SITI Energy Limited : A brief Introduction

Siti Energy Limited (SEL) is incorporated under Companies Act 1956 to inter-alia, implement the Piped Natural Gas (PNG) and Compressed Natural Gas (CNG) project for various application in the Domestic, Commercial, Industrial & Automotive sectors in Indian cities. SEL is working with clear objective to generate, accumulate, transmit, distribute, purchase, sell and supply any sources of energy whether from conventional sources such as Natural Gas, Oil, Diesel, Thermal, Hydro, Nuclear or from non conventional sources such as Tide, Wind, Solar and Geothermal including operation & maintenance and supply of energy source to be used for any purpose on a commercial basis to any customers or bulk distributors and to construct, lay down, establish gas transportation and distribution network power/energy generating station including building structures, works, machineries, eq uipments, cables and to under take or to carry on business of managing, owning, controlling, erecting, commissioning, operating, running, leasing or transferring to the third person, power/ energy plants and to act as consultant and advisors in relation to the business aforementioned with a clear vision. Petroleum and Natural Gas Regulatory Board (PNGRB) has issued Public Notice informing authorization of Moradabad City Gas Distribution Project by M/s SEL. SEL has also received No Objection Certificate (NOC ) from Government of Uttar Pradesh for Moradabad City Gas Distribution Network (CGDN). SEL is promoted by Essel Group which has varied national and global business interests in media and newspaper publishing, content broadcasting, film exhibition, theme pa rks, infrastructure development, lamitube manufacturing, etc. The group has a turnover of approx. INR 130 billion. Siti Energy Ltd. has the following vision : " To make the Indian cities Pollution free and Environment friendly, facilitate all the Industri es, business to progress to their heights without worrying for Energy ". Moradabad City Gas Distribution Network (CGDN) Project Following Activities / milestones have been achieved

Prima facie Authorization from PNGRB Demand Estimation & Commitment from major consumers Pipeline Route Survey Network Design and Detailed Feasibility Report Gas sourcing and transmission Tie Up Grant of NOCs / Licences by authorities / statutory bodies.

CNG sale since more than two years CGS , Steel Pipeline : Completed

Expansion Plans:

Gas supply to Industrial and Domestic sectors CNG corridors for nearby areas. Siti Gas in other major Indian cities

CNG For Automobile Purpose:

Natural Gas when compressed (CNG) is used in automobiles. Compressed Natural Gas provides easy starting, reliable idling and smooth acceleration. The life of an engine actually increases by using COMMPRESSED NAT URAL GAS. It eliminates frequent vehicle maintenance. Compressed Natural Gas is considered as an alternate fuel for transportation sector. CNG can be used in any vehicle with a regular internal combustion engine. CNG vehicles are much cleaner burning traditionally fueled vehicles due to its chemical composition. While Natural Gas is primarily methane where as petrol and diesel fuels contain numerous other harmful compounds that are released into the environment through vehicle exhaust.

PNG For Residential Purpose: Piped Natural Gas (PNG) is one of the cheapest forms of energy available to the residential consumer. In fact, Piped Natural Gas has historically been much cheaper than electricity as a source of energy. Not only is Piped Natural Gas cheap for residential consumer, it also has a number of varied uses. The best known use is for heating and cooking. The benefits of PNG at home are simply fascinating. PNG does not require storage space like ordinary LPG cylinders. Its supplied through safe pipes that are convenient. Whats even better is that you do away with the problem of LPG suppliers from entering your house. Visits of unacknowled ged LPG supplier could be dangerous for families especially for ladies who could be at home.. LPG cylinders are heavy and space occupying and gets irritating to change them every now and then. And the fact which most of us may not know is that we are never able to consume the entire gas from the cylinders as some gas is always left inside when we may presume it to be over. This slowly and indirectly affects our pocket as we pay more for less consumption. With PNG you pay for what you use. With convenient supply through pipelines and a meter which shows you the actual gas consumption, PNG makes your cooking more enjoyably and hassle free all the time. With PNG you bring back the happy moments and healthy appetite for the whole family. Piped Natural Gas is an environmentally friendly fuel, and is a great option for the environmentally conscious homeowner.

Introduction: Natural Gas

Natural gas is a naturally occurring hydrocarbon gas mixture consisting primarily of methane, with up to 20 % of other hydrocarbons as well as impurities in varying amounts such as carbon dioxide. Natural gas is widely used as an important energy source in many applications including heating buildings, generating electricity, providing heat and power to industry, as fuel for vehicles and as a chemical feedstock in the manufacture of products such as plastics and other commercially important organic chemicals. Natural gas is found in deep underground natural rock formations or associated with other hydrocarbon reservoirs, in coal beds, and as methane catharses. Petroleum is also another resource found near and with natural gas. Most natural gas was created over time by two mechanisms: biogenic and thermogenic. Biogenic gas is created by methanogenic organisms in marshes, bogs, landfills, and shallow sediments. Deeper in the earth, at greater temperature and pressure, thermogenic gas is created from buried organic material. Before natural gas can be used as a fuel, it must undergo processing to clean the gas and remove impurities including water in order to meet the specifications of marketable natural gas. The by-products of processing include ethane, propane, butanes, pentanes, and higher molecular weight hydrocarbons, hydrogen supplied (which may be converted into pure sulfur),carbon dioxide, water vapor, and sometimes helium and nitrogen. Natural gas is often informally referred to simply as gas, especially when compared to other energy sources such as oil or

coal. Natural Gas extraction by countries in cubic meters per year

Energy Demand & Supply Scenario: India

In the recent years, Indias energy consumption has been increasing at one of the fastest rates in the world due to population growth and economic development. Primary commercial energy demand grew at the rate of six per cent between 1981 and 2001 (Planning Commission 2002). India ranks fifth in the world in terms of primary energy consumption, accounting for about 3.5% of the world commercial energy demand in the year 2003. Despite the overall increase in energy demand, per capita energy consumption in India is still very low compared to other developing countries. India is well-endowed with both exhaustible and renewable energy resources. Coal, oil, and natural gas are the three primary commercial energy sources. Indias energy policy, till the end of the 1980s, was mainly based on availability of indigenous resources. Coal was by far the largest source of energy. However, Indias primary energy mix has been changing over a period of time.

Despite increasing dependency on commercial fuels, a sizeable quantum of energy requirements (40% of total energy requirement), especially in the rural household sector, is met by non-commercial energy sources, which include fuel wood, crop residue, and animal waste, including human and draught animal power. However, other forms of commercial energy of a much higher quality and efficiency are steadily replacing the traditional energy resources being consumed in the rural sector. Resource augmentation and growth in energy supply has not kept pace with increasing demand and, therefore, India continues to face serious energy shortages. This has led to increased reliance on imports to meet the energy demand. Coal India now ranks third amongst the coal producing countries in the world. Being the most abundant fossil fuel in India till date, it continues to be one of the most important sources for meeting the domestic energy needs. It accounts for 55% of the countrys total energy supplies. neighbouring countries. The traditional buyers of Indian coal are Bangladesh, Bhutan, and Nepal.

Oil and natural gas The latest estimates indicate that India has around 0.4% of the worlds proven reserves of crude oil. The production of crude oil in the country has increased from 6.82 MT in 1970/71 to 33.38 MT in 2003/04 (MoPNG 2004b). The production of natural gas increased from 1.4 BCM (billion cubic metres) to 31.96

BCM during the same period. The quantity of crude oil imported increased from 11.66 MT during 1970/71 to 81 MT by 2003/04. Besides, imports of other petroleum products increased from 1 MT to 7.3 MT during the same period. The exports of petroleum products went up from around 0.5 MT during 1970/71 to 14 MT by 2003/04. The refining capacity, as on 1 April 2004, was 125.97 MTPA (million tonnes per annum). The production of petroleum products increased from 5.7 MT during 1970/71 to 110 MT in 2003/04. Indias consumption of natural gas has risen faster than any other fuel in the recent years. Natural gas demand has been growing at the rate of about 6.5% during the last 10 years. Industries such as power generation, fertilizer, and petrochemical production are shifting towards natural gas

Futurescenario Increasing pressure of population and increasing use of energy in different sectors of the economy is an area of concern for India. With a targeted GDP growth rate of 8% during the Tenth Five-year Plan, the energy demand is expected to grow at 5.2%. Driven by the rising population, expanding economy, and a quest for improved quality of life, the total primary energy consumption is expected to about 412 MTOE (million tonnes oil equivalent) and 554 MTOE in the terminal years of the Tenth and Eleventh Plans, respectively (Planning Commission 1999). The International Energy Outlook 2005 (EIA 2005b) projects Indias gas consumption to grow at an average annual rate of 5.1%, thereby reaching 2.8 trillion cubic feet by 2025 with the share of electric power sector being of 71% by that time. Coal consumption is expected to increase to 315 MT over the forecast period. In India, slightly less than 60% of the projected growth in coal consumption is attributed to the increased demand of coal in the electricity sector while the industrial sector accounts for most of the remaining increase

