Refresher_City Gas network & Design.pptx

CGD network refresher

1. TRAINING PROGRAM ON CGD NETWORK Date:01.06.2023

2. CONTENT

3. CITY GAS DISTRIBUTION CONCEPT

4. CGD SYSTEM BASIC OUTLINE HP Network MPB Network CITY GATE Domestic and Commercial Users DRS DRS DRS MPA Network CNG Mother Stations LP Network

5. CGD NETWORK LAYOUT

6. CGD-INFRASTRUCTURE

7. CGD PRESSURE REGIMES Sr. No. Network Component Inlet from Inlet Pressure Outlet Pressure Outlet to 1 CGS Transmission line 99 - 60 barg 47-26 barg Steel Grid 2 Steel pipeline CGS 47-26 barg 26 – 14 barg DRS / CNG 3 DRS Steel pipeline 26 – 14 barg 4 – 1 barg MP MDPE pipeline 4 Service Regulators (SR) MP MDPE Pipeline 4 – 1 Barg 110 mBarg LP MDPE Pipeline 5 MP MDPE pipeline DRS 4 barg 4 – 1 barg Industrial MRS & Commercial Connections 6 LP MDPE Pipeline SR 110 mBarg 110 – 50 mBarg Regulator of Domestic / Commercial Connections 7 Industrial MRS MP MDPE pipeline Steel pipeline 4 – 1.5 barg 26 – 14 barg 1.5 barg or customer specific pressure within the supply range Industrial internal pipeline 8 Online / Mother CNG Station Steel Pipeline 26 - 14 barg 250 Barg Vehicle at 200 Barg 9 Domestic Connections LP MDPE Pipeline 110 – 50 mBarg 21 mBarg Meter & Gas Stove 10 Commercial Connections LP MDPE Pipeline MP MDPE Pipeline 110 – 75 mBarg 4 – 1 Barg 75 mBarg or customer specific pressure within the supply range Meter & Gas Stove

8. CITY GATE STATION (CGS) CGS is the location of Custody Transfer from Transmission Company to Distribution Company.

9. BATTERY LIMIT Distribution Zone Transmission Distribution City Gate Station Transmission Line

10. CITY GAS STATION (CGS)

11. CGS Mahawati , JS GA

12. CGS Mahawati , JS GA

13. PNG NETWORK

14. ACTIVITIES OF PNG PROJECTS

15. CGD PROJECT MANAGEMENT Detail Design & Engineering Planning & Schedules Tendering / Ordering of equipment & material Procurement Strategy Identification of materials & works Packaging for tendering & execution Process Design Basis Preparation Specifications Listing of equipment Process flow diagrams Pipeline Sizing Material Requisitions Receipt/ Dispatch Activity- wise plans and schedule Overall Project Schedule & Plan Financial Commitment Schedule Cash flow Plan Material & package cost estimation Mode of tendering inline with C& P Procedure Preparation of Master Vendor List

16. CGD PROJECT MANAGEMENT Inspection & Expediting of equipment & material Construction Management & Supervision Project Commissioning Category wise detailed Plan & Methodology for inspection Methodology for release of materials after inspection Deployment schedule of manpower for inspection Identification & finalization of number of packages in line with MWP Certification of contractor bills Methodology for Commissioning & start up Preparation of O&M Manual Disaster Management Plan Emergency Action Plan Health, Safety & Environment Plan

17. INTERNATIONAL STANDARDS S. No. STANDARD NO. DESCRIPTION 1 EN 12186 Gas supply systems - Gas Pressure Regulating Stations for Transmission and Distribution. Functional Requirements 2 EN 12279 Gas pressure regulating - installations on service lines 3 EN 1776 Gas supply systems - Natural gas measuring stations - Functional requirements 4 EN 1594 Gas supply systems- Pipeline for maximum operating pressure over 16 bar- Functional requirements

18. INTERNATIONAL STANDARDS S. No. STANDARD NO. DESCRIPTION 1 ASME B16.11 Forged Steel Fittings, Socket-Welding and Threaded 2 ASME B31.3 Process Piping 3 ASME B31.8 Gas Transmission and Distribution Piping Systems 4 ASME B16.5 Pipe line flanges and flanged fittings 5 ASME B16.9 Factory - Made Wrought Steel Butt welding Fittings 6 ASME- Boiler and Pressure Vessel Code Section- IX- Qualification Standard for Welding and Brazing Procedures, Welders, Brazers , and Welding and Brazing Operators 7 ASME Boiler and Pressure Vessel Code- II Part C- Specifications for welding Rods, Electrodes, and Filler Metals 8 ASME Boiler & Pressure Vessel Code Section - V, Non-destructive Examination 9 ASME Boiler and Pressure Vessel Code Section-II Materials Part A- Ferrous Material Specifications -

