Gas Design Guidlines For Mega Development and Sub-Development Rev2 PDF
Gas Design Guidlines For Mega Development and Sub-Development Rev2 PDF
Gas Design Guidlines For Mega Development and Sub-Development Rev2 PDF
CONTENTS
1 INTRODUCTION 7
2 SCOPE 7
3 DEFINITIONS 7
4 COMPETENCY 8
5 OBJECTIVE 8
6 DESIGN PRINCIPLES 8
7 DESIGN CRITERIA 9
8 DESIGN PARAMETER 10
13 RISK ASSESSMENT 16
14.1 HDPE High-density polyethylene pipe (Black Colour with Yellow Stripes) 16
14.4 Sleeves 16
15.1 General 17
16.2.2 Marking 22
16.3.2 Marking 23
18 PIPE INSTALLATION 26
19 VALVE INSTALLATION 28
19.1 General 28
19.3 Pre-Installation 28
21.1 Scope 29
21.10 Commissioning 33
22.1 Design 34
22.4 Crossing 35
23 CONSTRUCTION RECORDS 36
25 QUALITY CONTROL 38
APPENDIX 1 39
APPENDIX 2 40
APPENDIX 3 41
APPENDIX 4 42
APPENDIX 5 43
APPENDIX 6 44
1 INTRODUCTION
The purpose of this document is to describe the works related to the supply, installation, testing, pre
commissioning and commissioning of the buried gas pipelines for the gas distribution network at Lusail
Development.
2 SCOPE
Due to non-availability of Natural Gas the network shall be designed base on Synthetic Natural Gas
with similar Wobbe index. Later in future when Natural Gas became available, the system will be
converted to use Natural Gas without any major modification.
Marafeq is providing the guidelines for mega-development and sub-development whom undertaking the
design and construction of synthetic natural gas distribution systems which will be connected to
Marafeq’s gas piping system within its supply areas which include:
3 DEFINITIONS
Client – The master developer Lusail Real Estate Development Company (LREDC) or its
appointed representative.
Contractor – The organization or its appointed representative, responsible for execution of the
works
Competency - The possession of a minimum level of knowledge, experience and proficiency
required to collect appropriate information, make informed decisions, and physically take the
needed actions to deliver the high-quality service of gas piping system installation.
Marafeq – The utility company which provides District Cooling, Gas supply and Waste
Management services.
Mega-developer – The owner of the district.
4 COMPETENCY
Any contractor or person engaged in the design, construction, commissioning, inspection, operation,
maintenance or alteration of a pipeline should be competent to carry out such work. This may achieved
by an appropriate combination of education, training and practical experience.
5 OBJECTIVE
The Design Guidelines forms a part of a suite of technical documents and provides a platform for:
Engineering instructions
Management procedures
Work Procedures
Method statements
Material specifications
The objective of the Design Guidelines is to define the basis for the design of synthetic natural gas
distribution and utilization systems.
6 DESIGN PRINCIPLES
Protection of customers, public, property and environment from injury, damage or harm.
Project Name: Lusail Development Gas Distribution System
Design Guidelines for Mega-development and Sub-development Rev.02
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Assurance of a safe, reliable, effective, efficient and secure supply of natural gas to
consumers.
Achievement of a financially viable investment.
Making provisions to reasonably mitigate the risk and consequences of system failure,
naturally occurring hazards or third party interference.
Optimizing the use of the entire synthetic natural gas system during its operating life cycle.
Ensuring that any design is appropriate to serve current demands yet is flexible enough to
serve markets which are identified as being available during the design period.
Ensuring that the scope of impact of failure of one or more components on the gas supply to
consumers can be controlled and localized.
Minimizing the complexity of the system from both the construction and operational stand
points.
Providing synthetic natural gas measurement data for gas system management and fiscal
purposes.
7 DESIGN CRITERIA
The upstream synthetic natural gas supply shall be considered to be suitable, constant and
adequate to supply the peak demand as stipulated in the gas purchase contract.
To improve security of supply multiple sources shall be considered. Where possible, designs
should allow for routine operation and maintenance without interruption of supply to consumers.
Provision shall be made to incorporate means of control of synthetic natural gas flow within the
distribution system including isolation of damaged facilities or components.
The gas supply source pressure considered in design shall be determined based on the
synthetic natural gas supply contract and upstream design conditions.
The distribution system shall be designed without compression.
The distribution system shall be adequate for the design load at each stage of its development.
Distribution system shall be designed to supply a forecast hourly peak demand.
Distribution system design shall be based on the predicted peak hour flows anticipated twenty
five (25) years ahead.
The load that shall be applied during design should be diversified. Considerations in
determining the load diversity should include the nature of the facility being designed, the type
of load and the number of consumers.
The load diversities for pipelines, pressure reducing stations and mains shall be the same.
However this load diversity is different from that used for gas services, meter sets and
utilization piping systems.
