multi-dwelling buildings
 IGE/TD/4 - Gas Services
 IGE/TD/3 Edition 4; 2005 Steel and PE pipelines for gas distribution
 BS 6891 - Specification for installation of low pressure gas pipework of up to 28 mm
(R1) in domestic premises (2nd family gas)
 NFPA 54 – National Fuel Gas Code Handbook
 NFPA 58 – Liquefied Petroleum Gas Code
Local Authority Regulations:
6 DESIGN PRINCIPLES
Below is the design principles adopted by Marafeq to ensure safe delivery of gas to the end
users.
 All customers shall be provided with a Pressure Reducing Station (Customer

Primary Meter) Installation.
 Installations shall be designed to ensure gas consumption is measured accurately

and that metering and delivery pressure is constant.
 Where a primary meter is upstream of the regulator (high pressure line) a volume
converter shall be installed.
 For installations providing non-standard customer delivery pressures (e.g. large

commercial) a volume converter shall be installed.
 Filtration should also be installed where required.

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LUSAIL DEVELOPMENT
 Installations shall incorporate a regulator with a relief piped to the outside as well as
overpressure shut-off capabilities (OPSO) and under pressure shut off (UPSO)
capabilities. The regulator shall have an integral filter.
 Primary meters shall incorporate provisions for remote meter reading capabilities.
 Large non-standard (e.g. large commercial) installations should be designed

considering the pressure reduction system design basis and minimum functional
specification.
All Pressure Reducing Station (Customer Primary Meter) installation shall be installed in
locations that are;
 Easily accessible for inspection and meter reading;
 Preferably on the outside wall at ground level;
 Protected against physical damage, vandalism and the effects of severe weather
 Well ventilated such that any gas venting or leakage does not result in gas entering
the building
 Positioned to minimize risk from possible interference or 3rd party damage.
Where Consumer Secondary Meter Installations are desired by customers in Multi Storey
Buildings they should preferably be installed in common meter areas with secure access.
7 DESIGN CRITERIA
Pressure Reducing Station (Customer Primary Meter) installations shall be designed for:
 Maximum Inlet Pressure – Upstream network MOP plus 10%
 Minimum design inlet pressure is 1.2 bar for mains networks with MOP 4 bar.
Standard customer delivery pressures provided at the Pressure Reducing Station (Customer
Primary Meter) installation outlet is:
 Inside Villas – max 21 mbar (75 mbar before enter the villa)

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LUSAIL DEVELOPMENT
 Inside Multi Storey Buildings – max 75 mbar.
 Other standard pressures that may be used for external pipework not containing
branches for Multi Storey Buildings i.e. Risers is 350mbar.
External pipe work inside mechanical shaft or outside the building wall containing branch
connections to domestic consumers shall operate at a maximum pressure of 75 mbar.
External pipe work not containing branch connections shall operate at standardized pressures of
75 mbar or 350mbar.
Delivery pressures above 75 mbar at the Pressure Reducing Station (Customer Primary Meter)
outlet require special design consideration and shall be considered on an individual basis,
building designers should consult with the Marafeq prior to designing any customer installation
pipework that operates at pressures in excess of 75 mbar.
8 DESIGN PARAMETER
Refer to Marafeq’s Design Guidelines for Mega Development and Sub Development design
parameter Section 6 on document no: LUS-CPALL-MAQ-SPE-UT-0005
9 LOCATION OF PRESSURE REDUCING STATION (CUSTOMER PRIMARY

METER) SET
Gas service riser shall be piped to the preferred location A, B or C as mentioned in the figure 1.
Aboveground gas service riser shall

be protected with GRP sleeve, riser
height from ground level shall be A B C
1.2 meter
Ground level
Gas service line
4 bar gas mains Belowground gas service riser shall be

protected with UPVC pipe bend sleeve
Figure 1 Villa pressure reducing station location

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LUSAIL DEVELOPMENT
Where is possible for ease of access the Pressure Reducing Station (Primary Customer Meter)
box shall be installed in recess and lockable.
All Pressure Reducing Station (Primary Customer Meter) located at point A, B or C shall be
easily access.
Pressure shall be keep at 21 mbar or 75mbar depending on the length of pipe.
If 75 mbar pressures is use, secondary pressure regulator with over pressure and under
pressure shut-off valve (OPSO & UPSO) shall be installed prior to entering the Villas or Multi
Storey Buildings.
Only 1 mbar pressure drop is allowed on pipeline between the gas meter (21mbar) and the
apparatus.
Pipes installed crossing the wall shall be in sleeve and grouted with fire resistance sealant.
All service riser shall protected with GRP pipes and UPVC
Pipes crossing wall shall be in sleeve

and grouted with temperature
resistance sealant (mastic).
4 bar gas mains Gas service shall be installed

21 or 75 mbar pressure at 600 mm minimum depth
Figure 2
All belowground service risers shall be protected with UPVC sleeve bend and aboveground with
GRP pipes sleeve.
All belowground pipes shall be rise aboveground before entering the building.
All PRS pipe material shall be carbon steel or equivalent.
Pipe diameter 50 mm and above shall be installed with welded and flanges connection.