19. INTERNATIONAL STANDARDS S. No. STANDARD NO. DESCRIPTION 1 ISO- 15590-1 International Standard for Petroleum and natural gas industries - Induction bends, fittings and flanges for pipeline transportation systems 2 BS 6755: Part 2 Testing of Valves 3 DIN 30672, Part I Coatings of corrosion protection tapes and heat-shrinking products for pipelines for operational temperatures upto 50 o C 4 DIN 30670 Polyethylene coatings for steel pipes and fittings

20. OIL INDUSTRY SAFETY DIRECTORATE (OISD STANDARDS) S. No. STANDARD NO. DESCRIPTION 1 OISD-226 Natural Gas Transmission Pipelines & City Gas Distribution Networks 2 OISD-GDN-115 Guidelines on Fire Fighting, Equipment and Appliances in Petroleum Industry 3 Fire Protection Manual- TAC Fire Engines, Trailer Pumps and Hydrant Systems 4 OISD- Standard- 141 Design and Construction requirements for cross country hydrocarbon pipelines 5 OISD-Std-118 Layouts for Oil and Gas Installations

21. INTERNATIONAL STANDARDS S. No. STANDARD NO. DESCRIPTION 1 API Standard 1104 Welding of Pipelines and Related Facilities 2 API Specification 5L Specification for Line pipe 3 API Spec. 6D Specification for Pipeline Valves ( Gate, Plug, Ball and Check Valves) 4 API Standard 1102 Specification for steel pipeline crossing & highways.

22. INTERNATIONAL STANDARDS S. No. STANDARD NO. DESCRIPTION 1 AGA Purging Principles and Practices 2 IGE/TD/1 Steel Pipelines for High Pressure Gas Transmission 3 AGA: Report No. 7 Measurement of Gas by Turbine Meters 4 AGA Report No.3 Orifice metering of Natural Gas and other related Hydrocarbon fluids 5 AGA-Report No 8 Compressibility factors of Natural Gas and other related Hydrocarbon gases

23. RELATED CODES & STANDARDS Material standard:- API 5L / ISO 3183 - Specification for Line Pipe API 6D / ISO 14313 -Pipeline Valves Other codes:- API RP1102 -Recommended practice for Rail and Highway crossings API 1104 -Standard for welding pipeline and related facilities DNV OS-F101 -Submarine pipeline systems

24. PIPELINE CROSSING STANDARD ROU & Land Acquisition -Central/State Govt. as applicable (As per PMP Act 1962) National Highway Crossings -NHAI SH/ MDR/ ODR Crossings -PWD Railway Track crossings -Indian Railways Crossing through Forest land -Forest Authority River/Canal crossings -Irrigation/Canal Authority

25. RELATED CODES & STANDARDS

26. REGULATIONS GOVERNING CGD NETWORKS/ NATURAL GAS P/LS

27. REGULATIONS GOVERNING CGD NETWORKS/ NATURAL GAS P/LS

28. Other Applicable PNGRB REGULATIONS S No. Regulation for CGD Connotation 1 Guidelines for supplies to I&C customers Scope between entity and customer, cost and safety 2 Guidelines for supply to Multi-occupancy residential buildings Tertiary network up to stove, feasibility, maintain records 3 Commissioning and Gas charging of steel pipelines Guideline for safe commissioning, maintaining reports/records 4 Emergency Response and Disaster Management Plan Preparedness and relief during emergency 5 Declaring pipeline as Common Carrier or Contract Carrier Opportunity for competition Consumer friendly 6 Methodology for determination of capacity for pipeline and CGD Networks Service to customer. Level platform during bidding Spare Capacity for third party

29. STEPS OF DESIGN Requirement Analysis Source Details Availability of Product Pressure, Temperature Quality Geographical Location Demand Details No of Delivery Point Delivery Requirement Forecasting of Demand for Designed Life of pipeline Geographical distribution of customers

30. STEPS OF DESIGN Feasibility Study Route Study Shortest Route- NHAI-Expressway corridor/ PM&P Act/ Utilities Act etc. Least constraints Minimum no. of crossings Minimum Civic authorities Hydraulics Study Design Capacity Operating Capacity Pressure Drop Requirement of Boosting station Project Cost Estimation Implementation Plan Environment Impact Assessment Risk Analysis