Designs should minimize the types and size range of materials and use only material items for
which approved Material Specifications exist. All materials should be suitable for local climatic
conditions.
All materials, assemblies and installations shall assure correct functionality and full operability
taking due account of ambient conditions of the location.
The design shall allow construction to be undertaken using existing and/or reasonably
available methods, tools and equipment. Where appropriate industry best practices shall be
utilized.
The design shall be prepared considering the location of other utilities plant or obstructions,
where known.
The design shall include provision for Gas Services to be installed to every plot and/or building.
8 DESIGN PARAMETER
The following design parameters have been adopted by MARAFEQ due to the nature of the specific
local environment in which the synthetic natural gas distribution systems must be constructed.
Maximum
Calorific SNG Calorific SNG Specific
No. LPG Source Wobbe Index Operating
Value Value Gravity
Pressure
Net 2887
1 *LPG 1518 Btu/cf 1283 1.399 2 Bar
Btu/cf
Gross
2 *LPG 1545 Btu/cf 1283 1.449 2 Bar
3129 Btu/cf
**Natural 960 to
3 1283 – 1385 0.55 to 0.66 4 Bar
Gas 1050 Btu/cf
Notes: *LPG information from WOQOD LPG chemical composition table Appendix 2
Distribution and service line Maximum Operating Pressure (MOP) design shall be 2 bar and
minimum operating pressure shall be at 1.2 Bar for SNG system.
The Gas Distribution Network to be installed at a minimum, to comply with the recommended standards
and codes of practice listed below.
IGE/GL/9: Guidance for large consumers in dealing with Natural gas supply emergencies
IGE/SR/24: Risk assessment techniques
IGEM/TD/13 Ed 2: Pressure regulating installations for Natural Gas, Liquefied Petroleum Gas
and Liquefied Petroleum Gas/Air
IGE/SR/22: Gas Purging and Commissioning Method.
IGE/SR/23 2nd Imp: Venting of Natural Gas.
IGE/GL/1; edition 2; 2005 “Planning of gas distribution systems of MOP not exceeding 16 bars”.
IGE/GL/5; edition 2; 2005 “Procedures for managing new works, modifications and repairs”.
IGE/GM/8 Part 1 Non domestic gas meter installation
GBE/PL2 Technical Specification for Polyethylene Pipes and Fittings
ASME B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24 Metric/Inch
Standard
The network shall allow for gas services to be installed to every residential and commercial
premise in the sector.
The network should be looped when serving more than 200 consumers.
Looped networks may have single fed branches.
Looped networks should have a dual supply from feeder mains outside the sector.
Minimum design operating pressures for pipelines within the distribution network should be 1.2
bar.
The primary function of a gas service is to transport synthetic natural gas from a distribution main to
service isolation valve (SIV). Each gas service shall be sized to deliver the quantity of synthetic natural
gas that meets the connected customer requirements. A gas service is the takeoff from distribution line
to each individual plot.
For some installations, a flow limiting device (FLV) shall be installed near the main for
automatic restriction of gas flow in situations where excessive quantities of gas flow through the
pipe as a result of damage to the gas service.
For some customers, multi-occupancy buildings and commercial or industrial installations, an
underground service isolation valve (SIV) shall be installed for manually isolating the supply of
synthetic natural gas from the connected customers.
For all installations and customers, a riser shall be from below ground to above ground.
For all installations and customers, above ground pipe shall be that is thermally stable at
ambient temperatures.
For all installations and customers, an above ground ECV for manually isolating the supply of
synthetic natural gas from connected customers.
Shall consist of both buried and above ground components from the main to the outlet of the
Service Isolation Valve (SIV) and Emergency Control Valve (ECV).
Should install only one gas service to a plot. Conversely, a single gas service should not serve
multiple plots.
May be dual (i.e. two services from a single service tee).
Above ground service pipe shall be designed to take into account local climatic conditions.
Services should be external to buildings.
Underground Routing - The gas service shall extend underground from a connection to a
distribution main. The gas service should be routed perpendicular to the main directly towards
the plot boundary, building or plot external wall where synthetic natural gas is to be provided.
Also underground gas service piping shall not:
directly entering a building
For sizing the gas service length shall include the equivalent length of all valves and fittings,
including the service tee and flow limiting device, that comprise the service.
The maximum gas velocity within the gas service pipe shall be 15 m/s.
The maximum pressure drop over the gas service length shall be limited to 20% of the
minimum gas service inlet pressure.
It shall be referred to MARAFEQ Document for Pressure Reducing Station Guidelines No:
LUS-CPALL-MAQ-SPE-UT-0006.
13 RISK ASSESSMENT
Mega-developments shall comply with Marafeq requirements set out in the document no: LUS-CPALL-
MAQ-SPE-UT-0007, all Risk Assessment shall be finalized with compliance statement to this Design
Guidelines.
