Project Manager : Rajeev Valunjkar

Design Engineer : Bose Ramakrishnan

Design Engineer : Vinod Kumar

Germanischer Lloyd Industrial Services GmbH

Correspondence Address- India:
1st Floor, Dakshna Building, Plot No. 2
Sector 11, CBD Belapur, Navi Mumbai 400 614

Head Office:
Steinhoeft 9, 20459 Hamburg,
Germany

Ph +91 22 40781000, Fax +91 22 40123809

Ph- +49 40 36149 7700, Fax +49 40 36149 1718

Gvc-india@gl-group.com, www.gl-group.com

glis@gl-group.com, www.gl-group.com

INDEX

1. INTRODUCTION .....................................................................................................3
2. OBJECTIVE .............................................................................................................. 3
3. GLOSSARY .............................................................................................................. 3
4. REFERENCE CODE AND STANDARD ................................................................ 4
5. TYPICAL GAS NETWORK.....................................................................................5
6. DESIGN PHILOSOPHY...........................................................................................7
ANNEXURE-I
i)

Process & Instrumentation Diagram (P&ID)

a) City Gate Station (CGS)
b) Distribution Pressure Regulating Station (DPRS)

ii)
iii)
iv)
v)

Typical Medium Pressure Network

Typical Low Pressure Network
Galvanized Iron Network
Plot Plan
a) CNG Station

ANNEXURE-II
vi) Bill of Material
a)
b)
c)
d)
e)

vii)
viii)
ix)
x)
xi)
xii)

8, 6 and 4 Steel Pipeline

City Gate Station
Distribution Pressure Regulating Station
CNG Station
MDPE & Domestic Materials

Compressor Data Sheet

Control Valve Data Sheet for Metering Skid
Control Valve Data Sheet for DPRS
Valve Data Sheet
DG Set Data sheet
Control Valve Data Sheet For service regulator

CHAPTER 1
INTRODUCTION
This document is intended to be used as the Design document for Natural Gas Transmission and
Distribution networks for Mathura City which is being executed by M/S Saumya DSM Infratech Pvt Ltd.
The scope of this document covers the entire pipeline network Phase wise i.e., from City Gate Station to High
pressure Transmission Pipeline; Pressure Reduction Stations; Distribution pipelines; Spurlines for CNG
Stations; MDPE Distribution Pipelines, upto the appliance in case of domestic customers; and till the outlet
of the meter / Metering and regulating Station (MRS) in case of Industrial and Commercial (I&C) customers.
This document allows routing of pipeline not only in municipal and other regulatory boundary limits but also
along National highway/PWD right of way.
This document outlines and sets out the Design, Material selection, Systems, Construction and
Commissioning with specific supplementary requirements in accordance with Technical Standards and
Specifications including Safety Standards for City or Local Natural Gas Distribution Network issued by
PNGRB Regulation 6 of Schedule 1.
Although this document is intended for new pipeline systems, this would also adequately cover any
modification Later on. The operating pressure range covered under this document is 21 mbarg to 49 barg.

2. OBJECTIVE
This Document is intended to be used as a standard Guide for all Network Design related activities within
Saumya DSM. The document in its scope shall cover all
pipelines within Saumya DSM, i.e., Transmission & Steel Distribution, Medium and Low pressure PE
Distribution networks related to Mathura City Gas Distribution.

3. GLOSSARY
Abbreviations of the standard terms used in design basis document are as follows (in alphabetical order):
GENERAL ABBREVIATIONS
AV
:
Appliance cum Shut off Valve
CGS
:
City Gate Station
CP
:
Cathodic Protection
CRV
:
Creep Relief Valve
CS
:
Carbon Steel
DP
:
Design Philosophy
DRS
:
District Regulating Station
DPRS
:
Distribution Pressure Regulating Station
EIA
:
Environment Impact Assessment
ERW
:
Electric Resistance Welded
HDPE
:
High Density PolyEthylene
HSS
:
Heat Shrink Sleeves
HSE
:
Health, Safety and Environment
I&C
:
Industrial and Commercial
LDZ
:
Local Distribution Zone
LP
:
Low Pressure
MAOP
:
Maximum Allowable Operating Pressure
MCV
:
Meter Control Valve
MOP
:
Maximum Operating Pressure
MOEF
:
Ministry of Environment & Forest
PCB
:
Pollution Control Board

MRS
MDPE
MP
MR
NG
NPS
O&M
P&ID
PE
PRS
PRV
QRA
ROU
ROW
SDR
SOL
SP
SR
SRM
SRV
TPIA
3LPE

:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:

Meter Regulating Station

Medium Density PolyEthylene
Medium Pressure
Meter Regulator
Natural Gas
Nominal Pipe Size
Operations & Maintenance
Piping and Instrumentation Diagram
PolyEthylene
Pressure Reduction Station
Pressure Regulating Valve
Quantitative Risk Assessment
Right of Use
Right of Way
Standard Dimension Ratio
Safe Operating Limit
Supply Point
Service Regulator
Service Regulator Module
Safety Relief Valve
Third Party Inspection Agency
3 Layer Polyethylenes

CODES AND STANDARDS ABBREVIATIOS

AGA
ANSI
API
ASME
ASTM
BIS
CCOE
DIN
IGE
ISO
MSS
NACE
NFPA
OISD

:
:
:
:
:
:
:
:
:
:
:
:
:
:

American Gas Association

American National Standard Institute
American Petroleum Institute
American Society of Mechanical Engineers
American Society for Testing and Materials
Bureau of Indian Standards
Chief Controller of Explosives
Deutsche Institute for Norms
Institution of Gas Engineers
International Standard Organisation
Manufacturers Standardization Society
National Association of Corrosion Engineers
National Fire Protection Association
Oil Industries Safety Directorate

4. REFERENCE CODE AND STANDARD

Design of the pipeline and associated facilities shall be executed in accordance with PNGRBs Technical
Standards and Specifications Including Safety Standards for City Gas Distribution Network released in 2008.
Wherever PNGRB Standards are not sufficient, respective Standards such as ASME, ANSI, AGA, and API
Shall are followed.
Latest edition of Codes and standards shall be reffered while forming the detailed engineering. .

CHAPTER 2
TYPICAL GAS NETWORK
Schematic diagram:

The complete network is divided into following three categories based on the Operating Pressure Range:
Primary Network:
Steel Distribution Network (49 barg System)
Gas available at inlet to CGS shall be regulated to 49 barg pressure. Gas, at 49 bar is taken through
steel pipelines upto District Regulating Station (DPRS) to supply gas to secondary gas distribution
network. This steel network is also called Gas Mains or Distribution Mains or Ring Mains.
The allowable Maximum Velocity in the pipeline shall be not more than 30m/sec immediately after
pressure regulating valve.

Secondary Network:
Medium Pressure MDPE Distribution network (2 - 4 barg system)
From a DPRS, the gas after reduction of pressure to 2.0 4 barg, depending upon the load profile, is
fed into the Medium Density Poly Ehtylene (MDPE) distribution network. This is basically a low
pressure Distribution Mains that connects DPRS to various service regulators at commercial, industrial
and domestic consumers.
The network shall be sized for maximum flow velocity of 30m/sec.

Tertiary Network:
Low Pressure PE Distribution network (100 mbarg system)
The gas from Service Regulators shall be taken to individual customers through a low-pressure
pipeline network as indicated in Figure 1, Meter regulator (MR), installed in the premises of
Domestic customers, further regulates the pressure to 21 mbarg before feeding the appliance.
Above ground GI piping (100 mbarg system) upto Meter.

CHAPTER 3
DESIGN PHILOSOPHY
Front End Design was reviewed & original routing was not found technically advantageous &
commercially viable therefore the tap-off point was changed from GAILS SV 9 to SV10 existing
HBJ Pipeline. The pipeline routing was finalised after visiting the Right Of Way (ROW) of NHAI &
ROW of PWD roads. Pipe running through private lands has been strictly avoided.
Following are the input fed into Synergee software:

Base Data For The Hydraulic Studies

Pipeline Layout:
The proposed network lay out for Steel pipeline as given by Saumya DSM has been considered
as below

Individual Pipeline segment details are presented in below table.

Pipeline Segment
From
CGS
Junctiont point (JN01)
Junctiont point (JN01)
Dom&Comm Demand 1
(DEL02)
Dom&Comm Demand 1
(DEL02)
Dom&Comm Demand 2
(DEL03)
Dom&Comm Demand 2
(DEL03)
Dom&Comm Demand 4
(DEL05)

To
Junction point (JN01)
Industrial Demand Point
(DEL01)
Dom&Comm Demand 1
(DEL02)
Dom&Comm Demand 4
(DEL05)
Dom&Comm Demand 2
(DEL03)
Dom&Comm Demand 3
(DEL04)
Dom&Comm Demand 4
(DEL05)
Dom&Comm Demand 5
(DEL06)

Identification In
Map
LINE01

Length
Km
2.7

Inside
Diameter
In
8.125

LINE02

12.3

6.125

LINE03

26.7

6.125

LINE04

6.125

LINE05

3.9

6.125

LINE06

10

6.125

LINE07

15

3.5

LINE08

3.5

Material Specification for the Pipes: API 5L X52 ERW with 3LPE coating. The minimum Wall
thickness shall be 6.4 mm as per PNGRB (pg .no 17)

Peak Demands:
The Peak hour demand is estimated from the data provided by the SAUMYA DSM. The below
presented peak hour demand is considered while estimation the pipe size.
Industrial+CNG+ Domestic + commercial

28482 sm3/hr
(12% higher than Estimated)

The Total demand is equally distributed among 5 delivery points as shown in the above Network
Layout Diagram

Operating Pressures:
The network shall be operated at 49 5 barg pressure. The source station (CGS) out let pressure
shall be 49 -47 barg. The Minimum operating pressure at all delivery points shall be 5 barg.