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LUSAIL DEVELOPMENT
All steel pipes installed below ground shall be protected from corrosion with suitable method of
coating or wrapping.
Gas leak detector shall be installed in the Pressure Reducing Station and at the basement level
of the building.
Gas leak detector shall be install at minimum 300mm from the floor and shall have provision to
be installed at high level for future Natural Gas.
Pressure Reducing Station location shall be approved by MARAFEQ.
Refer to drawing number LUS-CPALL-MAQ-DWG-UT-30300 for details of gas service riser and
pressure reducing station (Customer Primary Meter) for Multi Storey Buildings.
pressure reducing station (Customer Primary Meter) for Villas.
9.1 Gas Meter Room
The building owner is responsible for the maintenance and installation of the metering room and
non-meter related equipment (for example the meter room lighting, mechanical ventilation,
alarms, locks, core holes, and cleanliness).
Gas meter room shall no closer than 3m vertically and horizontally from source of ignition or
electrical substation
Building owner/manager is required to provide certificates regarding:

 Fire classification of material used to build metering room
 All internal electrical installations should be Flame-proof enclosure – Ex’d’ or Explosion
proof enclosure - Ex’e’
Installation of double doors is preferred to provide adequate access for crew and equipment.
10 COMPONENT OF PRESSURE REDUCING STATION (CUSTOMER PRIMARY

METER) SET
Below is the list of component shall be available in the pressure reducing station.
 Gas meter (diaphragm, rotary or turbine type , unit reading shall be in cubic meter)
 Pressure regulator with OPSO & UPSO and relief valve
 Gas solenoid valve

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 Pressure gauge with valve

 Filtration unit where applicable
 Inlet ball valve (Emergency Control Valve)
 Outlet ball valve
 Cabinet (Steel or GRP) with lock
 Gas leak detector
Additional items for Multi Storey Buildings Pressure Reducing Station (Customer Primary Meter):-
 Inlet and outlet bypass valve for single stream unit

 Creep pressure relief valve
 Electronic volume corrector where applicable
11 ELECTRICAL APPARATUS
11.1 Electrical apparatus near to a gas meter

A gas meter and its associated fittings shall be fitted more than 1000 mm from an electricity
meter/electrical apparatus or more than 500 mm away from the electricity supply and distribution
cables, if this distance cannot be achieve a non- combustible partition made of an electrically
insulating material shall be placed between them.
11.2 Electrical Bonding
Where electrical cross bonding is applied to the gas installation pipes, a clamp shall be used to
make connection to the outlet side of the meter not further than 600 mm of the pipe run from the
meter.
11.3 Smart Meter Reading
All plot Pressure Reducing & Metering Station (PRMS) shall be provided with smart meter
reading and control capability with minimum requirement to read gas volume, corrected volume,
pressure, temperature, monitoring and controlling of solenoid valve and gas leak detection
system.
All Pressure Reducing & Metering Station (PRMS) shall be equipped with the automatic control
and monitoring PLC-HMI with ESD system, the automatic system shall be equipped with the
feature that capable to communicate and transfer the data on fiber optic communication on

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TCP/IP protocol to Lusail SCADA system which shall be located in Gas farm control room l The
PRMS system shall be able to control and monitor minimum gas volume, corrected volume,
pressure, temperature, solenoid valve and gas leak detection system
12.1 General
The Pressure Reducing Station equipment and pipes spool shall be protected from corrosion
and to be provided with piping color to easy identification of the pipelines and their content.
Pipeline colour coding shall follow to international acceptable standard.
The material surface to be painted shall be cleaned from any welding slag, dust, grease or
debris.
Various methods of surface preparation can be adopted e.g. degreasing, high pressure
Paint shall be in 3 layer coating system as given below:-
Procedure for painting shall be submitted to Marafeq for approval.
Color coding for SNG, LPG and NG steel piping:-
- Final coat for gas piping shall be Golden Yellow colour RAL 1007
Material surface to be painted shall be dry
Paint shall be fully cured before another layer to be applied.
Paint application shall follow manufacturer specification or procedure

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LUSAIL DEVELOPMENT
12.3 Painting Standard and Codes of Practices
ASTM 8117 Salt Spray (Fog) Testing
ASTM D4060 Abrasion Resistance of Organic Coatings by the Taber Abraser
ASTM D4541 Pull-Off Strength of Coatings Using Portable Adhesion Testers
ASTM D5162 Discontinuity (Holiday) Testing of Nonconductive Protective Coating on

Metallic Substrates
RAL840 HR Standard Colors
ISO 2409 Paints and Varnishes - Cross-cut test for adhesion
ISO 2808 Paints and Varnishes - Determination of film thickness
IS04624 Paints and Varnishes - Pull-off test for adhesion
ISO 4628 Paints and Varnishes - Evaluation of degradation of paint coatings
ISO 8501 Preparation of steel substrates before application of paints and related
products - Visual assessment of surface cleanliness.
products-Tests for the assessment of surface cleanliness-
products - Surface roughness characteristics of blast cleaned steel
blast-cleaned steel.
SSPC-SP1 Solvent Cleaning
SSPC-SP10/NACE2 Near-White Blast Cleaning
SSPC-PA1 Shop, Field & Maintenance Painting
SSPC-PA2 Measurement of Dry Coating Thickness with Magnetic Gauges
13 FABRICATION/INSTALLATION
Contractor shall be responsible for all fabrication and installation work for gas facilities located

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LUSAIL DEVELOPMENT
downstream of service line except for gas meter and its accessories.
The necessary approvals and permissions from the relevant authorities having jurisdiction shall
be obtained by the contractor prior to fabrication and installation work.
Material and design drawings submittal shall be prepared by customer or contractor for
submission to Marafeq for No Objection to Installs.
During the fabrication and installation of Pressure Reducing Station, Contractor is requested to
follow the contents of design documents/drawings reviewed by Marafeq.
Furthermore Marafeq will perform necessary inspection and witness in order to make sure that
the quality of Pressure Reducing Station is satisfactory in accordance with Marafeq’s minimum
requirements stated in the technical guidelines.
14 TESTING AND COMISSIONING OF PRESSURE REDUCING STATION
14.1 General
All Pressure Reducing Station pipe work shall be tested according to Marafeq’s Design
Guidelines for Mega Development and Sub Development Section 19 Testing and
Commissioning of Piping on document no: LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
As an additional requirement for steel pipe, testing may be one or all of the below given method.
1. Pneumatic or hydrostatic Test
2. Nondestructive test
 X ray
 Magnetic Particles Test
 Dye Penetrant Test
 Ultra sound test
Any installation shall be subject to strength test and tightness tests. Testing shall be carried out
prior to application of paint or other protective coatings and before the installation is put into
service.