14.1 HDPE High-density polyethylene pipe (Black Colour with Yellow Stripes)
All underground pipes are high density Polyethylene pipe of type PE 100, SDR 11 constructed
according to code prEN 1555-2 or ASTM D 2513.
14.4 Sleeves
For HDPE Pipe crossing under railway lines and sewage water lines) Steel Pipe Sleeves:
ASTM A 53/A 53M, Type E, Grade B, Schedule 40, galvanized steel, plain ends.
Cast-Iron Pipe Sleeves: Cast or fabricated "wall pipe," equivalent to ductile-iron pressure pipe, with
plain ends and integral water stop, unless otherwise indicated.
UPVC / GRP schedule 40 sleeves with 200mm concrete in casement as per normal practices.
Direct welding into PE pipe, by using socket fusion (125mm and below) or butt welding180mm and
above.
Ball polyethylene
a. Body: PE.
b. Ball: PE.
g. Include plastic valve extension and or extension spindle for steel valve
15.1 General
Only certified PE jointers shall be permitted to perform PE fusion jointing. Contractor shall provide
original certificates of certified PE jointer from the issuing body to Supervising Consultant for approval.
A method statement of construction for PE fusion joints shall be submitted by Contractor for Supervising
Consultant approval. Final approval shall be by Marafeq or its representative. This method statement of
construction shall ensure that all fusion joints are of high integrity, and shall include, but not limited to:
a) Procedures for the operation, maintenance, periodic inspection and testing of fusion tooling
and equipment.
Barcode labeled or auto recognition electro-fusion jointing shall be used and all fittings shall incorporate
fusion indicators.
The equipment used for joint construction shall provide fusion data in the form of a print out specific to
each joint and shall in addition, include the operator identification reference. These print outs shall form
part of the as laid records.
The electro-fusion control box shall deliver the correct fusion parameters to the electro-fusion fitting. A
power generator shall provide the power requirements of the control box, taking into account the
electrical characteristics of the control box.
Alignment clamps shall be used for all types of electro-fusion systems to minimize misalignment and
movement during electro-fusion of the joint.
1) Pre-Joint Checks
a. Ensure that the correct jointing parameters for the machine and pipe being welded are
checked with manufacturer’s specifications.
e. Ensure pipe and fittings to be jointed are compatible with each other.
h. To control dust contamination, when possible welding will be carried out in a simple
protective shelter. The floor or ditch should be covered by tarpaulin (or similar).
2) Jointing Process
a. Ensure correct fusion and cooling times are observed and adhere too.
b. Ensure all fusion indicators have raised. If not, cut out and make new weld.
c. Do not remove clamps from fittings until cooling time has elapsed.
d. Always ensure mark the completed joints with the numbers issued from the electro fusion
control box along with date, time, jointer number and machine number.
Each butt fusion will be assigned a number that is recorded on the fusion as-built drawing. The
number and date will also be marked using an appropriate marker, on the external surface of the pipe
adjacent to the fusion.
Cleaning of the heater faces will be undertaken by aborting a joint after heating as required but, at
minimum, will be done on the first joint of the day and for each change of diameter.
During fusing the alignment of the pipe will be checked and monitored. Additionally the joint will be
protected from contaminants (e.g. water, oil, dust, blowing sand.)
Manufactures recommended joint cooling time will be extended depending on the ambient temperature.
Completed Fusions will be subjected to an external visual inspection assessment. In addition to visual
inspection, the external fusion bead will be removed and some internal fusion beads may also be
removed. The removal beads will be subjected to testing (Refer IGE/TD/3 Edition 4 Appendix 7).
Removed beads shall be numbered and all pieces retained in storage.
Pre-Joint Checks
a. Ensure that the correct jointing parameters for the machine and pipe being welded are
checked with manufacturer’s specifications.
The trimmer blades must be clean and sharp and the trimmer must be square
with power in reverse to ensure a clean cut.
The heater plate must have a control system capable of maintaining a uniform
temperature over the area in contact with the pipe.
The hydraulic system must be effective and a gauge must be attached which
can accurately resolve pressures to be used.
e. Clean equipment to ensure oil and grease do not contact pipe surfaces.
f. To control dust contamination, welding is carried out in a simple protective shelter. The
floor should be covered by tarpaulin (or similar).
g. To ensure that heater plate is fully clean a dummy weld every time the plate has been
allowed to cool will be completed.
h. Dummy Welding: To ensure that contamination does not affect welds in installed pipes, it is
necessary to make a dummy weld at the start of any welding session after the plate has
been allowed to cool. It is only necessary to follow the welding cycle to the point where the
pipe is snapped from the plate. Following cooling, the surfaces may be retimed to allow
production welding to begin. Alternatively a scrap piece of pipe may be used and then
discarded.
i. Do not remove clamps from fittings until cooling time has elapsed.
j. Always ensure mark the completed joints with the numbers issued from the electrofusion
control box along with date, time, jointer number and machine number.