Key Assumptions for the unavailable data:

The availability of limited data leads to the assumptions for some key parameters. Though
enough care has been taken for the assumptions to be close to the possible realistic conditions,
client has to provide or confirm the assumed data. The key assumptions are presented below.

Assumption for Pipe:

Roughness
Heat transfer coefficient
: 0.014921
Elevation

: 0.0018 inch
: 1.08 Kcal/hr-m2-degC Friction Factor
: Flat elevation is assumed across the network

Assumption for Gas Composition:

Heat content
Specific gravity
CO2 content
Viscosity

:
:
:
:

37.26 MJ/m3
0.6
0.5 molecular %
0.01197006 cP

Base Conditions:
Atmospheric Pressure
Temperature
Ambient Temperature
at CGS
: 30 DegC

: 1.0156 bar a
: 15.5 DegC
: 27 DegC Gas Temperatures

Network Layout with Results

Pipe Line Parameters

Pipe Diameter Vs Total Length
The below Table gives the Length of the pipeline required for different Diameters.
Inside Dia

Total km

3.500

17.00

6.125

60.90

8.125

2.70

Table : Dia Vs Length

Gas Velocity in Pipeline

Pipes with the Highest Velocity (m/s)
Pipe Name

From Node
To Node

Line2

JN01

Velocity
(m/s)

Diameter
(in)

Length
(km)

6.5

6.1250

4.8

Pressure (bars-g/Pa)
From

To

12.3

48.13

40.07

8.1250

2.7

49.00

48.13

3.0

6.1250

26.7

48.13

43.68

1.8

3.5000

2.0

43.49

43.23

1.3

6.1250

3.9

43.68

43.55

1.1

6.1250

8.0

43.68

43.49

0.6

6.1250

10.0

43.55

43.48

0.3

3.5000

15.0

43.55

43.49

DEL01
Line1

CGS
JN01

Line3

DEL02
JN01

Line8

DEL05
DEL06

Line5

DEL03
DEL02

Line4

DEL05
DEL02

Line6

DEL04
DEL03

Line7

DEL03
DEL05

Pressure at Demand Point:

The below table presents the maximum attainable pressures at all the demand points with
the demand mentioned in section 4. The pressure at source point CGS is assumed at 49
barg.

Demand Point

Identification

Pressure
barg
49

Minimum
barg
5

Maximum
barg
49

City Gate
CGS
Station
Industrial
DEL01
40.07
5
49
Demand point 1
Dom& Comm
DEL02
43.68
5
49
Demand point 1
Dom& Comm
DEL03
43.55
5
49
Demand point 2
Dom& Comm
DEL04
43.48
5
49
Demand point 3
Dom& Comm
DEL05
43.49
5
49
Demand point 4
Dom& Comm
DEL06
43.23
5
49
Demand point 5
Table : Attainable Pressures at Demand points with CGS pressure as 49 barg

Head Loss along the Pipes:

Pipes with the Highest Headloss (kPa^2/km)

Pipe Name

From
Node

Headloss
(kPa^2/km)

Diameter
(in)

Length
(km)

To Node

Line2

JN01

Pressure (bars-g)
From

To

590761.8

6.1250

12.3

48.13

40.07

320421.6

8.1250

2.7

49.00

48.13

156157.8

6.1250

26.7

48.13

43.68

116197.8

3.5000

2.0

43.49

43.23

DEL01
Line1

CGS
JN01

Line3

DEL02
JN01

Line8

DEL05

DEL06
Line5

DEL03

29718.2

6.1250

3.9

43.68

43.55

21441.7

6.1250

8.0

43.68

43.49

6649.8

6.1250

10.0

43.55

43.48

3708.9

3.5000

15.0

43.55

43.49

DEL02
Line4

DEL05
DEL02

Line6

DEL04
DEL03

Line7

DEL03
DEL05

Station Parameters
CGS SUPPLY REPORT
SUPPLY
PRESSURE
STATION
BARG
CGS
49

CAPACITY
SM3/H
28482

Table 1.2: calculated supply capacity at CGS

DELIVERY REPORT
DELIVERY
DEMAND
STATION
SM3/H
DEL01
-18752
DEL02
-1946
DEL03
-1946
DEL04
-1946
DEL05
-1946
DEL06
-1946
JN01
0

CALC.
PRESSURE
BARG
40.07
43.68
43.55
43.48
43.49
43.23
48.13

Table 1.3: Pressures at the given Demand

Line Pack Calculations

Simulation studies have been carried out to calculate the maximum and minimum line
pack at the maximum and minimum operating pressures.
Note: The below presented line pack calculations are based on the available in put data
and assumptions. The accuracy of the data reflects in the line pack calculation also.