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LUSAIL DEVELOPMENT
Meters, regulators and associate equipment shall not be subjected to on site pneumatic or
hydrostatic test. It shall be tested by manufacturer in factory.
14.2 Acceptance Test
Acceptance Testing for Pressure Reducing Station is an additional requirement prior to put the
system in service.
Acceptance Test is a test conducted on each Pressure Reducing Station to determine if the
requirements of a design specification are met for operational. It involves specification checks,
physical tests and performance tests.
Testing generally involves running a suite of tests on the completed system. Each individual test,
known as a case and steps, exercises a particular operating condition of the installation
environment or feature of the system, and will result in a pass or fail outcome.
There will be two type of acceptance test.
1. Factory Acceptance Test (FAT)
2. Site Acceptance Test (SAT)
There is generally no degree of success or failure. The test environment shall be designed to be
identical, or as close as possible, to the anticipated installation environment, including extremes
of such.
These test procedure must each be accompanied by test a formal description of the operational
activities to be performed — intended to thoroughly exercise the specific procedure and a formal
description of the expected results.
Factory Acceptance Test is purposely to identify any equipment operational and condition prior
to send to site
Site Acceptance Test prior to making any gas commissioning, the primary meter installation shall
be tested for tightness/leak test and purged in accordance to the acceptable standard.
All medium of test shall be inert gas or air
14.3 Non-Destructive Test (NDT)

All Pressure Reducing Station pipe work and steel piping shall be tested according to Marafeq’s

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LUSAIL DEVELOPMENT
Design Guidelines for Mega Development and Sub Development Section 22 on document no:
LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
The evaluation report made by NDT Company (approved by Marafeq or Authority) shall be
submitted to Marafeq for review.
Pressure test shall not be performed until NDT Company and Marafeq or Third Party Inspection
Company confirms that all films and testing results are satisfactory.
Marafeq will reserve the right to not to connect Pressure Reducing Station service to service line
if the result is not satisfactory. Upstream high inlet pressure portion of Pressure Reducing
Station welded joint shall be tested using nondestructive and pneumatic method.
Pressure and leak test shall be according to Marafeq’s Design Guidelines for Mega
Development and Sub Development Section 19 Testing and Commissioning of Piping on
document no: LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
Marafeq will reserve the right not to connect Pressure Reducing Station to service if the testing
result is not satisfactory.
After the completion of Pressure Reducing Station pipe spools fabrication and station assembly,
they shall be subjected to pressure test (hydrostatic or pneumatic).
The Pressure Test will be witnessed by representative from Marafeq together with customer or
Marafeq representative. The Contractor is required to liaise with Authority on the arrangement
and should advise the parties involve accordingly.
In accordance with the requirement of IGE or BS standard requirement, customer/contractor is

requested to conduct pressure test not less than 1.5 times maximum operating pressure for not
less than two hours.
14.6 Pressure Reducing Station Foundation and box/cabinet Preparation

Customer/contractor is requested to prepare and install station foundation and box cabinet

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LUSAIL DEVELOPMENT
complies according to the standard listed in this document. The cabinet must have suitable
earthing connection.
 Size- The cabinet must be sized for all required equipment to be easily accessible
 Ventilation-It must have at least 10% ventilation
 Material- As per WOQOD requirements
 Door-PRS Cabinet of width 60 cm or less shall be provided with single hinged door fitted
with locking system whereas if the cabinet is wider than 60 cm shall be provided with
double egress door and appropriate gas safety sign must be imprinted.
 Cabinet Base- The base must be concrete and be a minimum of 100mm larger on each
dimension than the cabinet base and be at least 150 mm thick.
 MARAFEQ will visit the station site to check and make sure of the foundation/meter box
or cabinet conditions, after they have been completed
14.7 Commissioning and Start-up
Prior to commissioning of the Pressure Reducing Station, Contractor is required to perform Site
Acceptance Test (SAT) with the presence of Marafeq personnel. SAT is performed to confirm
that the Pressure Reducing Station meets Marafeq specifications and fully satisfied for
operation.
Marafeq personnel shall attend the SAT to check on the following items:
 Leakage from Piping
 Setting Pressure of Regulator, Slam Shut Valve and Relief Valve
 Regulators and Relief Valve Internal Leak Test
 Performance of Pressure Reducing Station
 Condition of Pressure Reducing Station Foundation/Box or Cabinet and Surroundings
 Other necessary items
Contractor shall inform MARAFEQ schedule of the SAT at least one week in advance and
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LUSAIL DEVELOPMENT
‘Commissioning Meeting’ shall be held before performing SAT to discuss the detail procedure to
commission the Pressure Reducing station and Regulator setting procedure.
When the SAT is successful and the result are satisfactory and all necessary approvals* from
the relevant authorities having jurisdiction are obtained, MARAFEQ will give the permission for
Gas-In to Customer.
Notes*
MARAFEQ will commission the gas facilities with Synthetic Natural Gas only after
customer/contractor obtaining No Objection Certificate (NOC) from Authority on internal piping
installation.
APPENDIX 1
Drawing
1. Pressure Reducing Station Installation Details for Multi Storey Buildings
LUS-CPALL-MAQ-DWG-UT-30300
2. Pressure Reducing Station Installation Details for Villas