Employer name.
Date of test.
Welding position.
Code/testing standards.
There are some special cases where it is needed to use steel piping instead of the HDPE piping, some
of these cases are the above ground crossings (Bridges) and in special cases were the use of steel is
recommended by the standards and Marafeq. The use of steel material shall be Sch 40 minimum and
all pipes, fittings and valves should be designed and installed as per the standards and installation
requirements below:
ASTM A106 Standard Specification for Seamless Carbon Steel Pipe for High-Temperature
Service
API 5 L Grade B Specification for Line Pipe
A105/A105M- Standard Specification for Carbon Steel Forgings for Piping Applications
ASME II Part C :Specifications for Welding Rods, Electrodes, and Filler Metals
ASTM A370 Rev A: Standard Test Methods and Definitions for Mechanical Testing of Steel
Products
API 1104 Welding of Pipelines and Related Facilities
ASTM: All ASTM relevant materials standards.
AWS D10.11M/ANSI D10.11 Guide for Root Pass Welding of Pipe without Backing Strip.
AWS A2.4 :Standard Symbols for Welding, Brazing, and Non-destructive Examination
AWS A3.0: Standard Welding Terms and Definitions.
AWS A5.1/A5.1M :Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding
AWS A5.5 :Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc Welding
AWS A5.17/A5.17M:Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding
AWS A5.18/A5.18M :Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding
NACE MR 0175- 2001: Petroleum and natural gas industries — Materials for use in H2S-
containing environments in oil and gas production
AWS QC1: Standard for AWS Certification of Welding Inspectors (2007)
API RP 2201: Safe Hot Tapping Practices in the Petroleum & Petrochemical Industries.
ISO 3690: Welding and Allied Processes - Determination of Hydrogen Content in Ferrite Steel
Arc Weld Metal.
ISO 21809-2:2007, Petroleum and natural gas industries – External coatings for buried or
submerged pipelines used in pipeline transportation systems - Part 2: Fusion-bonded epoxy
coatings.
Suitable 3 Layer Fusion Bonded Epoxy or Polyethylene coating shall be used for protection of pipe from
corrosion. The details procedure of application the coatings to be submit by contractor.
The pipes shall be provided with mill certificates and shall contain at minimum all mechanical and
chemical properties, heat number and production test results.
The wall thickness of the fittings shall match that of the pipe to which they will be welded.
Pipes with greater wall thickness will be acceptable provided the ends are counter bored to produce a
wall thickness matching that of the fittings.
Pipe ends will be beveled for welding in accordance with ANSI B16.25.
Pipe shall be minimum ASTM A106 Grade B Schedule 40 or API 5L Grade B Schedule 40
Pipes ends shall be fitted with a protective dust cap prior to shipping.
16.2.2 Marking
Pipes shall be clearly and permanently marked with the following information:
Fittings shall be manufactured from material with strength equal to or greater than that of the pipe and
shall be suitable for welding to the line pipe. The wall thickness of the fittings shall match that of the
pipe to which they will be welded.
Fittings with greater wall thickness will be acceptable provided the ends are counter bored to produce a
wall thickness matching that of the pipe. Ends will be beveled for welding in accordance with ANSI
B16.25. Flanges shall be welding neck with 1/16" raised face for Class 150 flanges. The material shall
be of carbon steel.
16.3.2 Marking
Fittings and flanges shall be clearly and permanently marked with the following information:
IGE/TD/4 Edition 4 PE and Steel gas services and service pipe work.
API 607 Fire Test for Soft-Seated Quarter Turn Valves
BS 5351 Specification for steel ball valves for the petroleum petrochemical and
allied industries.
ANSI B16.5 Pipe Flanges and Flanged Fittings
API 6FA Specification for Fire Test for Valves
BS 6755 Part 1 Testing of valve, specification for production pressure testing requirement
ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
GIS V7 Part 1 Specification for Distribution Valves Part 1: Metal-bodied line valves for use
at pressures up to 16 bar and construction valves for use at pressures up to 7 bar
All valves shall be turn clockwise to close, full bore and stop when fully open or close
All valves shall be metallic and manufactured with corrosion coated material
Valve shall be able to withstand 4 bar operating pressure and 7 bar test pressure
Valve 50mm and below shall be lever operated and shall be capable being remove
Belowground valve material shall be off ductile iron material with corrosion coating
Belowground valve shall have downpipe adapter and or extension spindle for steel valve
c. Stem: Steel
The parent material test certificates indicating the chemical analysis and mechanical properties.
Calibration certificates for the used equipment such as; thermometer, volt and ampere meters.
Welder’s certificates.
