GAIL (INDIA) LIMITED

GUIDELINES FOR MODEL PIPELINE

INSTALLATION

(TERMINAL /PRS/ IP / SV / RT/ DT/ MAINTENANCE BASE)

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 PREFACE

Over the years, GAIL as a national pipeline operator has contributed to the growth and development

of natural gas pipeline infrastructure and natural gas market in the country. In this process, GAIL,

since its inception has commissioned various natural & LPG pipeline projects to meet the clean fuel

of modern age as a catalyst towards growth. As these pipeline installations ( Terminals ,

Intermediate Pigging Stations, SV Stations, PR Stations , Receiving Terminals , Gas Dispatch

Terminals & Maintenance Bases) have been commissioned in various phases and with various

thought processes, it is felt essential to develop & devise the MODEL STATION guideline for up

keeping the GAIL’s stations in a unified standard to meet the noble objective of supply and

transportation of natural gas through its state of art natural gas transmission pipeline system in a

sustainable way. The need of model station guidelines are conceptualized by integrating the various

aspect of a gas installation which includes entrance , sign boards, Control Room , Process Area ,

Boundary wall , color coding, Approach Road & internal pathways , Electrical System, Sewerage

System, Sanitation and Sustainability initiatives.

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 CONTENTS

1. MAIN GATE & BOUNDARY WALL

2. WARNING SIGNS & DISPLAY BOARD

3. CONTROL BUILDING/ GUARD ROOM

4. PROCESS AREA & COLOR CODING OF PIPING ITEMS

5. CHAIN LINK / BARBED WIRE FENCING & ELECTRIC POLE

6. INTERNAL ROADS

7. STORM WATER DRAINAGE

8. EXTERNAL DEVELOPMENT

9. PARKING SHED

10. CONSTRUTION OF STORAGE SHED

11. LIST OF DOCUMENTS AVAILABLE

12. OTHER FACILITIES

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
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CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
1.0 MAIN GATE & BOUNDARY WALL

1.1 M.S. gate of size 4 m/ 5 m (with wicket gate as per requirement) x3 m high shall be provided. The
main entrance gate shall be painted black color with GAIL logo and sign board.

Board should be yellow color and writing over it in black color with GAIL logo.

1.2 BOUNDARY WALL

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
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i) 3 m high boundary wall with respect to finished ground level of terminal alongwith Y angle with
concertina coil on top of 600 mm height alongwith gate shall be provided for stations.
ii) R.C.C. Frame structure with precast wall panel of 100 mm thickness.
iii) M/s GAIL logo on each boundary wall column.

1.3 PAINTING

Main Surface: Morning Dream (Asian Paints)

Celestial Sun (Berger Paints)

Projections: Terracotta-N (Asian Paints)

Rust Red (Berger Paints)

Painting should be Water Resistant & Weatherproof.

2.0 WARNING SIGNS & DISPLAY BOARD

2.1 Various warning signs shall be painted & displayed at each terminal such as:-

i) Warning sign of Danger

ii) Name of Terminal
iii) Overhead Terminal Name
iv) Material Safety Data
v) General Safety Guidelines
vi) Board for prohibited area declaration & entry of banned articles. At security Gate
vii) P&ID and SOP
Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 viii) Safety instruction & Important telephone nos.
ix) Dos & DON’Ts
x) Warning instructions on equipment
The background of the board shall be yellow with black lettering.
Overhead terminal name

Display Board Sizes

- The display board shall be 7’ X 4’

- Background – White/ Yellow
- Lettering – Black (day glow paint)
- Colored GAIL logo (day glow paint)
- Location – Top of Building Entrance
- GAIL Name Font size: H=200 mm
- Terminal / SV Name Font Size: H=150 mm
- Slogan Font sixe: H=100 mm

Display Board Material

- Preferably in Water Resistant & Weatherproof Acrylic Sheet or suitable for outdoor
applications

Overhead Terminal Name Display

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 Material Safety Data

General Safety Guidelines

Terminal Name Outside Displayed

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
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 Assembly Point Sign Board

3.0 CONTROL BUILDING/ GUARD ROOM

3.1.1 EXTERNAL PAINTING

The external surfaces of building shall be finished with weather resistant External Acrylic Emulsion
Paint.

