CITY GAS DISTRIBUTION

O&M MANUAL
CHAPTER – 3
SOPS / WORK INSTRUCTIONS /
GUIDELINES / CHECKLISTS / FORMATS
A – Technical
3.1 City Gate Station
3.2 Odorant Handling Management
3.3 Steel Distribution & Industrial Supply Lines
3.4 PE Distribution Network Maintenance
3.5 Complaint Handling Gas Leak / Gas Escape
3.6 Customer Complaint and Request Handling
3.7 Service Regulator
3.8 Industrial Connection
3.9 Annual Maintenance Of Customer Connections
3.10 Calibration, Testing & Certification
3.11 Festival / Occasional Activity
3.12 Safe Guarding Pipe Lines From Third Party Damage
3.13 Modifications / Upgradation
3.14 Inspections / Audits
3.15 Preparation / Preservation / Updating Drawings
/Records
Module 3 of 9

Block - 15, 2nd Floor, Udyog Bhavan, Sector - 11, Gandhinagar – 382 011.
3.1 City Gate Station

City gas distribution is a facility, set-up for supplying piped natural gas, mainly as a
fuel to domestic, commercial and industrial customers, in city, town. The system
receives high pressure and unodorized gas from transporter, through transmission line
and supplies the same to the customers after filtration, pressure reduction, odorization
and check metering. The pressure reduction may be in four stages depending upon
the network design selected. The first pressure reduction is carried out at CGS,
second at CPRS / DRS, third at Service Regulator and forth and final at customer
premises. The odorization for imparting smell to gas is installed at City Gas Station
(CGS). The system has major assets like, city gate station (CGS), underground steel
distribution network, CPRS, DRS, MP PE network, service regulators, LP PE network,
and customer connections. The size, rating and type of the major and sub assets are
selected based on the pressure rating, capacity and other applicable criteria
considered for whole city gas distribution system for meeting the current and future
customer potential, health and safety of employees, customers and public at large,
environment protection, and complying the statutory, legal requirements, national and
international technical and safety standards / practices. The main objective of the
distribution company is to ensure safe and uninterrupted gas supply to customers for
24 hours, 365 days by manning the control room, round the clock, by deploying the
team of competent engineers and technicians, for handling various customer
complaints about gas leak / escape, customer queries and carrying out planned
operation and maintenance activities, as per annual operation and maintenance plan
for ensuring safe and uninterrupted gas supply and integrity of network.
3.2 Odorant Handling Management

1. General Information,

2. Abstract from IGE / SR /16,

3. Work instructions :-

1. Internal Transport / Shifting of Barrel,

2. Odorant transfer from barrel to storage tank,

3. Odorant transfer from storage tank to Odorizer tank,

4. Neutralizing and disposal of empty barrel,

4. Rhino logy - Standard Nose Training

Gas Smell Monitoring Report

1. General Information,
The natural gas being odorless, it is recommended by various international gas
engineering and safety standards and as per safe practices, the natural gas supplied
to customers through, the City Gas Distribution System should be odorized for
facilitating the early detection of gas, when it leaks, before it causes hazards like fire /
explosion and asphyxiation. Adequate odor / smell is imparted to piped natural gas by
continuously dozing controlled quantity of odorant chemical, in the flowing gas supply.
Normally Ethyl Mercaptan chemical is used as odorant. The dozing rate may vary
from 150 ml to 250 ml per 10000 m3 of gas supply to achieve the required smelling
sulphur content to 10 t0 12 ppm. The adequacy of sulphur content in dozing can be
periodically verified by Dragger tube test, at the remote active consumption points.
Similarly the adequacy of smell of odorant in gas supply has been regularly checked
by standard nose method, by trained and competent persons by smelling gas at
various points in the network, by carrying out special smell survey or during attending
customer complaints, and declaring / deciding and recording the sufficiency of odorant
smell in the gas at a particular dozing rate.
The Ethyl Mercaptan, being noxious smell nuisance producing chemical, the GPCB,
local authorities and public in general, are very sensitive, for various odorant related
activities like,
Import,
Transportation,
Storage,
Dozing and
Waste disposal of the empty odorant barrel,
Hence to meet the statutory requirements and to eliminate / handle the related
problems, it requires a comprehensive odorant handling management. Especially the
activities which comes in our purview like,
Storage,
Local / internal transport,
Dozing and Waste Disposal,
as shown in the following procedures / work instructions
2. Abstract from IGE / SR /16 :

1. Recommendations provide guidance to personnel involved in the odorization of

natural gas. The guidance contained in this document is based on almost 30; years
experience of odorizing both town gas and natural gas in the United Kingdom gas
industry.

2. The characteristic smell of gas was originally due to small amounts of hydrogen
sulphide and organic sulphur compounds residual in the production of town gas from
coal, Many supplies of a natural or substitute natural gas have insufficient or even no
sulphur compounds and therefore need to be odorized to give them a characteristic
smell before entering the transmission or distribution system in compliance with UK
legislation.

3. The odorant should be added in sufficient quantity to enable the gas to possess
a recognizable odour. A mixture of 1 percent gas in air with an odour intensity of 2 of
Al factory degrees on the sales scale is widely accepted as achieving this
requirement. This should enable a leak to be detected before it reaches the lower
flammable limit for gas in air (5 percent for natural gas). Where the gas contains toxic
components, for example, carbon monoxide, the addition of odorant should be
sufficient to enable a leak to be noticed before the concentration of the toxic
component reaches on unacceptable level.

4. Odorant injection in excess of the amount required for recognition of gas

escapes is undesirable because it is likely to cause widespread false alarms. The
quantity of odorant added to natural gas is therefore carefully controlled.

5. Odorant liquids are volatile, flammable and of noxious smell. Uncontained

odorant constitutes a hazard and is environmentally unacceptable.

6. British legislation requires that “no person shall supply through pipes any gas
which does not possess a distinctive smell”. It follows that should the level of
odorization fall below this requirement immediate corrective action is required to
comply with statute.

When new pipe is commissioned, particularly in a system of large volume, the pipe
surface may absorb odorant preferentially and, if the situation was not corrected,
would leave the gas odorant deficient. Corrective measures are thus of a temporary
nature until the process corrects itself by natural equilibrium.

GSPC GAS has installed three types of odorant systems for imparting peculiar smell
to natural gas, supplied through city gas distribution facilities, at various locations, as
shown in the table below.

Capacity of Storage
Sr. Vendor Year of
Odorizing Tank Location
No. Name Installation
Unit Capacity
1 M/s Control 200000 400 ltr (200 Navsari
Plus SCMD ltr per tank)
2 M/s Varicon 100000 400 ltr (200 Valsad
SCMD ltr per tank)
3 M/s Varicon 100000 400 ltr (200 Nadiad
SCMD ltr per tank)
4 M/s Varicon 100000 400 ltr (200 Gundlav
SCMD ltr per tank)
5 M/s Varicon 1200 200 ltr (200 Kalpataru,
SCMH ltr per tank) Gandhinagar
6 M/s Varicon 1200 200 ltr (200 Prince
SCMH ltr per tank) Gasoline,
Raison
7 M/s Varicon 1200 200 ltr (200 Kalol
SCMH ltr per tank)
8 M/s Varicon 1200 200 ltr (200 Chotila
SCMH ltr per tank)
 9 M/s Varicon 1200 200 ltr (200 Bharuch
SCMH ltr per tank)
10 M/s Varicon 200000 400 ltr (200 Rajkot
SCMD ltr per tank)
11 M/s Control 100000 400 ltr (200 Than
Plus SCMD ltr per tank)
12 M/s Control 50000 400 ltr (200 Chandkheda
Plus SCMD ltr per tank)
13 M/s Control 1000000 400 ltr (200 Morbi
Plus SCMD ltr per tank)
14 M/s Control 1000000 400 ltr (200 Vapi
Plus SCMD ltr per tank)
15 M/s. 500000 6 Gallons Hazira-Surat
KingTool SCFH
16 M/s. 1000000 20 Gallons Mora- Surat.
KingTool SCFH
17 M/s. 150000 2.22 CNG
KingTool SCFH Gallons Ichhapore-
Surat

Out of these three systems Dosador is more accurate, fully automatic, but complicated
for operation maintenance. The injector works as a pump after getting control signal
from PLC.
The Varicon is accurate and simple, the system uses the gas operated dosing pump.
While KingTool’s systems are very simple but not accurate. It works on capillary action
on wicks. The KingTool system another activity of transfer of odorant from storage
tank to odoriser is required to be carried out.
DOSAODOR-D, Odorant Injection System

General Description
DOSAODOR-D is a computerized odorization system that is proportional to the flow
rate of the gas in transit. The system operates by liquid-injection and it can be
installed in combination with traditional absorption-type devices. The entire
DOSAODOR-D system is completely configurable and can also be interfaced with
remote monitoring systems.
The equipment consists in a panel to be installed in the hazardous area and a
microprocessor control unit to be installed in the safe area, interconnected by electric
cables.
The system ensures the dosing rate while keeping the desired odorant concentration
level steady with any gas flow rate of the station, even when the latter is extremely
variable and extremely low.
This particular feature translates into a marked increase in safety within the sphere of
the distribution of natural gas for public use. In fact, by maintaining a constant level of
the concentration in all of the gas flow rates being supplied, any leakage of gas can
clearly be identified, thereby decreasing the possibility of accidents. In addition to this,
the possibility of having printed reports on the gas volumes, the amounts of odorant
emitted and the concentrations thereof, provides facility managers with objective aids
confirming the proper functioning of their systems. The objectives obtained with this
new system can be summarized as follows:
¨ Operational safety
¨ Extreme reliability
¨ Low maintenance requirements
¨ Simple use
¨ Dependability of the results
The system does not involve the use of dosing pumps or other complex devices for
the measurement of odorant flow rates. In fact, although they are now extremely
reliable, these devices still require periodical maintenance, which is a particularly
difficult procedure with parts that have come into contact with the odorizing liquid.
This system uses the differential pressure, which is always present between the
upstream and downstream sections of a reduction and metering gas station (min. 1
bar), and an electrically controlled injection unit that has been designed and certified
in accordance with international standards for electrical equipment in EEx areas with
risk of explosion.
DOSAODOR-D utilizes the high-pressure upstream gas as the pneumatic driving fluid
in order to inject the odorizing liquid in the downstream pipelines, creating a gas
driven pump.
The entire pneumatic panel is made of stainless steel without a painted finish or
screen printing as odorizing liquids are aggressive.
A procedure has been designed to perform the decontamination of the entire injection
circuit. In fact, although the chances are very slight, the need to intervene for system
maintenance may arise.
A special sampler provides for measurement of the liquid that has actually been
injected and informs the electronic control unit of any adjustments to be made, thereby
ensuring a marked level of reliability and overall precision of the system, which is self-
monitoring.
During routine operation, in the versions that include two injection devices, one is
stopped as a reserve for the other. The software provides for the exchange from one
to the other, in order to ensure that the same device does not always remain idle.
The concentration ratio is ensured by a special microprocessor electronic control unit
which receives as input either a digital volume signal from a flow computer/volumetric
counter or from an analog signal 4-20 mA that compares it with the concentration level
to be maintained and processes the correct electrical signal to be transmitted to the
injection device. The control unit supplies the proper voltage and current values to the
various equipment units and it contains the separation barriers to comply with the
directives involving system installations with the intrinsic safety. It must be installed in
the safe area and operates, on standard version, with 230 V 50 Hz or 12 V dc.
In the event of malfunctioning or power outages, the control unit saves the
programming data by means of a buffer battery and sends a signal to activate any
emergency devices (it normally restarts operation of the absorption-type emergency
system).
The system equipment complies with all parts of UNI-CIG 9463 ITALIAN standards.
The system equipment meets all the requirements established by European directives
concerning electric systems in hazardous areas.
This DOSAODOR-D system has been approved by SNAM for installation on REMI
stations.
The following table illustrates the correlation between the type of odorizing liquid used,
maximum odorizing liquid capacity and the maximum flow rate of the gas to be
odorized.
International Standards Units
Maximum Flow rate of gas that can be odorized Stm3/h
Maximum Odourant Flow Dosing Rate
Rate Litres / Hour 10 mg/Stm3 (Mercaptan)
1,3 130.000
4,0 400.000
8,0 800.000
14 1.400.000

American Standards Units

Maximum Flow rate of gas that can be odorized
MSCF/h
Maximum Odourant Flow Dosing Rate
Rate Gallon / Hour 0.62 lb/SMMCF (Mercaptan)
0.343 4,589
1.056 14,120
2.113 28,240
3.698 49,420
Testing and Starting
• Preliminary checks
• Priming the pneumatic panel
• Operation

Maintenance
•Procedures and Recommended Timing for routine / extraordinary

Routine / Extraordinary Maintenance

• Purging by means of Natural Gas
• Purging by means of Natural Gas and Neutralizing Liquid
• Replacement of the Filtering Cartridge
• Safety Valve Inspection and Valve
• SA/2 Filter / Regulator Maintenance

TESTING AND STARTUP

Neutralizing materials.
In order to proceed with startup the system, you should have available at least half a
liter of a liquid capable of neutralizing the effect of the odorant used. Normally, the
liquid most frequently used is a mixture of sodium hypochlorite (bleach) with
denatured alcohol and a small amount of “fragranced” liquid soap.

Preliminary checks
It is best to check that all of the pneumatic connections have been carried out properly
and that all of the connector pipe fittings are well-tightened, prior starting up the
system. Proceed as follows for these checks: (Use the diagram on page 23 as a
reference)
- Close the odorant input valve found at the base of the pickup tank.
- Open the three gas on/off valves found on the main line
(Upstream station, downstream regulators / upstream measurement, upstream
solenoid valve 10.1)
- Using a suitable spray, check for any gas leaks (check ALL fittings)
- Proceed by switching on the electronic control unit, following the information
contained in Chapter 3 on page 30.
(With this procedure, solenoid valves 8 and 10 will open automatically and will remain
open for no longer than 2 minutes. After this interval, the valves will close, activating
the control unit alarm with a signal indicating odorant recharge failure)
- Check the line section connecting the pneumatic panel with the odorant pickup
tank for any gas leaks.
If no leaks are detected, it is possible to proceed with priming the entire system.

Priming the pneumatic panel

Preparation procedures for the pneumatic panel are simple and in fact, they do not
involve any special operations. The only required procedures consist in the following:
• Open the 4 on/off gas valves found on the main line (Upstream filters,
Downstream regulators, Odorant injection, High-pressure gas supply to the
panel)
• Open the two on/off odorant valves found on the pneumatic panel
• Open the on/off odorant valve found at the base of the odorant storage tank
• Switch on the Dosaodor control unit
• Set the key to “Prog. -ON”
• Press the WASHING push-button located in the "SYSTEM" section of the
control unit
• Check the programmed data for accuracy
• Eliminate any alarms present by pressing the Red ALARM RESET - button
• Press the “PUSH” button for a length of time that is sufficient to drain the
section of the line joining the pneumatic panel with the injection point. Keep the
button pressed approx. 12 seconds for each meter of pipeline installed (DN 6 x
4 mm).
Once the priming / drainage phase is completed, the system is ready for operation.
Check Loc. 11 and make sure that the flow computer is transmitting the gas volumes
correctly. The Dosaodor control unit counter should increase correctly with respect to
the volume computer counter. Check the data programmed, carefully focusing on the
values entered for Locations from Loc: 00 to Loc: 005.
Switch off the Dosaodor control unit. Make sure that the key is on the
“PROGRAMMING-ON” setting. Press ENT and keep it pressed to power on the
control unit.
(This procedure sets to zero all of the internal counters)
Press the AUTOMATIC button located in the SYSTEM section and set the key to
Prog.-OFF. The system will start dosing the odorant proportionally to the flow rate of
the gas in transit. at page 23 is taken as a reference. The diagram shows the entire
odorization “chain”, recharging by means of transportable tanks, the absorption-type
emergency tank and the injection system.
We shall consider only the operation of the injection system here as the correlated
process with the absorption-type emergency tank devices is already well known.
Some preliminary considerations:
• By means of the slaved pneumatic valve (12), which is controlled by the
solenoid valve (10.1) located on the downstream section of the absorption-type tank
odorizer, the DOSAODOR control unit can activate or deactivate the operation of the
traditional absorption-type emergency tank circuit in the event of malfunctioning or
power drop.
• The liquid to be injected is collected through the bottom absorption-type
odorizer valve. If the latter is not present, collection takes place through the lower part
of the tank level indicator.
• Pressure intakes serving for driving the injection liquid are created through the
utilization of the intakes that are always present on the REMI plant equipment, taking
measures to double them by inserting a tee-pipe coupling and a second needle valve
for the purpose of keeping the existing intakes functional.
The pressure collected upstream from the primary reduction unit is sent to a Tartarini
pressure regulator, Mod. SA/2 (5). This regulator reduces the inlet pressure level from
a maximum of 75 bars to a set value equal to the station output pressure increased by
3 bars.
This pressure is sent to a second Tartarini regulator, Mod. SA/2 (6), where it is
reduced to a level equal to the station downstream pressure increased by 0.6 bar.
Therefore, whatever downstream pressure level exists, the pressure output from this
regulator will be greater by 0.6 bar, thereby ensuring a steady pressure differential,
which permits proper injection of the odorant. This second regulator is also capable of
handling a maximum input pressure of 75 bars.
In addition to the double pressure regulator, the regulation circuit also has a safety
valve (25), set at 14 bar in standard version and capable of guaranteeing safe
conditions should both regulators undergo malfunctioning at the same time.
This pressure is intercepted by the three-way solenoid valve (10) which under rest
conditions, provides for pressurizing the volume sampler (9) in which a known odorant
volume is found. A control pressure-gauge (20) is located on the sampler.
When the injector (11) is set into operation, the odorizing liquid is introduced into the
station downstream pipe and its volume will be replaced by an equal amount of
natural gas.
Once the quantity set and controlled by means of the sampler, has been injected, the
injection phase is terminated and solenoid valves (10) and (8) open. Then the
overpressure of 0.6 bar existing inside the sampler is discharged into the main pipe
downstream from the regulation point, but upstream from the measurement point and
thus that quantity of gas is measured regularly (this operation cannot be carried out in
stations complete with venturimetric gauge, in case of relief valve or pressure loss by
the measuring assembly, consisting of pipe + counter + valves). In this case some gas
shall be consumed, that cannot be measured. The quantity should be around 1 Sm3
each 10 liters of odorant. (for the connection see diagram a page 24). At this point, the
sampler (9) and the odorizer have the same pressure level. The odorizing liquid found
inside the absorption-type odorizer, which in this mode functions exclusively as a
storage tank, flows freely through the filter (7) and fills the sampler tank (9). The
volume of gas inside the sampler then flows through the solenoid valve (10) and is
then introduced into the main pipe upstream from the measurement point.
During the sampler (9) refilling phase, there is a gradual emptying of the absorption-
type tank (15). The volume of liquid taken from it, is replaced with equal volumes of
gas coming from the upstream branch of the odorizer itself
Once the established volume has been loaded, the two solenoid valves (8) and (10)
return to their rest positions, the sampler is pressurized once again and the system
resumes injection of the quantities calculated.
An analysis of the process explained above, makes it possible to state that the
DOSAODOR-D system does not “CONSUME” gas and that ALL of the gas collected
upstream from the pressure reduction unit is re-introduced downstream from it, but
upstream from the measurement unit.