CSWIP-WI-6-92: Requirements for the Certification of Visual Welding Inspectors (Level 1),
Welding Inspectors (Level 2) and Senior Welding Inspectors (Level 3) (fusion welding) in
accordance with the requirements of BS EN ISO 17637:2011 (2011).
a. Production, field weld & repair weld - IGE/TD/3 (Operating pressure equal and more than 2
bar) – 100% Visual Inspection, Min 10% NDT of total weld joint and 100% for bridge
crossing.
b. Production, field weld & repair weld - IGE/UP/1B (Operating pressure less than 2 bar) –
100% Visual inspection
Acceptance criteria for all welds shall be as per API 1104 - Welding of Pipelines and Related Facilities
or as per the project specification and appropriately repaired and re-inspected. The results of the
inspection shall be used to control the quality of welds.
The NDT for production welding will be done after the weld has cooled down to ambient temperature.
Welding requirement of pipeline shall also be referred to ASME B31.8 Transmission and Distribution
Piping System.
All costs for additional testing, or weld failure shall be paid by the Contractor. This includes costs for the
testing firm and the Contractor’s own costs.
The material transportation handling and storage is to be carried based on the IGE/TD/3 Edition 4.
18 PIPE INSTALLATION
Mains pipe shall be laid to a minimum top cover of 1.00 m at all locations other than Special Crossings.
Marker tape and Tracer Wire shall be laid 400 mm above the pipe along the entire length of the mains.
Minimum clearance of the mains shall be 600 mm from electric cables, 500mm from sewage water
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pipes, 250 mm from other utilities and 1200mm under roadway, railway lines in case of crossing and
1000mm in parallel with railway accessories. Where these minimum separation distances cannot be
achieved, sleeve with concrete encasement or concrete slabs shall be installed between the mains and
the cables utilities in question as per approved details.
The crossing on the railway groups with total width more than 20 meters is not allowed
The laying of the pipe and the making of connections shall be in accordance with IGE/TD/3.
During pipe laying operations the ends of pipes shall remain temporarily sealed with suitable stoppers.
The angle of intersection between a pipe crossing and the highway shall be as near to 90 degrees as
practicable. In no case shall this be less than 30 degrees.
The minimum bend radius for the installation of PE pipe shall be 15D (D) = outside diameter of pipe).
When a joint falls within the pipe bend section, then the minimum radius shall be 25 D.
The introduction of stresses shall be avoided during pipe installation, both in the polyethylene pipe or at
joints.
Prevent the PE pipe from being damaged by contact with sharp materials during its installation.
Ensure that the PE pipe is uniformly supported.
Ensure that no rock or sharp object/stone impingement exists at the pipe soil interface.
Ensure that when the pipe is laid within a sleeve, the sleeve ends to install pipe spacer in such
a way that no stress or cutting effect can be transmitted to the HDPE pipe.
19 VALVE INSTALLATION
19.1 General
Full bore polyethylene ball valves / Ductile Iron Gate valves or Steel Ball valve shall be installed in the
distribution mains system for the purpose of sectorisation and isolation where design requirements
dictate and a service ball valve before each plot boundary. The installation of these valves shall comply
with the following requirements:
19.3 Pre-Installation
Prior to installation, all valves shall be checked for defects or damage.
All valves shall be thoroughly cleaned internally immediately prior to installation and all ends shall be
kept closed with protective coverings when the valve is not being worked upon.
Following installation, and prior to commissioning, all valves shall be operated from open to closed and
closed to open positions, respectively.
Purge points shall be installed either side of all main valves and these pressure points shall be 32 mm
diameter reducing to 20 mm.
For valves of 200 mm diameter and above the valve shall include a gear assembly and for such valves
a precast concrete blocks (PCC) or reinforcement cement concrete (RCC) chamber shall be provided
so as to allow access to and operation of the valve/gear assembly. Valve size 200mm and above shall
use Ductile Iron Gate valve with block and bleed capability.
For all service valves a surface box shall be provided 300 mm clear opening ductile iron cover while
main valves shall have double triangular 600mm clear opening and also ductile iron cover. The surface
boxes shall be installed flush with the ground surface and the valve spindle and pressure points shall
terminate 100 mm below the underside of the cover. All ductile iron cover shall have client logo, “gas”
marking and material standard stamp on it, refer to the Typical Manhole Cover Details drawing number
LUS-CPALL-MAQ-DWG-UT-30306 in Appendix 4.
Security devices with valve identification markings shall be fitted to the spindle of valves to prevent un-
authorized operation.
Aluminum or Stainless Steel marker plates shall be installed on either buildings or securely fixed posts
adjacent to the location of all valves. The plates shall be coated with an epoxy type coating (colour
white) and the required lettering shall be silk screened (colour black). The layout of the marker plate
lettering and fixing arrangements shall be agreed with the Marafeq.
Completed installation of tracer wire should conduct a traceability and continuity test. The suitable
machine shall be used to doing the test. Contractor to ensure all connection and tracer wire are in good
condition and not damaged. If found any damage during testing, contractor to repair accordingly.
