PNGRB Regulations General Concepts Followed Up in CGDs

(G.S.R.
612 E)
STEEL PIPELINE
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SAFETY
Material PIPELINE
INTEGRITY
PNGRB
Regulations
Construction
Patroling
Operation
and Cathodic
maintenance protection
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STEELtitle
Click to edit Master PIPELINE
style
Steel Pipeline
MATERIAL
Steel Pipe BALL AND Fittings Insulation joints

GASKETS(ASME Flanges
(API 5L GLOBE (ANSI 150 TO B16.20)
Valves(API (ASME B16.9, ANSI 2500) (ASME B16.5)
PSL2) 6D)
ASME B16.25)
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STEELtitle
Click to edit Master PIPELINE
style
Steel Pipeline :Pipeline is all parts of physical facilities through which fuel moves
in transport including pipe, valves, fittings, flanges, pressures vessels, metering
stations, compressor units etc., attached to the pipe.
Steel pipe are the main component of steel pipeline which accounts approx. 95% of the
capital expenditure. IGL is using 3 layer polyethylene pipes of various diameter as
detailed below:
Sr. no. GRADE Thickness (mm) Strength
1. API 5L 6.4 60,000lb/psi
X60(12”,16”,18”)
2. API 5L Gr.B (4”,6”) 6.4 42000lb/psi
3. API 5L Gr.B (8”) 8.2 42000lb/psi
4. A106 SCHEDULE 6.4 42000lb/psi

80(2”)
Specification of line pipe is done based on API 5L ,ASTM A 106 HTCS.

For impact loads PSL2 standard is used.
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There are total 28 types of valves. BALL and

GLOBE Valves are manufactured as per API 6D.
Ball/globe Ball/globe
Valves Valves can
also be
classified as
FE/BW and
Manually
Actuated Full
operated
bore/Reduced
bore valves.
Underground Aboveground Aboveground Underground
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5
Ball Valves :These are used

for isolation. These are
basically ON/OFF Valves.
Since the pipelines in CGD is
of non piggable line, RB
valves are used and RB
valves are less expensive
than the FB valves.
In reduced bore ball valve,
the port of the valve will be
one pipe size lesser than the
OD of pipe.
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Globe Valves : Globe valves are used for throttling .Main
functions of globe valves are-
Regulating the flow while charging the gas , venting the gas in
pipeline .
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Insulation Joint: The Pipeline
Insulating Joint (PIJ) is a high-
resistance fitting used to
electrically isolate sections of a
pipeline to improve the
effectiveness of cathodic
protection systems and to
reduce ground-loop currents.
Thus, I.J. are used to separate
above ground pipeline to
underground(cathodically
protected) pipeline.
Insulating joints are monolithic
type and allows smooth passage
of pigs.
PRESSURE RATING of I.J is done
accordingtoANSI150TOANSI2500.
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Fittings: These are designed as per ASME B16.9, ASME

B16.25.
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• Flanges are designed as per ASME B16.5
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GASKETS are designed as per ASME B16.20 .
Spiral Wound gaskets
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PIPELINE LAYING DONE AS PER ASME B31.8
Stringing(spreading) of pipes
Welding of joints
NON DESTRUCTIVE TESTING
Coating of pipe joints
Holiday testing for lowering section
Coating repairs after Holiday Check and trenching
of graded land
Lowering
Padding of lowered section
Warning mat & HDPE duct laying
Backfilling
Pole Markers and RCC Markers Installation 12
12
G.S.R 612(E)
REQUIREMENT:PAGE NO. 10,SCHEDULE 1B :
QUALIFICATION OF PROCEDURES AND WELDERS
Welding procedures and welders for welding of gas pipelines shall be
qualified as per API 1104 and shall include toughness testing
requirements as applicable for the line pipe.
• SMAW- Shielded Metal Arc Welding