Maximum Line Pack

The below presented table shows the Maximum possible line pack in the Pipeline
considering 49 barg as maximum operating pressure.

Pipeline
Segment
LINE01
LINE02
LINE03
LINE04
LINE05
LINE06
LINE07
LINE08

From
CGS
JN01
JN01
DEL02
DEL02
DEL03
DEL03
DEL05

To
Junction
JN01
DEL01
DEL02
DEL05
DEL03
DEL04
DEL05
DEL06

Diameter

Length

Line Pack

Km

S m3

0.2064
0.1556
0.1556
0.1556
0.1556
0.1556
0.0889
0.0889

2.7
12.3
26.7
8
3.9
10
15
2

4995.6
12933
28074
8411.7
4100.7
10514.6
5150
686.7

TOTAL LINE PACK AT 49 BARG

74866.3

Fig-2
Thus all the results of Synergee software run are much with in allowable limits and
therefore the proposed route which is as per the input to Synergee mentioned
above are approved for construction.
Note: The Steel & PE pipeline construction will be carried out as per ASME B31.8
Gas Transmission and Distribution Piping Systems

Page 15 of 18

Sectionalising Valve
Primary Network is subdivided into sections by means of valves adequately located in
order to isolate a section for works or in case of up-set. All sectionalizing valves are
manually and locally operated. The sectionalisation valve spacing should be at 3 Km.
In this case these shall be Ball Valve (BW) as per API 6D Class300 of respective size
and shall be Fitted with double block and bleed facility.

District pressure regulating Station (DPRS)

DPRS for the network will be located at strategic locations to meet various demand
canters for Domestic/commercial/ Industrial segment. It shall have filtering unit,
pressure reduction system, and inlet and outlet isolation valves. The filtering unit
would remove entrained particles of size 5 microns and above and with final filtration
efficiency of 99.9%. This unit would comprise of borosilicate fibreglass cartridge. For
the DPRS Layout Please refer to Drawing no:SDSM/SG/ENG/PLN/DPRS/P&ID
01.
Installation of DPRS may be fenced or can be kept in brick wall room depending
upon site conditions.
INDIVIDUAL PRESSURE REGULATING STATION (IPRS)
These are located at the premises of an individual customer (Industrial) and having
facilities similar to DPRS but having metering facility also. Since there are no big
industries in the present Geographical area, we have considered 2 such facility to start
with for 2 industrial states.
SERVICE REGULATORS
Are located at customer premises for maintaining supply pressure and designed to
maintain safe condition even in the event of rupture in the regulator downstream
section.
CORROSION CONTROL
All though all the steel pipe shall have 3 Layer Polyethylene coating and the welding
joints and short radius elbows shall have Heat Shrink Sleeves, a detailed soil
resistivity survey shall have to be undertaken by competent agency to design Cathodic
Protection system for entire buried steel pipeline and the same shall have to be
implemented before commissioning of the steel network.
SECONDARY NETWORK

Page 16 of 18

The secondary network connects DPRS and the service regulator / individual pressure
regulating stations. These are MDPE pipe of 4 bar rating and therefore P80 grade of
SDR 11 as per IS 14885-2001MDPE pipe (Compounded Yellow pipe) is being
selected for Mathura city Gas Distribution Network. All MDPE pipes shall be laid
underground strictly in accordance with PNGRB Guidelines. A schematic drg no.
SDSM/SG/ENG/PLN/MP NETWORK 01, Rev 0 may be referred for this. The
MDPE pipes sizes have been selected to have thickness as specified in PNGRB
Guidelines.
Wall Thickness and
Standard Dimension Ratio for
Thermoplastic pipes
Minimum wall
Nominal outside
thickness in mm for
diameter in mm
Standard Dimension
Ratio, SDR
11
D

16
20
25
32
40
50
63
75
90
110
125

3.0
3.0
3.0
3.0
3.7
4.6
5.8
6.8
8.2
10
11.4

TERTIARY NETWORK
This connects the Service regulator/ Individual Meter Regulator to the customer
metering facilities. The underground pipe shall be of MDPE P80 Grade SDR-11 as
per IS 14885-2001(Compounded Yellow Pipe) and the above ground pipe shall be GI
pipe as per IS 1239 Part I as per Drg No SDSM/SG/ENG/PLN/LP NETWORK 01,
Rev 0 and Drg No SDSM/SG/ENG/PLN/GI NETWORK 01, Rev 0
BILL OF MATERIAL
BOM has been worked out with technical specifications and are appended as per
annexure II

Page 17 of 18

Page 18 of 18