21.1 Scope
This specifies the minimum criteria to be adopted for pressure testing and commissioning of
polyethylene and steel gas distribution mains and services operating at pressures up to 4 bar. Testing
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and commissioning shall be in line with the requirement specify in IGE/TD/3, IGE/SR/22, IGE /TD/1.
Prior to testing and commissioning, the pipes must be cleaned from any debris by carrying out pigging.
Pigging procedure must be provided by Contractors doing the pipe installation for supervision
consultant approval.
Intermediate pressure and low pressure testing criteria have been included in this specification to cover
situations where the normal operating pressure of isolated sections of main must be reduced due to
safety constraints.
The objective of the pneumatic test of polyethylene mains system and steel pipes is to prove the
integrity of the system before commissioning.
The pneumatic test sets out to ensure that any leakage is within permissible limits (Permissible
Pressure Loss).
The test shall take into account the fact that HDPE pipe creeps during the test, contributing towards any
measured pressure loss.
Any part of the supply network which is constructed, diverted, altered or renewed and cannot be
included in a sectional or overall pressure test i.e. a tie-in, shall be tested at the system Maximum
Operating Pressure (MOP) using leak detection fluid. Such occurrences shall be minimized and shall
be approved by the Supervising Consultant and final approval be by Marafeq or its representative.
Pressure Gauges.
Ball Valves.
Barometer.
c. Pipe is SDR 11, PE 100 (HDPE) or carbon steel pipes Schedule 40 as minimum.
d. The reference test temperature is taken as 20ºC. (The temperature is likely to be higher than
20ºC in which case the creep allowance provided will be higher. Refer to IGE/TD/3 table
A4.4).
The method of calculating the permissible pressure loss for a 24 hour test shall comply with section
A4.2 of IGE/TD/3.
The piping system should be clean and free from any debris, dirt, waste particle and mud prior
testing works. Suitable procedure to be taken consideration by contractor to implement the
cleaning works.
All caps, plugs, bends, tees and other fittings on mains incorporating flexible joints shall be
restrained against any movement during the test.
The trench shall be backfilled up to 200mm at least to secure the pipes in position before
pneumatic pressure is applied.
All temporary pipe, fittings and equipment fitted to the section of main under test shall be
appropriately pressure rated.
The stand pipe used for the purpose of pressurizing the main shall be fitted with a pressure
relief valve to ensure over-pressurization of the main does not take place.
Consideration shall be given to means of minimizing noise during pressurization and de-
pressurization.
Where the main is exposed and accessible to the public, notices warning that pressure testing
is in progress shall be prominently displayed and the area securely cordoned off.
Before final pressurisation commences a visual check shall be made to ensure that the test
section is secure for pressurization.
No person shall enter any excavation whilst the test pressure is being raised, the main is under
test or the main is being depressurized.
Throughout the duration of the test, the system shall be examined at regular intervals to ensure
that all anchorage points are secure and that no hazards exist.
Prior to pressure testing, the completed pipe work section shall be cleaned and free from
construction debris and foreign matter.
Mains to be tested shall generally be isolated into sections of and each section shall be tested
individually unless there is no intermediate valve in between.
Immediately upon satisfactory completion of the sectional tests, the whole of the main shall be
subjected to a pneumatic soundness test at maximum working pressure 1.5 MOP.
Following the satisfactory completion of the final tests, the main shall be purged and connected
to the live main in accordance with IGE/TD/3 and the tie-in joints tested under operating
conditions with leakage detection fluid.
Mains which are not commissioned immediately following testing shall be de-pressurized and
replaced with nitrogen at 2 bar for monitored appropriately. This pressure will maintain until
commissioning works.
Test instruments shall be fitted so that they can be read and operated without entering the
trench or standing in line with the end of the main.
Closed valves shall not be used as end caps. All valves shall be tested in their open position.
Where a valve is fitted at the extremities of the main under test the valve shall be securely
blanked and anchored against movement.
Dry air shall be introduced under controlled conditions into the main or service until the
appropriate test pressure is reached. Care shall be taken to ensure that the pipe-work is not
subject to over pressurization.
No person shall enter the trench whilst the test pressure is being raised, during the test or whilst
the main is being depressurized.
Before the start of the test period the temperature of the air in the pipe shall be allowed to
stabilize before the test period is commenced. This shall be indicated by a stable pressure
reading.
When the test has been completed to the satisfaction of the Supervising Consultant and
submitted to Marafeq or Engineer for final acceptance, the air pressure shall be released
through suitable vents in a controlled manner until the whole of the main is at atmospheric
pressure.
The Supervising Consultant and or Marafeq or Engineer shall confirm by checking the gauges
installed at all extremities that the pressure within the whole of the main has been reduced to
atmospheric pressure. The Consultant shall record this information on the test certificate before
authorizing further work to proceed.
If the leakage still happen after rectified all the visible connection and fittings, contractor to use other
suitable method to find the leakages.
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Any leakage on a HDPE fusion joint should not be repaired and the joint should be cut away and
remade.