• Electrodes Used- 6010, 7010
INSPECTION OF WELDS
All Non Destructive Testing (NDT) including radiographic examination
shall be performed in accordance with the requirements of API 1104.
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 23, SCHEDULE 1D
Casing Requirements under Railroads,
Highways, Roads or Streets
Steel casing at road/railway crossings, when
provided to meet statutory requirements, shall
be designed in accordance with API 1102.
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Method of Crossing : Push Boring method
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 31, SCHEDULE 1D:
High Pressure Distribution System: Based on operation and
maintenance flexibility requirements,
-In steel distribution mains valve spacing should normally not
be more than 3 km
OISD 226,PAGE NO. 48, CLAUSE 5.2.3:

STRATEGIC VALVES
Such valves shall be installed to facilitate maintenance of system and to
allow for speedy isolation in the event of damage. The location of the
strategic valves shall be decided based on the risk associated with
maintaining the gas supply and to facilitate maintenance, repair,
modification, testing and commissioning etc. In no case, distance between
two strategic valves shall exceed 3 KM for steel pipelines.
IGL is following the same. 16

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G.S.R 612(E)
REQUIREMENT: PAGE NO.16, SCHEDULE
1D:Buried piping inside the CGS area shall
have a minimum depth of cover of 1.2 m.
Where buried pipes come out of the ground,
the underground coating on the pipe will
continue for a length of at least 300 mm
above ground.
IGL IS FOLLOWING THE SAME.
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G.S.R 612(E)
REQUIREMENT:PAGE NO.22,SCHEDULE 1D:
Clearance between Pipelines or Mains and other underground
structures
(a) When a buried steel pipeline or main has to cross any existing
underground pipeline, cable, drain or other services, the pipeline
shall be laid at least 300 mm below from such services.
IN IGL THE PIPELINE IS LAID AT LEAST 500 mm BELOW OTHER UTILITIES
Underground Cable
500 mm
Pipeline 18
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G.S.R 612(E)
(b) When laid parallel to any existing underground
cable, drain or other utilities, the pipeline or main
shall be laid with a clear distance of at least 300
mm from existing utility.
IN IGL THE PIPELINE IS LAID AT LEAST 1M
PARALLEL TO EXISTING UTILITIES. Wherever it is
not possible due to some constraints ,some
reinforcement is being done.
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G.S.R 612(E)
(c) As far as practical, a minimum separation of
three (3) meter should be maintained between
the steel pipeline or main and footing of
transmission tower.
IGL FOLLOWING THE SAME
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G.S.R 612(E)
(f) While laying more than one new hydrocarbon
pipelines or mains in the same trench, clear separation
of minimum 500 mm shall be maintained between
adjacent pipelines.
IN IGL THE CLEAR SEPARATION OF AT LEAST 1M IS
MAINTAINED BETWEEN ADJACENT PIPELINES
Pipeline
1M
Pipeline
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REQUIREMENT:
OISD 226 clause no.5.5, page No. 49
PIPELINE MARKERS
Route markers shall be placed on the entire
pipeline at a distance not exceeding 50 meter
and also at bends in the city.
G.S.R 612(E)
PAGE NO. 38 ,SCHEDULE 1E :
DISTRIBUTION PIPING MAINTENANCE.
• Markers: Markers shall be positioned along
entire network at a maximum spacing of 100
meters in urban area and 200 meters within
industrial parks for steel mains.
RCC MARKERS ARE PLACED AT EVERY 50M and
POLE MARKERS ARE PLACEDB AT EVERY 150M.
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• Protection from Hazards
A warning tape of Yellow colour shall be laid 200 mm above the pipe.
In IGL ,tape is layed 500mm above the pipe.
• OISD 226,PAGE NO. 51, CLAUSE 6:At identified locations pipelines shall be
provided with impact protection from excavating machinery as indicated in
the fig 1(a) where ‘h’ shall not be less than 500 MM. & 1(b) where ‘h’ shall
not be less than 250 mm.
Figure 1 (a) Concrete Slab