31. STEPS OF DESIGN Basic Engineering Process Design and Sizing Optimization Studies Economic optimization Process optimization Sizing optimization Route Surveys Detailed Route Surveys of shortlisted ones Investigation of routes with Other utilities operators Construction equipment providers General public Civic Authorities

32. STEPS OF DESIGN Detailed Engineering Engineering Design Basis Route Engineering and Analysis Defining Chainage Elevation Profiles Crossing Profiles Spur line Profiles Specifications and Job Standards Engineering for Procurement Installation Engineering and Construction Procedures based on applicable codes & standards

33. STEPS IN THE DESIGN OF GAS DISTRIBUTION SYSTEM D emand is estimated based on survey of units covering domestic, commercial, industrial and transport sectors. Demand forecast projection is carried out for 20-25 years. Peak hour consumption estimated for network design . The system is designed for 20-25th year projected demand at peak load in a phased manner. Reconnaissance Route Survey to identify suitable routes for laying pipelines, locations for CGS, DRS & CNG Station

34. STEPS IN THE DESIGN OF GAS DISTRIBUTION SYSTEM Network design and optimization with available software Steel MDPE Design of PNG Domestic & Industrial facilities Design of Mother Station and Daughter / Daughter booster station for CNG supply to automobiles National / International standards and industry best practices adopted for design.

35. INTERDISTANCE- CNG FACILITIES (OISD-179)

36. INTERDISTANCE –T4S

37. PIPELINE NETWORK DESIGN Supply and demand centres Transmission P/Line, STPL and City Gate Station Network simulation with future & 3rd party demand Codal Requirement of Steel pipelines, ASME 31.8, Laying Methodology Corrosion Control (Cathodic Protection - TCP & PCP), Codal Requirement of MDPE pipelines, Laying Methodology, Various fittings, jointing, saddle & transition fittings

38. PIPELINE THROUGHPUT VS DIAMETER

39. PIPELINE DESIGN Consideration:- ROUTE SELECTION Pipeline length Obstructions & Sensitive areas Installation Limitations Crossings Surveys:- Topographical Geo-technical Population Density Index Soil Resistivity

40. PIPELINE DESIGN (MATERIAL SELECTION) Materials:- Carbon Steel Alloy Steel Coated Carbon Steel Non Metallic Material Consideration:- Nature of product Product Temperature & Pressure Design life Material Chemistry Coating Requirement Product Conditioning Corrosion Inhibitors Corrosion Allowance

41. SOFTWARE USED SynerGEE GAS - Network modeling for gas distribution and transmission PIPELINE STUDIO - Pipeline design, planning and hydraulic analysis AUTO PIPE - Pipeline stress analysis OFFPIPE - FEA modelling and structure analysis HYSIS - Material flow simulation analysis CAESAR - Pipeline flexibility and load analysis TL NET - flow transfer study in single phase TG NET - flow transfer study in single phase GASWORKS - Simulation & modelling software

42. SynerGEE Gas Inputs from design philosophy : Pipeline sizing, in general, is carried out by ‘Panhandle (A)’ formula. Efficiency of Pipe line - 90% Roughness of Pipe line - 65.4 micron The proposed route and length of Transmission network is estimated based on a detailed route survey, desktop study, load profile, population density, proximity to buildings, EIA and HAZOP as applicable.

43. CONFIGURED SETTINGS Min and Max - Design Pressure Constraints. Velocity – Optimum and Maximum Base values - Atmospheric Press, Temp Pressure & Elevation. GAS properties - Heat content, Specific Gravity,CO2 content, Viscosity Node Properties - Max Allowable pressure, Min. Allowable pressure, Source Gas Temp Pipe properties - Efficiency ,Friction factor, Roughness, Gas flow Temp.

44. Outputs from SynerGEE Gas Minimum pressure in the network Maximum velocity in the network Flow as obtained by diversity factor. Detailed customized reports

45. SynerGEE Gas

46. STRESS IN PIPELINE Hoop Stress - Hoop Stress remains constant through out the wall thickness and equal to σ h = PD/2t P = design pressure, psi D= Outside diameter, in t = pipe wall thickness Longitudinal Stress - it also remains constant throughout the wall thickness and equal to half of Hoop stress- σ l = PD/4t

47. PIELINE DESIGN EQUATION For Gas Pipeline, Allowable Stress is (ASME B31.8) S= S Y FET S Y= specified minimum yield stress, psi. F= design Factor, E= weld joint factor T= Temperature derating factor.