21.10 Commissioning
The purpose of commissioning is to gasifying the pipeline with fuel gas (SNG, NG or LPG). Therefore it
is necessary to remove or purge the air, inert gas or nitrogen gas in the existing or new pipeline using
the fuel gas. Two basic methods can be employed for the purging operation
a. Ram Purging- purge gas is fed continuously at one end of the pipe work and the gas mixture
being vented off/flared at the other end under a steady and continuous condition until the
total content of the pipe work is replaced by the purge gas
b. Cycle Purging (pressure and vent) – the content inside the closed pipe work system is
diluted by introducing inert gas with minimum at 10% (Nitrogen) of the total pipe volume and
then introduce the fuel gas into the pipeline. Once the pipeline is full with the inert gas and
fuel gas, the mixture shall be vented off until gas percentage is 48 - 50% (SNG Gas) from
the vented content (it shall be more than 95% for Natural Gas). This process is repeated
until the required dilution off fuel gas/air is achieved or the replacement of the purge gas is
completed.
The Gas contractor through their Supervising Consultant shall submit a detailed procedure with
accompanying sketch(s) for all commissioning operations, 48 hours prior to the planned commissioning
date. The procedures shall be subjected to the Marafeq approval.
The planning and execution of the commissioning of mains must avoid large networks and excessive
lengths of feeder mains being commissioned at any one time.
The following criteria shall apply when planning and preparing a commissioning procedure:
Looped sections of main shall be minimized and where the purge section contains a loop, it
shall be physically isolated by closure of a valve
Branch sections shall be purged simultaneously or sequentially.
Flow stopping on live mains shall be by a double block and bleed system.
Purge velocities shall not exceed 20 m/s
All vent pipes shall be manned during purging operations and equipped with flame arrestors.
c. Contractor to take consideration for tie-in works and submit the detailed procedure prior
the activity.
22.1 Design
Civil works for below ground service piping will be in accordance with:
IGE/TD/3
Project specifications
The International codes, project requirements and requirements of the local approving
authorities.
Trench depths shall be sufficient to provide 1000 mm of cover to mains piping and service piping.
Cover shall be measured to the top of the pipe. Trench widths shall be a minimum of 400 mm or pipe
diameter plus 150 mm on each side of the pipe, whichever is the greater. However, where rapid
trenching techniques are used the trench need only be of sufficient width to allow fine filling material to
surround the pipe completely. The mains shall be protected against mechanical damage by means of
concrete slabs or steel plates at a height of 150 mm above the gas pipes, be embedded in sand or soil
and be compacted with backfill material firmly and evenly before making good of the road surface.
Excavation shall be by means of hand and/ or machine as expedient and it shall be the Contractor’s
responsibility to locate and protect all services, utilities, etc. encountered during excavation.
The width of the trench shall be maintained until commencement of backfilling and the Contractor shall
be responsible for providing any necessary shoring and supports for such purpose, if required, and for
ensuring the safety of workmen and other persons who may enter the excavated trench.
Excavations shall be kept free from water at all times and before commencement of excavation the
Contractor shall determine the water table level and, if considered necessary, install a well point
dewatering system.
Trench bottoms shall be uniformly graded to provide a firm base for the pipe along its length. The bed
and sides of the trench shall be free from loose stones and other sharp objects which may damage the
pipe during or after installation. Pipe bedding should be free from stones minimum distance of stones
away from pipe should be 150mm
22.4 Crossing
Sleeves and carrier pipes below roadway and railway shall be installed in accordance with the
Authorities’ requirements and shall have a minimum cover of 1,200 mm measured from the top of the
pipe to the ground level.
Installation of road crossings by open cut methods shall be so scheduled to minimize interruption to site
traffic and the Contractor shall co-ordinate such activities with the Supervising Consultant, Marafeq and
other third party contractors.
Pipe crossing the road not meeting the minimum depth requirement shall be installed in sleeve with
concrete encasement.
The pipe surround shall apply 150mm on top of pipe by using stone free material. The sample of
material shall submit in detail for Engineer’s approval.
The trench shall be further backfilled and hand tampered, with stone free material (dune/wash) to a
level 400 mm above the top of the pipe.
At this level a warning tape shall be laid along the length of the pipe. The tape shall be supplied in
accordance with Warning Tape with tracer wire or as specified by the Marafeq. The trench shall be
further backfilled to the finished level with the excavated material and compacted with a mechanical
hand compactor. Backfill material should be well compacted to avoid trench settlement.
The surface box should be constructed with either solid blocks or precast concrete. Blinding concrete
Project Name: Lusail Development Gas Distribution System
Design Guidelines for Mega-development and Sub-development Rev.02
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should be provided prior to installation of the pre-cast concrete/solid block. Bitumen coating should be
provided on the surface of the plaster where it comes in contact with the soil.