18 | P a g e
1. ALL UNITS ARE IN MILLIMETER UNLESS OTHER
INDICATED.
2. THIS DRAWING SHALL BE READ IN CONJUNCTION
WITH MARAFEQ GAS GUIDELINES.
3. THE PRS CABINET MUST BE PROVIDED WITH 10%
VENTILATION OPENING.
4. TWIN STREAM PRS INSTALLATION SHALL BE USED
FOR SPECIAL APPLICATION SUCH AS HOTELS,
MALLS, AND HOSPITALS.
LEGEND SYMBOL DESCRIPTION
SCHEMATIC DIAGRAM FRONT VIEW SCHEMATIC DIAGRAM FRONT VIEW
SINGLE STREAM PRS INSTALLATION DETAIL TWIN STREAM PRS INSTALLATION DETAIL
FRONT VIEW SIDE VIEW ISOMETRIC VIEW

PRESSURE REDUCING STATION
INSTALLATION DETAILS
FOR MULTI-STOREY BUILDINGS
N.BATARAO 09.01.2012
J.KENYON 09.01.2012
A.ABUSHAIKHA 09.01.2012
PRESSURE REDUCING STATION INSTALLATION DETAIL (EXTERNAL VIEW) GAS SERVICE RISER LUS-CPALL-MAQ-DWG-UT-30300
NTS
Z:\Projects\Lusail Development\Project Guidelines & Technical Requirements\Gas\Superseded\Pressure Reduction Station (PRS)\PRS Drawing\LUS-CPALL-MAQ-DWG-UT-30300.dwg, Layout1, 4/29/2012 12:48:05 PM
INDICATED.
LEGEND
SYMBOL DESCRIPTION
SCHEMATIC DIAGRAM FRONT VIEW
PRS INSTALLATION DETAIL OPTION 1

FOR VILLAS
SCHEMATIC DIAGRAM FRONT VIEW P.K.S 22.05.2012
M.K.Y 22.05.2012
PRS INSTALLATION DETAIL OPTION 2 PRS INSTALLATION DETAIL (EXTERNAL VIEW) LUS-CPALL-MAQ-DWG-UT-30301
REV
1
NTS
LUSAIL DEVELOPMENT
Gas Distribution System Design

Guidelines for Pressure Reducing Station
(Primary Customer Meter)
REASON
REV DOCUMENT APPROVED
FOR DATE STATUS PREPARED BY CHECKED BY
NO. HISTORY BY
ISSUE
James Abdullah
0 IFR 22-12-2011 PFC D. Reed Phillips
Kenyon Abushaikha
WOQOD’s
James Abdullah
1 IFA 09-01-2012 comments A D. Reed Phillips
incorporated Kenyon Abushaikha
PRS detail for villas Abdullah
2 IFI 12-04-2012 included A Muhamad Kamal D. Reed Phillips
Abushaikha
Lusail comments Abdullah
3 IFI 10-05-2012 incorporated A Muhamad Kamal D. Reed Phillips
Abushaikha
Additional
Abdullah
4 IFI 12-11-2014 requirement on gas A Muhamad Kamal D. Reed Phillips
meter Abushaikha

IFR Issued for Review/Comment(s) PFC Preliminary for Comment A Approved
IFA Issued for Approval
LUSAIL DEVELOPMENT
CONTENTS
1 INTRODUCTION 4
2 SCOPE 4
3 OBJECTIVE 4
4 GENERAL 4
5 DESIGN STANDARDS 5
7 DESIGN CRITERIA 7
9 LOCATION OF PRESSURE REDUCING STATION (CUSTOMER

9.1 Gas Meter Room 10
10 COMPONENT OF PRESSURE REDUCING STATION (CUSTOMER

11 ELECTRICAL APPARATUS 11
11.1 Electrical apparatus near to a gas meter 11
11.2 Electrical Bonding 11
11.3 Smart Meter Reading 11
12 PAINTING AND COLOR CODES 12

12.1 General 12
12.2 Technical Details 12
12.3 Painting Standard and Codes of Practices 13

2|Page
LUSAIL DEVELOPMENT
13 FABRICATION/INSTALLATION 13
14 TESTING AND COMISSIONING OF PRESSURE REDUCING STATION14

14.1 General 14
14.2 Acceptance Test 15
14.3 Non-Destructive Test (NDT) 15
14.6 Pressure Reducing Station Foundation and box/cabinet Preparation 16
14.7 Commissioning and Start-up 17
APPENDIX 1 18

3|Page
LUSAIL DEVELOPMENT
1 INTRODUCTION
The purpose of this document is to describe the works related to the supply and installation of
the gas service riser and pressure reducing station and metering (customer primary meter) for
Villas and Multi Storey Buildings in gas distribution network at Lusail City project development.
2 SCOPE
The design guidelines are the basis of Marafeq’s synthetic natural gas distribution and
associated utilization systems within its gas supply areas. The scope of these guidelines is
covering the work from gas service riser to the primary meter set for Villas and Multi Storey
Buildings.
Gas utilization systems:

 Gas service riser.
 Pressure Reducing Station (Customer Primary Meter) installations for Villas and
Multi Storey Buildings.
3 OBJECTIVE
The design guidelines form a part of technical documents and provide a platform for:
 Work procedures
The objective of the design guidelines is to define the basis for the design of synthetic natural
gas distribution and utilization systems.
4 GENERAL
Gas supplied to domestic or commercial customers shall be metered to enable the
Gas Utility Company to charge for energy consumed.