Overview Of Indian Natural Gas Scenario & Role Of GAIL & ONGC
Natural gas has emerged as the most preferred fuel due to its inherent environmentally benign nature, greater efficiency and cost effectiveness. The demand of natural gas has sharply increased in the last two decades at the global level. In India too, the natural gas sector has gained importance, particularly over the last decade, and is being termed as the Fuel of the 21st Century. Production of natural gas, which was almost negligible at the time of independence, is at prese nt at the level of around 87 million standard cubic meters per day (MMSCMD). The main producers of natural gas are Oil & Natural Gas Corporation Ltd. (ONGC), Oil India Limited (OIL) and JVs of Tapti, Panna Mukta and Ravva. Under the Production Sharing Contracts, private parties from some of the fields are also producing gas. Government have also offered blocks under New Exploration Licensing Policy (NELP) to private and public sector companies with the right to market gas at market determined prices. Out of the total production of around 87 MMSCMD, after internal consumption, extraction of LPG and unavoidable flaring, around 74 MMSCMD is available for sale to various consumers. Most of the production of gas comes from the Western offshore area. The on-shore fields in Assam, Andhra Pradesh and Gujarat States are other major producers of gas. Smaller quantities of gas are also produced in Tripura, Tamil Nadu and Rajasthan States. OIL is operating in Assam and Rajasthan States, whereas ONGC is operating in the Western offshore fields and in other states. The gas produced by ONGC and a part of gas produced by the JV consortiums is marketed by the GAIL (India) Ltd. The gas produced by OIL is marketed by OIL itself except in Rajasthan where GAIL is marketing its gas. Gas produced by Cairn Energy from Lakshmi fields and Gujarat State Petroleum Corporation Ltd. (GSPCL) from Hazira fields is being sold directly by them at market determined prices. Natural gas has been utilised in Assam and Gujarat since the sixties. The re was a major increase in the production & utilisation of natural gas in the late seventies with the development of the Bombay High fields and again in the late eighties when the South Bassein field in the Western Offshore was brought to production.

UTILISATION OF NATURAL GAS

The gas produced in the western offshore fields is brought to Uran in Maharashtra and partly in Gujarat. The gas brought to Uran is utilised in and around Mumbai. The gas brought to Hazira is sour gas which has to be sweetened by removing the sulphur present in the gas. After sweetening, the gas is partly utilised at Hazira and the rest is fed into the Hazira-Bijaipur-Jagdhishpur(HBJ) pipeline which passes through Gujarat, MadhyaPradesh, Rajasthan, U.P., Delhi and Haryana. The gas pr oduced in Gujarat, Assam, etc; is utilised within the respective states. Natural Gas is currently the source of half of the LPG produced in the country. LPG is now being extracted from gas at Duliajan in Assam, Bijaipur in M.P., Hazira and Vaghodia in Guja rat, Uran in Maharashtra, Pata in UP and Nagapattinam in Tamil Nadu. Two new plants have also been set up at Lakwa in Assam and at Ussar in Maharastra in 1998-99. One more plant is being set up at Gandhar in Gujarat. Natural gas containing C2/C3, which is a feedstock for the Petrochemical industry, is currently being used at Uran for Maharashtra Gas Cracker Complex at Nagothane. GAIL has also set up a 3 lakh TPA of Ethylene gas based petrochemical complex at Auraiya in 1998-99.

Natural Gas Allocation & Supply Scenario

As against the total allocation of around 118 MMSCMD, the gas supplies by GAIL is of the order of 63 MMSCMD spread over about 300 major consumers. Around 32% is supplied to the fertiliser sector, 41% to power, 4% to sponge iron and the balance 23% (including shrinkage) goes to other sectors.

All India Region-Wise & Sector-Wise Gas Supply By GAIL - (2003-04)

(MMSCMD) Region/Sector HVJ & Ex-Hazira Onshore Gujarat Uran K.G. Basin Cauvery Basin Assam Power 12.61 1.66 3.57 4.96 1.07 0.41 0.04 Fertilizer 13.63 1.04 3.53 1.91 1.33 S. Iron 1.24 Others 9.81 2.08 1.41 0.38 0.25 0.29 Total 37.29 4.78 9.85 7.25 1.32 0.74

Tripura Grand Total

1.37 25.65 20.15 2.58

0.01 14.23

1.38 62.61

OIL is also supplying around 3 MMSCMD in Assam against allocations made by the Govt. Around 8.5 MMSCMD of gas is being directly supplied by the JVs/private companies at market prices to various consumers. This gas is outside the purview of the Government allocations.

IMPORT OF NATURAL GAS TO INDIA THROUGH TRANSNATIONAL GAS PIPELINES.

1. Iran-Pakistan-India (IPI) Pipeline Project
In pursuance of Government decision in February 2005, Minister (P&NG) led a delegation to Pakistan during 4-8 June 2005. During the talks, the two Ministers reviewed the Iran -Pakistan-India gas pipeline proposal. They agreed that the project, which envisaged supply of gas to Pakistan and India through a transnational pipeline, would go a long way in meeting the energy security requirements of the two countries, and thus should be seen as a significant project for the benefit of the people of these countries. The Indian and Pakistani delegations agreed to exchange information in regard to the financial structuring, technical, commercial, legal and related issues to realize a safe and secure world class project. To this end, it was agreed that the momentum pertaining to the project should be accelerated by constituting a Joint Working Group at the Secretary level at the earliest, which will meet regularly and report the progress to the Ministers to facilitate definitive decisions by them.

2. Myanmar-Bangladesh-India Gas Pipeline Project.

To pursue the matter at the Government level, for bilateral and trilateral discussions with Myanmar and Bangladesh, the Minister (P&NG) visited Yangon during 11-13th January 2005. A Memorandum of Understanding (MOU) for cooperation in the petroleum sector between the two Governments was signed. The MOU provides for furthering cooperation in the hydrocarbon sector and for establishing a cooperative institutional relationship in the field of petroleum industry on the basis of equality and mutual advantage, taking into account the possibilities for cooperation available in each country. The two Governments will designate a body of experts comprising three re presentatives of each party to

3. Turkmenistan-Afghanistan-Pakistan-India (TAPI) pipeline

Daulatabad area of Turkmenistan has reported to have sufficient gas reserves. The Governments of Turkmenistan-Afghanistan-Pakistan (TAP) proposed the transnational gas pipeline to exploit the available gas reserves in Turkmenistan. They designated ADB as the lead development partner. ADB has carried out the study and approached India for participating in the project.

Composition & Properties of Natural Gas

1. Typical Composition
Methane Ethane Propane C02 Others 88% 5% 1% 5% 1%

2. Properties Of Natural Gas Property Appearance Density & Phase Boiling Point Flash Point Explosive Limit Maximum Flame Temperature Color Odor Calorific Value Specific Gravity Value/significance Clear gas and burns with a blue flame 0.717 kg/m3, gas -161.6 C -1880C 5 to 15% in air 2148 0C Colorless Odorless 8500 kcal/scm 0.65(approx)
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3. Advantages Of Natural Gas Over Conventional fossil fuels: It is not toxic like H2S and NH3. It is not corrosive like acid gases. It does not contaminate ground water. Simplest carbon structure.

Complete and clean burning fuel. Least possible particulate emission. Environment friendly.

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Government Regulations On CGD Market

Technical Standards:
In city gas distribution , some of the widely used standards referred for establishing the gas network and ensuring the safety of customers include: 1. 2. 3. 4. PNGRB Norms ASME B31.8 OISD Standards Gas Cylinder Rules,2004

A. PNGRB:
The Petroleum and Natural Gas Regulatory Board (PNGRB) was constituted under The Petroleum and Natural Gas Regulatory Board Act, 2006 (NO. 19 OF 2006) notified via Gazette Notification dated 31st March, 2006. The Act provide for the establishment of Petroleum and Natural Gas Regulatory Board to protect the interests of consumers and entities engaged in specified activities relating to petroleum, petroleum products and natural gas and to promote competitive markets and for matters connected therewith or incidental thereto. Further as enshrined in the act, the board has also been mandated to regulate the refining, processing, storage, transportation, distribution, marketing and sale of petroleum, petroleum products and natural gas excluding production of crude oil and natural gas so as and to ensure uninterrupted and adequate supply of petroleum, petroleum products and natural gas in all parts of the country.

B. ASME B31.8: ASME B31.8 is the most widely used Code for the design, operation, maintenance, and repair of natural gas distribution and transmission pipelines. It covers the following aspects: - Causes and modes of pipeline failure - Considerations for pipe fabrication and material specifications - Evaluation of pipeline defects - Pipeline repair techniques - How code requirements address these issues - Differences between B31.8 and US DOT gas pipeline regulations C. OISD: The Oil Industry Safety Directorate (OISD) is a regulatory and technical directorate in India. It was established in 1986 by Ministry of Petroleum and Natural Gas. The OISD formulates and implements safety standards for the oil industry.