Maintenance
Procedures and Recommended Timing for routine/extraordinary maintenance
operations
The DOSAODOR-D system, made by O.M.T. Tartarini that you have purchased has
been manufactured with state-of-the-art technology and materials currently available.
Thanks to all this, we succeeded in manufacturing a system requiring one routine
maintenance intervention each three solar years.
ROUTINE Maintenance
For routine maintenance operations, you have to be provided with the relevant
maintenance Kit. It includes all spare parts that have to be replaced in the system so
as to renew it and have it in compliance with the functional specifications, for which it
has been originally designed.
These are the operations to be carried out:
- Wash by means of Natural Gas (see paragraph 5.2)
- Close all valves on the pneumatic panel
- Close the needle cock located on the pipe detecting the odorizing pressure (low
pressure branch)
- Close the odorant outlet cock located on the tank from which the odorant is
picked up.
- Cut off power supply to the electronic control unit
- De-pressurize the panel by loosening the joint located in the upper left part of
the control cylinder
- Replace all rubber parts inside the two pressure Filter-Regulators model SA/2
(the operations to be performed are described in the attached bulletin)
- Fully replace the two-way injection solenoid valve located on the top left of the
pneumatic panel
- Replace the moving group located inside the three-way solenoid valve that is
used to control opening/closing of the licking circuit.
ATTENTION: the moving group of the three-way solenoid valve is slightly different
from the one of the two-way valve. In fact it has a further pad on the upper part.
- Replace the filtering cartridge located inside the filtering group
- Restart the system, by meeting the instructions described under par. 4.

Emergency repair maintenance

It shall be carried out in case the system stops injecting the necessary odorant
quantity. This situation is detected by the control unit, which also prints the cause of
the problem.
To perform maintenance operations specifically trained staff is required. More in
particular, the operators shall have to be able to perform mechanical/pneumatic
interventions, and be well informed on all instructions related to safety operations, that
have to be met during any intervention on systems managing flammable and/or
odorizing liquids.
Purging by means of Natural Gas
The purging operation has to be completed before any routine maintenance
intervention on the DOSAODOR-D odorizing system. It drains out all the odorizing
liquid present in the injection system to allow the dismantling of some parts without
particular problems (odor) for the operators.
The odorant inside the DOSAODOR-D system is placed inside the container. Only a
min. part is injected to the gas line the procedure for s/d and purging the system.
Set the key switch to PROGRAMMING - ON. Set the selector switch to WASHING.
Close the “Low Pressure” inlet/outlet cock Make sure that ALL other cocks are open
Press and simultaneously release the PUSH and ALARM RESET buttons for at least
10 times, alternating pauses of 2 seconds on both positions.
(This way the odorizing liquid – in the level gauge - is sent back into the main tank)
Open the “Low Pressure” inlet / outlet cock
Set the selector switch to INJECTOR - 1
Press the PUSH button and keep it pressed. Set the key switch to PROGRAMMING –
OFF and keep this position for at least 60 seconds.
(This way the odorizing liquid – in the delivery pipes – is sent back into the gas pipe)
Set the key switch to PROGRAMMING - ON.
If you have the second injector, set the selector switch to INJECTOR - 2, and repeat
the above-described instructions.
Set the selector switch to EXCLUDED.
Set the key switch to PROGRAMMING - OFF.
At this point all valves of the system have to be closed and you can perform
maintenance operations on the involved parts.
After completing al operations, to restart the system open back the system valves, set
the key switch to PROGRAMMING - ON, set the selector switch to AUTOMATIC,
press the ALARM RESET button and then set the key switch to PROGRAMMING -
OFF.

Washing by means of Natural Gas and Neutralizing Liquid

The purging operation has to be completed before any extraordinary maintenance
intervention and/or before dismantling the DOSAODOR-D odorizing system. It drains
out all the odorizing liquid present in the injection system, refines its components by
recycling a neutralizing liquid and then allows partial and/or full dismantling of the
system without particular problems (odor) for the operators.
The odorant inside the DOSAODOR-D system is placed inside the container. Only a
min. part is injected to the gas line.
To perform the following operations, you'll need the portable washing kit (optional),
arranged by O.M.T. Tartarini for the refinement of DOSAODOR-D systems.

Procedure for Shut Down, Washing

1) Perform ALL operations described in the previous paragraph (4.5).
2) Set the key switch to PROGRAMMING - ON.
3) Set the selector switch to WASHING.
4) Close all cocks of the odorizing system, in particular:
- Odorant inlet/intake
 - Odorant outlet/injection
- “High Pressure” gas intake
- “Low Pressure” gas intake (the cock is on the gas main pipe)
5) Connect the neutralizing liquid delivery to the intake next to the odorant inlet
cock located under the tank by means of the pipe included in the equipment
6) Connect the neutralizing liquid return from the intake next to the odorant outlet
cock located under the tank by means of the pipe included in the equipment
7) Connect the filter outlet/inlet to the intake next to the cock, “Low Pressure” gas
intake, by means of the pipe included in the equipment
8) Slowly open the liquid inlet and outlet cocks on the DOSAODOR-D system and
the washing panel.
9) Pour 150 cm3 of neutralizing liquid into the main tank of the washing panel.
10) Simultaneously press the PUSH and ALARM RESET buttons for at least 20
seconds and then release them. (All liquid accesses the circuit, the
DOSAODOR-D circuit is filled with neutralizing liquid)
11) Set the selector switch to INJECTOR - 1
12) Press the PUSH button and keep it pressed. Then set the key switch to
PROGRAMMING - OFF.
(The neutralizing liquid is injected into the right tank on the washing panel)
13) Keep this function until when no more liquid comes out of the right tank of the
washing panel,
14) Set the key switch to PROGRAMMING - ON.
15) In case you have the second injector, set the selector switch to INJECTOR - 2,
and repeat the operations from 9 to 14.
16) Set the selector switch to EXCLUDED.
17) Repeat the operations from 10 to 14 to remove all possible neutralizing liquid
deposits from the suction circuit.
18) Restore all original pneumatic connections.
At this point all valves of the system have to be closed and you can perform
maintenance operations on the involved parts.
After completing al operations, to restart the system open back the system valves, set
the key switch to PROGRAMMING - ON, set the selector switch to AUTOMATIC,
press the ALARM RESET button and then set the key switch to PROGRAMMING -
OFF.

Replacement of the Filtering Cartridge

Before replacing the filtering cartridge, all devices mounted on the pneumatic panel
have to drain out the odorizing liquid they contain. To do this, follow the instructions
reported in paragraph 5.2. After completing the operation with the gas, close all on-off
valves of the system and proceed as follows:
- Loosen the lower cap of the T-filter located in the lower part of the panel.
- Take out the cartridge by means of a small screwdriver.
- Fit back the new cartridge and place back the closing cap.
- Open all valves and make sure that there are no leaks
- Restart the system as described under paragraph 4.

Safety Valve Inspection

The safety valve is inspected and calibrated without being removed from its position.
The procedure:
Set the key switch of the control unit to PROGRAMMING - ON. Set the selector switch
of the control unit to WASHING. Close the “Low Pressure” inlet/outlet cock Close the
odorant inlet cock located in the lower part of the panel. Make sure that ALL other
cocks are open.
Keep the ALARM RESET button pressed and press and release the PUSH button
leaving two seconds pause between pressing and releasing until when the pressure
indicated by the manometer on the sampling cylinder reaches the following values:
- 14 bar for DOSAODOR-D systems
- 38 bar for DOSAODOR-D/AP systems (High Pressure)
Make sure that during the operation no gas comes out of the draining silencer (19) of
the safety valve. In case there are, increase its triggering values as described here
under.
After reaching the desired calibration pressure, proceed as follows:
- Remove the draining silencer (19) located in outlet position of the safety valve.
- Fit a wrench for screws with inside hexagonal cap of 3 mm into the gas exhaust
hole until reaching the regulation plate.
- Rotate the regulation plate until when the gas starts coming out.
- Mount back the silencer on the safety valve.
- Open all valves of the system
- Set the key switch to PROGRAMMING– ON
- Set the selector switch to AUTOMATIC
- Press the ALARM RESET button
- Set the key switch to PROGRAMMING - OFF.
Varicon System for Odorizing Gas
3. Work instructions:
Work instructions - 01
Work instruction for Internal Transport / Shifting of Barrel
Sr. Responsibi
Work instruction
No. lity
Ensure that the barrel to be transported is full of odorant and
1 O&M. In-
there is no leak from both the leads, as checked by smell
charge /
and soap solution.
Keeping the barrel always in upright position having leads
2 O&M. In-
on the top. carefully shift the barrel from storage room to the
charge /
place of lifting outside the storage room,
Safely lift the barrel into the van, taking care that the barrel
3 O&M. In-
does not fall down and ensure, keeping the barrel always in
charge /
upright position having leads on the top..
Place the barrel in the van, firmly and keep hold of the same
4 O&M. In-
during transportation by tying the rope around the barrel and
charge /
keeping persons around the barrel.

5 Instruct the driver of the maintenance van for safe and slow O&M. In-
driving after educating him about the hazard involved. charge /
After reaching at dosing site, slowly unload the barrel,

6 keeping rubber tyre on the ground near the van for safety O&M. In-
precaution, in case of falling of barrel. Drive away the van charge /
from site, to safe place
Place the barrel on the hand pulled trolley carefully and shift
7 O&M. In-
the same to the designated place near storage, tank,
charge /
remove the trolley away.

8 Similarly return back the empty barrel from site to storage O&M. In-
room, taking safety precaution all the way. charge /
Immediately after completion of shifting of full barrel to the
9 O&M. In-
dosing site, place ice on and around barrel, for condensing
charge /
the vapor generated during transportation / shifting.
 Work instructions - 02
Work instruction for odorant transfer from Barrel to Storage tank
Sr.
Work instruction Responsibility
No.
Ensure that Written intimation regarding transfer of
O&M. In-charge /
01 odorant is given to Location, GPCB, 48 Hrs. in
Shift In charge
advance, stating date and time of transfer.
Obtain safety work permit before starting the transfer O&M. In-charge /
02
procedure. Shift In charge
O&M. In-charge /
03 Inform Control room before starting the Job.
Shift In charge
Check the emergency preparedness / availability of
saw dust, dry sand, detergent powder, sodium O&M. In-charge /
04
hypochlorite in required quantities and fire Shift In charge
extinguishers etc. are ensured.
For safety, use personal protective equipments like O&M. In-charge /
05
hand gloves, mask respirator, face mask, etc… Shift In charge
Dilute the Hypo, add water and Surf washing powder,
O&M. In-charge /
06 measure the PH of the solution, it should be more than
Shift In charge
7PH. Prepare such solution in 4 nos. of full buckets. .
Connect the one end of vent tube to the vent point on
tank and another to the carbon filter immersed in O&M. In-charge /
07
bucket full with Hypo solution and Surf detergent, for Shift In charge
neutralizing the vapour from tank.
Safely transport the full Odorant barrel / drum to the
O&M. In-charge /
08 Platform at the specified location, using transporting
Shift In charge
truck / trolley.
Place the ice on barrel / drum as well as on tank to O&M. In-charge /
09
settle / condense the vapour of EM. Shift In charge
Connect air motor inlet of the pump to N2 cylinder. And
O&M. In-charge /
10 check the functioning of barrel pump by actual
Shift In charge
operating it with the water. Also observe / record the
 minimum N2 pressure required for safe pump speed.
Start / continue depressurizing the odorant tank by
crack opening the vapour vent valve & checking the O&M. In-charge /
11
bubbling in the bucket and smell in the surrounding Shift In charge
area to ensure effective neutralizing of odorant vapour.
Open all 4 nos. of valves on glass level indicator of the
O&M. In-charge /
12 tank. Observe / Record the current odorant level in the
Shift In-charge
tank, if any.
Slowly open the bigger lead of the drum and insert the
O&M. In-charge /
13 barrel of the pump into the drum, ensuring neutralizing
Shift In charge
of vapour from barrel. Using hypo soaked cloth.
Connect the pump discharge to the odorant tank & O&M. In-charge /
14 check the integrity of discharge piping by safe opening Shift In charge
of the tank and pump liquid valves.
If everything is normal, start filling by operating the
barrel pump, by opening and setting N2 regulator on O&M. In-charge /
15
cylinder, to predetermined value, set during trial run on Shift In charge
water.
During pump operation, Continue depressurizing of
the tank, ensuring, vapour pressure in the tank
O&M. In-charge /
16 remains near to zero and there is effective neutralizing
Shift In charge
of vapour in solution bucket. If required change
solution / carbon filter.
O&M. In-charge /
17 Observe the rise of odorant level in the tank.
Shift In charge
Continue Monitoring the EM level and vapour pressure
18 in the tank and smell in the surrounding to ensure O&M. In-charge /
effective transfer and neutralizing of EM vapour from Shift In charge
tank.
Stop the N2 supply as soon as transfer of odorant
O&M. In-charge /
19 from drum to tank gets completed & the same is
Shift In charge
confirmed by net rise in odorant level in the tank.
 Observe / Record the final odorant level in the tank.
Close vapour valve / liquid fill valve and all 4 nos. of
Shift In-charge /
20 level indicator valves of the tank. Fit the plugs on tanks
Technician
and lead on barrel and check for leakage.
21 Disconnect all the arrangements made for transferring
Odorant. Clean air pump & its associated components
by running in 1/2 to 5-percentage concentration Shift In-charge /
Sodium hypochlorite solution and then in clean water, Technician
and shift barrel and all the accessories at their
designated place / hazardous waste room.
 Work instructions - 03
Work instruction For Odorant transfer
from storage tank to Odorizer tank
SR NO ACTIVITY Responsibility

Normally lean hours / non peak hours are selected for O&M. In-charge
1
transfer of activity. / Shift In-charge
Obtain safety work permit (Ref.Doc.) before starting O&M. In-charge
.2
the transfer procedure. / Shift In-charge
O&M. In-charge
3 Inform Control room before starting the Job.
/ Shift In-charge
Check the emergency preparedness / availability of
saw dust, dry sand, detergent powder, sodium O&M. In-charge
4
hypochlorite in required quantities and fire / Shift In-charge
extinguishers etc .are ensured.
For safety, use personal protective equipments like O&M. In-charge
5
hand gloves, mask respirator, face mask etc. / Shift In-charge
6 Open all 4 nos of valves on storage tank level gauge
Observe / Record and mark the initial level in both O&M. In-charge
7
tanks. .and pressure in storage tank. / Shift In-charge
Close the gas (bypass) inlet and outlet valves of O&M. In-charge
8
odorizing tank. / Shift In-charge
Open the vapour balancing valve of odorizing tank O&M. In-charge
9
and check the leakage, by soap solution. / Shift In-charge
Open the feed valve of odorizing tank and check the O&M. In-charge
10
leakage, by soap solution. / Shift In-charge
If there is no leakage /smell, then, open the vapour
O&M. In-charge
11 valve on storage tank allow the pressure to equalise /
/ Shift In-charge
stabilize and observe / record the final pressure.
Start transferring of odorant by opening the liquid
O&M. In-charge
12 outlet valve on the feed line, at the bottom of storage
/ Shift In-charge
tank.
 Continue transfer, till the required level is shown, in O&M. In-charge
13
the level gauge of odorizing tank. / Shift In-charge
Record the final levels of both the tanks and O&M. In-charge
14
pressure in the storage tanks / Shift In-charge
Work permit is signed off and Control room is Shift In-charge /
15
informed for completion of the job. Technician
Make entry in the Logbook
16 Shift In-charge
Prepare Odorant Transfer Report
Waste material generated during maintenance work
17 is collected in the dustbin, and disposed off at Shift In-charge
designated place.
 Work instructions - 04
Work instruction For Neutralizing and disposal of empty barrel
Pour the used solution and excess ice pieces, in the
Shift In charge /
1. empty odorant barrel Close the barrel and keep it for
Technician
10 -15 minutes.
Prepare one bucket detergent solution and pour it in
Shift In charge /
2. empty barrel. Close the barrel and keep it for 5 -10
Technician
minutes.
Prepare two bucket of lime solution (use 15 kg of
Shift In charge /
3. lime powder) and pour it in empty barrel. Shake / roll
Technician
the barrel for proper mixing of solution in the drum.
Shift the barrel carefully at Hazardous Waste Shift In charge /
4.
Storage area on CGS. Technician
Mark the identification number on the barrel and
5.
apply form -8 stickers on the barrel.
Sign off Work permit is and inform Control room for Shift In-charge /
6.
completion of the job. Technician
Make entry in the Logbook (Ref. Doc. Keep the
7. record of empty drum Prepare Odorant Transfer Shift In charge
Report (Ref. Doc
Collect the waste material generated during
8. maintenance work in the dustbin, and dispose off, at Shift In-charge
designated place.
Send the empty barrels to the land fill site, by hiring
9. GPCB approved transporter, when the accumulation
of empty barrels reaches to tempo load.
Ensure that the tempo driver is carrying the relevant
papers as per TREM card, especially list of
10.
emergency telephone number and emergency
handling procedure.
4. Rhinology Standard Nose Training

After imparting adequate training in rhino logy- the laboratory training giving
awareness of different intensity of smell at different odorant dosing rate in a close
room, to selected persons from various field / working crews determine on site / at
active sampling point the odor intensity / smell level of odorized natural gas after
adjusting the gas concentration in air at 20 % of LEL and provide the feedback to
control room to ensure adequate dosing and ultimate smell level

Training of Rhinologist

Important Properties of Natural gas

Natural gas is
• Flammable
• Non-toxic
• Tasteless
• Colorless
• Odorless

In case of gas leakage / escape

For safety reason, majority of the population must be able to identify / detect
Leakage / Escape of Natural gas easily well before the inflammable mixture
gets developed.