4|Page
LUSAIL DEVELOPMENT
The Pressure Reducing Station (Customer Primary Meter) installation is to be provided by the
gas plot developer and is used for billing purposes. All gas meter installed shall be calibrated to
International Organization of Legal Metrology (OIML) standard.
A Pressure Reducing Station (Customer Primary Meter) installation typically comprises of inlet
isolation valve which may be the ECV, a pressure regulator to control the delivery pressure and
a meter fitted with an outlet valve.
Customers requiring the measurement of gas usage for each of their consumers may install
Consumer (Secondary) Meter Installations at their discretion.
All installed gas meter shall be calibrated by approved third party.
5 DESIGN STANDARDS
Pressure Reducing Station (Customer Primary Meter) shall be designed and installed with
minimum requirement complying to the below listed reference standards and codes of practice.
 IGE/GM/6 – Diaphragm and RD Meter Installations, > 6m3/hr, MOP ≤ 75 mbar
 IGE/GM/8, Part 1 – Meter Installations I & C – Design, MOP ≤ 38 bar
 IGE/GM/8, Part 2 – Meter Installations I & C – Location & Housing, MOP ≤ 38 bar
 IGE/GM/5 – Electronic Gas Meter Volume Conversion Systems
 IGE/SR/25 – Hazardous Area Classification of Natural Gas Installations
 IGE/TD/13:2001 - Pressure regulating installations for transmission and distribution
systems
 BS EN 1359:1999 - Gas meters. Diaphragm gas meters
 BS EN 12480:2002 - Gas meters. Rotary Positive Displacement (RPD) gas meters
 BS EN 12261:2002 - Gas meters. Turbine gas meters
 BS EN 12405-1:2005 - Gas meters. Conversion devices. Volume conversion.
 BS 6400 – Specification for the Installation of domestic-sized gas meters maximum
rated capacity not exceeding 6 m3/h (2nd and 3rd family gases)
Part 1 Natural Gas (low pressure)
Part 2 Natural Gas (medium pressure)

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LUSAIL DEVELOPMENT
 IGE/UP/15- Gas In Flats: Gas Installations In Multi-Occupancy Buildings
 IGE/UP/2 - Gas installation pipe work, boosters and compressors on industrial
and commercial premises
 IGE/G/5 - Gas in flats and other multi-dwelling buildings
 IGE/TD/4 - Gas Services
 IGE/TD/3 Edition 4; 2005 Steel and PE pipelines for gas distribution
 BS 6891 - Specification for installation of low pressure gas pipework of up to 28 mm
(R1) in domestic premises (2nd family gas)
 NFPA 54 – National Fuel Gas Code Handbook
 NFPA 58 – Liquefied Petroleum Gas Code
Local Authority Regulations:
6 DESIGN PRINCIPLES
Below is the design principles adopted by Marafeq to ensure safe delivery of gas to the end
users.
 All customers shall be provided with a Pressure Reducing Station (Customer

Primary Meter) Installation.
 Installations shall be designed to ensure gas consumption is measured accurately

and that metering and delivery pressure is constant.
 Where a primary meter is upstream of the regulator (high pressure line) a volume
converter shall be installed.
 For installations providing non-standard customer delivery pressures (e.g. large

commercial) a volume converter shall be installed.
 Filtration should also be installed where required.

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LUSAIL DEVELOPMENT
 Installations shall incorporate a regulator with a relief piped to the outside as well as
overpressure shut-off capabilities (OPSO) and under pressure shut off (UPSO)
capabilities. The regulator shall have an integral filter.
 Primary meters shall incorporate provisions for remote meter reading capabilities.
 Large non-standard (e.g. large commercial) installations should be designed

considering the pressure reduction system design basis and minimum functional
specification.
All Pressure Reducing Station (Customer Primary Meter) installation shall be installed in
locations that are;
 Easily accessible for inspection and meter reading;
 Preferably on the outside wall at ground level;
 Protected against physical damage, vandalism and the effects of severe weather
 Well ventilated such that any gas venting or leakage does not result in gas entering
the building
 Positioned to minimize risk from possible interference or 3rd party damage.
Where Consumer Secondary Meter Installations are desired by customers in Multi Storey
Buildings they should preferably be installed in common meter areas with secure access.
7 DESIGN CRITERIA
Pressure Reducing Station (Customer Primary Meter) installations shall be designed for:
 Maximum Inlet Pressure – Upstream network MOP plus 10%
 Minimum design inlet pressure is 1.2 bar for mains networks with MOP 4 bar.
Standard customer delivery pressures provided at the Pressure Reducing Station (Customer
Primary Meter) installation outlet is:
 Inside Villas – max 21 mbar (75 mbar before enter the villa)

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LUSAIL DEVELOPMENT
 Inside Multi Storey Buildings – max 75 mbar.
 Other standard pressures that may be used for external pipework not containing
branches for Multi Storey Buildings i.e. Risers is 350mbar.
External pipe work inside mechanical shaft or outside the building wall containing branch
connections to domestic consumers shall operate at a maximum pressure of 75 mbar.
External pipe work not containing branch connections shall operate at standardized pressures of
75 mbar or 350mbar.
Delivery pressures above 75 mbar at the Pressure Reducing Station (Customer Primary Meter)
outlet require special design consideration and shall be considered on an individual basis,
building designers should consult with the Marafeq prior to designing any customer installation
pipework that operates at pressures in excess of 75 mbar.
8 DESIGN PARAMETER
Refer to Marafeq’s Design Guidelines for Mega Development and Sub Development design
parameter Section 6 on document no: LUS-CPALL-MAQ-SPE-UT-0005
9 LOCATION OF PRESSURE REDUCING STATION (CUSTOMER PRIMARY

METER) SET
Gas service riser shall be piped to the preferred location A, B or C as mentioned in the figure 1.
Aboveground gas service riser shall

be protected with GRP sleeve, riser
height from ground level shall be A B C
1.2 meter
Ground level
Gas service line
4 bar gas mains Belowground gas service riser shall be

protected with UPVC pipe bend sleeve
Figure 1 Villa pressure reducing station location