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The main responsibilities OISD are:

Standardization; Formulation of the disaster management plan; Accident analysis; Evaluation of safety performance.

OISD has framed rules and guidelines for safe distances to be observed for various facilities in an oil installation. All the new liquefied petroleum gas (LPG) bottling plants in India are designed based on the guidelines of OISD. Further, The LPG plants can be started only after the approval of OISD. OISD has also issued guidelines for the safe operations of petrol stations and standards related to petroleum installations.

D. Gas Cylinder Rules,2004:

It is a draft published under explosives ACT 1884 and states following procedures with respect to CNG cylinders: Filling possession & import of cylinders Marking on cylinders Repairing of gas cylinders Testing handling & use General precautions

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The Natural diagram:

Gas

Structure

In

India

can

be

classified

according

to

the

following

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14

Natural Gas Production, Transmission & Distribution

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Major Components Of A CGD Network CNG System:

CNG is an acronym for compressed natural gas. The natural gas has less density as compared to liquid fuels and it is compressed to over 200 Kg/cm2 pressure to make it CNG for the use automobile. Fuel characteristics Characteristics Toxic to skin Toxic to lungs Specific gravity Source CNG No No 0.55 Natural gas Petrol Moderate Moderate 3.4 Petroleum Diesel Moderate Moderate 4 Petroleum

The fundamental purpose of a CNG station is to dispense natural gas to vehicle. Where, practical CNG stations have been located close to the suction side of a compressor. At these stations natural gas is tapped from pipeline and connected to the suction side of a compressor. The natural gas is then compressed and then transferred to the storage cylinders(cascades) and held until a vehicle is connected. When it has not been possible to locate a dispensing station close to a transmission pipeline; motherdaughter station has been used whereupon a mother station compress the gas into cascades which are then transported by a road vehicle to daughter dispensing outlet. In some cases mother station also acts as a dispensing station. MEASURE THE INCOMING GAS AT CITY GAS STATION FILTRATION REDUCE THE PRESSURE OF THE GAS ODORIZATION PIPING

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CNG stations are of four major types depending upon the structure and operations:
1. CNG Mother Stations: Mother Stations are connected to the pipeline and have high compression capacity. These stations supply CNG to both vehicles and daughter stations through mobile cascades . The Mother Station requires heavy investment towards compressor, dispensers, cascades, pipelines etc.

2. CNG Online Station: CNG vehicle storage cylinders need to be fitted at a pressure of 200 bars. Online stations are equipped with a compressor of relatively small capacity ,which compresses low-pressure pipeline gas to the pressure of 250 bars for dispensing CNG to the vehicle cylinder.

3.CNG Daughter Station: The Daughter Stations dispense CNG using mobile cascades. These mobile cascades at daughter stations are replaced when pressure falls and pressure depleted mobile cascade is refilled at Mother Station. The investment is least among all types of CNG stations.

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4.CNG Daughter Booster Station: Installing a booster compressor can eliminate drawbacks of daughter stations. The mobile cascade can be connected to the dispensing system through a booster. Daughter booster is designed to take variable suction pressure and discharge at constant pressure of 200 bars to the vehicle being filled with CNG.

The Various Components of a CNG Station are:

1. METERING SKID
These skids have filters , regulators, PSVs, Gas Metering systems. Filters: for gas filtering up to 100 microns from the main gas pipe line. Regulators: to reduce the pressure of the main gas pipe line pressure to the required inlet pressure. (From 25 bar to 14-15 bar). PSV: Pressure Safety Valve. Gas Meters: Turbine Meters for measuring the gas quantity.

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PROCESS CONDITION
FLUID- Natural gas FLOW- working 1000 SCMH PRESSURESKID INLET 2 TO 4 BARG SKID OUTLET- 1 TO 3 BARG DESIGN -19 BARG TEMPERATURE: WORKING: 0T0 60 0C DESIGN: 65 0C

INLET SIZE- 4 *150 # OUTLET SIZE- 4 *150#

SKID OVERVIEW:
The skid has one end connection &one outlet end connection, with 50 SCMH flow through outlet meter and having design pressure of skid as 19 bar at 650c. The skid is provided with one stream of pressure control valve with built in slam off valve & built in creep relief valve and metering using RPD meter.

SKID PROCESS:
The system is continuous operating type for natural gas regulating &metering skid. The skid can be basically considered to be in 2 sections. PRESSURE REGULATION required pressure at outlet. METERING: Gas flow is measured using RPD meter.

: variable pressure at inlet of the skid will be regulated to

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SKID COMPONENTS: 1. CARTRIDGE FILTER

Remove solid particle Horizontal vessel with borosilicate fiber glass type filter element. Remove particle of size 5 micron Differentiation pressure gauge across inlet and outlet. Manual drain valve (to remove accumulate condensate).

2. PRSSURE CONTROL VALVE WITH INTEGRAL SLAM SHUT OFF VALVE

Regulate outlet pressure irrespective of inlet pressure. If impulse pressure increases above set value, the valve slams shut. The valve will remain closed till manually reset.

WORKING PRINCIPLE:
Controlled pressure is set to pre determined values. Any consumption result in decrease in drop of outlet pressure. This causes reduction in the compensation force below the pilot valve diaphragm. So compensating force open the pilot valve. Pilot valve gives pressure to lower chamber of main valve diaphragm .this lift diaphragm &open the main valve.

3. METERING
We have a turbine meter and a flow computer. The flow computer receives pressure &temperature signals from built in sensors, flow signals from turbine meter. Flow computer is programmed to carry out all the monitoring functions.

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1. ODORIZATION UNIT

Natural gas introduced into any system should have a distinctive odor strong enough to detect its presence in the air not exceeding 20%of the lower limit of flammability. To achieve this, the injection of odorizing agent shall be done to ensure perception of CNG leakage by smell. The odourisation pumping as well as filtration system shall have 100% stand-by capacity as per OSID Standard. Chemicals we are using: ETHYL MERCAPTAN Boiling point: 35 C +/-1. Physical state: liquid. Appearance: Colorless liquid.

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2. COMPRESSORS
Compressors are used for increasing the suction pressure.(17-19 bar to 250 bar).Air Actuated Valves starts the engine of the compressor. Air coming from air compressors at a pressure of 7-8 kg/cm 2 is stored in a vertical vessel which provides storage of compressed air at constant pressure for pneumatic startup of the gas compressor. During pneumatic startup firing takes place and the compressor engine then continues to operate.

COMPRESSORS ARE CLASSIFIED AS:

According To The Number Of Stages. According To The Capacity According To The Design Of The Crank Case According To The Arrangement Of The Cylinders According To Prime Mover Used For Driving The Crank Shaft (I.E. Motor Driven Or Engine Driven) Compressors of the following make are generally used: Chicago Pneumatic DR(Dresser Rand) Safe Delta Sulzer Knox western BPCL

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SCADA Diagram of a 3 Stage Compressor GAS ANALYSIS AND ADDITIONAL OPERATING DATA OF CHICAGO PNEUMATIC COMPRESSOR USED BY SEL Gas composition Nitrogen Carbon Dioxide Hydrogen Sulfide Methane Ethane Propane Iso Butane Normal Pentane Water vapour Molecular Weight 28 44 34 16 30 44 58 72 18 WT% 0.057 3.068 86.1 7.27 2.34 0.52 0.0053 -

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CYLINDER DATA AND PERFORMANCE SERVICE STAGE CYLINDER CYLINDER DIA (in.) STROKE (in.) CYLINDER TYPE MATERIAL STAGE(ONE) INLET PRESSURE INLET TEMP. DISCHARGE PRESSURE DISCHARGE TEMP. BHP SPEED CAPACITY AT INLET CNG 1 CYLINDER 1 4 7 DA C.I 2 CYLINDER 2 3.125 7 SAHE F.S CYLINDER 1 16.31 30 53.2 120 203 685 1200 CYLINDER 2 52.1 55 117 116.11 203 685 1200 3 CYLINDER 3 3.125-2.25 7 SACE F.S CYLINDER 3 115.08 55 255 123.33 203 685 1200

KSCG DEG C KSCG DEG C HP RPM SCMH

C.I Cast iron F.S. Forged Iron KSCG kg/cm2 SACE Single Acting Frame Fluid DA- Double Acting SAHE Single Acting Outer End Make Chicago Pneumatic Model NG 1200M Belt drive V- belt drive

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3. PROIRITY PANEL
Priority panel is to decide the supply of CNG from compressor discharge to either Dispensers/Stationary cascades/Mobile cascades. And as well as priority of first to fill Low bank/ Medium bank/ High bank of the dispenser or stationary cascade.