Figure 1 (b) Slab with support for
Impact protection of pipelines
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G.S.R 612(E)
REQUIREMENT:PAGE NO.44,Schedule 1G:
MISCELLANEOUS ODOURISATION
A pre - determined quantity, equivalent to a max 12.5 ppm
Ethyl Mercaptan, or any other odorant shall be dosed into the
gas stream.
OISD 226 , PAGE NO.49 , CLAUSE 5.7 :
PNG ODOURISATION:
Natural gas supplied through PNG distribution shall
have a distinct odour, strong enough to detect its
presence. In case ethyl mercapton is used as odorant,
the concentration range shall be 7 to 12.5 PPM.
IN IGL ODOURANT LEVEL KEPT TO 10 PPM ON AN AVERAGE.
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G.S.R 612(E)
REQUIREMENT:PAGE NO. 31 SCHEDULE 1D:
GAS SERVICE LINES
General Provisions Applicable to Steel, Copper and Plastic Service
Lines
Service lines shall be sized for a maximum flow velocity of 15 m / sec.
OISD 226, PAGE NO. 16,CLAUSE NO. 7.2.2 : Pressure limiting devices
Pipe size shall be such that gas velocities in the piping shall not be
more than 20 mtr / sec for unfiltered gas and 40 mtr/ sec for filtered
gas at peak condition. Sound pressure level shall be the maximum
limit prescribed by environment dept.
IGL PRACTICING THE SAME
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Hydrostatic Testing is carried out by following API 1110 (RP)

Hydrostatic Test is carried out to ensure the integrity of the
pipeline.
G.S.R 612(E)
REQUIREMENT:PAGE NO. 24, SCHEDULE 1D:
Testing after Construction General Provisions
Hold-up time for the pressure testing shall be minimum 24
hours for underground and four hour aboveground pipeline.
• IGL FOLLOWING THE SAME
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Activities carried out in Hydrostatic testing

 Volume Calculation for water filling
 Thermal Stabilization
 Thermo couple installation
 Test Pressure = 1.4 X Design Pressure
 Pressure Cycling – 50%, 75% and 100% pressure cycles
(Air Volume Calculation)
 Hold Pressure- After getting the clearance for Air
Volume Calculation, the pressure will be kept hold for
24 Hours
 Recording of Pressure and Temperatures in graphs
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• Functional check of all SVs and functional check of all
Under Ground Isolation Valves should be done at least
quarterly but IGL doing it monthly.
• Monitoring of valve chambers are carried out once in
every month and draining of water & cleaning of mud,
painting of rusted portion, replacement of damaged
man hole caps are carried out on regular basis.
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PNGRB requirement:-
G.S.R 612(E)
PAGE NO. 39, Schedule 1E:Leakage Surveys
Highly congested areas shall be surveyed using
gas detectors at least once in three months.
Other less congested areas shall be surveyed at
least once a year.
• In ,IGL implementation of the same is in
process.
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Sectionalizing Valve Stations:
Sectionalizing Valve(s) shall be provided with blow down or vent line connection to
isolate the pipeline section and evacuate the pipeline section in case of an
emergency and repair.
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• Checking of PASSING VALVES/SV's is being

done QUARTERLY.
• LEAKAGE FROM VALVES/S.V.'s/ FLANGES is
being done MONTHLY.
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• Depth Survey is being done AS AND WHEN REQUIRED.
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According to standards min. 3 m gap should be

maintained from power cable ( >=66 kv). IGL is
maintaining the same ,otherwise installing P CELLS
Polarization cell
A device inserted in the earth connection of a
structure that drains only a small current from the
source used to provide cathodic protection for the
structure, but provides a low resistance path to
currents from high d.c. voltages and all a.c. voltages
carried by the structure.
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IMP-PNGRB ACT,REQUIREMENT: PAGE NO. 9,