When person must get alerted?

LEL of natural gas is 5 % gas in air.
Generally safety factor is taken 5.
Therefore general public must get alerted or must have warning when leaked
gas is at or below a level of 20 % of LEL i. e. 1 % natural gas in air
How general public can detect the leaked gas?
Possible alternative solutions for detection of Leakage / escape by general
public,
• Add colour to Gas (not practicable)
• Install gas detector (difficult to implement)
• Add smell to gas by odorisation (most practical & adopted solution)

Purpose of odorization

Detection of the leakage / escape of natural gas by smell well before the
concentration of gas in the area become hazardous by general public.
Requirements
Distinctive odor readily perceptible to normal person in the area where natural
gas is present in concentration of not more than one part gas to ninety - nine
parts air.

Important factors in natural gas odourisation

• Type of smell /odor
• Smell Level / Odor intensity

Selection on EM as odorant

Distinctive and non confusable smell - Smell different from commonly found in
household or environment
Most of the distribution companies are using Ethyl Mercaptan as an odorant
because,
• the most evil smelling substance
• possess the highest odor intensity / strongest odor
• having readily identifiable unpleasant smell
 Smell Level / Odor Intensity

It is strength of smell / odor which positively indicate / perceive / detect gas

leakage
• too low - people will not be able to detect the leak, safety concern
• Adequate - people will be able to readily / easily detect the leaked gas
• too high - result in trivial report of leakage / escape, irritating to eyes,
skin and respiratory tract, may cause headache, vomiting, nervous system
depression, etc

Limit of perception

It is the threshold of odor sensation.

Odor Threshold of EM: 0.2 ppb

Odor alert level

Level of odor intensity which is perceived (detected) by every person with average
sense of smell.

Scale of Odor Intensity / Smell Level

Odor Intensity
Sensation
(olfactory degrees)
0 No odor
0.5 Very feeble odor (limit of perception / detection)
1 Slight odor -feeble
2 Medium odor (alert level)
3 Strong odor
4 Very strong odor
5 Upper limit of sensation
Reason of low odor intensity
• No dosing
• Inadequate injection -low dosing rate
• loss of odorant from odorized gas
Odorant Dosing Rate
Dosing rate is depends on
• LEL of the gas to be odorized
• Odorant Concentration in air at the alert level - constant value for
specific odorant
• Safety factor - normally 5
Loss Odor / Smell from Odorized gas
• Odorant sorption by surface (particularly with rusty surfaces or new
piping (steel or plastic)
• Odorant oxidized by oxygen / iron oxide to disulfides
• Sorption by soil
• Sorption in hydrocarbon condensates

About Rhinologist
Person trained in odor assessment
Role of Rhinologist
• Primary judgment / Estimation of smell & smell level / odour intensity
• Consistently in judgment of smell level
• Determining odourisation adequacy

Test Facilities
Air tight / locked Odorant Chamber / Room
• Size - 500 to 1000 cu feet
• Odorant and Gas/Air mixture device.
• Exhaust fan with separator to isolate the chamber
• Air tight - close fitting doors (lined with aluminum sheet)
• Mixing / Recirculating fans
• Carbon air filter for air intake to chamber
 • device to measure odorant concentration in the chamber / room
Odorimeter
• is a device to prepare known odorant/air or air / gas mixture

Laboratory training & test of Rhinologist

• Let panel members sit or stand at once in a chamber at isolated place in the
chamber
• Introduce odorant in the chamber & mix with air in the chamber by recirculation
fans.
• Measure the odorant concentration in the chamber
• For preliminary trials, tell panel members value of odorant concentration
• Expose members to known concentration
• Allow member to sniff the mixture and judge the smell level.
• Ventilate the chamber
• After an interval of at least 15 minutes, expose the members to various odor
intensities (concentrations)
• After several trials, do not tell members the value of odorant concentration in
the chamber and let them judge the smell level
• Match the assessment by nose with Odor intensity scales (established for
known concentration)
• determine on site / at sampling point the odor intensity / smell level of odorized
natural gas after adjusting the gas concentration in air at 20 % of LEL
• provide the feedback to operation group to ensure adequate smell level
 Gas Smell Monitoring Report

Month
Location

Status Odo
riser
Sr. Customer
Date Location Suffi tank Remarks
No. Code Low High
cient Lev
el

Asst. Manager (O&M)

O&M Contractor GSPC GAS
3.3 Steel Distribution Network Maintenance
Content :
1. General Information,
2. Monitoring & Maintenance Activities & Frequencies of Steel Distribution
Network,
3. Procedure for Maintenance of Steel Distribution Network..
Annexure: 01 Guidelines and Work Instruction for Network Patrolling &
Surveillance
Format for Gas Pipeline Patrolling Report
Format for Patrolling Report of Pipeline Crossing Like Bridge, Canal, Main
Road, Highway, Railway
Annexure: 02 Work Instructions for Valve Chamber Maintenance
Format Valve Chamber Maintenance Report
Annexure: 03 Work Instructions for Pressure Drop Test of Gas Pipeline
Format for Pressure Drop Test Report
Annexure: 04 Work Instructions for Surface Gas Detection Survey on Gas
Pipeline Route
Format for Surface Gas Detection Survey Report
Annexure: 05 Gas Leak Classification and Action Criteria
Annexure: 06 Transformer Rectifier (TR) Units Monitoring and Maintenance
Format for TR Monitoring Report
Format for Preventive Maintenance of TR Unit & Anode Junction Box
Annexure: 07 Pipe - To - Soil Potential (PSP) Monitoring
Format for PSP Monitoring Report
Annexure: 08 Test Lead Point (TLP) Maintenance
Format for Test Lead Point (TLP) Maintenance Report
Annexure: 09 Anode Ground Bed Monitoring and Maintenance
Format for Anode Ground Bed Monitoring Report
Annexure: 10 Insulating Joint (IJ) Monitoring and Maintenance
Format for Insulating Joint (IJ) Monitoring Report
Annexure: 11 Formats for Facility / Equipment History Card
Annexure: 12 Coating Repair
4. Procedure for Steel Network Emergency Handling
Annexure: 13 List of Additional Items for Handling Emergency on Steel
Network Annexure: 14 Work Instruction for Attending Gas Leak / Escape on
Steel Gas Network
Annexure: 15 Work Instruction for Attending Damage on Steel Network
resulting in Gas Escape or Gas Fire

5. Procedure for Steel Network Modification, Extension / Installation and

Commissioning
Annexure: 16 Format for Planning & Procedure for Steel Network Shutdown
Job for Modification or Connection of New Network with Existing Network
1. General Information :

In a typical City Gas Distribution network, Underground Carbon Steel (CS) network is
major asset / component of total installation. It can be categorized as Transmission
Pipeline and Distribution Pipelines. Transmission pipelines are trunk lines or spur
lines operated generally at above 20 bars. Transmission lines are operated and
maintained by GSPL. Distribution pipelines starts after City Gas Station (CGS),
spreads in city up to inlet of CPRS, DRS and CNG Station and it operates at
pressure range from 15 to 19 bars.

Carbon Steel pipelines are normally of API-5L Grade – A or B material and sizes
varies from 4” to 16” in distribution network. They are first coated with 3 Layer PE
coating or Fusion Bonded Epoxy (FBE) Coating and then they are welded, NDT
tested, laid underground at normally 1 m depth and finally hydro tested to 1.5 times
Max operating pressure. The underground steel network is protected against
corrosion by coating the pipes and applying impressed current Cathodic protection.
Special care is taken during installation and operation maintenance for rail, road and
nala, canal crossings.

2. Monitoring & Maintenance Activities & Frequencies for Steel

Distribution Network.

Underground CS gas distribution network is safe against high pressure because of

adequate strength of pipe material and welding technology. However there are two
threats (a) Corrosion (b) Third party damage

Following activities shall be carried out as per suggested frequencies for

maintenance of CS gas pipeline network.

Network Maintenance
 Sr. Activity Frequency
Update Network Drawing to incorporate all
1 As and When
extensions, modifications of network.
2 Patrolling & Surveillance of Network Monthly
Patrolling of Crossing – Bridge, Culvert, Khadi,
3 Monthly
Canal, Road, High Way, River & Railway
Emergency Patrolling & Third Party
4 Coordination if work is going on or near gas As and When
pipeline route
5 Leak detection survey of network Quarterly
6 Lock Pressure Test of network Quarterly
Half Yearly
7 Valve Chamber Preventive Maintenance
(Pre-Monsoon, Post Monsoon)
8 Operation and Greasing of Valves Half Yearly

Cathodic Protection Maintenance

Sr. Activity Frequency
1 Transformer Rectifier (TR) Unit Monitoring Daily
2 Pipe to Soil Potential Monitoring Bi -Monthly
3 Anode Ground Bed Monitoring Half Yearly
4 Insulating Joint (IJ) Monitoring Half Yearly
Preventive Maintenance of Test Lead Points
5 Yearly
(TLP)
Preventive Maintenance of TR unit and Ground
6 Yearly, As per Mfr. Guidelines
Bed
7 Earthing Resistance Monitoring Half Yearly
8 Earthing Pit Maintenance Yearly
9 Special Survey like CPL, CAT, DGVC, etc.. As per GSPC Gas Requirement
10 Repair of Damaged Coating As & When
The frequencies and the extent of the work are based on requirements set down in
ANSI/ASME B31.8, NACE RP 01-69, operational experience and good engineering
practice. The operation and maintenance frequencies should be reviewed
considering the upcoming standards of Petroleum and Natural Gas Regulatory
Board (PNGRB) on City Gas Distribution.

3.0 Procedure for Maintenance of Steel Distribution Network :

Sr. Activity Steps Responsibility

01 On receipt of O&M contract, contractor shall take specification O&M
Contractor
 / detail of distribution network, as-built drawings, testing In-charge

reports and other construction records from GSPC Gas

02 O&M contractor shall visit overall site along with related staff O&M
Contractor
members to make themselves aware about route, type of In-charge
laying, special crossing, and type of coating and size of
pipeline.
03 As built drawings / schematic etc of network shall be taken O&M
Contractor
over from GSPC Gas or from its contractor in soft copy and In-charge
same shall be updated regularly with repairs / modifications /
extensions carried out over the time period.
04 As mentioned above “Steel Gas Network maintenance activity O&M
Contractor
and suggested frequency”, Annual maintenance plan is In-charge
prepared and approval is taken from GSPC Gas
05 Emergency and interconnection valve chambers shall be O&M
Contractor
identified in consultation with GSPC Gas as per requirement In-charge
of flow curtailment / emergency stoppage of Gas supply. The
one copy of same is handed over to control room for
information and coordination.
06 Emergency vehicle shall be equipped with all necessary valve O&M
Contractor
keys to operate valves, pipe piece for leverage, leak clamps, In-charge
tools tackles and consumables to handle the gas leak or fire
emergency on gas network
07 Contractor shall arranged, in consultation with GSPC Gas, the O&M
Contractor
leak clamps of various size, in appropriate numbers to arrest In-charge
the leak / puncture / damage on steel network
A Network Patrolling & Maintenance
08 All above listed maintenance activities shall be commenced O&M
Contractor
immediately after taking over as per concerned work In-charge
instruction Annexure – 01, Annexure – 02, Annexure – 03,
Annexure – 04 and report shall be prepared.
09 Based on the findings of monitoring and patrolling activities, O&M
Contractor
necessary actions shall be planned in consultation with GSPC In-charge
Gas and same shall be implemented / executed to maintain
 the overall safety and integrity of network.
10 In case of breakdown of valve chamber or valve, it shall be O&M
Contractor
repaired / reconditioned In-charge
11 In case of pressure drop is more than 1.0 bar in a particular O&M
Contractor
section, pressure drop test in sub-sections (small sections of In-charge
particular big section) through other valves shall be
conducted. Pressure drop in particular small section shall be
found out / located
12 Vigorous Surface / Subsurface Gas Detection Survey O&M
Contractor
immediately to identify probable gas leak location shall be In-charge
arranged
13 Post surface gas detection survey, the action/s, shall be O&M
Contractor
initiated & ensured as per Leak Classification and Action In-charge
Criteria (Annexure -05)
14 Excavation at probable gas leak location shall be arranged O&M
Contractor
and the cause of gas leak shall be identified. In-charge
15 Repair rectification of gas leak shall be arranged in O&M
Contractor
consultation with GSPC Gas In-charge
16 Report and records of maintenance shall be prepared and O&M
Contractor
submitted to GSPC Gas O&M In charge regularly In-charge
B Cathodic Protection (CP) System
17 Contractor shall take over CP System detail specification, O&M
Contractor
installation and commissioning report, Initial CPL Survey In-charge
Report and as-built drawing from GSPC Gas or it’s contractor.
18 O&M contractor shall visit all CP site along with related staff O&M
Contractor
members to make themselves aware CP Installation and In-charge
Protection Level. In case of any abnormalities same shall be
reported to GSPC Gas within seven days for rectification
19 Cathodic Protection being a specialized activity, O&M O&M
Contractor
Contractor should employ qualified staff or should train them In-charge
for effective monitoring and maintenance of CP System
20 All listed CP maintenance activities shall be commenced O&M
Contractor
immediately after taking over as per concerned work In-charge
 instruction Annexure – 06, Annexure – 07, Annexure – 08,
Annexure – 09, Annexure – 10 and report shall be prepared.
21 Based on the findings of monitoring and maintenance O&M
Contractor
activities, necessary actions shall be planned in consultation In-charge
with GSPC Gas and same shall be implemented / executed to
maintain overall effectiveness of CP System.
22 History Card of TR Units, Anode Ground Beds and TLPs shall O&M
Contractor
be maintained as per Annexure – 11 and shall be submitted to In-charge
GSPC Gas, half yearly for review & comment
23 Coating shall be repaired as per the work instruction given in O&M
Contractor
Annexure – 12 In-charge
24 Report and records of monitoring and maintenance shall be O&M
Contractor
prepared and submitted to GSPC Gas O&M In charge In-charge
regularly
25 O&M Contractor shall execute / manage special CP Survey O&M
Contractor
like CPL Survey, DCVG Survey, CAT Survey, etc… in In-charge
consultation and guidance of GSPC Gas.
C Takeover of Extended Network
26 On receiving intimation regarding charging of a particular O&M
Contractor
network or extension of network from GSPC Gas Company In-charge
or it’s contractor, O&M contractor shall visit overall site along
with related staff members to make themselves aware about
route, type of laying and size of pipeline
27 'As Built Drawing' Laying Reports and Pressure Test reports O&M
Contractor
shall be taken over from Construction Contractor / GSPC Gas In-charge
28 All valve chambers shall be inspected for proper construction, O&M
Contractor
its cover, tagging & marking and gas leak. In case of any gas In-charge
leak, potential hazard or poor construction same shall be
reported to Construction Contractor and or GSPC Gas within
seven days
29 Awareness program including site visit shall be organized for O&M
Contractor
each member of O&M team In-charge
30 The extended network shall be included in Annual O&M
 Maintenance Plan and maintenance activities shall be started Contractor
In-charge
as per above procedure
31 Staff shall be regularly trained and educated for network O&M
Contractor
route, O&M procedures and HSE Aspects In-charge
 ANNEXRURE - 01
Guidelines and Work Instruction For Network Patrolling & Surveillance

ANSI/ASME B 31.8 states, “Distribution mains shall be patrolled in areas where

necessary to observe factors which may affect safe operation. The patrolling shall be
considered in areas of construction activity, physical deterioration of exposed pipe
and supports, or other natural causes, which could result in damage to the pipe. The
frequency shall be determined by the severity of the conditions which could cause
failure or leakage and subsequent hazards to public safety”.

In practice, informal patrol may be carried out in vulnerable areas by Supervisors in

their daily movement around their area of responsibility i.e. If an important supply
main is located along road XYZ and there is excavation work being performed in its
general proximity, then it would be proper for a Supervisor to travel that road in any
traverse he may make of the general locality.

All rail, road and major waterway crossings should be inspected on a regular basis to
observe surface conditions, indications of leaks, general construction activity and
any other factors which may affect the safe operation of gas system.

When a threat to the gas system from third party excavation is observed by a
Supervisor or Inspector then that person must take the appropriate action on site to
ensure the gas pipe is not damaged. It may be necessary in some circumstances to
arrange for an Inspector to be positioned on site to ensure the integrity of the gas
system is maintained.

Role of a Patrol Person

A patrol person plays an important role and is the front line defense against hazards
which the safety and security of the system. This important role should be
recognized by contractor management and care taken to ensure patrol persons are
provided with the appropriate skills and facilities to perform their duties. One of the
basic skills required by a patrol person is the ability to read plans. It is also important
the patrol person can communicate in a verbal and written form, and accuracy is to
be encouraged as an essential feature. It may be necessary for training courses to
be held for the development of patrol persons.
A typical duties and responsibilities for patrol persons are as follows. These are for
information and guidance.

• Inspect the work of other authorities and private organizations carrying

out work in the vicinity of a transmission pipeline.

• Report immediately any unusual developments or occurrences along a

pipeline route which may have some affect on the normal operation or
maintenance of the pipeline.

• Supervise any maintenance personnel under his control.