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LUSAIL DEVELOPMENT
Where is possible for ease of access the Pressure Reducing Station (Primary Customer Meter)
box shall be installed in recess and lockable.
All Pressure Reducing Station (Primary Customer Meter) located at point A, B or C shall be
easily access.
Pressure shall be keep at 21 mbar or 75mbar depending on the length of pipe.
If 75 mbar pressures is use, secondary pressure regulator with over pressure and under
pressure shut-off valve (OPSO & UPSO) shall be installed prior to entering the Villas or Multi
Storey Buildings.
Only 1 mbar pressure drop is allowed on pipeline between the gas meter (21mbar) and the
apparatus.
Pipes installed crossing the wall shall be in sleeve and grouted with fire resistance sealant.
All service riser shall protected with GRP pipes and UPVC
Pipes crossing wall shall be in sleeve

and grouted with temperature
resistance sealant (mastic).
4 bar gas mains Gas service shall be installed

21 or 75 mbar pressure at 600 mm minimum depth
Figure 2
All belowground service risers shall be protected with UPVC sleeve bend and aboveground with
GRP pipes sleeve.
All belowground pipes shall be rise aboveground before entering the building.
All PRS pipe material shall be carbon steel or equivalent.
Pipe diameter 50 mm and above shall be installed with welded and flanges connection.

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All steel pipes installed below ground shall be protected from corrosion with suitable method of
coating or wrapping.
Gas leak detector shall be installed in the Pressure Reducing Station and at the basement level
of the building.
Gas leak detector shall be install at minimum 300mm from the floor and shall have provision to
be installed at high level for future Natural Gas.
Pressure Reducing Station location shall be approved by MARAFEQ.
pressure reducing station (Customer Primary Meter) for Multi Storey Buildings.
pressure reducing station (Customer Primary Meter) for Villas.
9.1 Gas Meter Room
The building owner is responsible for the maintenance and installation of the metering room and
non-meter related equipment (for example the meter room lighting, mechanical ventilation,
alarms, locks, core holes, and cleanliness).
Gas meter room shall no closer than 3m vertically and horizontally from source of ignition or
electrical substation
Building owner/manager is required to provide certificates regarding:

 Fire classification of material used to build metering room
 All internal electrical installations should be Flame-proof enclosure – Ex’d’ or Explosion
proof enclosure - Ex’e’
Installation of double doors is preferred to provide adequate access for crew and equipment.
10 COMPONENT OF PRESSURE REDUCING STATION (CUSTOMER PRIMARY

METER) SET
Below is the list of component shall be available in the pressure reducing station.
 Gas meter (diaphragm, rotary or turbine type , unit reading shall be in cubic meter)
 Pressure regulator with OPSO & UPSO and relief valve
 Gas solenoid valve

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 Pressure gauge with valve

 Filtration unit where applicable
 Inlet ball valve (Emergency Control Valve)
 Outlet ball valve
 Cabinet (Steel or GRP) with lock
 Gas leak detector
Additional items for Multi Storey Buildings Pressure Reducing Station (Customer Primary Meter):-
 Inlet and outlet bypass valve for single stream unit

 Creep pressure relief valve
 Electronic volume corrector where applicable
11 ELECTRICAL APPARATUS
11.1 Electrical apparatus near to a gas meter

A gas meter and its associated fittings shall be fitted more than 1000 mm from an electricity
meter/electrical apparatus or more than 500 mm away from the electricity supply and distribution
cables, if this distance cannot be achieve a non- combustible partition made of an electrically
insulating material shall be placed between them.
11.2 Electrical Bonding
Where electrical cross bonding is applied to the gas installation pipes, a clamp shall be used to
make connection to the outlet side of the meter not further than 600 mm of the pipe run from the
meter.
11.3 Smart Meter Reading
All plot Pressure Reducing & Metering Station (PRMS) shall be provided with smart meter
reading and control capability with minimum requirement to read gas volume, corrected volume,
pressure, temperature, monitoring and controlling of solenoid valve and gas leak detection
system.
All Pressure Reducing & Metering Station (PRMS) shall be equipped with the automatic control
and monitoring PLC-HMI with ESD system, the automatic system shall be equipped with the
feature that capable to communicate and transfer the data on fiber optic communication on

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LUSAIL DEVELOPMENT
TCP/IP protocol to Lusail SCADA system which shall be located in Gas farm control room l The
PRMS system shall be able to control and monitor minimum gas volume, corrected volume,
pressure, temperature, solenoid valve and gas leak detection system
12.1 General
The Pressure Reducing Station equipment and pipes spool shall be protected from corrosion
and to be provided with piping color to easy identification of the pipelines and their content.
Pipeline colour coding shall follow to international acceptable standard.
The material surface to be painted shall be cleaned from any welding slag, dust, grease or
debris.
Various methods of surface preparation can be adopted e.g. degreasing, high pressure
Paint shall be in 3 layer coating system as given below:-
Procedure for painting shall be submitted to Marafeq for approval.
Color coding for SNG, LPG and NG steel piping:-
- Final coat for gas piping shall be Golden Yellow colour RAL 1007
Material surface to be painted shall be dry
Paint shall be fully cured before another layer to be applied.
Paint application shall follow manufacturer specification or procedure

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12.3 Painting Standard and Codes of Practices
ASTM 8117 Salt Spray (Fog) Testing
ASTM D4060 Abrasion Resistance of Organic Coatings by the Taber Abraser
ASTM D4541 Pull-Off Strength of Coatings Using Portable Adhesion Testers
ASTM D5162 Discontinuity (Holiday) Testing of Nonconductive Protective Coating on