Main Surface: Morning Dream (Asian Paints)

Celestial Sun (Berger Paints)
Column/ Chhajja Projections: Terracotta-N (Asian Paints)
Rust Red (Berger Paints)

3.1.2 INTERNAL PAINTING

The internal surfaces of building shall be finished with Acrylic Washable Distemper.

Main Surface: Summer Dew (Asian Paints)

Airy Lemon (Berger Paints)

3.2 DOORS, WINDOWS AND VENTILATORS

3.2.1 All windows and ventilators shall be aluminum glazed (min. 5mm thick glass). The windows/
ventilators shall be partially/ fully openable or sliding windows as per requirement.

3.2.2 All doors shall be aluminium glazed (min. 5mm thick glass) / laminated with prelaminated particle
board as per requirement.

3.2.3 Toilet doors shall be of high grade PVC with PVC door frame.

3.2.4 Glass: Tinted (Smoke Grey color) for doors and windows
Frosted for Toilet ventilators

3.2.5 Aluminum Frame: Anodized

3.2.6 All windows shall have Venetian Blinds (Cream colour)

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
3.3 FLOORING

3.3.1 KOTA STONE

Size: 600 mm x 600 mm.

3.3.2 VITRIFIED CERAMIC TILES

Size: 600 mm x 600 mm

3.3.3 ACID RESISTANT TILES

Size: 300 mm x 300 mm

3.3.4 ANTI-SKID CERAMIC TILES

Size: 300 mm x 300 mm

3.3.5 CERAMIC WALL TILES

Size: 300 mm x 450 mm

Control Room Building / Guard Room

4.0 PROCESS AREA & COLOR CODING PIPING ITEMS

4.1 R.C.C Paving shall be provided for entire process area with approach road to internal road.

4.2 Color coding of piping shall be followed as per ANSI/ ASME A13.1 – 2007.

As per above code, color of piping of various services shall be as per below mentioned table

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 Black on
FLAMMABLE
Yellow

COMBUSTIBLE FLUIDS White on

Brown

TOXIC & CORROSIVE FLUIDS Black on

Orange

FIRE QUENCHING FLUIDS White on

Red

OTHER WATER White on

Green

COMPRESSED AIR White on

Blue

4.3 Pipe Marking System

Markers shall be located so that they are readily visible to plant personnel from the point of normal
approach. Pipe markers shall indicate about pipe contents, direction of flow and whether hazardous or
safe, outside diameter of pipe, piping material specification etc.
Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 Place of Markers”

• To indicate direction of flow by labeling with arrows at one or both ends of the lable
• To be visible from the point of normal approach near valves, flanges and changes in pipe
direction
• Both sides of ceiling, wall or floor penetrations
• At any line entry or re-entry point
• On straight pipe runs
• Every 50 feet

4.4 Pipe Marker size

Letters height shall be as recommended against respective pipe outside dia.

4.5 Color for various service piping & component

Piping Flammable gas (natural gas, LPG) – Canary Yellow
Piping Fire water line piping - white on red
Piping Process/ Inst air - white on blue
Structural support - grey
RCC support - grey
Structural platform & ladder - grey
Hand rails - golden yellow
Valves - Agatha grey
Scrapper Receiver/ Launcher - Canary/ Golden yellow
Insulation joint - grey
Filters, Scrubber, any other vessel - canary yellow
Metering Skid - Valves grey, support grey and rest all
canary yellow

5.0 CHAIN LINK / BARBED WIRE FENCING/ ELECTRIC POLE

5.1 Chain link fencing shall be of 3 m height. Barbed wire fence of 0.6 m height shall be provided on top
of chain link fencing.