Schedule 5
Thickness assessment and periodic review against
baseline values
Periodic thickness assessment for all CGD network
skids and pressure vessels and comparison to
baseline values shall be done once a year.
• IGL is planning to carry out the thickness survey.
Thickness gauges are to be purchased. At various
places during shut down, thickness survey has
been done.
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OISD 226,PAGE NO. 19, CLAUSE 9.2.5 :
Cathodic Protection System:
In addition to protective coating, buried pipelines shall
also be provided with cathodic protection system. CP system
shall be designed in accordance with NACE-RP-0169.
•During construction period pipeline shall be protected by
temporary sacrificial anode based cathodic protection system.
This may not be provided in case Permanent Cathodic
Protection system is provided within 6 months of start of
pipeline construction.
•For Impressed Current Cathodic Protection System, it shall
be ensured that continuous power supply is maintained in
cathodic protection system.
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OISD 226,PAGE NO. 19, CLAUSE 9.2.5 :
Test leads points (TLPs) shall be installed at 1
km interval and at all crossings on pipeline for
taking electrical measurements to ensure
adequacy of the CP system.
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• OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection
of Cathodic Protection System
A. Pipe to Soil Potential (PSP) Readings shall be

taken as follows:
i) PSP readings at feeding points shall be monitored
fortnightly.
ii) The PSP reading ( ON potential) at the test lead
points for entire pipeline shall be taken once in a
quarter. The PSP survey results shall be plotted
graphically to identify and locate cathodic holidays.
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• CATHODIC PROTECTION (CP) is an electrical

method of preventing corrosion.
• Initially pipeline will be protected by
providing Temporary Cathodic Protection
for a period of 2 years and converting it into
Permanent Cathodic Protection.
• According to NACE SP0169, PSP reading

should be taken quarterly.
IGL takes ON READING on monthly basis.
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OFF READING: It is the potential reading when TR unit is
OFF. OFF reading is more important than ON reading as in
case of OFF reading, voltage drop in the earth is not
included.
OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection of
Cathodic Protection System
Instant pipe to soil “OFF” potential readings at test lead
points of entire pipeline shall be taken once in a year. For
the purpose of logging the instant OFF PSP, care shall be
taken to minimize the effect of polarization decay., by
logging the reading within the first 1 or 2 seconds of
simultaneous switching of all Cathodic protection station
affecting that section of the pipeline. The PSP survey results
shall be plotted graphically to identify and locate cathodic
holidays. 40
40
OISD 226,PAGE NO. 30,CLAUSE 12.3.5: Inspection of Cathodic
Protection System
Cathodic protection rectifiers shall be inspected once in two
months.
According to NACE SP0169 TR unit monitoring should be
done fortnightly.
But IGL does it WEEKLY.
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• CURRENT DENSITY: It is the current per unit

geometrical area of the protected structure,
coated and uncoated, in contact with the
electrolyte.
• It require summation of current taken by
temporary as well as permanent CP and dividing
it by total area. Current Density is calculated to
know whether current is supplied as per initial set
requirement.
• IGL has carried out survey for 200 km and
balance is under process.
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NATURAL POTENTIAL: IGL do it once in year.

Natural Potential reading is taken to ensure that
interference is not occuring because of other
stray current. Normally natural potential is-.45V
to -.75V .If natural potential reading in TLP is
coming -1.1,-1.2 etc.It means interference is
occurring.
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• According to ASME B 31.8S Closed Interval Potential
Logging Survey should be done once in 5 year .IGL is
doing the same.
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CORROSION SURVEY AS PER OISD NORMS:
OISD 226,PAGE NO. 30,12.3.6 :Coating Survey

Pearson Survey / Direct Current Voltage gradient
(DCVG) / Continuous Potential Logging (CPL) survey
/ Current Attenuation Test ( CAT) shall be carried
out once in 5 years. Insulating joints and couplings
shall be inspected once in a year.
• IGL is doing the same.
DCVG Meter 45
45
Potential Gradient Associated with a Cathodically-Protected pipeline
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46
Inline DCVG
Survey
Technique
47
47
INTERFERENCE SURVEY:
Electrical Interference
Electrical interference due to following shall also be
considered in cathodic protection design:-
Fault Currents
Fault current resulting from lighting or upset conditions of
electrical facilities could result in serious damage to
coating and pipe wall and danger to personnel. These
adverse effects may occur where a pipeline or main is
close to the grounding facilities of electrical transmission
line structures, sub-stations, generating stations or other
facilities that have high short circuit current-carrying
grounding networks.
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48
Pipeline Integrity is-
“Ability of a pipeline to contain the product in required circumstances”
OISD 226 PAGE NO. 29 ,CLAUSE 12.3.3: Pigging