• Maintain liaison with other authorities and bodies who are concerned
with works which could affect pipelines. Further, maintain good
relations with the owners of properties traversed by pipelines. Good
communications and in particular keeping people informed on the
location and importance of pipelines, is a primary defence against
interference being caused by third parties.

• As required, prepare and forward routine reports.

Work Instruction for Network Patrolling

1. Divide total network route in sub-route / section such that total network can
be patrolled once in month.
2. Ensure that each member of patrolling team aware about the route of
pipeline, size of pipeline, type of coating and depth.
3. Observe following along the route
• Excavation work on / near gas pipeline
• Civil work / construction near gas pipeline
• Erosion of soil from gas pipeline route
• Surface faulting, subsidence, flooding on gas pipeline route
• Encroachment by slums other temporary structure
 • Encroachment by lorry / galla / tea house
• Other potential hazards
• Valve Chambers and it’s top cover
• District Regulator station it’s fencing / cabinet / gates
4. In case of Excavation / Civil / Construction work on / near gas pipeline,
meet with site supervisor / concerned person and get detail like
• the type of work and purpose
• use of excavation machines or other machines
• depth of excavation
• distance from gas pipeline
• work duration / completion date
• drawing of construction work
• name of contractor, address and contact detail
5. Provide them awareness about gas network, it’s hazards and pipeline
drawing. Brief them a safety precautions to be taken to prevent damage to
gas pipeline
6. Provide them a contact address and telephone numbers for consultation in
case of any difficulty
7. In case of erosion of soil from gas pipeline route, take depth and length of
erosion. Investigate probable cause of soil erosion. In case of soil erosion
due to reason/s of third party, coordinate with them to prevent them.
Initiate action to restore eroded site properly
8. In case of encroachment on / near gas pipeline, report it to concerned
authority to shift / prevent them. Make them aware about gas pipeline
route and it’s hazards. Explain them safety precaution to be taken to
prevent any incident
9. While patrolling, check the pipeline markers condition
10. While patrolling, keep the speed of vehicle such that all above observation
can be made effectively. Walk Survey / Patrolling is preferable in case of
congested area or other utility activities going on.
11. Report findings of Patrolling activity in specified format
12. Update the contact address and telephone numbers of concern third party
utility agencies on regular basis.
 13. Keep the communication device and list of contact numbers of related
utility agency while patrolling.
14. Use cotton dress and safety shoes while pipeline patrolling activity
15. Use helmet if require to go near construction site
16. Observe and check for trip / fall hazards while pipeline patrolling activity
17. While driving during pipeline patrolling activity, Follow “Safe Driving”
instructions
Patrolling / Inspection of Pipeline Crossing like Railways, HighWays, Culverts,
Bridges, Canal to be carried out as per follow

18. Check the condition of soil, sign of excavation or erosion.

19. Check the condition of vent pipe, casing drain etc
20. Check the gas leakage from casing vent pipe line
21. Check the availability and condition caution / sign boards and pipeline
markers near crossing. Ensure the display of emergency telephone
numbers on caution / sign board
22. Check the position of pipeline, placing of the pipeline to its original
position. Note down If it is shifted from its position.
23. Check the pipeline supports and its condition. Note down if it is corroded
or damaged or stolen
24. Check the condition of pipeline & support painting or coating
25. Note down the abnormal condition in Gas Pipeline Patrolling Report and
plan remedial action/s in consultation with GSPC Gas

Liaison with Other Authorities

It is important that O&M Contractor develops a co-operative relationship with other

authorities, particularly authorities responsible for public construction work. Other
authority personnel should where practical, be provided with Network Drawings, and
be regularly reminded of the location of strategically important mains.

They should also be acquainted with the hazardous properties of gas and the
potential effect of escaping gas on the safety of the public. It should be emphasized
and encouraged that in the event of an emergency that prompt co-operative action
would be required.

Apart from the essential day to day contact with other Authorities, O&M Contractor
shall formally correspond with the appropriate other Authorities on a yearly basis.
 Gas Pipeline Patrolling Report

Date of Patrol :
Network / Area :
Pipeline Section : Size : Length :

Sr. Pipe
Check Point Location Observation / Findings
No. Size
01 Excavation work on
/ near gas pipeline

02 Civil / construction
work on / near gas
pipeline

03 Erosion of soil
04 Encroachment
05 Surface
subsidence,
flooding
06 Any other potential
Hazard
07 Damage to Pipeline
markers
08 Damage to Valve
Chamber/s
09 Damage to District
Regulator Station/s
Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 Patrolling Report of Pipeline Crossing
Like Canal, Main Road, Highway, Railway

Date of Patrol :
Network / Area :

Sr. Observation / Observation / Observation /

Check Point
No. Findings Findings Findings
Crossing -1 Crossing -2 Crossing -3
01 Crossing Detail
02 Location
03 Size & Length
04 Excavation work on /
near gas pipeline
05 Civil / construction
work on / near gas
pipeline
06 Erosion of soil
07 Encroachment
08 Surface subsidence,
flooding
09 Condition of Drain &
Vents
10 Condition of TLP
11 Damage to Pipeline
Warning Boards &
Markers
12 Gas Leak Survey
(Leak % & Location)
Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 02
Work Instruction for Valve Chamber Maintenance

This activity consists of (a) Gas Leak Check (b) Partial / Full Valve Operation (c)
Valve Greasing (d) Cleaning and (e) Tag number painting.

1. Ensure that each member of team are aware about natural gas and it’s
hazards
2. Ensure that each member of team aware about the risk involve in valve
chamber maintenance activity, it’s potential hazard and preventive
measures.
3. Supervisor & team shall be made aware of pipeline network route and
valve chamber locations.
4. Plan the job in advance and ensure appropriate work permit for job.
5. Ensure availability and use of appropriate PPEs and Safety Items as per
“Annexure – PPEs Matrix” during valve chamber maintenance activity
6. Ensure the availability of necessary tools tackles and other items in good
working condition, required for valve camber maintenance activity.
7. Ensure the availability of wireless set / mobile phone at site. After reaching
site, first, establish contact with control room before start of activity.
8. Cordoned the site appropriately and place caution board along the road
site valve chamber.
9. Clean the top cover of valve chamber and note it’s tag number
10. Open the valve chamber top cover, one by one, gentle by holding & lifting
from both sides manually. Take utmost care to prevent, falling of top cover
inside chamber.
11. Remove all the top covers and keep them aside without creating
obstruction.
12. Check the gas leak inside valve chamber using calibrated gas detection
instrument. Supervisor should be trained for operation of gas detection
instrument and measurement of gas leak.
13. Check the flange joints and threaded joint, using bubble test (soap
solution) for any gas leak.
14. In case of gas leak from valve, first attend the gas leak. If require arrange
resources from control room / main office.
15. In case of valve chamber is more than 1.5 meter deep, and seems to be
confined space, first check the oxygen level before entering in valve
chamber. Entry should not be permitted if oxygen level is less than 19.5%.
16. Use ladder to enter inside deep valve chamber.
17. Carry out dewatering / cleaning of valve chamber first.
18. Operate the valve partially or fully depending upon gas flow and line pack
availability for customers. Ensure that gas supply is not affected to any
customer. Avoid valve operation in case of any doubt.
19. Grease / Lubricant the valve in case of valve is jam or operating hard.
20. Paint the tag number of valve chamber on top of cover, if it is faint or
erased.
21. Carry out white wash of valve chamber from inside and outside top civil
portion.
22. Carry out oil paint of specified colour and type, to valves inside the
chamber and metal portion of valve chamber top cover once in year after
monsoon.
23. Close the valve chamber top covers gently, lifting & holding from both
sides manually. Take utmost care, to prevent dropping of top cover inside
chamber.
24. Remove caution board/s and cordoning tape / device from site and restore
site to safe level.
25. Provide message to control room and take activity further.
26. Prepare report of valve chamber maintenance activity in a specified
format.
27. After completion of activity, close out work permit and keep the record of
same.
 Valve Chamber Maintenance Report

Date of Maintenance

Cleaning
V/C Leak Operation Tag No Any
Greasing & White Painting
No Test of Valve Painting Damage
Wash

Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 03
Work Instruction for Pressure Drop Test of Gas Pipeline
1. Divide total network route in sub-route / section such that total network can
be tested once in quarterly.
2. Ensure that each member of team aware about the exact route of pipeline,
size of pipeline, valve chamber location, interconnection between network
3. Ensure that each member of team are aware about natural gas and it’s
hazards
4. Ensure that each member of team is aware about the risk involve in testing
activity, it’s potential hazard and preventive measures
5. Ensure the availability of portable / mobile calibrated gas detection
instrument in good working condition 1% LEL, for this activity.
6. Conduct Pr Drop Test during festival days / holidays where gas
consumption is low, or on days where customer provide shutdown.
7. Intimate affected customers and control room for gas supply stoppage.
8. Lift the top covers of valve chamber carefully & confirm “0” leakage with
gas detection instrument inside valve chamber.
9. Install a calibrated pressure gauge with least count of 0.1 bar on upstream
and downstream point of section.
10. Isolate upstream and downstream valves of pipeline section which is to be
tested. Isolate interconnection valves / tap-off valves of section to be
tested
11. Observe and note the pressure on pressure gauge and start the hold
period.
12. Hold the section at pressure for two hours.
13. Observe the pressure at upstream and downstream after completion of
hold period and record it in specified format.
14. Remove the pressure gauges and open the isolated valves
15. Carefully close the top cover of valve chambers.
16. Prepare report of Pressure Drop Test in specified format.
17. Intimate affected customers and control room for gas supply resumption
 PRESSURE DROP TEST REPORT

Feeder / Section under LPT: Date:

Valve Initial Final Valve

LPT Pressure
Valve Detail Location: Closing Locked Locked Opening
Hours: Drop
Time: Pressure: Pressure: time:

LPT OBSERVATION TABLE

Time Line Pressure Valve Position Remarks

Pressure Gauge Detail

Sr. Pressure Least Calibration

Gauge Make Dial Size Remarks
No. Range Count Date

Conclusion / Observation:

LPT Taken By: Checked By: Approved By:

 ANNEXRURE - 04
Work Instruction for Surface Gas Detection Survey
On Gas Pipeline Route

Surface Gas Detection Survey is a continuous sampling of the atmosphere at or near

ground level for buried gas pipeline and / or adjacent to aboveground gas facility with
a gas detector instrument cable of detecting a concentration of 50 ppm gas in air at
the sampling point.

Pressure Lock Test is indicative only, and it required shutdown of pipeline as well as
special operational skill whereas Gas Leak Survey / Surface Gas Detection is easy
and effective to identify the gas leak on network with spot identification.

1. Divide total network in section / sub-section such that total network can be
surveyed once in a quarter.
2. Ensure that each member of team aware about the exact route of pipeline,
size of pipeline and depth.
3. Ensure that each member of team are aware about natural gas and it’s
hazards
4. Ensure that each member of team aware about the risk involve in survey
activity, it’s potential hazard and preventive measures
5. Ensure the availability of portable / mobile calibrated gas detection
instrument in good working condition having least count of 10 ppm, for
survey activity.
6. Start the gas leak detection survey activity with zero chainage or with
known location / landmark location.
7. After reaching site, first start the gas leak detection instrument and then
walk along the gas pipeline route at the normal speed.
8. For buried pipeline, take sampling just above 2” (not more than 2”) from
ground. However it should not be touch to ground or water body to prevent
probe chock up.
9. Sampling should also be taken at ground surface opening such as
manholes, catch basins, sewer, power telephone duct openings, traffic
signal / junction boxes, curb line / cracks of pavements
10. While survey, ensure that probe do not rub in soil getting chocked with
dust and water.
11. Carefully observe the hooter / indicator of instrument while survey /
walking.
12. Note, if instrument shows some indication of gas leak. Survey surrounding
place thoroughly for gas leak intensity. Observe for gas smell.
13. Check for any other flammable gas leak from surrounding.
14. Confirm gas leak, by check at site twice / thrice.
15. Note the gas leak spot along with leak intensity in specified report and
carry out survey further.
 Surface Gas Detection Survey Report

Date of Leak Survey :

Network / Area :

Gas Detection Instrument Detail :

Type : Range :
Calibration Date : Calibration due date :

Pipeline Section Leak Survey Leak Intensity

From To Size Length Result (% LEL)

Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 05
Gas Leak Classification and Action Criteria
(Based on ASME B 31.8)
Any leak, minor or major should be attended at the earliest opportunity, however
when not possible below table may be followed.

Leak Definition Action Criteria Example

Grade

01 A leak that represents an Requires prompt Escaping gas that

existing or probable hazards action to protect life has ignited
to persons or property and and property. Any gas indication
requires immediate repair or Continuous action of gas which has
continuous action until the until the condition migrated into or
condition are no longer are no longer under a building or
hazardous hazardous into tunnel
Any reading at the
outside wall of a
building or where
gas would likely
migrate to an
outside wall of a
building
Any reading of
20% LEL or greater
in a confined space
Any reading of
40% LEL or greater
Any gas lea that
can be felt, seen or
heard and which in
location that may
endanger the
general public or
 property
02 A leak that is recognized as Leaks can be Any reading of
being non hazardous at the repaired or cleared 40% LEL or less
time of detection but that has within six month if it
requires repair based on is not harmful to
probable future hazard human. It should be
reevaluated at least
once in every
month
03 A leak that is recognized as This leakage Any reading of
being non-hazardous at the should be 20% LEL or less
time of detection and can be reevaluated at
reasonably expected to every quarterly till it
remain non-hazardous get rectified within
one year.
 ANNEXRURE - 06
Transformer Rectifier (TR) Unit Monitoring and Maintenance

Monitoring of Transformer / Rectifier units. ( T/R unit )

⇒ Note down the AC Input (Volt & Amp), DC output and Corrosion voltage (PSP)
readings for each T/R unit on daily basis.
⇒ Compare the DC output and PSP of TR unit with previous days. It should be in same
range. If there is significant increase or decrease, investigate further.

Preventive maintenance of T/R unit

Preventive maintenance is to be carried out as per Mfr Guidelines / O&M Manual. Following
activities shall be carried out half yearly.

⇒ Cleaning of TR unit. Clean internal circuit using blower.

⇒ Clean and tighten all bolts current carrying connections.
⇒ Apply light film of Petroleum jelly on contacting surface to maintain low resistance
contacts & overheat.
⇒ Clean all ventilating screens in air-cooled units so air flow will be completely un-
obstructed.
⇒ Check indicating meters for accuracy with standard high precision millimeter.
⇒ Check the earthing connection and it’s resistance
⇒ Replace poor / damaged insulated wires.
⇒ Check all protective devices like fuses, circuit breakers or lightning arrestors for its
satisfactory operating condition.

Trouble Shooting of Transformer / Rectifier units. ( T/R unit )

Case 1 : If unit shows the DC current zero and DC voltage more than set value, Take
following corrective measures, also refer Mfr O&M guidelines

⇒ Check The anode ground bed circuit, if it is open, then carry out anode ground bed
maintenance.
⇒ If the anode circuit is closed, then check all fuses of unit and replace faulty one.

Case 2 : If unit shows the DC current zero and DC voltage zero, take following corrective
measures,
⇒ Check out put fuses of unit and replace faulty one.
⇒ If they are ok. then check control cards and replace faulty one.

Case 3 : If unit shows no panel light, take following corrective measures,

⇒ Check input fuses and replace faulty one.
⇒ If they are ok, check the electric supply to the unit and ensure electrical supply.
⇒ If supply is available and still unit is not working then check cables for fault.
 TR Monitoring Report

• Month :
• Frequency :
• Stations : (Name and Tag)
• Pipeline Network :

T/R UNIT READINGS :

Date A.C.Input D.C.Output Gr.Bed Ref.
Resist. Voltage
Voltage Current Voltage Current ohm. Voltage
(V) (A) (V ) (A) ( -V )

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 Preventive Maintenance of TR Unit
& Anode Junction Box

• Date :
• Station :
• Section Covered :
• Approach :
1. Transformer / rectifier Unit details : Manufacturer
Rating of Unit :
Operating Mode : Auto / Manual
2. Visual Inspection & Maintenance of TR :
Sr.
Description Status
No
1 Operation of Lock Ok / Not Ok
2 Identification of tag. Ok / Not Ok
3 Indication lamp / LDS Ok / Not Ok
4 Cleaning Inside / Outside using blower
5 Damage to T/R
6 Tightening of connection
7 Body and Paint Condition
8 Status of control Cards
9 Earthing Connection
10 Electrical fittings/glands
11 Lamps & indicators
12 Fuses, Plugs & Sockets
13 Current Regulation Switches
14 Voltage Regulation Switch
3. Working Parameters :
Sr. Description / Parameter. Acceptable Actual Value
No Value
1 A.C.Input voltage in V
2 A.C.Input current in A
3 D.C.Input voltage in V
4 D.C.Input current in A
5 Resistance in ohm V / I
6 PSP at drain point
Ref. Cell : 1
Ref. Cell : 2

4. Visual Inspection & Maintenance of Anode Ground Bed and Junction Box :
Sr.
Description Status
No
1 No. Of Anodes
2 Operation of Lock Ok / Not Ok
3 Identification of tag. Ok / Not Ok
4 Cleaning Inside / Outside using blower
5 Any damage
6 Tightening of connection
7 Body and Paint Condition
8 Electrical fittings/glands

Action Required:
Remark: This format shall be reviewed and revised based on CP guideline or O&M Manual
provided by mfr.

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 07
Pipe - To - Soil Potential (PSP) Monitoring

Monitoring of Pipe - to - Soil (PSP) potential

⇒ Take pipe - to - soil (PSP) potential reading by using Cu - Cuso4 half-cell and
calibrated Multimeter, at all test points bi-monthly. Prepare the graph of PSP
reading with in line of -0.85 V and Max line of -1.45 V

⇒ If the readings cross the max. / Min. limit (i.e. - 0.85 V to - 1.45 V), investigate
further
⇒ Note down the PSP readings and observation in standard format
⇒ Cary out analysis annual for significant change of PSP.