23 CONSTRUCTION RECORDS
As-built drawings including details of surface construction, depth of cover, pipe protection, etc.
Welder qualifications.
NDT records.
Quality control procedures and documentation.
Inspection records.
In order to assess the Contractor’s proposal through Supervising Consultant , Marafeq, the Engineer’s
has the right to request the complete list of material, apparatus and various fittings that the Contractor
envisages using for the execution of the work with the detailed manufacturers details associated with
the selected materials and equipment.
During the work preparation period of 30 days, the Contractor, through its Supervising
Consultant shall submit to the Marafeq or Engineer’s:
A detailed program for the work per construction phase. The work shall be in a multi-utility
environment. The construction program should take into consideration the other utilities and
adapt to this situation.
Full set of shop drawings including layout plans and combined profiles.
One set of complete detailed construction drawings for the work; these drawings shall provide
all information necessary for their comprehension and verification.
The design calculation notes, which may be supplied in different files for restitution to the
Contractor after examination.
If necessary, within a period of 15 (fifteen) days after return of the draft construction drawings
accompanied by all observations by the Engineer, the drawing up of a new rectified drawing to
take the observations into account.
Detailed list of suppliers and specification of materials and equipment showing particularly the
compliance with the Engineer specification.
Method of statement including:
- Description of the project.
- Objectives-Execution of Work.
- Reference Documents.
- Material.
This list is not exhaustive; the Engineer may ask the Contractor at any time for any specific construction
or technical drawing.
25 QUALITY CONTROL
The Contractor should be able to document and demonstrate that all the activities relating to quality
throughout the process from confirmation of order to design/development, purchasing, manufacturing
and delivery to the customer have been carried out in a properly monitored and well organized fashion.
As a minimum, the Contractor should provide a quality manual in which the quality system is described.
The areas of responsibility and authority with regard to quality should be clearly defined such that the
performance of the system and the authority of the quality system manager can be assessed.
The quality system should be based on the requirements laid down in the international standard for
quality systems, ISO 9001.
APPENDIX 1
TYPICAL PRESSURE TEST CERTIFICATES FORM IN: IGE/TD/3 Edition 4:
APPENDIX 2
APPENDIX 3
APPENDIX 4
NOTES
SPECIFICATIONS:-
TYPE: CLASS 'B' 125
LOADING - 125 KN
MATERIAL - DUCTILE IRON (500/7)
STANDARD - EN 124 D-400
SECTION A-A
SECTION A-A
DRAWING TYPE:
DETAILED DESIGN
CLIENT:
PROJECT :
LUSAIL DEVELOPMENT
LUS-CPALL-MAQ-DWG-UT-30306 0
DRAWING SCALE:
LUSAIL DEVELOPMENT
APPENDIX 5
NOTES
CLIENT:
UTILITIES PROVIDER:
PROJECT :
LUSAIL DEVELOPMENT
ENLARGED PLAN GAS DISTRIBUTION NETWORK
PLAN VIEW ENLARGED PLAN SCALE 1:1 (DETAIL D)
DRAWING NAME:
LUS-CPALL-MAQ-DWG-UT-30303 1
DRAWING SCALE: AS SHOWN @A1
LUSAIL DEVELOPMENT
APPENDIX 6
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE
STATED.
LEGEND
T - CONNECTION
ASPHALT ROAD
ASPHALT ROAD
UNMADE
UNMADE
I L QA I L QA I L QA I L QA
A A A A
T
S
S
S
T
T
S
LU
LU
AR
AR
LU
LU
AR
AR
G A S G A S
PAVING TILE
G A S G A S
EDGE OF ASPHALT
EDGE OF ASPHALT
EDGE OF KERB
PAVING TILE
EDGE OF KERB
1 09.04.12 ISSUED FOR APPROVAL
DRAWING TYPE:
DETAILED DESIGN
UTILITIES PROVIDER:
PROJECT :
LUSAIL DEVELOPMENT
GAS DISTRIBUTION NETWORK
DRAWING NAME:
APPROVED BY:
A.ABUSHAIKHA DATE:
DATE:
30.04.2012
D.R.PHILIPS 30.04.2012
LUS-CPALL-MAQ-DWG-UT-30304 1
DRAWING SCALE: NTS @A1
KEYPLAN:
NOTES
ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE
STATED.
LEGEND
T - CONNECTION
ASPHALT ROAD
LUSAIL QATAR LUSAIL QATAR
GAS GAS
PAVING TILE
PAVING TILE
EDGE OF KERB
EDGE OF KERB
1 09.04.12 ISSUED FOR APPROVAL
DRAWING TYPE:
DETAILED DESIGN
ISOMETRIC VIEW
STONE MARKER FOR
UTILITIES PROVIDER:
HARDSCAPE AREAS
PROJECT :
LUSAIL DEVELOPMENT
LUS-CPALL-MAQ-DWG-UT-30305 1
DRAWING SCALE: NTS @A1