Pigging operation shall be carried out for all pigable pipelines at least
once in a year for wet gas and once in 3 years for dry gas. Records of
quantity and quality of deposits (pig residue) collected after pigging shall
be chemically examined. Depending upon the out come of the chemical
analysis and review pigging frequency shall be increased.
12.3.4 Intelligent Pigging
Intelligent pigging survey ( IPS) shall be carried out once in 10
years and this data shall be compared with the data collected during
electronic geometric pigging .
NON-PIGGABLE LINE
PIGGABLE LINE-
101 KM - Planning for carrying out pigging is under progress.
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49
DA Model Process
Pre Assessment
Gathering data and deciding if the data is sufficient to be able to conduct
Dry Gas-Internal Corrosion Direct Assessment.
Indirect Inspection
The operator is required to conduct flow modeling to determine the critical angle for water
transport where forward motion is prevented by gravity and surface tension.
Direct Examination
Dig site verification, Coating assessment, Corrosion assessment, NDE.
Post Assessment
Reassessment Intervals, Remaining Life, DA effectiveness & Health assessment
As per standards DIRECT ASSESSMENT should be done once in 5 year.

IGL is planning to carry out the DA.
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PATROLING
REQUIREMENT:PAGE NO.
(PNGRB GSR612E-Schedule 1E) 39,GSR612E-Schedule 1E
Patrolling
Patrolling schedule shall be
such that entire primary
network is inspected at least
Entire primary once in three (3) month and
network –at least secondary network is
inspected at least once every
once in three month to observe surface
months conditions, construction
activity, encroachments, soil
wash outs and any other
Secondary factors that may affect the
network-at least safety and operation of the
once every network.
IGL IS DOING THE PATROLING
month ROUND O’ CLOCK. 51
51
Either onsite or offsite emergency plan should be approved yearly.
G.S.R.612(E) REQUIREMENT:
PAGE no. 37, schedule 1E:
Training shall include mock safety drills, at least twice a year.
The training program should cover following:
1.Hazardous characteristics of Gas.
2.Familiarization with commissioning, operation and maintenance
procedures.
3.Hands on experience on operation of emergency and manual shut
down systems.
4.Effective isolation of any gas leak.
5.Safety regulations and accident prevention.
6.Firefighting equipment operation and its upkeep.
7.First Aid and Housekeeping.
IGL does safety drills quarterly.

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IMP-PNGRB ACT,REQUIREMENT:PAGE NO.25
Schedule 9
Review of Internal Audit
• Internal Audit as per the checklist for CGD
Networks provided by Petroleum and Natural
Gas Regulatory Board shall be carried out by
the CGD entity every year;
IGL IS PRACTICISING THE SAME.
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IMP-PNGRB ACT,REQUIREMENT:PAGE NO.25
Schedule 9
Review of External Audit:
External Audit (EA) by third party, approved by the
Board, as per the methodology specified by the
Petroleum and Natural Gas Regulatory Board once
every 3 years.
IGL IS PRACTICISING THE SAME.
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Sr. Description Status in IGL
no.
1 Design/ specification documents Available
2 Route maps, alignment sheets, crossings, drawings, Piping and Instrumentation Available
Diagrams, station layouts Pipe Book/ Installation Records
3 Surveillance inspection and maintenance reports Available
4 Records and maps showing the location of CP facilities and piping Not available
5 CP Monitoring report Available
6 Leak burst and repair records Available
7 History cards of equipment Not available