Metallic Substrates
RAL840 HR Standard Colors
ISO 2409 Paints and Varnishes - Cross-cut test for adhesion
ISO 2808 Paints and Varnishes - Determination of film thickness
IS04624 Paints and Varnishes - Pull-off test for adhesion
ISO 4628 Paints and Varnishes - Evaluation of degradation of paint coatings
products - Visual assessment of surface cleanliness.
products-Tests for the assessment of surface cleanliness-
products - Surface roughness characteristics of blast cleaned steel
blast-cleaned steel.
SSPC-SP1 Solvent Cleaning
SSPC-SP10/NACE2 Near-White Blast Cleaning
SSPC-PA1 Shop, Field & Maintenance Painting
SSPC-PA2 Measurement of Dry Coating Thickness with Magnetic Gauges
13 FABRICATION/INSTALLATION
Contractor shall be responsible for all fabrication and installation work for gas facilities located

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LUSAIL DEVELOPMENT
downstream of service line except for gas meter and its accessories.
The necessary approvals and permissions from the relevant authorities having jurisdiction shall
be obtained by the contractor prior to fabrication and installation work.
Material and design drawings submittal shall be prepared by customer or contractor for
submission to Marafeq for No Objection to Installs.
During the fabrication and installation of Pressure Reducing Station, Contractor is requested to
follow the contents of design documents/drawings reviewed by Marafeq.
Furthermore Marafeq will perform necessary inspection and witness in order to make sure that
the quality of Pressure Reducing Station is satisfactory in accordance with Marafeq’s minimum
requirements stated in the technical guidelines.
14 TESTING AND COMISSIONING OF PRESSURE REDUCING STATION
14.1 General
All Pressure Reducing Station pipe work shall be tested according to Marafeq’s Design
Guidelines for Mega Development and Sub Development Section 19 Testing and
Commissioning of Piping on document no: LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
As an additional requirement for steel pipe, testing may be one or all of the below given method.
1. Pneumatic or hydrostatic Test
2. Nondestructive test
 X ray
 Magnetic Particles Test
 Dye Penetrant Test
 Ultra sound test
Any installation shall be subject to strength test and tightness tests. Testing shall be carried out
prior to application of paint or other protective coatings and before the installation is put into
service.

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LUSAIL DEVELOPMENT
Meters, regulators and associate equipment shall not be subjected to on site pneumatic or
hydrostatic test. It shall be tested by manufacturer in factory.
14.2 Acceptance Test
Acceptance Testing for Pressure Reducing Station is an additional requirement prior to put the
system in service.
Acceptance Test is a test conducted on each Pressure Reducing Station to determine if the
requirements of a design specification are met for operational. It involves specification checks,
physical tests and performance tests.
Testing generally involves running a suite of tests on the completed system. Each individual test,
known as a case and steps, exercises a particular operating condition of the installation
environment or feature of the system, and will result in a pass or fail outcome.
There will be two type of acceptance test.
1. Factory Acceptance Test (FAT)
2. Site Acceptance Test (SAT)
There is generally no degree of success or failure. The test environment shall be designed to be
identical, or as close as possible, to the anticipated installation environment, including extremes
of such.
These test procedure must each be accompanied by test a formal description of the operational
activities to be performed — intended to thoroughly exercise the specific procedure and a formal
description of the expected results.
Factory Acceptance Test is purposely to identify any equipment operational and condition prior
to send to site
Site Acceptance Test prior to making any gas commissioning, the primary meter installation shall
be tested for tightness/leak test and purged in accordance to the acceptable standard.
All medium of test shall be inert gas or air
14.3 Non-Destructive Test (NDT)

All Pressure Reducing Station pipe work and steel piping shall be tested according to Marafeq’s

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Design Guidelines for Mega Development and Sub Development Section 22 on document no:
LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
The evaluation report made by NDT Company (approved by Marafeq or Authority) shall be
submitted to Marafeq for review.
Pressure test shall not be performed until NDT Company and Marafeq or Third Party Inspection
Company confirms that all films and testing results are satisfactory.
Marafeq will reserve the right to not to connect Pressure Reducing Station service to service line
if the result is not satisfactory. Upstream high inlet pressure portion of Pressure Reducing
Station welded joint shall be tested using nondestructive and pneumatic method.
Pressure and leak test shall be according to Marafeq’s Design Guidelines for Mega
Development and Sub Development Section 19 Testing and Commissioning of Piping on
document no: LUS-CPALL-MAQ-SPE-UT-0005 Rev01.
After the completion of Pressure Reducing Station pipe spools fabrication and station assembly,
they shall be subjected to pressure test (hydrostatic or pneumatic).
The Pressure Test will be witnessed by representative from Marafeq together with customer or
Marafeq representative. The Contractor is required to liaise with Authority on the arrangement
and should advise the parties involve accordingly.
In accordance with the requirement of IGE or BS standard requirement, customer/contractor is

requested to conduct pressure test not less than 1.5 times maximum operating pressure for not
less than two hours.
14.6 Pressure Reducing Station Foundation and box/cabinet Preparation

Customer/contractor is requested to prepare and install station foundation and box cabinet