The 9 bank priority panel has following lines in priority - Car dispenser high - Car dispenser medium - Car dispenser low - Car cascade high - Car cascade medium - Car cascade low - Bus dispenser - Bus dispenser cascade - Mobile cascade(LCV)

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4. CASCADES
CNG Cascades are consisting of series of high-pressure cylinders arrayed in a manner to supply CNG to other vehicles. These cascades are known for their robust build quality. They also have a high working, test and burst pressure parameters than CNG cylinders used in the vehicle. The cascades are filled in three modes viz. low, medium, high. The cascades are filled at a pressure of 250 bars. The gas withdrawn from a cascade in the reverse mode. Cascades are primarily of two types: Stationary cascades: they are commonly installed in utility companies or other locations including automotive working stations, bus depots and garages.

Features: Consists of an assembly of components Used to draw the gas from a distribution pipe Compress gas into the storage system Located outdoors at ground level

Mobile CNG Cascades: these are used for transportation of CNG. It is a structural container with an array of cylinders which can be loaded on a carrier truck and transported from one place to another. It is also called LCV(light commercial vehicle) and is used to transport CNG from Mother station to daughter station.

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Features: Consists of assembly of components Require a booster compressor Designed to draw CNG from a CNG supply source Dispense it into vehicle mounted cylinders

5. DISPENSERS
Dispenser is used to supply the CNG from compressor/ cascade to the vehicles (up to 200 bars).The flexible hoses fitted on the dispenser shall be mechanically and electrically continuous. The design, material and construction of hoses shall be suitable for CNG and shall withstand not less than four times the maximum working pressure of the system. Dispenser consist of three banking system low, medium, high. SS316 tubing is used in dispensers. The main components of dispenser are: Coalescent filter: it removes oil content in the CNG. Particulate filter: this filters out the dust and dirt particles present in the gas. SOVs(solenoid operated valves) Mass flow meter: it comprises of a sensor and a transmitter.

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Isolation valve: it is used to isolate the hose from the dispenser in case of any leakage from the hose or three way valve Safety valve: it is used prevent the excess pressure which can be there under abnormal conditions. The valve is set in a way whenever pressure in dispenser reaches above a particular pressure, it pops up and discharges the excess pressure in the atmosphere. 3-way valve: it is used to dispense the gas into vehicle. Some common dispensers used in CNG station are: Compaq SAFE FTI TGT Nuovo Pignone

The flow of compressed gas into the dispenser is accordingly: The compressed gas from the priority panel goes to the dispenser through three pipes transporting gas at low, medium or high pressures. The compressed gas goes through the gas filters. Gas filters are according to the pipes as low, medium or high. The compressed gas from the low pressure pipe is going to go in low gas filter and accordingly. Then the compressed gas passes through the actuators. There are NRVs (No Return Valve) fitted. After passing through NRV the gas cannot return back into the system. The compressed gas then goes through the main pipe and flows through the mass flow meter where the amount of gas flowing into the dispenser is measured. There is a safety valve besides the mass flow meter to release high pressure gas safely and instantaneously into into the atmosphere with any hazard. Then the compressed gas goes into refueling probe. There is an electrical panel too in the dispenser that sets all the valves and the flow of CNG through the probe is controlled. The electric panel calculates the total price of gas filled in a vehicle. The dispensing unit shall be of a type approved by the chief Controller of Explosives/Statuary Authorities.

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Inside view of the Compac dispenser installed at SITI Energy.

6. VEHICLE REFUELLING PROBE

This is a CNG refueling device fitted at the end of the refueling hose at the dispenser units suitable for insertion into the vehicle refueling valve probe. These are the standards of New Zealand Standard no. NZS425: Part 1:1980.

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8. ELECTRICALS
Electric distribution panel are used for distributing the power supply to all cng station utilities like: All motors, fans All station lightings All dispensers All office buildings

9. GAS GENSETS
Gas generators are those equipments which are used to produce electrical energy by using natural gas. They are generally used when there is a problem of electricity and act as generators as their name suggests. There are two genets used one of which is active and other is standby. The inlet is air/ natural gas in the ratio 3:1 which is mixed in the carbonator. There are 6 cylinders on either side of the genset and in which there is a piston which keeps on compressing the gas and increasing the pressure. Now there are two crank shafts of which one is active and the other is monitor. When both of them rotate against each other, friction is produced and spark eventually is formed. Now there is a filter used in the genset which is used to remove the air that comes along with gas. Water is used as the coolant in this process. The temperature generally in this process is around 40 degree Celsius. There are air coolers that are used to maintain the temperature around 40 degrees Celsius. There is a battery connected which acts as the source for the spark to be produced. Air suction is another component which is used to suck the air and send air to the air purifier. The power produced is around 635 MW. The inlet pressure is 2 bars that comes from the metering skid.

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10.

AIR COMPRESSOR

These air compressors are driven by electric motor to compress the air at 8 bar to be stored in the vessel. This air is used to operate the Actuators to On/Off Valves automatically in Dispensers, Compressors.

CODES STANDARDS AND ACTS

For CNG station installations and operations, maintenance following standards are followed:

NFPA USA API-11P BIS OSID-116,118,164,179 FACTORY RULE PETROLEUM ACT AND RULE GAS CYLINDER RULE-2004 SWPV RULE

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OPERATIONS SAFETY
1. The compressor should be operated in a safe operating condition, and should be regularly
inspected. 2. Log sheets and maintenance records must be kept as required by the equipment supplier. 3. Before starting the compressor unit, be absolutely sure that nobody is carrying out maintenance or repair work on the compressor. 4. The compressor must be operated within the parameters outlined in the technical specification. 5. Ensure that no person is in contact with pipe work or any other part of the compressor unit which heat up during operation. 6. Keep clear of hot exhaust pipe, manifolds etc. 7. Never carry out any repair work when the compressor is operating. 8. For compression of gases special precautions are necessary. All applicable safety regulations concerning the use of compressed gas, especially for flammable gas must be strictly observed. 9. Electrical equipment and its protection must comply with the regulations applicable to the government concerned. 10. Safety valve discharge gases must be piped away from the working area.

Parameters to be considered during/after CNG station design as Per Gas Cylinder Rules, 2004
1. The licensed premises shall be used only for the purpose and facilities it is licensed for. 2. CNG Shall be dispensed only into those cylinders of motor vehicles, which are approved by the Chief Controller and have passed the periodic statutory tests under these rules conducted by a testing station recognised by the Chief Controller. 3. The CNG cascades, dispensers, compressor, piping, and other fittings shall be of a design suitable for CNG in conformity to OISD Standard 179. 4. The cascade should be made in a well-ventilated shed having a light roof or canopy with at least one side open. An area of at least l meter around the cascade shall be provided within the shed and the same shall be demarcated either by raised platform or by curb wall. In case, the cylinder cascade is mounted on LCV (Light Commercial Vehicle), the same shall be made totally immovable by suitable application of brakes and chokes. 5. No cylinder shall be filled with CNG in excess of the design working pressure. 6. Inter-distances between various equipments, storage cascades, dispensers, etc. installed in CNG dispensing station shall observe safety distances as per Table 10 & ll. 7. The dispenser for dispensing CNG shall be of a type approved by the Chief Controller. 8. The vehicle shall have approved type of CNG kit fitted in accordance with guidelines of Ministry of Road Transport and Highways, Govt. of India.

32

9. No motor vehicle shall be fuelled while the engine is running and, where the vehicle is licensed for the conveyance of more than six passengers on hire, while any passenger remains in the vehicle. 10. Warning signs with the words "STOP VEHICLE", "NO SMOKlNG, "NO OPEN FLAME PERMITTED", "FLAMMABLE GAS", shall be displayed at dispensing station and compressor areas prominently. 11. All electrical fittings and equipment such as compressors, motors, switches, starters, etc., installed in the premises used for compressing and filling of CNG shall be of flameproof construction conforming to IS:2l48 or such other specification as approved by the CCOE. 12. No alterations of addition shall be carried Out to the premises without prior approval ofthe licensing authority.