8 Pipeline Pigging Report Not Applicable
9 Material certification including dimension, metallurgy, DT and NDT, strength, Available

tightness, performance and functional report .
10 Welding records Available
11 PQR, WPS & Welder qualification records Available 55
55
Sr.no. Description Status in IGL Remarks
12 Third Party technical audit report of infrastructure Available

before Gas-IN
13 Commissioning reports Available
14 Non-conformance/ deviation reports Not Available

15 Calibration records of Inspection, Measuring & Metering Not Available
and Test equipment –LOCATOR,PRESSURE GAUGE
16 Audit compliance reports Available
17 Statutory clearances Available
18 Approved drawings/documents Available
19 HAZOP/ Risk assessment studies/ compliance to Available with
recommendations F&S
20 All operation & maintenance manuals Partly Available
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Sr.no. Description Status in IGL Remarks
1 Cathodic Protection Design documents. Partly available

2 Soil Resistivity Survey Report Partly available
3 Electrical Interference Report Not Available

4 Inspection and maintenance report Available
5 Material certification reports Material Available

certfication including dimension, metallurgy,
performance and functional
6 Material test reports Available
7 Approved drawings/documents Available
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57
• Passing test of U/G,SV valves
• Current Density Measurement.
• Thickness survey.
• Leakage survey-Highly congested areas shall be surveyed using gas detectors at
least once in three months. Other less congested areas shall be surveyed at
least once a year.
• INTERFERENCE SURVEY.
• Instant pipe to soil “OFF” potential readings at test lead points of entire
pipeline shall be taken once in a year.
• DIRECT ASSESSMENT
• LINE PIGGING FOR CHECKING PIPELINE INTEGRITY-
Plan to convert non piggable lines to piggable lines : 101 KM.
51 km(12”)-Bawana to Bijwasan
23 km(12”)-Dhaula kuan to Mukarba Chowk
27km(8”)-Noida to Greater Noida.
• Records for O & M.
• Records for corrosion control.
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PNGRB Regulations General Concepts Followed Up in CGDs

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(G.S.R.

Steel Pipe BALL AND Fittings Insulation joints

4. A106 SCHEDULE 6.4 42000lb/psi

Specification of line pipe is done based on API 5L ,ASTM A 106 HTCS.

There are total 28 types of valves. BALL and

Underground Aboveground Aboveground Underground

Ball Valves :These are used

Fittings: These are designed as per ASME B16.9, ASME

• Flanges are designed as per ASME B16.5

Spiral Wound gaskets

• SMAW- Shielded Metal Arc Welding

OISD 226,PAGE NO. 48, CLAUSE 5.2.3:

IGL is following the same. 16

Figure 1 (a) Concrete Slab

IGL PRACTICING THE SAME

Hydrostatic Testing is carried out by following API 1110 (RP)

Activities carried out in Hydrostatic testing

• Checking of PASSING VALVES/SV's is being

According to standards min. 3 m gap should be

IMP-PNGRB ACT,REQUIREMENT: PAGE NO. 9,

A. Pipe to Soil Potential (PSP) Readings shall be

• CATHODIC PROTECTION (CP) is an electrical

• According to NACE SP0169, PSP reading

But IGL does it WEEKLY.

• CURRENT DENSITY: It is the current per unit

NATURAL POTENTIAL: IGL do it once in year.

CORROSION SURVEY AS PER OISD NORMS:

OISD 226,PAGE NO. 30,12.3.6 :Coating Survey

Potential Gradient Associated with a Cathodically-Protected pipeline

OISD 226 PAGE NO. 29 ,CLAUSE 12.3.3: Pigging

As per standards DIRECT ASSESSMENT should be done once in 5 year.

IGL does safety drills quarterly.

6 Leak burst and repair records Available

7 History cards of equipment Not available

9 Material certification including dimension, metallurgy, DT and NDT, strength, Available

12 Third Party technical audit report of infrastructure Available

14 Non-conformance/ deviation reports Not Available

1 Cathodic Protection Design documents. Partly available

3 Electrical Interference Report Not Available

5 Material certification reports Material Available

7 Approved drawings/documents Available

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