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complies according to the standard listed in this document. The cabinet must have suitable
earthing connection.
 Size- The cabinet must be sized for all required equipment to be easily accessible
 Ventilation-It must have at least 10% ventilation
 Material- As per WOQOD requirements
 Door-PRS Cabinet of width 60 cm or less shall be provided with single hinged door fitted
with locking system whereas if the cabinet is wider than 60 cm shall be provided with
double egress door and appropriate gas safety sign must be imprinted.
 Cabinet Base- The base must be concrete and be a minimum of 100mm larger on each
dimension than the cabinet base and be at least 150 mm thick.
 MARAFEQ will visit the station site to check and make sure of the foundation/meter box
or cabinet conditions, after they have been completed
14.7 Commissioning and Start-up
Prior to commissioning of the Pressure Reducing Station, Contractor is required to perform Site
Acceptance Test (SAT) with the presence of Marafeq personnel. SAT is performed to confirm
that the Pressure Reducing Station meets Marafeq specifications and fully satisfied for
operation.
Marafeq personnel shall attend the SAT to check on the following items:
 Leakage from Piping
 Setting Pressure of Regulator, Slam Shut Valve and Relief Valve
 Regulators and Relief Valve Internal Leak Test
 Performance of Pressure Reducing Station
 Condition of Pressure Reducing Station Foundation/Box or Cabinet and Surroundings
 Other necessary items
Contractor shall inform MARAFEQ schedule of the SAT at least one week in advance and
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‘Commissioning Meeting’ shall be held before performing SAT to discuss the detail procedure to
commission the Pressure Reducing station and Regulator setting procedure.
When the SAT is successful and the result are satisfactory and all necessary approvals* from
the relevant authorities having jurisdiction are obtained, MARAFEQ will give the permission for
Gas-In to Customer.
Notes*
MARAFEQ will commission the gas facilities with Synthetic Natural Gas only after
customer/contractor obtaining No Objection Certificate (NOC) from Authority on internal piping
installation.
APPENDIX 1
Drawing
1. Pressure Reducing Station Installation Details for Multi Storey Buildings
2. Pressure Reducing Station Installation Details for Villas


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INDICATED.
4. TWIN STREAM PRS INSTALLATION SHALL BE USED
FOR SPECIAL APPLICATION SUCH AS HOTELS,
MALLS, AND HOSPITALS.
LEGEND SYMBOL DESCRIPTION
SCHEMATIC DIAGRAM FRONT VIEW SCHEMATIC DIAGRAM FRONT VIEW
SINGLE STREAM PRS INSTALLATION DETAIL TWIN STREAM PRS INSTALLATION DETAIL

FOR MULTI-STOREY BUILDINGS
N.BATARAO 09.01.2012
J.KENYON 09.01.2012
PRESSURE REDUCING STATION INSTALLATION DETAIL (EXTERNAL VIEW) GAS SERVICE RISER LUS-CPALL-MAQ-DWG-UT-30300
NTS
Z:\Projects\Lusail Development\Project Guidelines & Technical Requirements\Gas\Superseded\Pressure Reduction Station (PRS)\PRS Drawing\LUS-CPALL-MAQ-DWG-UT-30300.dwg, Layout1, 4/29/2012 12:48:05 PM
INDICATED.
LEGEND
SYMBOL DESCRIPTION
SCHEMATIC DIAGRAM FRONT VIEW
PRS INSTALLATION DETAIL OPTION 1

FOR VILLAS
SCHEMATIC DIAGRAM FRONT VIEW P.K.S 22.05.2012
M.K.Y 22.05.2012
PRS INSTALLATION DETAIL OPTION 2 PRS INSTALLATION DETAIL (EXTERNAL VIEW) LUS-CPALL-MAQ-DWG-UT-30301
REV
1
NTS

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LUSAIL DEVELOPMENT

Gas Distribution System

Document No.: LUS-CPALL-MAQ-SPE-UT-0005

REASON ISSUED PREPARED CHECKED APPROVED

Muhamad Abdullah D. Reed

Muhamad Vinod D. Reed

REASON FOR ISSUE: STATUS

Project Name: Lusail Development Gas Distribution System

2.1 Gas distribution systems 7

2.2 Gas utilization systems: 7

9 CODES, STANDARD AND SPECIFICATIONS 11

9.1 Institution of Gas Engineers & Managers (IGEM): 11

9.2 British Standards Institute: 11

9.3 European Standards Institute: 11

9.4 National Fire Protection Association: 12

9.5 American Society of Mechanical Engineers 12

9.6 Gas Industry Services, UK 12

9.7 Local Authority Regulations: 12

10 DISTRIBUTION MAINS (MOP UP TO 4 BAR) 12

10.1 Design Standards 12

10.2 Design Criteria 12

10.3 Feeder Mains 13

10.4 Sector Mains 13

Project Name: Lusail Development Gas Distribution System

10.5 Mains Valves 13

10.6 Feeder Mains Valves 13

10.7 Sector Mains Valves 13

10.8 Design Parameters 14

11 GAS SERVICES DESIGN BASIS 14

11.1 Design Standards 14

11.2 Design Criteria 14

11.3 Design Parameters 15

12 PRESSURE REDUCING STATION (CUSTOMER PRIMARY METER) 16

14 PRODUCTS (HDPE PIPES, VALVES AND ACCESSORIES) 16

14.2 HDPE Fittings (Black Colour) 16

14.3 HDPE Transition Fittings 16

14.5 PE Ball Valves 16

15 JOINTING OF PIPES, FITTINGS AND VALVES 17

15.2 Electro-fusion Jointing 17

15.3 Butt-Fusion Jointing 19

15.4 PE Welder Qualifications 20

16 STEEL PIPE, FITTINGS AND VALVES 20

16.1 Pipe and Fittings Codes and Standards: 21

16.2 Steel Pipe 22

16.2.1 Technical Details 22

Project Name: Lusail Development Gas Distribution System

16.3 Steel Fittings 23

16.3.1 Technical Details 23

16.3.3 Gasket, Bolt & Nuts 23

16.4 Steel Valves 23

16.4.1 Valve Codes and Standards: 23

16.4.2 Technical Details 24

16.5 Cathodic Protection: 25

16.6 Welding Qualification Record: 25

16.7 Steel Pipeline Welding Inspector Qualifications 25

16.8 Inspection & Testing 26

16.9 Cost for NDT inspections and tests 26

17 MATERIAL HANDLING AND STORAGE 26

19.2 Valve Locations 28

19.4 Valve Installation Details 28