CNG SAVINGS ON AUTORICKSHAW

PETROL CNG

NEW RICKSHAW PRICES COST OF FUEL(Rs/LTR) COST OF FUEL (Rs/Kg) FUEL AVG.(Km/Lit/Kg) COST PER KM(RS/Kg) AVG. RUNNING PER DAY(KMS)

80,000 73.18 35 2.09 150

1,25,000 57.65 45 1.28 150

FUEL COST PER ANNUM SAVING AGAINST PETROL(Rs/YR)

1,14,427 -

70,080 44,347

PAY BACK OF RICKSHAW IN YEARS

2.71

33

CNG SAVING ON CARS

AUTO-LPG COST OF THE KIT COST OF FUEL(Rs/LTR) Cost of fuel(Rs/KG) FUEL AVG FOR MARUTI 800(Km/Kg) 19,500 41.00 18 PETROL 73.18 18.50 CNG 40,000 57.65 20

COST PER Km AVG RUNNING PER DAY(Km)

2.27 40

4.06 40

2.88 40

COST PER ANNUM SAVING AGAINST PETROL(Rs/YEAR)

33,142 26,134

59,276 -

42,048 17,228

SAVING AGAINST LPG(Rs/Yr)

PAY BACK OF KIT INVESTMENT IN YEAR

.74

2.32

34

PNG System:
PNG implies Piped Natural Gas i.e. natural gas which is supplied through pipes to homes and establishments. PNG is continuously supplied through the Hazira-Vijaypur-Jagdishpur (HVJ) pipeline of GAIL. Characteristics and advantages over LPG system Pollution free Uninterrupted supply at all times Less storage area occupied as compared to LPG cylinders Gives a cost benefit of 10% as compared to LPG Environmental friendly and clean source of fuel

Characteristics Composition Relative density Auto ignition temperature

LPG Mixture of propane & butane b/w 1.4-2.1 b/w 410-470 deg C

PNG Primarily methane 0.65 570 deg C

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Calorific Value

10900 kcal/kg

13570 kcal/kg

1 scm of natural gas is equivalent to:

Wood 5-7 kg Coal 3-4 kg Furnace oil 2 kg LPG 0.9 kg Electricity 11.4 kwh

Major components of PNG network

1.
DPRS(Distribution pressure regulating station/district regulating station) Located at various demand centers for domestic/commercial users typically consists of: Gas filter Heater(if required) Pressure reduction skid Inlet and outlet isolation valve Its main function is to reduce the pressure from 19 kg/cm2 to 4kg/cm2. The capacity of the DPRS is determined based on the peak hour load.

2.

IPRS (Individual pressure regulating station) Located at the premises of an individual customer Having facilities similar to DPRS Filtration facilities provided

3.

MRS (Metering and regulating station) Located at the premises of an individual customer. Filtration facilities provided. PIPELINES & FITTINGS: Steel, MDPE, G.I

4.

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G.I pipe

Copper tubing

MDPE pipeline

Carbon steel pipes

Copper fittings

Carbon steel fittings

37

Plastic fittings

Split tee

Important constraints to be considered while lying of PNG network as per standards of PNGRB & ASME B31.8
The area under consideration shall be classified under location class 1, 2, 3 or 4. Consideration shall also be given to following loads while selecting nominal wall thickness t as per ASME B31.8 as appropriate: - Overburden loads - Dynamic and seismic loads - Cyclic and vibratory loads - Internal pressure fluctuations Geo-technical loads Pipeline on bridges should be avoided. Upstream dry gas filter(s) shall be installed when rotary or turbine meters are used. Protection against overpressure of pipeline or mains downstream of city gas station shall be provided by means of: - Active/monitor regulator system - Pressure relief valve(s) - Over pressure shut-off valve(s) Sound pressure levels shall be limited to 100 dba. In order to prevent over pressurization of piping downstream of regulators/control valve, creep valve should be provided.

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When steel pipelines or mains are installed in areas that are normally under water, anti-buoyancy measures adopted shall be such that specific gravity of resulting installation is 1.10 or more. When a buried steel pipeline or main has to cross any existing underground pipeline, cable, drain or other services, the pipeline shall be laid at least 300mm below such services. Clear distance between new steel pipeline and main running parallel to existing pipeline should be minimum 5.0 meters when heavy conventional construction equipment is expected to be utilized. Use of ductile iron piping is not permitted in pipelines and mains used in CGD networks regardless of operating hoop stress. Plastic pipe shall not be used for pipeline and distribution mains operating at pressure in excess of 100 psig. Nominal wall thickness of plastic pipe shall be calculated as per following formula P=2S * (t / (D-t)) * 0.32 Threaded joints in plastic pipe are not permitted. Plastic piping joints shall be made by electro fusion fittings only. Joining of plastic piping by butt fusion method, solvent cement method, heat fusion method is not permitted. Use of thermoplastic piping in above ground piping is not permitted unless the piping is completely protected against deterioration. Thermoplastic piping shall not be tested at material temperature above 120 deg F. Test medium shall be air or nitrogen for test pressure up to 100 psig. For test pressure more than 100 psig, water shall be used as test medium. Test duration shall be minimum 24 hours for plastic distribution mains of length greater than 1 km and minimum 4 hours for length shorter than 1 km. DPRS/IPRS shall normally be equipped minimum two safety devices. In steel distribution mains valve spacing should normally be not more than 3 km. In plastic distribution mains valve spacing should normally note more than 1 km. Customer meter shall preferably be located in a well ventilated area. Service lines shall be sized for a maximum flow velocity of 15m/sec. All plastic pipe and fittings shall be laid underground and shall not be exposed. The buried lines shall be provided with minimum cover of 1.0 m. For transition from plastic pipe to G.I. pipe, transition fittings should be used. Use of ductile iron service lines is not permitted. Piping connecting consumer meter set assembly to consumer gas appliance shall be either G.I or copper upto last valve located near actual appliance. A metal seated leak detection cum excess flow shut off valve shall be provided near the appliance. Appliance shall be connected to gas line with a flexible and braided hose as per IS 9573. In no case the length shall be more than 1.5 meters. Both ends of the clam shall be firmly clamped on the nozzle by metallic clamps.

LAYING OF PIPELINE COMPLIANCE

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Road signs, warning lamps and barrier systems shall be locations which are accessed by pedestrians or vehicles.

provided on highway or other work

Underground utilities shall not be disturbed or altered without the prior consent and approval of the owner or authority concerned. Electricity cables shall be treated as "Live, unless the owner certifies them as "Dead".' The dead cable shall also be checked for any residual voltage. Where open cut techniques are used, a warning tape of Yellow colourshall be laid above the pipe, the difference in elevation of the pipe and warning tape shall be minimum of 200 mm. As built drawing and pipe book shall be maintained. Trench width shall be at least 300 MM. The bed of the trench shall be free of sharp objects, stones etc. The trench should be padded with soft soil / sand to minimum of 100 mm below the pipe.

At identified locations pipelines shall be provided with impact protection from excavating machinery as indicated in the fig 1(a) where h shall not be less than 500 MM. & 1(b) where h shall not be less than 250 mm.

40

500 mm

fig 1(a)

41

25 0 m m

fig

1(b)

Where it is necessary to cross or run close to any other utility, a minimum of 250 mm clearance shall be maintained. In case the clearance is less, appropriate protection measures shall be taken. The relative position of PNG pipeline with respect to other underground utilities shall be as shown alongside: Provision shall be made for locating the buried PE pipe by installation of electrical conductive wire or plastic coated metallic tape or any alternate proven locating method. trace

PIPE LINE MARKER

Route markers shall be placed on the entire pipeline at a distance not exceeding 50 meter and also at bends in the city. Additional sign/ markers shall be installed to indicate the presence of a pipeline at road, highway, railroad, stream crossings and locations where there is a probability of damage or interference. Further, warning signs shall be displayed on the service line to consumer premises.

42

A marker shall be marked in easily readable local language with at least the following: Name of PNG distribution company Contact telephone number(s) in emergency. Location code Warning- High Pressure Gas Line and Other Utilities to take permission from PNG Distribution Company before digging etc.

Working of PNG Network

Supply of natural gas at 40 bar from the main cross country pipeline(carbon steel pipeline network) to CGS. Pressure reduction skid with 50% redundancy reduces the pressure from 40 bar to 17-19 bar and odorizes the gas to facilitate leak detection. Then with the help of skid the pressure is further reduced to 2-4 bar and is provided to large scale industrial consumers. Tappings from this pipeline transfer natural gas to various areas where depending upon the demand, DRS are installed for further reduction in pressure from 19 bar to 4 bar.

43

Piping system downstream of MDPE pipeline whose grade, nominal outside diameter, wall thickness, tensile strength and parameters are calculated from various software available in the market. Downstream of DRS, MRS are provided which further reduce the pressure to 2 bar. At the customer premises, transition joint is provided which allows change of pipelinetype from MDPE to GI due to safety and durability constraints. Service regulator reduce the pressure from 2-4 bar to 100 mbar. GI risers enable the pipeline tobe raised uptil the customer meter which again reduces the pressure from 100 mbar to 21 mbar. Isolation valves are also provided for emergency shut-off of gas supply. And finally the gas is supplied to customer appliance through copper tubings.

Metering & regulatory system

Metering system : Generally rotary or turbine meter are used for metering facilities. Gas flow
is generally measured by RPD meters.