PSP Monitoring of Cased crossing

⇒ Monitor the PSP of Carrier Pipe and Casing Pipe at both the end
⇒ Carrier pipe PSP should be between -0.85 volt to -1.4 volt and Casing Pipe PSP
should be below -0.85 volt
⇒ In case Casing pipe PSP is found between -0.85 volt to -1.4 volt then expose the
casing at both end to find out the shorting of casing and carrier pipe
⇒ Carry out further investigation / remedial actions in consultation with GSPC Gas

Trouble Shooting in case PSP is Abnormal

⇒ If the P.S.P value is more than - 1.45 V, reset the T/R unit, and keep
the P.S.P value - 1.45 V. at drain point.
⇒ If the P.S.P value is less than - 0.85 V, check half-cell condition and/or cable
connection. And if require repair it.
⇒ If the problem is not rectified then consult CP expert or GSPC Gas.
 PSP Monitoring Report

• Date :
• Frequency :
• Stations : (Name and Tag)
• Pipeline Network :

PSP Readings
Sr. Type of Chainage PSP in Condition of TLP
TLP No Location
No TLP in KMS Volt
1
2
3
4

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 08
Test Lea Point (TLP) Maintenance

Maintenance of TLP

Refer Mfr guidelines / O&M Manual for maintenance of TLP. Following activities are to be
carried out yearly as part of preventive maintenance.

⇒ Cleaning of TLP outside and inside.

⇒ Carry out lubrication of hinges and lock of TLP.
⇒ Check the cable connection, it’s tag and tighten if found loose
⇒ In case of damaged cable, replace cable.
⇒ In case of damaged TLP, carry out necessary repair or replacement.
⇒ Check the tag number and if require paint / display
⇒ Carry out painting & numbering once in a two year.
 Test Lead Point (TLP) Maintenance Report

• Date :
• Frequency :
• Stations : (Name and Tag)
• Pipeline Network :

Repair /
Lubrication Replace
Cleaning Cable Painting
Sr. of ment
TLP No Location Inside / Connecti and Tag
No. Enclosure Requirem
Outside on No
and Lock ent

1
2
3
4

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 09
Anode Ground Bed Monitoring and Maintenance

Monitoring of Anode ground bed

⇒ Monitoring of anode ground bed is to be carried out at anode

junction box by Multimeter.
⇒ Refer Mfr guidelines / O&M Manual for monitoring of ground bed.
⇒ Note down the readings and observation in standard format
⇒ Cary out analysis annual for significant change of PSP

Maintenance of Anode ground bed

⇒ Refer Mfr guidelines / O&M Manual for maintenance of ground bed

 Anode Ground Bed Monitoring Report

• Date :
• Frequency :
• Stations : (Name and Tag)

• Pipeline Network :
• Ground Bed Details :
• Ground Bed Configuration :
• Anode Quantity :
• No of Cable markers :

Current Out put of individual Anodes :

Current
Anode No Shunt measurement ( mV )
( mA )

Current output of complete ground bed :

Anode Current at T/R unit :
Total Anode Current measured at AJB with calibrated instrument :

Remark: This format shall be reviewed and revised based on CP guideline or O&M Manual
provided by mfr.

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date

ANNEXRURE - 10
Insulating Joint (IJ) Monitoring and Maintenance
Monitoring of Insulating Joint (IJ)

⇒ Take the PSP reading on upstream and downstream side FROM.

⇒ At downstream side (pipeline side) it should be between -0.85 volt to -1.4 volt and on
upstream it should be below -0.85 volt
⇒ Check the gas leak using gas detector and soap solution
⇒ Check the support condition of IJ
⇒ Note down the PSP readings and observation in standard format
⇒ Cary out analysis annual for significant change of PSP.

Maintenance of Insulating Joint (IJ)

⇒ In case of earthing of IJ with soil, support of any metallic part, remove the earth contact
/ metallic contact.
⇒ In case of electrically passing of IJ, plan replacement in consultation with GSPC Gas.
⇒ In case of gas leakage from IJ joint, plan replacement in consultation with GSPC Gas
 Insulating Joint (IJ) Monitoring Report

• Date :
• Frequency :
• Pipeline Network :

Sr. IJ Tag Location Size PSP PSP Leak Test

Remark
No No of IJ (Inch) Upstream Downstream (%)

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 11

Facility / Equipment History Card

Name of Equipment : Equipment No:

Location

Sr. Date Of Breakdown / Problem Maintenance Work In

Remark
No. Maintenance Detail Activity Done Charge

O&M Contractor In charge GSPC Gas O&M In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 12
Coating Repair

⇒ Refer coating Mfr guidelines for repair work

⇒ The coating repair material should be compatible to original pipeline coating
material
⇒ Surface preparation to be carried out as per coating mfr guideline
⇒ Technician shall be trained for coating repair work
⇒ Keep record of coating repair consisting area of repair work, type of coating
material used, chainage and location
5. Procedure for Steel Network Emergency Handling :

Steel network being strong material pipeline, are less susceptible to damage by third
party. However chances are there if work is carried out with excavation machines
without precautions and knowledge. Steel pipeline are more prone to leak due to
corrosion if pipeline is not cathodically protected adequately.

Like PE Network, following emergency situation can come on steel network for which
O&M Contractor is required to prepare adequately.

1. Gas Leak (b) Gas Escape due to damage (c) Gas Fire (d) Explosion

As mentioned in the “Complaints Handling – Gas Leak & Escape” O&M Contractor is
required to establish a control room which operates round the clock to receive the
gas leak, fire, and explosion related complaint/s. They are also required to establish
emergency team of adequate manpower working in shift round the clock and
emergency vehicle equipped with necessary tools tackles and safety items to attend
such emergency in CGD zone with response time of less than 30 minutes. Annexure
– 13 provides additional items which shall be kept in Emergency Vehicle for handling
emergency on steel network

The procedure “Complaint Handling - Gas Leak / Gas Escape” shall be followed
for steel network also. Annexure-14, 15 provide work instruction for attending gas
leak / escape and third party damage specific to steel gas network.
 ANNEXURE – 13
List of Additional Items for Handling Emergency on Steel Network

SR. DESCRIPTION SIZE NOS. REMARK

1 Valve Keys of each size & type 01 set
2 Leverage pipe piece 02 Nos
Overall Steel Network Drawing With All
3 VALVE CAHMBER Details 01 Nos
Leak clamps (2” to 6”)
Leak clamps of higher size to be kept
4 ready at main office / control room 01 set
Spanner Set (Open & Ring) of
appropriate size depending upon size 01 set
5 of studs & bolts

The above list is indicative. O&M contractor shall review it in consultation with GSPC
Gas and incorporate all necessary items to handle gas leak / escape, gas fire &
explosion emergency on steel network effectively & efficiently
 ANNEXURE – 14

Work Instruction for Attending Gas Leak / Escape on

Steel Gas Network

Following actions shall be taken on site by the Emergency Team,

• Inform the control room immediately upon arrival on site.
• Assess the situation and need to protect human life & property
• Record the gas concentration using calibrated gas detector instrument
• Evacuate affected area and display caution boards
• Cordon and secure the affected area
• Close off access roads
• Dampen the soil with water to prevent sparks
• When the exact location of the leakage is determined Identify or locate suitable
main line and or valve chambers for isolation purpose.
• Inform the Control Room of the findings and progress being made.

[ A ] Leakage from Valve Chamber :

1) Open the top cover of valve chamber carefully without falling top cover inside
the chamber
2) Measure the gas concentration using calibrated gas detector in and around
valve chamber
3) Identify the gas leak source / location
4) If gas concentration is below 20% LEL, inside valve chamber then try to
attend gas leak in chamber
5) Tighten thread / flange joints of valves or vent drain facility inside the valve
chamber
6) If gas leak can not be attended thro tightening plan for shutdown in
consultation with GSPC Gas
7) If gas concentration is above 20% LEL, inside valve chamber then plan for
shutdown in consultation with GSPC Gas
8) Meanwhile keep the affected area cordoned off with display of caution board
and monitor the gas leak.

[ B ] Leakage from Steel Pipeline :

1) Measure the gas concentration using calibrated instrument on pipeline route

2) Identify the probable gas leak source & location
3) If gas concentration is below 20% LEL, start exposing gas pipeline
4) Keep the area wet using water to avoid spark while excavation
5) Once the pipeline is exposed and gas leak is thro corroded pipe (pin hole,
puncture, crake) then install “leak clamp” and stop leakage temporarily.
6) Carry out gas leak survey using soap solution and calibrated instrument.
7) Expose pipeline further and find out extent of corrosion.
8) Plan the replacement of pipeline taking shutdown in consultation with GSPC
Gas
9) If gas concentration is above 40% LEL, then plan for shutdown of particular
pipeline section and then carry out excavation and repair of pipeline
 ANNEXURE – 15
Work Instruction for Attending Damage on Steel Network resulting in
Gas Escape or Gas Fire

Steel gas pipeline is less susceptible to damage due strength of material however
work without knowledge and precaution using excavation machine can damage the
steel gas pipeline.

The damage of steel gas pipeline can cause gas escape from small quantity to large
quantity and may result in fire or explosion if it receives spark.

Normally gas escape is in form of jet. Gas jet in open area is little safe as it disperse
up in atmosphere. However in city area it is very risky as gas can accumulate in
nearby building and may result in gas fire or explosion affecting the human life and
properties.

Sometimes after getting spark, gas escape converted in jet fire. Gas jet fire is much
safer then gas escape if fire is not affecting the surrounding properties or human life.

Hence one should never try to extinguish gas jet fire if it is not affected to human life
& surrounding properties. The gas escape is more danger as it can go & accumulate
in surrounding building.

1. Upon receipt of information of damage to Gas line by control room, Emergency

Team shall rush to site and take following actions
 • Inform the control room immediately when arrived on site.
• Assess the situation and need to protect human life & property
• Record the gas concentration using calibrated gas detector instrument
• Evacuate affected area and display caution boards
• Cordon and secure the affected area
• Close off access roads
• Dampen the soil with water to prevent sparks
• When the exact location of the leakage is determined Identify or locate
suitable main line and or valve chambers for isolation purpose.
• Inform the Control Room of the findings and progress being made.

2. Identify the pipeline section affected, related valves and nos of customer
affected.
3. Communicate it to GSPC Gas thro control room and plan for shutdown of
particular section by closing isolation valves.
4. Communicate to all customers for stoppage of gas supply and ask them to
isolate their main inlet valve
5. After getting consent from GSPC Gas for isolation of section, first close
upstream valve gradually to allow gas of pipeline section to consume by
downstream customers.
6. In case of jet fire, isolate the upstream valve gradually allowing gas
consumption by downstream customers.
7. Monitor the gas fire becoming low. After sufficient low gas fire, first extinguish
fire using DCP type fire extinguisher and the fully close upstream valve.
8. After sufficient low pressure, close downstream valve of section
9. Install vent pipe (3 m high from ground level) on one of vent valve of isolated
section and vent off remain gas from affected pipeline section
10. Identify the type & extent of damage to steel pipeline by exposing affected area.
11. Check leak can be arrested by leak clamps or by replacement of pipe piece.
12. If damage area can be covered by leak clamps then install leak clamps
properly.
13. Charge the gas line. Increase pressure step in step of 2 bars.
14. On each pressure step, take a leak test using soap solution and gas detector
instrument and ensure no gas leak.
15. Finally commission the pipeline section and communicate to control room
16. Provide message to all customer for resumption of gas supply and ask them to
gradually open their main inlet valve
17. Plan the permanent repair in consultation with GSPC Gas
 6. Procedure for Steel Network Modification, Extension / Installation
and Commissioning

On request of GSPC Gas, Steel network shall be installed /

O&M Contractor
1. extended at specified area with deployment of adequate
In-charge
manpower and machinery
A proposed laying drawing shall be taken from GSPC gas along O&M Contractor
2.
with material & laying / installation specification/s. In-charge
If required, site visit shall be organized to discuss site issue,
O&M Contractor
3. HSE risk and detail planning along with engineer in charge of
In-charge
GSPC Gas
Request for Excavation permission is forwarded to concerned O&M Contractor
4.
authorities in consultation with GSPC Gas In-charge
The items which are to be brought by contractor shall be O&M Contractor
5.
procured as per specification provided by GSPC Gas In-charge
O&M Contractor
6. All receivable materials / items shall be issued from GSPC Gas.
In-charge
Close coordination shall be ensured with various authorities for
permission of excavation & gas distribution network installation O&M Contractor
7.
and shall be received and copy of it shall be handed over to In-charge
GPSC Gas
Concerned utility departments shall be given advance intimation O&M Contractor
8.
regarding proposed Steel Network laying / extension. In-charge
Trenching / Excavation shall be carried out as per the O&M Contractor
9.
procedure “Safe Working for Excavation” In-charge
Steel pipeline welding, laying / extension including testing and
O&M Contractor
10. Valve Chamber installations shall be carried out as per
In-charge
specification provided by GSPC Gas and reported.
The procedure for connection of new / extended network with
existing charged network and it’s commissioning shall be O&M Contractor
11.
prepared as per the format provided in Annexure - 16 and shall In-charge
be submitted to GSPC Gas for review and approval.
 Engineer In Charge of GSPC Gas or Thirty Party Inspector shall
be invited for review of completeness of steel network
O&M Contractor
12. installation / extension work before charging / commissioning.
In-charge
Punch List shall be prepared and work to be completed before
commissioning shall be noted down.
After completion of pending works, new / extended network
O&M Contractor
13. shall be connected with charged network and shall be
In-charge
commissioned as per the approved procedure
As built drawings shall be prepared and submitted to GSPC
O&M Contractor
14. Gas. The existing network drawings shall be updated for
In-charge
network addition / extensions
Material Consumption Statement shall be prepared and
submitted to GSPC Gas for review. The overall material O&M Contractor
15.
reconciliation shall be carried out as per the requirement of In-charge
GSPC Gas
 ANNEXURE – 16
Format for Planning & Procedure for Steel Network Shutdown Job for
Modification or Connection of New Network with Existing Network

a. Job Detail
b. Proposed Date of Job and Time Duration
c. Drawing of Existing Network, showing location of shutdown, isolation section /
network, major affected customers, purging points, venting points,
d. Drawing of proposed modification showing modified network, additional
valves, venting point, gas measurement point.
e. Section to be isolated Network Area, Size, Length
f. Name & Nos. of Affected DPRC, CPRS, IPRS & CNG Station
g. Nos. of Affected Customers – Domestic, Industrial, Commercial & CNG
h. Name of Affected Customers - Industrial, & CNG
i. Proposed Date & Tentative Time Duration for Gas Supply Affect
j. Section to be depressurized / vented- Network Area, Size, Length, Volume
k. Gas volume venting loss
l. Section to be purged with Nitrogen- Network Area, Size, Length, Volume
m. Nitrogen cylinder / volume required
n. Tools Tackles list and it’s arrangement for shutdown job
o. Equipment & Instrument list and it’s arrangement
p. Fire, Safety and Communication item list and it’s arrangement
q. Manpower list and it’s arrangement
r. Check List of Preliminary Work to Be Completed before Taking Shutdown Job
⇒ Pre-fabrication and testing of steel pipeline
⇒ Pipeline Material List and it’s procurement / arrangement
⇒ Permission for various authority for installation and excavation
⇒ Arrangement of Nitrogen Cylinder / Tanker
⇒ Arrangement of NDT testing
⇒ Advance Communication to affected customer
⇒ Welder qualification
s. Valve operation sequence for section isolation, venting, pre-purging, post-
purging and commissioning
t. Procedure for shutdown job

Sr. Time Duration

Activity Location Responsibility
No. From To

u. Review, Comment and Approval from GSPC Gas

3.4 PE Distribution Network Maintenance

Content :

6. General Information,

7. MP PE net work of CGD,

8. LP PE net work of CGD.

9. The Procedure for Maintenance of PE Network.

Annexure: 01 Guidelines and Work Instruction for Network Patrolling

Format for Gas Pipeline Patrolling Report

Annexure: 02 Work Instructions for Valve Chamber Maintenance

Format Valve Chamber Maintenance Report

Annexure: 03 Work Instructions for Surface Gas Detection Survey on Gas

Pipeline Route

Format for Surface Gas Detection Survey Report

Annexure: 04 Gas Leak Classification and Action Criteria

Annexure: 05 Work Instructions for Pressure Drop Test of Gas Pipeline

Format for Pressure Drop Test Report

10. Procedure for PE Network Installation / Extension and Commissioning

1. General Information :

In a typical City Gas Distribution network, Underground Polyethylene (PE) network is

major asset / component of total installation and it flows natural gas from Supply
station to intake arrangement of consumer at pressure 4 bars or less.

The material adopted for mains and the underground portion of service pipe in the
general distribution system is High Density Polyethylene (HDPE) Grade 100. This
material is selected because of its cost effectiveness, tensile strength, and the
strength of PE fused joints. The diameter ranges for pipes are normally
‘standardized’ at 125, 90, 63 and 32mm for mains, and 32 and 20mm for Services.

PE materials are specified to conform with AS/NZS 4131 – Polyethylene (PE)

Compounds for Pressure Pipes and Fittings and ISO 4437 – Buried Polyethylene
(PE) Pipes for the Supply of Gaseous Fuels.

Polyethylene is manufactured by polymerization of the hydrocarbon ethylene.

Polyethylene pipe is a general description and covers pipes made of polyethylene of
different density, molecular weight and molecular weight distribution. The final
performance of the pipe is directly influenced by the physical properties of the
polyethylene resins used.

The most commonly used classification of PE is by density, and expressed in kg/m3,

as below,

Low Density, in which the density ranges between 910-940 kg /m3. and the product
exhibits high flexibility and retention of properties at low temperatures.