5.2 Aluminium Paint of Silver colour on chain link fencing and barbed wire.

5.3 Electric Pole: Aluminium Paint of Silver colour

Black paint at the bottom of pole (approx. 2 feet)

6.0 APPROACH ROADS & PAVE AREA– RCC

6.1 Carriageway : 3 m wide

6.2 Berm on both sides: 0.75m

6.3 Minimum turning radius: 6 m

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
7.0 STORM WATER DRAINAGE

7.1 Open brick masonry drains shall be provided on both sides of the roads and also on inside periphery
of plot.

8.0 EXTERNAL DEVELOPMENT

8.1 UNMANNED SMALL/ BIG GAS INSTALLATIONS

Combination of following:
- Cement concrete pavements
- Paver Blocks on walkways
- Stone aggregate (63 mm & above) – to be laid over polyethylene sheet
- Paver blocks under station piping

8.2 MANNED SMALL/ BIG GAS INSTALLATIONS

Combination of following:
- Cement concrete pavements
- Paver Blocks on walkways
- Stone aggregate (63 mm & above) - to be laid over polyethylene sheet
- Paver blocks under station piping
- Lawn/ grass at the entrance of building

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
9.0 PARKING SHED

At all manned terminal vehicle parking shed of adequate size shall be provided considering space
availability inside/ outside the terminal.

10.0 CONSTRUCTION OF STORAGE SHED

As per requirement of O&M Storage shed may be constructed at selected SV/IP station on the
pipeline under the jurisdiction of respective maintenance base of each region of GAIL. The typical
design of Storage shed attached as (Annexure-1) of this document may be referred. However the
same may be altered/modified to fit with the size of vacant space/area available as well as
requirement of maintenance base at the location.

11.0 LIST OF DOCUMENTS AVAILABLE AT MODEL TERMINAL:

Category-1: Land belongs to GAIL

1. Visitor Register & Material Movement Register

2. Copy of Land record or Status
3. Mutation status in the name of GAIL
4. List of Authorized person & Organogram
5. Consent to establish & Consent to operate by PCB
6. PESO / CCOE approval of the installation
7. Prohibited Area Declaration
8. Emergency Action plan & Telephone numbers
9. Material Safety Data Sheet & Pipeline Drawing
10. Hazardous Area Classification
11. List of nodal officers of mutual aid partners ( if applicable)
12. Any other document to comply statutory obligations as applicable

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
 Category-2: Land does not belong to GAIL

1. Visitor Register & Material Movement Register

2. Occupancy Status ( In case of customer premises / Rented Premises)
3. List of Authorized person & Organogram
4. Consent to establish & Consent to operate by PCB (If applicable)
5. PESO / CCOE approval of the installation
6. Emergency Action plan & Telephone numbers
7. Material Safety Data Sheet & Pipeline Drawing
8. Hazardous Area Classification
9. List of nodal officers of mutual aid partners ( if applicable)
10. Any other document to comply statutory obligations as applicable

12.0 OTHER FACILITIES

1. 24 Hrs Security Man Guarding

2. CCTV Surveillance ( PTZ & fixed type both)
3. Fire Extinguishers ( As per GAIL’s Policy)
4. Permanent Electrical Power
5. Emergency Back Up Power
6. Lighting (Indoor & outdoor) & Earthing protection
7. Drinking Water
8. Toilet(s)
9. Technical O&M requirements as per GAIL’s Policy

Prepared by : Reviewed by : Issued by: Document Number: Rev. No. Date of Issue:
GAIL/CO/MODEL
GM(O&M)-CO CGM(O&M)-CO ED(O&M)-CO 01 20-05-2019
STN/01/REV
CGM(O&M)-NCR ED(O&M)-NR ED(O&M)-CO GAIL/CO/MODEL STN/01 00 01-09-2017
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