TYPES OF FLOW METERS Meter

Rotary Principle The rotational movement of the crank shaft serves as the primary flow element and may produce electrical pulses for a flow computer A small internal turbine measures the speed of the gas, which is transmitted mechanically to a mechanical or electronic counter Advantages These are highly machined precision instruments capable of handling higher volumes and pressures than diaphragm meters Turbine gas meters infer gas volume by determining the speed of gas moving through the meter Diagram

Turbine

44

Ultrasonic flow

These meters measure the speed of gas by measuring the speed at which sound travels in the gaseous medium within the pipe

Inexpensive varieties of ultrasonic meters are available, which can be used to measure flow in any dia. of pipe without modification

Diaphragm/Bellow

Diaphragm expands These are positive and contracts, liver displacement type converts linear meters. motion of it in rotary motion of crank shaft.

Orifice

A type of differential meter which infer the rate of gas flow by measuring the pressure difference across a deliberately designed and installed flow disturbance

They are well accepted and understood in the industrial applications since they are easy to field-service and have no moving parts.

Regulating System
A pressure regulator is a valve that automatically cuts off the flow of a liquid or gas at a certain pressure. Regulators are used to allow high-pressure fluid supply lines or tanks to be reduced to safe or usable pressures for various applications. A regulator includes a restricting element, a loading element, and a measuring element: The restricting element is a type of valve. It can be a globe valve, butterfly valve, poppet valve or any other type of valve that is capable of operating as a variable restriction to the flow. The loading element applies the needed force to the restricting element. It can be any number of things such as a weight, a spring, a piston actuator, or more commonly the diaphragm actuator in combination with a spring. The measuring element determines when the inlet flow is equal to the outlet flow. The diaphragm is often used as a measuring element because it can also serve as a loading element. In the single-stage regulator shown below, a diaphragm is used with a poppet valve to regulate pressure. As pressure in the upper chamber increases, the diaphragm is pushed upward, causing the poppet to reduce flow, bringing the pressure back down. By adjusting the top screw, the downward pressure on the

45

diaphragm can be increased, requiring more pressure in the upper chamber to maintain equilibrium. In this way, the outlet pressure of the regulator is controlled.

TYPES OF PIPELINE:
STEEL PIPELINE:
a. The steel piping shall be designed for maximum operating pressure of 19.0 bar at temperature ranging between (-) 29 Deg. C to (+) 65 Deg. C. b. For underground steel piping network, suitable corrosion protection like cathodic protection, wrapping/ coating etc shall be applied. c. The above ground mains shall be painted yellow for identification. d. The cast iron pipes shall not be used in the PNG network as a carrier of natural gas.

POLY ETHYLENE (PE) PIPELINE:

The PE piping, tubing, fitting and other components shall conform to requirement of ASME B 31.8 or equivalent as approved by statutory authority. The PE piping shall be designed for maximum operating pressure of 4.0 bar at temperature ranging between (-) 29 Deg. C to (+) 65 Deg. C. PE piping shall not be used in water / rail crossing. There are two types of Poly ethylene Piping:

1. High density poly-ethylene (HDP):

High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a polyethylene thermoplastic made from petroleum. It takes 1.75 kilograms of petroleum (in terms of energy and raw materials) to make one kilogram of HDPE. HDPE is commonly recycled, and has the number "2" as its recycling symbol.

Properties:
The mass density of high-density polyethylene can range from 0.93 to 0.97 g/cm 3. Although the density of HDPE is only marginally higher than that of low-density polyethylene, HDPE has little branching, giving it stronger intermolecular forces and tensile strength than LDPE. The difference in strength exceeds the difference in density, giving HDPE a higher specific strength. It is also harder and more opaque and can withstand somewhat higher temperatures (120 C/ 248 F for short periods, 110 C /230 F continuously). High-density polyethylene, unlike polypropylene, cannot withstand normally requiredautoclaving conditions. The lack of branching is ensured by an appropriate choice of catalyst (e.g., Ziegler-Natta catalysts) and reaction conditions. HDPE contains the chemical elements carbon and hydrogen.

46

Medium density polyethylene (MDPE): Medium-density polyethylene

3

(MDPE) is a type of polyethylene defined by a density range of 0.9260.940 g/cm . It is less dense than HDPE, which is more common. MDPE can be produced by chromium/silica catalysts, Ziegler-Natta catalysts or metallocene catalysts. MDPE is defined by a density range of 0.9260.940 g/cm 3.MDPE has good shock and drop resistance properties. It also is less notch sensitive than HDPE. Stress cracking resistance is better than that of HDPE. MDPE is typically used in gas pipes and fittings, sacks, shrink film, packaging film, carrier bags, and screw closures.

MDP E Density Young modulus/ modulus Tensile strength(t ) Elongation @ break Brittleness, low temperature Vicat Specific heat (c) E modulus/ Tensile 0.926-0.940 g/cm 172379 MPa 12.419.3 MPa 100150% -118 C 99-124 C 1.916 kJ/kg.K
3

T MDPE specificat ions

Advantages of PE over steel:

PE is non-conductor and there is no subject to galvanic corrosion. It is almost completely resistant
to inorganic chemicals and most organic chemicals. It is a thermoplastic material and is easily joined by heating and pressuring together two components to form a joint as the parent components. Because of its flexibility, small diameter pipe can be coiled into long lengths for easy transport and installation. Its flexibility also allows PE in the smaller sizes to squeezed shut in an emergency situation thus reducing the need for the installation or large numbers of expensive and potentially high maintenance system block valves.

47

Disadvantages of PE over steel:

The pipe is softer and more susceptible to damage during transport, installation and future third party activities in the vicinity of the installed pipe. Because of its thermoplastic nature PE is weaker at higher temperatures. At full design pressure it should not operate at temperatures above 40C. lts use is therefore restricted to underground only. Because of its thermoplastic expansion (10 times greater than steel) temperature changes need to be taken into account during construction. It has a tendency to cold flow or creep under load. An internal stiffener is required to prevent cold flow whenever a mechanical joint is employed.

Pipeline System
Pipeline network consists of steel pipeline, polyethylene pipeline, galvanized iron pipeline and finally copper pipeline. A typical CGD network should consist of the following

Primary network: A medium pressure distribution system comprising of pipelines, gas mains or
distribution mains normally constructed using steel pipes and connects one or more trans mission Pipeline to respective CGS or one or more CGS to one or more DRS. The maximum velocity in the pipeline network should be limited to 100 ft / sec (30 m/sec)immediately after pressure regulating instrument.

Secondary Network: A low pressure distribution system comprising of gas mains or distribution Mains
usually constructed using thermoplastic piping (MDPE) and connects DRS to various service regulators at commercial, industrial, and domestic consumers. The network should be sized for maximum flow velocity of 100 it / sec (30 m/sec).

Tertiary Network: A service pressure distribution system comprising of service lines service regulators
and customer /consumer meter set assemblies constructed using a combination of thermoplastic (MDPE) piping and Gl /copper tubing components. Tubing /Hose pipe for connecting consumer meter set assembly and consumer appliance: The connection between consumer meter set assembly and gas appliance may be made by GI pipes or copper tubing or steel reinforced rubber hose. Steel reinforced rubber hose shall conform to IS: 9573

48

LAYING OF PIPELINE NETWORK

Laying of the pipeline starts alter the issue of right of issue and the route of pipelines under the City gas pipeline project. Excavation works are performed so as to enable the pipe to be laid inconformity with the levels depths, slopes, curves, dimensions and instructions shown on drawings, specifications.

The detailed process of laying of the PE is handed over to the contractors. The various steps or the technical requirements for the PE laying are as follows, PE Excavation. PE Trenching. PE laying. Electro fusion jointing. PE Valve chamber. PE testing. Tap off from in operation gas mains. PE route marker.

PE Excavation
Excavation for the PE starts after the issue of right of issue and the route of pipelines under the City gas pipeline project. Excavation works are performed so as to enable the pipe to be laid inconformity with the levels depths, slopes, curves, dimensions and instructions shown on drawings, specifications. lt is done under the direction of the company. Trail holes refers to the small pits which are generally dug before the actual excavation processor determining the pipe route and locate other underground plant or investigate possible obstruction if any e.g. telephone wires, cables, water lines, pipelines belonging to other companies. The trial holes are normally preplanned i.e. the location of between the trial holes is normally at a distance of 25m. They are excavated to a depth of pipe and an addition of 250mm. These holes are not closed immediately. They are protected and fenced. The trial holes are planed in such a way that there are no abandoned trenches and also to avoid insufficient trial holes. The excavated trench is maintained on stacked centre line as per the sheets approved and also taking into account of the curves of the pipelines. Proper care is taken while trenching to ensure all underground structures and utilities are disturbed to the minimum. The crossings wherever necessary is provided and maintained for the general public property owners or tenants to cross and also to move any stock from one side of the trench to another. Trenching is made in sufficient slopes on sides in order to minimize collapsing of the trench. In places, where there is any danger of landslides the pipeline trench is maintained open for time required to lay the line i.e. the work in that area is completed in less time and covered. The soil stability is analyzed in areas like drainage, ditch etc.