48. WALL THICKNESS ANALYSIS GAS PIPELINE (ASME B 31.8, Cl. 841.11) t= PD/ 2SFET Where t Nominal wall thickness P Design Pressure S Specified Minimum Yield Strength F Design factor E Longitudinal Joint Factor T Temperature De-rating Factor D Out side Diameter of pipe

49. LONGITUDINAL DESIGN FACTOR (E)

50. PIPELINE DESIGN (LOCATION CLASSIFICATION) Location Class Basis (No. of buildings ,X) Design Factor (F) Location Class- 1 X≤ 10 0.72 Location Class- 2 10<X<46 0.60 Location Class- 3 X>46 0.50 Location Class- 4 Multistory 0.40

51. MINIMUM YIELD STRENGTH(PSI) Specifications MYS(psi) API 5LX Grade X42 42,000 API 5LX Grade X46 46,000 API 5LX Grade X52 52,000 API 5LX Grade X56 56,000 API 5LX Grade X60 60,000 API 5LX Grade X65 65,000 API 5LX Grade X70 70,000 API 5LX Grade X80 80,000 API 5LX Grade X90 90,000

52. EXERCISE What is the nominal wall thickness for a 42 inch submerged arc welded pipeline designed for 800 psi pressure operating in a densely populated area. The pipeline is of the type 5LX G-80 and product operating temperature 40’C. t= PD/ 2SFET P Design Pressure = 800 PSI D Out side Diameter of pipe = 42 inch S Specified Minimum Yield Strength = F Design factor = E Longitudinal Joint Factor = T Temperature De-rating Factor = t= (800 X 42) / ( 2 X 80000 X 0.40 X 1 X 1)= 0.525 inch

53. POLYETHENELENE PIPELINE MRS(Minimum Required Strength) The MRS value represents the long-term circumferential stress in the pipe under which the break may occur after 50years at the earliest. Stress = MRS/ C, where C is overall service coefficient The minimum value of C for the material to be used for Gas application is 2. MAOP(Max. allowableOperatingPressure ) MAOP= (20* MRS) / [C * (SDR-1)]. Standard Dimension Ratio SDR= Dn / En Standard followed by CGD entities - IS 14885:2001

54. POLYETHENELENE PIPELINE Base resin The PE resins of “Third Generation” (PE 100 or MRS 10) in full compliance with detailed specification is being used. First Generation is PE 63, second PE 80 & Third generation is PE 100. Wall thickness The MDPE network designed and qualified for a MOP of 4 bar. The “Network analysis” and resulting structure and behaviors are based on such design. PE line pipes wall thickness shall be in accordance with the following SDR Gas mains (ND≥ 90mm):SDR17.6 Gas mains and Service lines (ND≤ 90mm):SDR11. Service lines (ND= 20mm): SDR9

55. POLYETHELENE PIPELINE Process Design Wey-mouth Formulae ◦ Q = 0.11672 * (d)2.664 * {(p12-p22)0.544 / (S * L)1/2} Velocity V = Q / A Velocity for filtered gas to be 40 m/s & unfiltered gas to be 20 m/s. Being a complex network , required specialized tools for Planning & Designing the network. Synergee software for designing the PE Network is generally used.

56. PNG DOMESTIC & COMMERCIAL CONNECTION Process Design ◦Poly flow Formulae ◦ Q = 1.522786 * 10-3 * (d)2.623 * {(h/L)0.541} Peak Gas flow is assumed @ 0.4 SCMH for one house S tandardize the design of PNG Network as follows; ½”GI pipes up to G +4 apartments OR 5 connections in case of raw house. 1”GI Pipe above 5th Floor apartment OR above five connections in raw house

57. PNG DOMESTIC & COMMERCIAL CONNECTION

58. TYPES OF PIPELINE COATING COAL TAR ENAMEL (CTE) FUSION BONDED EPOXY (FBE), SINGLE AND DUAL LAYER 3 LAYER POLYETHYLENE (3LPE) 3 LAYER POLYPROPYLENE (3LPP)

59. LINE PIPE COATING Desirable Characteristics of coating Effective Electrical Insulator Effective moisture Barrier Ability to Resist Development of Holidays Adhesion to Pipe Surface Ease of Repair Non Toxic Interaction with Environment Hardness / Abrasion Resistance Penetration Resistant Soil Stressing Resistant

60. IRON OXIDE TO STEEL TO IRON OXIDE CYCLE Materials:- Carbon Steel Alloy Steel Coated Carbon Steel Non Metallic Material Consideration:- Nature of product Product Temperature & Pressure Design life Material Chemistry Coating Requirement Product Conditioning Corrosion Inhibitors

61. ANODIC & CATHODIC REACTIONS Anodic reaction : Fe Fe + 2e Cathodic reaction : ½ O + H O +2e 2OH Fe and 2OH react further to form ferrous hydroxide precipitate : Fe + 2OH Fe (OH) Ferrous hydroxide is oxidized to ferric hydroxide Fe(OH) + ½ O + ½ H O Fe(OH) If ferric hydroxide is dry, the hydroxide sludge dehydrates to form insoluble ferric oxide which known as rust : 2Fe (OH) Fe O + 3 H O Fe O , FeO , Fe(OH) , Fe(OH) are found as corrosion products on metal surface.