Medium Density, in which the density ranges between 930-940 kg/m3. MDPE base
resin is manufactured using slow polymerization process. The pipe exhibits high
flexibility and ductility, slow crack growth resistance and crack propagation
resistance. It is extensively used in the installation of gas distribution networks.
High Density. HDPE resins are also manufactured by a low-pressure process. The
density ranges from 930-960 kg/cub m. HDPE tends to be stiffer than the other
classifications and has high application in the electrical and communication industry
also.
Typical values to the most commonly used properties of PE 80 and PE100 pipe are
given in the following table.
Property Test Method PE 100 PE 80
Density kg/m3 ISO1183D, ISO1872- 954- 950
2B 967
Tensile Yield Strength MPa ISO527 >=19 20
Elongation at Yield % ISO527 7 10
Tensile Break Strength MPa ISO527 27-30 27
Elongation at Break % ISO527 > 800 > 800
Tensile Modulus Mpa Short Term Ref. AS/NZS 2466 1250 700
Long Term Ref. AS/NZS 2466 550 200
Hardness Shore D DIN 53505 59 59
Notched Impact Strength kJ/m2 ISO179/1eA 35 35
(23°C)
Melt Flow Rate 190/5, g/10min. ISO1133 0.39 – 0.7 –
0.54 1.0
Thermal Expansion × 0.0004/°C DIN53752 2.4 2.4
Thermal Conductivity W/m.k (20°C) DIN52612 0.43 0.43
Crystalline Melt Point °C DIN53736 125 125
Dielectric Strength kV/mm DIN53481 70 70
Surface Resistivity Ohm DIN53482 >1015 >1015
Volume Resistivity Ohm. Cm DIN53482 >1015 >1015
Poissons Ratio μ 4 4

The design of PE distribution piping systems is not significantly different from steel
systems laid for cross country transportation of Gas. The difference is essentially
related to the physical / strength characteristics of both materials.
Advantages of polyethylene (PE) over steel are as follows,

• Polyethylene is a non-conductor and therefore is not subject to galvanic

corrosion. It is almost completely resistant to inorganic chemicals and most
organic chemicals.

• Polyethylene is a thermoplastic material and is easily joined by heating and

pressing together two components to form a joint as strong as the parent
components.

• Because of its flexibility, small diameter pipe can be coiled into long lengths
for easy transport and installation.

• Its flexibility also allows polyethylene in the smaller sizes to be squeezed shut
in an emergency situation thus reducing the need for the installation or large
numbers of expensive and potentially high maintenance system block valves.

Disadvantages of polyethylene (PE) pipe compared to that of steel

• The pipe is softer and more susceptible to damage during transport,

installation and future third party activities in the vicinity of the installed pipe.

• Because of its thermoplastic nature PE is weaker at higher temperatures. At

full design pressure it should not operate at temperatures above 40(C. Its use
is therefore restricted to underground installations.

• Because of its thermal expansion (10 times greater than steel) temperature
changes need to be taken into account during construction.

• It has a tendency to cold flow or creep under load. An internal stiffener is

required to prevent cold flow whenever a mechanical joint is employed.
• PE is subject to degradation if exposed to direct sunlight for a prolonged
period of time.

Distribution network – Mains & Services

High Density Grade PE100 polyethylene (HDPE) is adopted for all distribution mains
with all jointing to be by the electro fusion process. The sizes of mains are
standardized in the following four outside diameters - 125, 90, 63 and 32 mm.

Distribution services running from the PE mains to the customers appliance (s) are
constructed of polyethylene for their underground section (from main to a PE/GI
transition fitting, situated adjacent to the outside of the customer’s premises), and
then screwed galvanized iron (GI) pipe thereafter. The size of services was
standardized to 32 mm and 20 mm

2. MP PE network of CGD

The PE Network of City Gas Distribution system is laid underground, at average 1.00
meter depth, along the road side in the residential areas and industrial townships.

The PE Network carries the gas at pressure from 4.0 to 5.0 bars. The PE pipes and
fittings selected for the network are of PE 100.

3. LP PE network of CGD

Similarly, the underground PE pipe lines laid at average depth of .8 to 1 meter along
the roads of street and township carry the low pressure gas of 100 mbar. from
service regulators to the various domestic and commercial customer connections in
the residential areas and townships. The isolation valves housed in valve chambers
are provided at regular distance of about 1 kilometer, for section isolation during
repair maintenance and LPT. The pipe sizes of the low pressure PE network ranges
from 32 mm diameter to 90 mm diameter.
Like any other PE network, the major activity associated with gas charged LP PE
network, is repairing of pipelines, when they are damaged mostly by other utilities
and occasionally by rat bites.

The complaints, for such damages are received from customers / public or damage
is found during route patrolling / walk surveys, mostly detected as gas smelling on
the network.

For ensuring timely response and safe PE repairing, written work instructions are
prepared and implemented as given below. The trained and experienced PE welders
are employed for repairing job. The availability and conditions of critical items /
equipments like PE pipes / fittings /portable power generator / PE welding machines
and accessories are regularly checked and audited as per cheek list based audit.
4.0 Procedure for Maintenance of PE Network.

As seen above, PE distribution network is safe against corrosion unlike steel network
however they are prone to damage by third party and rat bite. Hence it needs vigilant
and vigorous patrolling of network and effective coordination with other utility
agencies to prevent damage to pipeline.

Following activities shall be carried out as per suggested frequencies for

maintenance of PE network.

Sr. Activity Frequency

01 Update Network Drawing to incorporate all Regular
extensions, modifications of network.
02 Awareness to all concerned persons about Regular
network and it’s extension / modification
03 Patrolling Weekly - Total network &
Valve chambers
and
Daily - If third party work is
Third Party Coordination if work is going on or going on or near gas
near gas pipeline route network

04 Valve Chamber Maintenance Bi-Monthly

Pre Monsoon
Post Monsoon
05 Surface Gas Detection Survey Quarterly
06 Pressure Drop Test (Lock Test) of Network Yearly

The frequencies and the extent of the work are based on requirements set down in
ANSI/ASME B31.8, operational experience and good engineering practice. Based on
past experience, some of the frequencies may be adjusted.

Procedural Steps :
Sr. Activity Responsibility
01 On receipt of O&M contract, contractor shall take O&M
specification / detail of distribution network, as-built Contractor
drawings, testing reports and other construction records In charge
from GSPC Gas
02 O&M contractor shall visit overall site along with related O&M
staff members to make themselves aware about route, type Contractor
of laying and size of pipeline In charge
03 As built drawings / schematic etc of network shall be taken O&M
over from GSPC Gas or from its contractor in soft copy and Contractor
same shall be updated regularly with repairs / modifications In charge
/ extensions carried out over the time period.
04 All above listed maintenance activities shall be Work In charge
commenced immediately after taking over as per
concerned work instruction Annexure – 01, Annexure – 02,
Annexure – 03, Annexure – 05
05 Post surface gas detection survey, the action/s, shall be O&M
initiated & ensured as per Leak Classification and Action Contractor
Criteria (Annexure -04) In charge
06 In case of pressure drop is more than 1.0 bar in a particular O&M
section, pressure drop test in sub-sections (small sections Contractor
of particular big section) either through valve chambers or In charge
squeezing of section shall be conducted. Pressure drop in
particular small section shall be found out / located
07 Vigorous Surface / Subsurface Gas Detection Survey O&M
immediately to identify probable gas leak location shall be Contractor
arranged In charge
08 Excavation at probable gas leak location shall be arranged O&M
and the cause of gas leak shall be identified. Contractor
In charge
09 Repair rectification of gas leak shall be arranged as per O&M
“Procedure for attending Gas leakage / Gas Escape on PE Contractor
 distribution network” In charge
10 Report and records of maintenance shall be prepared and O&M
submitted to GSPC Gas O&M In charge regularly Contractor
In charge
11 On receiving intimation regarding charging of a particular O&M
network or extension of network from GSPC Gas Company Contractor
or its contractor, O&M contractor shall visit overall site In charge
along with related staff members to make themselves
aware about route, type of laying and size of pipeline
12 'As Built Drawing' Laying Reports and Pressure Test O&M
reports shall be taken over from Construction Contractor / Contractor
GSPC Gas In charge
13 All valve chambers shall be inspected for proper O&M
construction, it’s cover, tagging & marking and gas leak. In Contractor
case of any gas leak, potential hazard or poor construction In charge
same shall be reported to Construction Contractor and or
GSPC Gas within three days
14 Awareness program including site visit shall be organized O&M
for each member of O&M team Contractor
In charge
15 The extended network shall be included in Annual O&M
Maintenance Plan and maintenance activities shall be Contractor
started as per above procedure In charge
16 Staff shall be regularly trained and educated for network O&M
route, O&M procedures and HSE Aspects Contractor
In charge
 ANNEXRURE - 01
Guidelines and Work Instruction For Network Patrolling

ANSI/ASME B 31.8 states, “Distribution mains shall be patrolled in areas where

necessary to observe factors which may affect safe operation. The patrolling shall be
considered in areas of construction activity, physical deterioration of exposed pipe
and supports, or other natural causes, which could result in damage to the pipe. The
frequency shall be determined by the severity of the conditions which could cause
failure or leakage and subsequent hazards to public safety”.

In practice, informal patrol may be carried out in vulnerable areas by Supervisors in

their daily movement around their area of responsibility i.e. if an important supply
main is located along road XYZ and there is excavation work being performed in its
general proximity, then it would be proper for a Supervisor to travel that road in any
traverse he may make of the general locality.

All rail and major waterway and road crossings should be inspected on a monthly
basis to observe surface conditions, indications of leaks, general construction activity
and any other factors which may affect the safe operation of gas system.

When a threat to the gas system from third party excavation is observed by a
Supervisor or Inspector then that person must take the appropriate action on site to
ensure the gas pipe is not damaged. It may be necessary in some circumstances to
arrange for an Inspector to be positioned on site to ensure the integrity of the gas
system is maintained.
Role of a Patrol Person

A patrol person plays an important role and is the front line defense against hazards
which the safety and security of the system. This important role should be
recognized by contractor management and care taken to ensure patrol persons are
provided with the appropriate skills and facilities to perform their duties. One of the
basic skills required by a patrol person is the ability to read plans. It is also important
the patrol person can communicate in a verbal and written form, and accuracy is to
be encouraged as an essential feature. It may be necessary for training courses to
be held for the development of patrol persons.
A typical duties and responsibilities for patrol persons are as follow these are for
information and guidance.

• Inspect the work of other authorities and private organizations carrying

out work in the vicinity of a transmission pipeline.

• Report immediately any unusual developments or occurrences along a

pipeline route which may have some affect on the normal operation or
maintenance of the pipeline.

• Supervise any maintenance personnel under his control.

• Maintain liaison with other authorities and bodies who are concerned
with works which could affect pipelines. Further, maintain good
relations with the owners of properties traversed by pipelines. Good
communications and in particular keeping people informed on the
location and importance of pipelines is a primary defence against
interference being caused by third parties.

• As required, prepare and forward routine reports.

Work Instruction for Network Patrolling

26. Divide total network route in sub-route / section such that total network can
be patrolled at least once in week.
27. Ensure that each member of patrolling team aware about the route of
pipeline, size of pipeline and depth.
28. Observe following along the route
• Excavation work on / near gas pipeline
• Civil work / construction near gas pipeline
• Erosion of soil from gas pipeline route
• Surface faulting, subsidence, flooding on gas pipeline route
• Encroachment by slums other temporary structure
• Encroachment by lorry / galla / tea house
• Other potential hazards
• Valve Chambers and it’s top cover
• District Regulator station it’s fencing / cabinet / gates
29. In case of Excavation / Civil / Construction work on / near gas pipeline,
meet with site supervisor / concerned person and get detail like
• the type of work and purpose
• use of excavation machines or other machines
• depth of excavation
• distance from gas pipeline
• work duration / completion date
• name of contractor, address and contact detail
30. Provide them awareness about gas network and its hazards. Brief them a
safety precautions to be taken to prevent damage to gas pipeline
31. Provide them a contact address and telephone numbers for consultation in
case of any difficulty
32. In case of erosion of soil from gas pipeline route, take depth and length of
erosion. Investigate probable cause of soil erosion. In case of soil erosion
due to reason/s of third party, coordinate with them to prevent them and to
take restore eroded site properly
 33. In case of encroachment on / near gas pipeline, report it to concerned
authority to shift / prevent them. Make them aware about gas pipeline
route and its hazards. Explain them safety precaution to be taken to
prevent any incident
34. While patrolling, check the pipeline markers condition
35. While patrolling, keep the speed of vehicle such that all above observation
can be made effectively.
36. Report findings of Patrolling activity in specified format
37. Update the contact address and telephone numbers of concern third party
utility agencies on regular basis.
38. Keep the communication device and list of contact numbers of related
utility agency while patrolling.
39. Use cotton dress and safety shoes while pipeline patrolling activity
40. Use helmet if require to go near construction site
41. Observe and check for trip / fall hazards while pipeline patrolling activity
42. While driving during pipeline patrolling activity, Follow “Safe Driving”
instructions

Liaison with Other Authorities

It is important that O&M Contractor develops a co-operative relationship with other

authorities, particularly authorities responsible for public construction work. Other
authority personnel should where practical, be provided with Network Drawings, and
be regularly reminded of the location of strategically important mains.

They should also be acquainted with the hazardous properties of gas and the
potential effect of escaping gas on the safety of the public. It should be emphasized
and encouraged that in the event of an emergency that prompt co-operative action
would be required.

Apart from the essential day to day contact with other Authorities, O&M Contractor
shall formally correspond with the appropriate other Authorities on a yearly basis.
 Gas Pipeline Patrolling Report

Date of Patrol :
Network / Area :
Pipeline Section : Size : Length :

Sr. Check Point Pipe Size Location Observation / Findings

01 Excavation work on /
near gas pipeline
02 Civil / construction
work on / near gas
pipeline
03 Erosion of soil
04 Encroachment
05 Surface subsidence,
flooding
06 Any other potential
Hazard
07 Damage to Pipeline
markers
08 Damage to Valve
Chamber/s
09 Damage to District
Regulator Station/s
Remarks :

Work In charge O&M Contractor In-charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 02
Work Instruction For Valve Chamber Maintenance

This activity consists of (a) Gas Leak Check (b) Partial / Full Valve Operation (c)
Valve Greasing (d) Cleaning and (e) Tag number painting.

28. Ensure that each member of team are aware about natural gas and it’s
hazards
29. Ensure that each member of team aware about the risk involve in valve
chamber maintenance activity, it’s potential hazard and preventive
measures.
30. Supervisor shall be made aware of pipeline network route and valve
chamber locations.
31. Plan the job in advance and ensure appropriate work permit for job.
32. Ensure availability and use of appropriate PPEs and Safety Items as per
“Annexure – PPEs Matrix” during valve chamber maintenance activity
33. Ensure the availability of necessary tools tackles and other items in good
working condition, required for valve camber maintenance activity.
34. Ensure the availability of wireless set / mobile phone at site. After reaching
site, first, establish contact with control room before start of activity.
35. Cordoned the site appropriately and place caution board along the road
site valve chamber.
36. Clean the top cover of valve chamber and note it’s tag number
37. Open the valve chamber top cover, one by one, gentle by holding & lifting
from both sides manually. Take utmost care to prevent, falling of top cover
inside chamber.
38. Remove all the top covers and keep them aside without creating
obstruction.
39. Check the gas leak inside valve chamber using calibrated gas detection
instrument. Supervisor should be trained for operation of gas detection
instrument and measurement of gas leak.
40. Check the flange joints and threaded joint, using bubble test (soap
solution) for any gas leak.
41. In case of gas leak from valve, first attend the gas leak. If require arrange
resources from control room / main office.
42. In case of valve chamber is more than 1.5 meter deep, and seems to be
confined space, first check the oxygen level before entering in valve
chamber. Entry should not be permitted if oxygen level is less than 19.5%.
43. Use ladder to enter inside deep valve chamber.
44. Carry out dewatering / cleaning of valve chamber first.
45. Operate the valve partially or fully depending upon gas flow and line pack
availability for customers. Ensure that gas supply is not affected to any
customer. Avoid valve operation in case of any doubt.
46. Grease / Lubricant the valve in case of valve is jam or operating hard.
47. Paint the tag number of valve chamber on top of cover, if it is faint or
erased.
48. Carry out white wash of valve chamber from inside and outside top civil
portion.
49. Carry out oil paint of specified colour and type, to valves inside the
chamber and metal portion of valve chamber top cover once in year after
monsoon.
50. Close the valve chamber top covers gently, lifting & holding from both
sides manually. Take utmost care, to prevent dropping of top cover inside
chamber.
51. Remove caution board/s and cordoning tape / device from site and restore
site to safe level.
52. Provide message to control room and take activity further.
53. Prepare report of valve chamber maintenance activity in a specified
format.
54. After completion of activity, close out work permit and keep the record of
same.
 Valve Chamber Maintenance Report

Date of Maintenance:

Cleaning
Leak Operation Tag No Any
V/C No Greasing & White Painting
Test of Valve Painting Damage
Wash

Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 03

Work Instruction for Surface Gas Detection Survey

On Gas Pipeline Route

Surface Gas Detection Survey is a continuous sampling of the atmosphere at or near

ground level for buried gas pipeline and / or adjacent to aboveground gas facility with
a gas detector instrument cable of detecting a concentration of 50 ppm gas in air at
the sampling point.

16. Divide total network route in sub-route / section such that total network can
be surveyed at least once quarter.
17. Ensure that each member of team aware about the exact route of pipeline,
size of pipeline and depth.
18. Ensure that each member of team are aware about natural gas and it’s
hazards
19. Ensure that each member of team aware about the risk involve in survey
activity, it’s potential hazard and preventive measures
20. Ensure the availability of portable / mobile calibrated gas detection
instrument in good working condition having least count of 10 ppm, for
survey activity.
21. Start the gas leak detection survey activity with zero chainage or with
known location / landmark location.
22. After reaching site, first start the gas leak detection instrument and then
walk along the gas pipeline route at the normal speed.
23. For buried pipeline, take atmosphere sampling just above 2” (not more
than 2”) from ground.
24. Sampling should also be taken at ground surface opening such as
manholes, catch basins, sewer, power telephone duct openings, traffic
signal / junction boxes, curb line / cracks of pavements
25. While survey, ensure that probe do not rub in soil getting chocked with
dust and water.
 26. Carefully observe the hooter / indicator of instrument while survey /
walking.
27. Note, if instrument shows some indication of gas leak. Survey surrounding
place thoroughly for gas leak intensity. Observe for gas smell.
28. Check for any other flammable gas leak from surrounding.
29. Confirm gas leak, by check at site twice / thrice.
30. Note the gas leak spot along with leak intensity in specified report and
carry out survey further.