49

The bottom of the trench is normally maintained in the square form to the maximum extent with the equipments so as to avoid the hand grading at the bottom of the trench. The bottom of the trench is made free of loose rocks, pebbles and trim protruding routes from the sides of the trench wall. A stretch of 12m is allowed to remain excavated before joining or backfilling. Any kind of rock which cannot be drilled using sledge hammer, chisel is considered as hardrock. Any other Plain cement concrete (PCC) or Reinforced cement concrete (RCC)encountered during excavation are removed in supervision of authorities as the cost of removing those type of obstructions is high.

PE Trenching
Trenching refers to the making of holes i.e. opening the ground wide apart. It is classified into 2 types, Open Cut. Boring.

Red boring
Red boring refers to the boring of ground without opening the ground wide apart using the normal tools i.e. by hand.

Machine Boring
When the boring is not possible b red boring, machine boring is made use of. This happens when hard obstructions are encountered. The design of the depth of the trench varies for different locations as follows, For distribution main l.5m Minor water crossing or canal l.5m Uncased or cased road crossing l.5m Rail or road cased crossing l.5m Normal areas 1.2m The above mentioned depths may vary depending on the locality. In case of any difficulties in maintaining the required depth due to unavoidable factors the new depth shall be decided and put in to effect in the particular area only. The width of the trench is maintained in wide enough to provide bedding around the pipe and to prevent damage to the pipe inside the trench. The distance between the ground and the bottom edge of the pipe is 50 mm for 63mm diameter pipelines and 100 mm for pipes larger than 63 mm which included the 90 and 125 mm pipes.

50

The following clearances are provided between the external wall of the gas pipe and the external surface of the other underground assets in the locality. 150 mm where the gas pipe crosses other assets, other than electric cables where the clearance is 300mm.And 300 where the gas pipe to be laid is on a similar alignment to the other assets.

ln places where this clearance cannot be maintained due to various reasons, suitable barrier protections are installed between the pipe and the service line like the electric cable. Half round hume pipe is constructed along the trench. All the works in the municipal or public roads are required to be executed as per there code sand conduct with a view to cause minimum inconvenience to pedestrian and vehicular traffic. All the trenching works are carried out with proper caution. E.g. before commencing of the excavation the caution board & information board as per the standard size, shape and color are installed at the site. The crown of the backfilled earth is maintained between 50mmand l00mm and is free from sharp edged stones & boulders. The site is maintained neat and clean without causing any nuisance to the public until the completion of the work. In case of rain dewatering is done prior to back filling. This is maintained strictly for the protection of the gas pipeline. While back filling the mud or the soil is cautiously done such that there is no extraneous material or hard lumps of soil near the laid pipeline which could damage the line or the coating or leave void spaces in between the fillings. The surplus material is neatly crowned over the trench and adjacent excavated areas on both sides of the trench. Little extra allowance of mud is put over the trench such that it comes to the normal level during settling. In cases where rock, gravel, lumps of hard soil or materials are encountered at the time of trench excavation, sufficient sand is placed around and over the pipe to form a protective cushion extending at least to a height of 100 mm above the top of the pipe. Thorough and proper compaction is done where in places where the trench is dug like, the drive or road ways. Special compaction methods are adopted. Trench excavated in dikes which belonging to the property of railways or which are the part of the main roads are graded and backfilled in their original profile and condition. The backfill materials if required are supplied. PE warning grid or mat are placed on the distribution main and on service lines inside premises after backfill of the trench up to a height of 300mm after the sand bedding. The warning mat is unrolled centrally over the pipe section and thereafter the backfilling is done. All the excavated material which will be required for backfilling are kept separately and properly. ln areas of roads or pedestrian places the refilling are done immediately to avoid inconvenience to the public. The back filling is assumed to be complete after the joining of pipes are complete. During the backfilling of the trenches in private society remises, municipal remises and panchayat premises, watering and ramming or mechanical compaction are carried out. Excess soil in the area is cleared off the site and is dumped at suitable location. Experienced supervisor is always present at the site to decide on various factors in the required situations. A third party officer is also made to be always available on the site. A prior information of excavation is given to the people in the area where the work is to commence in advance for their prior arrangements.

51

Turf is replaced in highly developed grass area. ln lesser grassed area top soil are replaced during the restoration process. In areas where the restoration works cannot be completed immediately, alternate arrangements are done temporarily for the traffic and the pedestrians.

Boring
In some areas where the normal trenching cannot be carried out, trenchless technology is carried out which is known as the boring. This is mainly done while the crossing of the roads. The boring is carried as per the requirement. The survey of the underground utilities is done before the boring process so that the other pipelines are not damaged. The cost of boring is costly i.e. 5times the normal trenching. Hence, the boring is done in required areas only. In areas like road junction, front of the society main gates, crossings are done in phases during the night times due to the traffic problems. The works are done so as to finish the work in night itself lf in case any area is left uncovered or not completed by night, steel plates are provided are for the movement of traffic in daytime.

PE lying

The laying of the MDPE pipelines commence only after the ensuring of the proper dimensions and clean surface of the trench. The trench bottom is made to be free from the presence of cuts, stones, roots, debris, stakes and rock projections up to 150 mm below the underside of the pipe and any other material which could make perforations or tearing of the pipe wall. After ensuring of all the above factors, the MDPE coil is uncoiled smoothly inside through proper process and care inside the trench ensuring no damage to pipe coil during lying. lt is ensured that the pipe caps are provided before the lowering of the pipeline. The trench after this is released for backfilling leaving adequate lengths open to the ends for joining. Before lowering of the pipeline a sand bedding of fine soil is done at the trench bottom. Similarly after lowering of the pipe the trench is filled with sand around and up to 100mm from the top of the pipe. Proper inspections of pipes and fittings are done before the releasing of the latter from the store and the defects are reported to store authorities. Proper care is taken for PE pipe and fittings after issued film the store till the transporting storing sheltering the pipe near the trench, uncoiling of` the pipe by proper process and sufficient man power, lowering of pipe in the trench or pulling of the pipe through the trench such that no extremely damage is caused to the pipe.

Electro fusion jointing

Jointing of the pipes is normally carried out by the electro fission process based on the requirements. Proper care is taken during the EF jointing such that there is no failure of the joint.

Electro fusion

52

Electro fusion is a simple method of joining PE pipes in circumstances where butt fusion is not practicable, such as where valves, elbows, and tees must be added. Prefabricated fittings aroused, incorporating an electrical heating coil which melts the plastic of both the fitting and the pipe, causing them to fuse together. The characteristics of the fitting to be welded, such as the fusion time, are registered via a barcode on the fitting. On swiping the sensor over the bar code the required setting time and temperature are set and on click of start the process starts. An electro fusion control unit (ECU) supplies the electrical energy necessary to heat the coil. When the coil is energized, the material adjacent to it melts and forms an expanding pool which comes into contact with the surface of the pipe. The continued introduction of heat energy causes the pipe surface to melt and a mixing of pipe melt and fitting melt takes place, this is vital to produce a good weld. Following the termination of the heat cycle, the fitting and the pipe are left to cool and the melted material solidifies to form a sound joint. Hot and cold zones, sometimes called melt and freeze zones, are formed after energizing the coil. The length of these zones is particularly important. Each zone ensures that fusion is controlled to a precise length of the socket of the fitting and that the melt pressure is also controlled throughout the entire jointing process. The precisely controlled pitch and positioning of the coil in relation to the inner surface of the socket ensures uniform heat distribution. The basic fusion parameters: temperature, pressure and time, are controlled by the ECU which is programmed to establish these parameters from the barcode read from the fitting itself The ECU also provides a permanent record of the procedure followed. Compact ECUs are now available that allow in-trench electro fusion welding to be carried out safely by just one man. The effectiveness of electro fusion depends on attention to preparation of the jointing surfaces and ensuring that the surfaces to be welded have satisfactory contact during the welding and cooling cycles. The pipe surfaces to be fused need to be scraped to remove the surface oxidation layer prior to fusion. Pipe clamps or other approved methods of restraining, aligning and re-rounding the pipes during the fusion cycle should be used. To prepare the jointing surfaces the pipe surface must be scraped with an appropriate pipe scraper, as recommended by the pipe or fitting manufacturer, to remove the entire surface of the pipe over the area indicated, to a depth approximately 0.3mm. Metal files, rasps, emery paper etc are not suitable end preparation tools. Following scraping the scraped surface must be wiped with an authorized lsopropanol impregnated pipe wipe, as recommended by the pipe or fitting manufacturer, to remove any dust residue. Methylated spirits, acetone, methyl ethyl ketone (MEK) or other solvents are not recommended for wiping the scraped surface. The prepared surfaces must completely dry before proceeding. The resulting joint, when properly made, is as strong as the original pipe and can withstand all the loads applied during routine installation and operation. All the fittings related to electro fusion are according to the design standards. The pipeline is normally flushed with air to remove dust, water mud etc which would have entered the pipe during the laying process. Before jointing the packing sand is placed under the pipes on both the sides of the joint to keep the pipes in line and correct during the jointing process. The alignment clamps with correct size are used whenever necessary to align the pipe during the electro fusion jointing cycle. lt is a usual practice to make a joint of electro fusion fitting on the same day of laying.