62. CORROSION MITIGATION FOR EXTERNAL SURFACE CRITERIA OF C.P. FOR STEEL AND CAST IRON Pipeline AS PER NACE SP0169 A negative ( Cathodic) potential of at least 850 mV with the cathodic protection applied. These potential is measured with respect to saturated Copper/ Copper Sulphate reference electrode contacting electrolyte. A Minimum of 100 mV of Cathodic Polarization between the Pipeline surface and a stable reference electrode contacting the electrolyte. The formation of decay of Polarization can be measured to satisfy the criterion.

63. THREE LAYER PE COATING

64. FITTINGS & FLANGES Sr. No Description Specification 1. Elbows up to 2” ASTM A 234, Sch 80 2. Elbows above 2” ASTM A 234, Sch 40 3. Tees ASTM A 216 4. Flanges & Blinds ASTM A 105, 300# 5. Reducers ASTM A 216 6. Weldolets ASTM A 105, 300# 7. Insulation Joints ASTM A 105, 300#

65. GLOBE VALVE Used to regulate flow Cut-away shows stem seal plug and seat

66. BALL VALVE Typically used as block valve “Quarter-turn” valve Cut-away shows ball and seat

67. CHECK VALVE Used to prevent backflow Piston check Swing check

68. SECTIONALIZING VALVE (SV)STATION Used to isolate gas pipeline network in case of planned shut down or in emergency situation. Spacing as per ASME B 31.8 for gas pipeline As per T4S amendment dated 25.09.2020,interdistance can be enhanced beyond municipal areas + buffer. Location Class Inter distance of SVs Location Class- 1 32 KMs Location Class- 2 24 KMs Location Class- 3 16 KMs Location Class- 4 8 KMs Municipal Areas 3 KMs

69. MAIN ENGINEERING REPORT COMPONENTS Reports:- Design Basis Route Selection Report Wall Thickness Analysis Seismic Design Report Crossing Design Report Drawings:- Route Map Pipeline Schematic & Alignment SV & Chamber Other General Drawings

70. Thank You

71. FOR CGD Available Gas Source Geographical analysis of city Area of city Location, near by cities Segmentation of city into charge areas Major Highways passing through city Population Identification of Industrial area Commercials Infrastructure planning like Hospital, schools & other town planning Demand forecasting based on future planning

72. FOR CGD Route finalization based on Load distribution Future demand Vehicle movement details Trend of Increase in vehicles Field surveys for industrial & commercial Dispute of land owners with Govt. on land acquisition Sizing of pipe line Present load Demand build up Segment wise potential & realizable demand

73. DEMAND BUILD UP

74. FOR CGD Route finalization based on Load distribution Future demand Vehicle movement details Trend of Increase in vehicles Field surveys for industrial & commercial Dispute of land owners with Govt. on land acquisition Sizing of pipe line Present load Demand build up Segment wise potential & realizable demand

75. CNG SUPPLY CHAIN CNG Compressor Storage Cascade Dispenser CNG Vehicle Mobile Cascade Mobile Cascade Mobile Cascade Booster Dispenser CNG Vehicle Mobile Cascade Dispenser CNG Vehicle CNG Compressor Storage Cascade Dispenser CNG Vehicle 19-22 Kg/cm 2 g <=200 Kg/cm 2 g <=200 Kg/cm 2 g <=200 Kg/cm 2 g 19-22 Kg/cm 2 g 250 Kg/cm 2 g <=200 Kg/cm 2 g STEEL PIPELINE – NATURAL GAS CARRIER MOTHER STATION DAUGHTER BOOSTER STATION DAUGHTER STATION ONLINE STATION

76. STEEL PIPELINE DESIGN Process Design Wey-mouth Formulae Q = 0.0813 * (d)2.6667 * {(p12-p22)1/2 / (S * L)1/2 } Velocity V = Q / A Velocity for filtered gas to be 40 m/s & unfiltered gas to be 20 m/s maximum.