Surface Gas Detection Survey Report

Date of Leak Survey :

Network / Area :
Gas Detection Instrument Detail :
Type : Range :
Calibration Date : Calibration due date :

Pipeline Section Leak Survey Leak Intensity

From To Size Length Result (% LEL)

Remarks :

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
 ANNEXRURE - 04
Gas Leak Classification and Action Criteria
(Based on ASME B 31.8)

Leak
Definition Action Criteria Example
Grade
01 A leak that Requires prompt action Escaping gas that has ignited
represents an to protect life and Any gas indication of gas
existing or property. Continuous which has migrated into or
probable hazards action until the under a building or into
to persons or condition are no longer tunnel
property and hazardous Any reading at the outside
requires immediate wall of a building or where
repair or gas would likely migrate to an
continuous action outside wall of a building
until the condition Any reading of 20% LEL or
are no longer greater in a confined space
hazardous Any reading of 40% LEL or
greater
Any gas leak that can be felt,
seen or heard and which in
location that may endanger
the general public or property
02 A leak that is Leaks can be repaired Any reading of 40% LEL or
recognized as or cleared within six less
being non month if it is not
hazardous at the harmful to human. It
time of detection should be reevaluated
but that has at least once in every
requires repair month
based on probable
future hazard
03 A leak that is This leakage should be Any reading of 20% LEL or
recognized as reevaluated at every less
being non- quarterly till it gets
hazardous at the rectified within one
time of detection year.
and can be
reasonably
expected to remain
non-hazardous
 ANNEXRURE - 05
Work Instruction for Pressure Drop Test of Gas Pipeline
18. Divide total network route in sub-route / section such that total network can
be tested at least once in a quarter.
19. Ensure that each member of team aware about the exact route of pipeline,
size of pipeline, valve chamber location, interconnection between network
20. Ensure that each member of team are aware about natural gas and it’s
hazards
21. Ensure that each member of team aware about the risk involve in testing
activity, it’s potential hazard and preventive measures
22. Ensure the availability of portable / mobile calibrated gas detection
instrument in good working condition 1% LEL, for this activity.
23. Conduct Pressure Drop Test between 00.30 A.M to 3.00 A.M (night).
24. Intimate commercial customer for gas supply stoppage.
25. Intimate Storage type Gas Geyser customer for gas supply stoppage
26. Lift the top covers of valve chamber carefully & confirm “0” leakage with
gas detection instrument inside valve chamber.
27. Install a calibrated pressure gauge with least count of 0.1 bar on upstream
and downstream point of section.
28. Isolate upstream and downstream valves of pipeline section which is to be
tested. Isolate interconnection valves / tap-off valves of section to be
tested
29. Observe and note the pressure on pressure gauge and start the hold
period.
30. Hold the section at pressure for two hours.
31. Observe the pressure at upstream and downstream after completion of
hold period and record it in specified format.
32. Remove the pressure gauges and open the isolated valves
33. Carefully close the top cover of valve chambers.
34. Prepare report of Pressure Drop Test in specified format.
 PRESSURE DROP TEST REPORT

Feeder / Section under LPT: Date:

Valve Initial Final Valve

Valve LPT Pressure
Location: Closing Locked Locked Opening
Detail Hours: Drop
Time: Pressure: Pressure: time:

LPT OBSERVATION TABLE

STREAM - 1 ( Other Sectors )

Time Line Pressure Valve Position Remarks

Pressure Gauge Detail

Sr. Pressure Least Calibration

Gauge Make Dial Size Remarks
No. Range Count Date

Conclusion /
As shown above, there is no pressure drop, during Lock Pressure Test, for 2 hours.
Observation:

Work In charge O&M Contractor In charge

Name Name
Signature Signature
Date Date
Procedure for PE Network Installation / Extension and Commissioning

On request of GSPC Gas, PE network shall be installed /

O&M Contractor
16. extended at specified area with deployment of adequate
In charge
manpower and machinery
A proposed laying drawing shall be taken from GSPC gas along O&M Contractor
17.
with material & laying / installation specification/s. In charge
If required, site visit shall be organized to discuss site issue, O&M Contractor
18. HSE risk and detail planning along with engineer in charge of In charge
GSPC Gas
Request for Excavation permission is forwarded to concerned O&M Contractor
19.
authorities in consultation with GSPC Gas In charge
The items which are to be brought by contractor shall be O&M Contractor
20.
procured as per specification provided by GSPC Gas In charge
O&M Contractor
21. All receivable materials / items shall be issued from GSPC Gas.
In charge
Close coordination shall be ensured with various authorities for O&M Contractor
permission of excavation & gas distribution network installation In charge
22.
and shall be received and copy of it shall be handed over to
GPSC Gas
Concerned utility departments shall be given advance intimation O&M Contractor
23.
regarding proposed PE Network laying / extension. In charge
Trenching / Excavation shall be carried out as per the O&M Contractor
24.
procedure “Safe Working for Excavation” In charge
PE laying / extension including testing and Valve Chamber O&M Contractor
25. installations shall be carried out and reported as per In charge
specification provided by GSPC Gas.
The procedure for connection of new / extended network with O&M Contractor
existing charged network and its commissioning shall be In charge
26.
prepared and shall be submitted to GSPC Gas for review and
approval.
Engineer In Charge of GSPC Gas or Thirty Party Inspector shall O&M Contractor
27.
be invited for review of completeness of PE installation / In charge
 extension work before charging / commissioning. Punch List
shall be prepared and work to be completed before
commissioning shall be noted down.
After completion of pending works, new / extended network O&M Contractor
28. shall be connected with charged network and shall be In charge
commissioned as per the approved procedure
As built drawings shall be prepared and submitted to GSPC O&M Contractor
29. Gas. The existing network drawings shall be updated for In charge
network addition / extensions
Material Consumption Statement shall be prepared and O&M Contractor
submitted to GSPC Gas for review. The overall material In charge
30.
reconciliation shall be carried out as per the requirement of
GSPC Gas
3.5 Complaint Handling Gas Leak / Gas Escape

Content :

11. General Information,

12. Procedure for Complaint Handling - Gas Leak / Gas Escape

Annexure: 01 List of Tools-Tackles and Safety Items for Emergency Vehicle

Annexure: 02 Receipts of Gas Leak / Escape Complaint
Annexure: 03 Initial Precautions To Be Taken When Arriving On Site
Annexure: 04 Work Instruction for Detection and Repairing / Rectification of
Leakage at Down Stream Domestic / Commercial Installation
Annexure: 05 Work Instructions for Attending Gas Leak / Escape from
Service Line & PE Network
Annexure: 06 Work Instruction for Attending Damage on PE network
Annexure: 07 Work Instruction for attending Fire and or Explosion at a
Building
Annexure: 08 Work Instruction for Operating & Maintenance Gas Detector
Instruments
Annexure: 09 Work Instructions for Making Bar Holes for Detecting the
Presence of Gas below Ground
Annexure: 10 Work Instructions for Line Valve Closure, Depressurization of
Section by Gas Venting and Re-commissioning of same
Annexure: 11 Work Instructions for PE Pipe Squeezing
Annexure: 12 Work Instructions for Electrofusion Reinforcement Clamp
Welding
Annexure: 13 Work Instruction for Pipe Jointing using Electrofusion
Couplings
Annexure: 14 Work Instructions for Use of Electrofusion Welding Machine
Annexure: 15 Guidelines for Earthing Of Installation While Carrying Out
Maintenance Activity on GI Gas Pipelines
Annexure: 16 Work Instructions for Evacuation of Building/s In Case Of Gas
Accumulation
Annexure: 17 PE Damage / Fire / Explosion Incident Report
1. General Information :

Procedure and facilities shall be established for receiving and handling various
complaints related to network / installation of city gas distribution system from the
customers, public and employees. The receipt and handling of complaints shall be
managed through control room manned for 24 x 7 (round the clock) by experienced
and trained O&M team.

The complaints from various agencies may be categorized in to (a) Technical (b)
Non-technical and (c) Emergency Complaint such as

Emergency Complaint (Gas

Non technical
Technical Complaint smell /leak /escape /fire
Complaint
/explosion)
Low flame / pressure Change of name Fire / Explosion
Temporary disconnection Bill not received Gas Leakage (U/G)
Reconnection Change of address PE Damage
Meter Complaint / Meter fast Improper address,
Joint Failure
name
Stove Complaint Higher gas bill Rat Bite
Alteration of gas piping Cheque related issue Gas Leakage (A/G)
No proper restoration / repair Delay in gas connection
Transition Fitting Leakage
at premises
Delay in charging of gas
GI Pipe / Fitting Leakage
connection
Audco Valve Leakage
Regulator (Adaptor / Bush)
Meter (Adaptor / Hex Nut)
Gas Tap
Rubber Tube
No Gas Complaint
SSV Shut OFF (OPSO)
Saddle Drilling
The emergency complaints must be handled on priority within a response time for
controlling / mitigating hazards and consequences by every ready and well equipped
emergency vehicle.

For handling the complaint / emergency effectively and safely, written procedure and
training to the persons should be ensured for Initial communication while receiving
the complaint, communication at site and communication in case of fire and
explosion on network / in customer premises. For handling the various emergencies,
site contingency plan and emergency response plan should be available and regular
mock drill should be carried out.

2. Procedure for Complaint Handling - Gas Leak / Gas Escape

O&M Contractor is required to establish a control room which operates

round the clock to receive the gas leak, fire, and explosion related
complaint/s. They are also required to establish emergency team of
adequate manpower working in shift round the clock and emergency
vehicle equipped with necessary tools tackles and safety items as listed
in (Annexure – 01) to attend such emergency in CGD zone with
response time of less than 30 minutes.
Procedural Steps:
Sr.
Activity Steps Responsibility
No.
1 Gas Escape complaints from customers, fire brigade, other
utility agencies, contractors and any other source shall be
received by the O&M Contractor Control room.

O&M Control
It shall be recorded in detail as per guidelines given in
Room
Annexure -02

Safety advice shall be imparted to the person reporting the

escape as per guidelines given in Annexure -02
2 In case of small gas leak / gas smell complaint from domestic O&M Control
Room
/ commercial connection, a competent technician shall be
dispatched along with necessary tools tackles to attend the
same.
In case of gas leak from PE service line, heavy gas leak, PE
damage, fire or explosion complaint, an Emergency Team
along with Emergency Vehicle equipped with necessary tools
– tackles shall be dispatched to site.

This instruction can be given by radio, mobile telephone or by

direct speech. The competent person will proceed to site as
quickly as possible.

Response time for any gas escape compliant shall be

recorded and maintained within 30 minutes.
3 The team shall reach the site with a fully equipped emergency Competent
Technician /
vehicle as quickly as possible. Emergency
Upon reaching site, the team shall, Team

a) Report to the control room and note the response time.

b) Attempt to make contact with the person who reported the
gas leak / escape complaint
c) Assess the situation with the safety precautions detailed in
Sr.
Activity Steps Responsibility
No.
Annexure- 03
d) In the case of a Fire / Explosion it shall be dealt as per
work instruction given in Annexure - 07
4 In case of internal / downstream leak / escape (on domestic or
commercial connection), the competent person shall detect
gas leak and shall repair it in accordance with Annexure- 04.
Competent
Technician
Before carrying out any maintenance on the installation,
proper earthing of installation shall be carried out as per
Annexure - 15
5 In case of gas leak / escape is suspected to be on PE
Emergency
network/ service line (on the upstream / external side), same
Team
shall be attended / repaired as per Annexure - 05.
6 In case of gas escape due to PE damage, it shall be made
safe and leakage shall be repaired as per Annexure-06. It Emergency
shall be reported to GSPC Gas as per format given in Team

Annexure -17
7 In case of Fire / Explosion, it shall be attended as per
Emergency
Annexure-07. It shall be reported to GSPC Gas per format
Team
given in Annexure -17
8 Details of actions taken at site shall be conveyed to the
control room for necessary communication to O&M Contractor
In charge and GSPC Gas Co
9 Depending on the incident / situation emergency team shall Emergency
ask for additional resources through control room. Team
10 In case of multiple complaints, the appropriate decision /
priority shall be taken / given based on the requirement to
Shift In-charge
protect Life and Property / O&M
The priority shall depend upon the known information like: the Contractor
In charge
volume of gas escaping, the chances of gas ingress to
property and ignition.
Sr.
Activity Steps Responsibility
No.
11 Details of the Gas Escape, Fire & Explosion Complaint, its
cause/s and repairs, etc. shall be recorded systematically and
O&M
shall be analyzed every month and discussed in review Contractor
In charge
meeting with GSPC Gas Company. On the basis of review
corrective and preventive actions shall be Initiated.
12 Material used shall be recorded and reconciliation shall be
carried out as per requirement of GSPC Gas Company. The O&M
Contractor
items consumed from Emergency vehicle should be In charge
replenished upon return to base.
 ANNEXURE – 01
List of Tools-Tackles and Safety Items for Emergency Vehicle

SR. DESCRIPTION SIZE NOS. REMARK

1 Base Wireless in Vehicles 1
2 Intrinsically Safe Portable Wireless 1
3 DCP TYPE FIRE EXTINGUISHER 5.0 kg 2
4 Calibrated GAS DETECTORS L.C 1% LEL 2
5 Public Announcement System 1/2 MILE 1
6 Gum Boot PAIR 2
7 Fire Retardant Suit 2
8 Reflactory Jacket 2
9 Industrial Safety Helmet 2
10 First Aid Box with listed items 1
Overall Network Drawing With All
1
11 VALVE CAHMBER Details
12 Flameproof Torch 1
13 Normal Torch 1
Prepare list as per type &
14 Valves of all size valves 1 set size of valves
Pipe Pieces For Leverage to Operate
15 Valve 2
Review based on size of
16 Vent Pipe 3 meters long 1/2" x 3 m 1 vent valves and outlets
Leak Clamps (Set) Prepare list as per type &
17 1 set size of pipes
18 Squeeze Tools 2 set Prepare list as per type &
19 Hydraulic Squeeze Tools 2 set size of pipes
Review List base on
20 Tool Box requirement
21 Spanners SET 1
22 Brass Hammer 1 KG 1
23 Brass Wedges 1
Brass Wire Brush 6" x 1" 1
Screw Spanner 6" , 8" 2
Pipe Wrench 8" , 12" 2
Hacksaw with blade. 1
 Chisel 8" 1
24 PE Pipe Cutter/saw. 1
25 Teflon Tape ROLL 5
26 Calibrated Pressure Gauge 0 - 4, 0-14 bar 1 Each.
27 Welding Mirror Set with controller. 1
28 Electrofusion welding Unit 1
Electro Fusion Couplers / saddles & Prepare list as per type &
29 supporting clamps 1 set size of pipes
30 Screw Jack With Tomy Bar 1

31 Pipe Thread Dye set with wrench. 1/2", 3/4",1" 1

32 Gas Tap 6, 10 mm 3
33 NP Cap 5
34 Neoprene Rubber Tube 1
35 CAF -Full Face Gasket - 3 Mm 1" 4
36 CAF - Ring Gasket - 3 Mm 1" 4
37 Grease Stick Box Set 1
38 Regulator Adapter (Dom & Com.) 2 each
39 O ' Ring For Meter cap and liner 6
40 O' Ring For Regulator 6
41 Excavation Appliances
Trikam, Pawda, Tagara 1 set
Prepare list as per type &
Pe Pipe / Fittings
42 size of pipelines / network
0.5 Mtr Long Pipe pieces. Each Size 01 set
Equal Tee Each Size 01 set
Transition Fittings Each Size 01 set
coupler Each Size 01 set
Electrofusion Reducer coupler Each Size 01 set
90 Deg. Elbow coupler Each Size 01 set
Prepare list as per type &
size of pipelines /
43 G.I. Pipe / Fittings network
Hex Nipple 1/2 '', 1” 3 each
Equal Tee 1/2 '', 1” 3 each
Elbow 1/2 '', 1” 3 each
Union 1/2 '', 1” 3 each
Ball Valve / Plug Valve 1/2 '', 1” 3 each
Cap 1/2 '', 1” 3 each
 Plug 1/2 '', 1” 3 each
Coupling 1/2 '', 1” 3 each
Tee 1'' X 1/2'' 1
Reducer 1 '' X 1/2 '' 1
1/2 '' 3
Nipple 1/2 '' X 3” , 6”' 3

The above list is indicative. O&M contractor shall review it and incorporate all
necessary items to handle gas leak / escape, gas fire & explosion emergency
effectively & efficiently
 ANNEXURE – 02
Receipt of Gas Leak / Escape Complaint
Control room operators shall obtain following information from the caller person and
shall make record of it in Log book
Customer Details : (whichever is applicable?)
• Name, Address, Telephone number, Customer Number
Gas Escape Detail :
• Type of leak,
• Damage
• heavy gas escape
• gas leak with whistling sound
• gas smell
• Gas Fire / Gas Explosion
• Other Fire but near to gas installation
• Precise location / spot of gas leak ,
• After isolation valve of gas connection (downstream),
• Before isolation valve of gas connection (upstream) ,
• on service line,
• on road side PE network
Loss of Human Life or Damage to Property :
• Preliminary Detail of injury / fatality and nos.
• Preliminary Detail of property damage / loss
Safety Advice:
The following safety advice shall be provided to the caller person by the Control
Room Operator.
• to close the isolation valve to stop the gas supply.
• to turn off all gas appliances such as; hot plate, gas geyser, oven etc.
• to open doors and windows to ventilate the gas
• Not to operate any electrical appliances.
• Avoid smoking and or any source of ignition.
 ANNEXURE – 03
Initial Precautions To Be Taken When Arriving On Site

1) Don’t use door bell.