53

The electro fusion joint is inspected before the restoration of the trench so as to ensure the leakage. In case of leakage the joint is redone with a separate coupler to prevent future damages to line. The time of electro fusion for the normal 90mm MDPE is around 42secs and a temperature of48 deg C is to be maintained. This reading is noted from the meter. The various types of the joints which are used in the coupling or jointing of the MDPE pipes are normally 3 types

I. Coupler II. Elbow Ill. Tee

Preparing a MDPE Pipeline for saddle mounting.

54

Electrodes of the electro fusion machine performing their task of fusion at a specified temperature for a fixed time read through a bar code written on the saddle

PE Valve chamber
At certain areas the installation of the PE stop valves and the construction of the valve chamber is required. The valve chamber can be constructed in any type of soil. It includes conveying and spreading the stuff embankment within 200mm from the end of the cutting with all required lead and lift to required gradient and chamber. The cement, bricks, coarse sand are supplied and the fine gravel (machine crushed). The ratio of cement, coarse and aggregate 40mm is 1:4:8. The necessary PCC work in the annular space is carried between PE pipe and brick wall for sealing. The fix heavy duty RCC manhole chamber circular cover with square frame with the desired load capacity and the dimensions mentioned in the designed standard drawing. The remaining PCC work around the precast frame is carried out to fix the precast frame on the chamber to avoid any displacement. The PE stop off valves are installed in pipe system operating at the pressure above l l0mbarg.The distance between each stop off valve is l500m approximately for l25mm dia. pipe and2000m for 90mm dia. pipe. This scope covers the necessary reopening of the charged pipe i.e. providing temporary bypass, squeeze off`& cutting of PE pipe, installation of PE stop off valve, removal of` temporary by pass, construction of` valve chamber as mentioned above. In case of delay in construction of valve chamber on any charged or uncharged pipeline, the PE stop off valve is properly wrapped and is backfilled in such a manner that the valve is not damaged.

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PE Testing

Pressure testing is carried out with compressed air or nitrogen gas. The progressive pressure testing for the main pipelines and all the PE l00 pipelines SDRll are carried out at a pressure of 6barg, for a time period of 24 hours. The reading of pressure is taken for everyone hour. The leakages in the pipeline can be found out by this method. Any unaccountable loss in pressure in the line during the test period implies the leakage in the pipe, else vice versa. The stabilization period throughout the length of the pipe is normally half an hour which is assumed. All the measuring instruments which are used are totally tested and approved by the company. All the testing are witnessed by the company authorities. Purging is also done with the help of nitrogen. The nitrogen cylinders used are checked for their label, certification and tests. The testing carried out during the commissioning process includes the testing of the charged line for the composition of the gas. The methane content in the gas is tested using the specified meters. The oxygen content in the line is also checked up. The maximum allowable range of oxygen in the line is 0-2%. Normally the oxygen content in the line is 0.2%. The testing is done with all necessary regulators, hoses and connections, which are in good condition and working order. A record of all the purging plan before the commencing of the purging work is kept as preference drawing. The plan includes the provision of the following materials and equipments. Fire extinguisher. Purging adaptor Purge stack with flame trap and gas sampling point. Gas sampling equipment Squeeze off tool.

The design of PE pipe networks should follow conventional network practices with the installation of valves at convenient or critical locations. The valves can then be operated to isolate sections of the pipe network for maintenance. Additionally however PE pipe networks have the advantage that more localized isolation can be implemented by the use of pipe squeeze-off`. Squeeze-off is used in routine and emergency situations to stop or nearly stop flow in PE pipe by flattening the pipe between parallel bars.PE pipe squeeze-of utilizes the ductility of` PE by allowing the pipe to be squeezed together rusing relatively simple but specially designed squeeze-off tools thus preventing the flow of fluid and isolating the pipe section. It is important that only specifically designed tools are used and that the squeezeoff controls are set for the specific diameter and SDR of the pipe in order to control the degree of compression of` the PE pipe and prevent any damage. The squeeze off tools are generally mechanically operated up to about 125mm diameter and hydraulically operated for larger diameters. However squeeze-off equipment is not readily available for the largest diameters of PE pipe. It is important to follow the manufacturers instructions when using these tools and to use tools appropriate for the pipe diameter and SDR. Also the tools need to be capable of resisting the operating pressure of` the pipe, and there are limits to the pressures that they can sustain.

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Properly implemented squeeze-off, using the correct tools, is not expected to cause damage to the PE pipe, which regains its circular cross-section after the tool is released. However squeeze-off is not recommended to be done more than once at any location. lf repeated flow control is required a valve or an appropriate flow control device should be installed in the system. Squeeze-off is not intended as a means to throttle or partially restrict flow. Complete flow stoppage may not occur in all cases. When squeezing larger pipes, particularly at higher pressures, some seepage is likely. When seepage is not acceptable, it may be necessary to vent the pipe in-between two squeezesoffs. Any work performed must be downstream of the second squeeze-off. Inflatable bag flow stopping equipments can also be used for PE pipes. A Saddle needs to be fixed to the pipe, through which the inflatable bags are inserted. It is important that the correct saddle fitting is used compatible with the equipment being used. Reference should be made to the manufacturers instructions. Adequate and sufficient trench is provided for commissioning process or providing tap off There opening of any trench might be required during the commissioning process. . The maximum trench dimensions which might be required during the commissioning is 2.5m by lm.

PE Route Marker

The route marker can be defined similar to a milestone. The PE route marker shows the routeof the laid pipeline. This is for the easy reference for finding the route. The Route markingprocess is to be completed before the commissioning process. The route marker is normally laid for lines in which the pressure of the line is greater than 110mbarg. The distance between each route marker is approximately 300m. The precast of RCC mix of 1:1.5:3 is required for the route marker stone. The route marker stone is casted as per the design requirements. For easy understanding of the route marker in the diagrams it is represented by the yellow color. A 6mm smooth thick cement plastering work is to be done over the projected route marker including scaffoldings, curing etc.

Tap of from charged gas mains

The taping process from the charged gas line is a tedious and t ime taking work. This is done in case of emergency purposes. The number of live connections from the charged lines cane minimized by proper planning and synchronizing medium pressure network charging for particular area. The flow stopping devices are used such as squeezers. These are used only on the MDPE lines as they have their property of regaining their alter squeezing. The method to be used for each connection, the number and type of flow stop devices to be used is to be determined by the company.

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Records to be maintained
The various records which is maintained to ensure the proper laying of the line and also the cost of laying is as follows, Daily progress report. Approval for technical deviation if any. Material reconciliation report as in the designed format. The testing report of the PE network with reference drawings as per the desired codes Employees presence registers on site during the PE laying. Other specific documents wherever necessary. Organizational chart before the starting of the work. Details of tools resources and tackles before start.

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CONCLUSION
On Demand / Supply Terms
Large gas finds from domestic sources Availability of gas is increasing. Dependence on liquid fuels is decreasing As a result of above factors the opportunities for utilization of natural gas in sectors like fertilizer, power and city gas is also increasing. Moreover environmental constraints on reduction of carbon emissions and the government declarations on the increase in the subsidy of LPG have also boosted the growth of CGD network.

Which standard to follow ?

ln city gas distribution, safety is given prime importance i.e. while referring standards such as PNGRB/ASME B3 l .8 etc. then standard providing maximum safety factor is considered.

On technical terms
City gas distribution is a highly complex system consisting of network of pipelines, compressors, metering and regulating facilities and pressure reduction skids; hence requires highly trained personnel to control their operation. Effective monitoring of the network can be achieved with the help GIS/GPS/MMI/SCADA systems. Pipeline laying activity involves great risk and responsibility as the engineers need to incorporate maximum design factors, safety factors and rugged material specifications in order to ensure optimum operation and safety against unavoidable accidents. Continuous and effective functioning of the system can be achieved by means of Conducting Performance Tests & Schedule Maintenance within regular intervals of time. The operating company are emphasizing on the connection of their dispensing stations directly to their pipelines rather than opting for DBS.

On human grounds:
Team work and feeling of collective responsibility are the only mantras to ensure success story of an industry. Employee retention and talent pool conservation also important factors to consider

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BIBLIOGRAPHY
- Regulations of Petroleum And Natural Gas Regulatory Board - ASME B31.8 (Design ,Installation And Testing) - Gas Cylinder Rules ,2004 - OISD STD -179 - www.sitienergy.com - www.agniinternational.com - www.petroleum.nic.in - www.kgbasin.in - www.gglonline.net - www.gailonline.com - www.wikipedia.com - www.mahanagargas.com - www.adanigas.com - www.iglonline.net -

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