2) Don’t switch ON/OFF any electrical equipments
3) Isolate the gas supply.
4) Provide maximum ventilation by opening doors and windows.
5) Keep unauthorized persons out.
6) Use appropriate Personal Protective Equipments (PPE).
7) Don’t allow naked flame / smoking.
8) Don’t use Torch - unless it is explosion proof.
9) Use only Flame proof / Explosion proof equipment
10) Don’t operate Pager or Mobile Phone or Wireless Hand Set where gas is or is
suspected to be present in the atmosphere unless intrinsically safe. Switch
OFF mobile phone or wireless hand set before entering in gaseous
atmosphere.
11) Check the gas leak, using calibrated Gas Leak Detection Instrument.
12) Check for gas presence particularly above head height and around pipe
installation
13) Check all points of gas ingress like bathroom / Toilet / drainage trap Check all
possible points of gas ingress.
14) Check outside the property for the presence of gas by bar holing as per
Annexure - 09
15) Check drains and other utilities inspection chambers for the presence of NG.
16) If gas reading of 40% LEL is preset in the atmosphere of the building ask
occupants to leave the premises and follow the Evacuation work instruction
detailed in Annexure - 16
17) Check the surrounding properties for ingress of gas. if gas concentration is
found to be 40% LEL or above inside any of the properties then evacuate the
said property
18) If the gas is confirmed anywhere at 40 % LEL or above within a property ask
customer to cut off electric mains supply -if installed outside the premises, do
not switch off - if installed inside
 ANNEXURE – 04

Work Instruction for Detection and Repairing / Rectification of Leakage

at Down Stream Domestic / Commercial Installation

1) Coordinate with customer and open door / windows of house / premises.

Advise them not to operate any electrical appliances
2) Detect gas leak using Gas Detection Instrument or Bubble test using soap
solution
3) Once the leakage point is located, necessary actions are initiated as
mentioned in “Repair Instruction”
4) Before taking any maintenance, on the domestic / commercial installation
carrying out earthing as per Annexure – 15
5) After the repairing or rectification, carry out leak test using gas detector and
bubble test to ensure no gas leak.
6) Resume the gas supply and inform the customer.
7) If leakage is not identified on gas pipe line installation then check the
soundness of the appliances (gas leak from appliance) with gas detector or
soap solution, if leakage is observed then disconnect the appliances from the
gas pipeline and inform to customer for repairing.
8) Remember Checks for leakage from other potential sources must also be
made ( Refer Annexure - 03) such as from:
• Check all points of gas ingress like bathroom / Toilet / drainage trap
• Check leakage from LPG cylinder if present in premises
• Check smell of other chemicals / pesticides
• Check External area of the property
• Check neighboring property
Repair Instruction :

• For leakage from joints and inherent defects in GI pipes and fittings:
a) Re-open the pipe & fittings from the nearest free joint & move towards
the point of leakage.
b) Apply a minimum of 3 clockwise overlaps of Teflon tape onto all
external threads (excepting those of the meter and regulator adaptor).
c) Tighten all pipes and fittings
d) Check for any sign of leakage with neutral soap solution.
• For leakage from union nut, meter connector, regulator connector
a) Loosen the connector / nut and slide it back
b) Remove the damaged seal & replace it
c) Push the connector / nut on the counter part & replace it
d) Tighten the connector to the correct torque.
e) Check for any sign of leakage with neutral soap solution.
• For any leakage from joints where it is not required to loosen any free joints,
tighten the nut or screw and check for any sign of leakage with soap water
solution.

Sr.
Component Probable Causes Action to be Taken
No.
1. Seam Leakage / Replace GI Pipe
GI Pipe Corrosion Replace GI Pipe
2. Hex Nipple Cracked / inherent Replace Hex Nipple
Tighten Hex Nipple
Defect
Hex Nipple Joint Loose
3. Coupling Cracked / inherent Defect Replace coupling
Coupling Joint Loose Tighten coupling
4. Elbow Cracked / inherent Defect Replace Elbow
Elbow Joint Loose Tighten Elbow
5. Reducer Cracked / inherent Defect Replace Reducer
Reduce Joint Loose Tighten Reducer
Sr.
Component Probable Causes Action to be Taken
No.
6. Tee Cracked / inherent Defect Replace Tee
Tee Joint Loose Tighten Tee
7. Cap Cracked / inherent Defect Replace Cap
Cap Joint Loose Tighten Cap
8. Plug Cracked / inherent Defect Replace Plug
Plug joint Loose Tighten Plug
9. Reducing Tee Cracked / inherent Defect Replace Reducing Tee
Reducing Tee Joint Loose Tighten Reducing Tee
10. Union Cracked / inherent Defect Replace Union
Union Joint Loose Tighten Union
Nut Loose Tighten Nut
Seal Missing Replace Seal
Seal Damaged Replace Seal
11. Valve Cracked / inherent Defect Replace Valve
Valve Joint Loose Tighten Valve
Valve Gland Tighten Valve Gland /
Replace Delta Ring
Valve Seat leak Tighten Valve seat
12. Gas Tap Gas Tap Joint Loose Tighten Gas Tap.
Gas Tap Lever Loose Tighten Gas Tap Lever
Screw - but ensure
handle can be operated.
Gas Tap Passing Replace Gas Tap
Cracked / inherent Defect
13 Regulator Cracked / inherent Defect Replace Regulator
Damaged
Regulator Connector Tighten Connector
Loose
Regulator Adapter Joint Tighten Adapter
Loose
Mismatching Adapter Replace Adapter
Sr.
Component Probable Causes Action to be Taken
No.
Thread Seal Damaged. Replace Seal
14 Meter Seal Missing Place New Seal
Cracked Adapter Replace Adapter
Meter Body Leak Replace Meter
Meter Connector Loose Tighten Connector
Meter Adapter Loose Tighten Adapter
Mismatching Adapter Replace adapter
Thread
Seal Damaged Replace seal
Cracked Adapter Replace Adapter
15 Neoprene Tube Poor quality / cracked / Replace Tube / Hose
Hose leaking Replace Tube / Hose
Cracked at the ends Replace Tube/ Hose
Damaged by Rat / Insect
Bites
 ANNEXURE – 05

Work Instruction for Attending Gas Leak / Escape

From Service Line & PE Network

Following actions shall be taken on site by the Emergency Team,

• Inform the control room immediately upon arrival on site.
• Assess the situation and need to protect human life & property
• Cordon and secure the affected area
• Close off access roads
• Record the gas readings using calibrated gas detector instrument.
• When the exact location of the leakage is determined Identify or locate suitable
main line and or valve chambers for isolation purpose.
• Dampen the soil with water to prevent sparks
• Inform the Control Room of the findings and progress being made.

[ A ] Leakage from Transition fitting :

Before taking any maintenance, on the domestic / commercial installation carrying

out earthing as per Annexure – 15

9) After taking above necessary safety precautions, dig a pit to expose the
affected portion.
10) Ensure all effected customers have been notified and have had their supplies
isolated at the control valve.
11) Squeeze the 20mm PE pipe & apply wet cloth to avoid static current &
intimate customer for gas supply stoppage.
12) Cut leaked transition fitting & remove transition fitting.
13) Remove burrs from PE pipe & transition fitting.
14) Install 1/2”x 20 mm transition fitting along with 20 mm dia coupler properly.
15) Weld 20-mm dia. coupler with Electrofusion unit as per Annexure – 14 section
-B
16) Allow the joint to cool down to ambient temperature.
17) Soundness Test the outlet pipe work.
18) If Soundness Test is satisfactory open squeeze tool & ensure no leakage
condition & intimate customer for gas supply resumption
19) Put back R.C.C. guard properly & back fill pit.
20) Collect the scrap / old materials / packing material from the site & dispose it to
a designated scrap yard.

[ C ] Leakage form isolation valve or from G.I. fitting upstream of isolation valve.

1) Follow instruction steps 1& 2 of above [ A ].

2) Squeeze the 20-mm PE pipe & apply wet cloth to avoid static current &
intimate customer for gas supply stoppage.

Case - 1 Leakage from Isolation valve

3) Reopen GI pipe / GI fittings from Transition fitting up to isolation valve

4) Replace isolation valve in case valve is damaged / in-built defect.
5) Open isolation valve & Tighten isolation valve after applying Teflon tape on
pipe thread.
6) Retighten all GI pipes / GI fittings after applying Teflon tape.
7) Open squeeze tool & ensure no leakage condition & intimate customer for gas
supply resumption. Apply no squeeze tape.
8) Put back R.C.C. guard properly & back fill pit.

Case - 2 Leakage from Union / Tee before isolation valve :

9) Reopen GI pipe / GI fittings from PVC saddle/ Transition fitting up to union.

10) Replace Union / Tee in case union body is damaged / in-built defect.
11) Open Union / Tee & Tightened it after applying Teflon tape on pipe thread.
12) Replace “O” ring, if seal inside union is damaged / crushed.
13) Retighten all GI pipes / GI fittings after applying Teflon tape to pipe threads.
14) Open squeeze tool & ensure no leakage condition & intimate customer for gas
supply resumption
15) Put back R.C.C. guard properly & back fill pit.

Case - 3 Leakage from G.I. fitting (Elbow, Hex nipple, Coupling, Plug, Cap, Tee,
Reducing tee, Pipe nipple, Reducer) before isolation valve:

16) Reopen GI pipe / GI fittings from Transition fitting up to GI fitting/s.

17) Replace GI fitting (Elbow, Hex nipple, Coupling, Plug, Cap, Tee, Reducing
tee, Pipe nipple, Reducer) in case GI fitting body is damaged / in-built defect.
18) Open GI fitting (Elbow, Hex nipple, Coupling, Plug, Cap, Tee, Reducing tee,
Pipe nipple, Reducer) & Tightened it after applying Teflon tape, on pipe thread.
19) Retighten all GI pipes / GI fittings after applying Teflon tape on pipe thread.
20) Open squeeze tool & ensure no leakage condition & intimate customer for gas
supply resumption
21) Put back R.C.C. guard properly & back fill pit.

[ D ] Leakage form PE pipe due to Rat bite

1) Follow instruction steps 1& 2 of above [ A ].

2) Squeeze the PE pipe on one / both side of damaged PE pipe (ensure double
squeeze off on upstream side) & apply wet cloth to avoid static current.
3) Vent the residual gas safely.
4) Cut & remove damaged PE pipe.
5) Clean PE pipe & remove burrs from PE pipe.
6) Install E.F. coupler (1 No. OR 2 nos. with short piece)
7) Weld saddle with electrofusion unit as per Annexure – 14 section - B
8) Allow cooling the joint to ambient temperature.
9) If downstream connection is satisfactory open squeeze tool & ensure no
leakage condition & intimate customer for gas supply resumption.
10) Inform Control Room about restoration of supply.
11) Back fill pit.
12) Collect the scrap / old materials / packing material from the site & dispose it
to a designated scrap yard for further disposal
 ANNEXURE – 06
Work Instruction for Attending Damage on PE network

18. Upon receipt of information of damage to Gas line by control room, Emergency
Team shall rush to site and take following actions
• Inform the control room immediately when arrived on site.
• Assess the situation and need to protect human life & property
• Cordon and secure the affected area
• Close off access roads
• Record the gas readings using calibrated gas detector instrument.
• When the exact location of the leakage is determined Identify or locate
suitable main line and or valve chambers for isolation purpose.
• Dampen the soil with water to prevent sparks
• Inform the Control Room of the findings and progress being made.

19. For damage affecting the gas supply more than 100 nos. of customers, it shall
be informed to GPSC Gas Company immediately.
20. Depending on the severity of the damage the engineer may request additional
resources and assistance from control room.
21. In the event of the escaping Gas igniting a decision will be made by the
Engineer on site whether to extinguish the flame before isolating the gas supply
considering all the aspects on site and keeping in mind that:
• If the flame is not impinging on any material / structure it can be safer to
leave the gas burning until the supply can be stopped than have an
uncontrolled gas escape
• The surrounding area can be kept cool by water spray if available
• Fire from escaping gas from a poly-ethylene pipe will cause the poly-
ethylene to melt and escalate the intensity of the fire.
• Assistance from the Fire Brigade should be sought however the control of
the site and gas should be with Emergency team.
22. Communication (personal / thro public announcement system) will be done to all
affected Domestic / Commercial customers for temporary stoppage or
termination of gas supply requesting customers to turn off their gas suppliers at
the isolation valve
23. All effected properties will be visited to check that their Gas supply has been
isolated at the meter control valve. Records will be kept of those supplies that
have been isolated and those where access to the meter / property cannot be
gained.
24. The control room shall be kept informed of the situation on site at least every
hour and as and when circumstances change.
25. A repair shall be undertaken as per the Type list below :
TYPE A.- Permanent Repair Requiring A Cut Out Of Section – Involving Squeeze – Off
Tools
• A trench is prepared for fixing of squeeze tool on PE pipe. Dampen the
excavated area with water to prevent static sparks.
• Squeeze off pipe as per Annexure - 11
• Ensure zero methane by sampling the atmosphere with a gas detector.
• Fit either
• electro-fusion coupler – as per Annexure – 14
• or new section of pipe as per Annexure – 13 & 14
• or electro fusion clamp – as per Annexure – 12
TYPE B. Permanent Repair Requiring A Cut Out Of Section – Involving Operating
Valves
• Identify leakage area and excavate a trench for undertaking repair. Dampen the
excavated area with water to prevent static sparks
• Identify Valves to be isolated for pipe section.
• Follow Annexure – 10 for isolation of pipeline section and venting of gas to
depressurize the section
• Ensure zero methane by sampling the atmosphere with a gas detector
• Undertake a repair by either
ƒ electro-fusion coupler – as per Annexure – 14
ƒ or new section of pipe as per Annexure – 13 & 14
ƒ or electro fusion clamp – as per Annexure – 12
26. The pipe-work shall be purged with nitrogen to remove air if pipeline volume is
more than 2 m3.
27. After completion of repair / installation of Electrofusion coupler, up-stream valve
shall be throttled or squeezing tool shall be opened slowly for a moment and
NG shall be locked in the section. Lock pressure test shall be carried out for
10 minutes with NG at working pressure where ever possible. Gas leak test
shall be carried out by soap solution / gas leak detectors on repaired portion
28. After completion of repair and leak testing pipeline shall be pressurized (re-
commissioned) as per Annexure – 10.
29. Announce to all customers that gas supplies have been restored - for any
problems to contact the site representative.
30. Inform Control room that the job is over
31. Backfill trench and restore site to a safe level.
 ANNEXURE – 07
Work Instruction for attending Fire and or Explosion
at a Building

1. Upon receipt of information by control room, Emergency Team shall rush to

site and take following actions
2. Inform the control room immediately when arrived on site.
3. Assess the situation and need to protect human life & property
4. Cordon and secure the affected area
5. Close off access roads
6. Record the gas readings using calibrated gas detector instrument.
7. When the exact location of the leakage is determined Identify or locate suitable
main line and or valve chambers for isolation purpose.
8. Dampen the soil with water to prevent sparks
9. Inform the Control Room of the findings and progress being made.
10. Control room shall inform to GSPC Gas Company immediately through O&M
Contractor In charge.
11. In the event of a fire or explosion at a Building the gas supply in to the
building will be physically isolated, either by closure of the service isolation or
if necessary by squeeze off of PE service line or isolate gas supply to
distribution main from nearest valve chamber / chambers depending upon the
site situation
12. Necessary actions are initiated in consultation with GSPC Gas Co through
O&M Contractor In charge
13. Collect maximum information at site:
• Photographs of the damage and Gas Installation
• Time & cause of Fire / Explosion
• Any injury or fatality
• Witness statements
• Severity of fire / explosion
• Source of substantial gas leakage / Gas escape (If natural gas is
suspected)
14. Assess the site situation and if local resources are not in a position to control
the situation (like Rapid deterioration of the situation on site, Involvement of
Mob, media and police) then inform control room for more resources like
security guards, barricading devices and additional manpower.
15. Ensure occupants are evacuated to a safe place and also ensure evacuation
from adjacent and opposite properties even such properties are not at risk
16. Before entering the customer premises, follow the safety measures as per
Annexure – II
17. Ensure the safety of own and team before entering unsafe building / structure
or customer premises
18. Assess the possible extent of gas pipeline installation and its integrity. (It is
possible that force of explosion might have damaged the gas pipeline
installation)
19. Inspect the internal gas pipe work installation and undertake leak test, using
gas detector and soap solution as per Annexure - III
20. Check for the presence of LPG appliances and bottles. If possible inspect the
condition of this equipment
21. Undertake a leakage survey of the external / upstream Gas Supply Pipe
network within a hundred meter radius of the property with a calibrated gas
detector instrument having least count of at least 1% LEL.
22. If leakage or damage is discovered as per above steps then do not conclude
immediately on the cause of Fire / Explosion at site. Try to collect the findings
and preserve evidence. All site conditions and actions are accurately and
carefully recorded.
23. It is ensured that anyone of team members do not make any comments /
discussion with third party (Including customer) regarding the possible cause
or liability for Fire / Explosion.
24. Convey the findings of site to GSPC Gas Company, through O&M Contractor
in charge and decide further course of action/s.
25. If it is clearly identified that natural gas is not the cause of the fire / explosion
then conclude the investigation in consultation with GSPC Gas Co through
O&M Contractor in charge.
26. In case of no possible entry / access in the customer premises to check the
condition of gas pipeline installation then the gas supply to property / house is
disconnected and temporary seal is applied on isolation valve.
27. Inform actions taken at site to O&M Contractor in charge through control
room before leaving site.
 ANNEXURE – 08
Work Instruction for Operating & Maintenance
Gas Detector Instruments

1. Adequate numbers of Gas Detection Instrument shall be procured by O&M

Contractor with least count of 1% LEL minimum and calibrated for Natural
Gas (Methane)
2. Train the technician and operators thoroughly for operation of gas detection
instrument
3. Operate the instrument as per guideline given by manufacturer of instrument
4. Ensure calibration of gas detection instrument as per the frequency
recommended by manufacturer of instrument.
5. Ensure spares and maintenance of instrument as per recommendations of
manufacturer of instrument

ANNEXURE – 09
Work Instruction for Making Bar Holes
for Detecting the Presence of Gas below Ground

1. Ensure the safety precautions as follows,

• Use a cable locator to locate cables before striking the searcher bar
• Personnel engaged in bar holing work shall be equipped with and
use protective clothing including goggles, gloves and steel toe-
capped safety footwear.
• Ensure hands and feet are kept well away from the spike tip.
Always carry the tool with the spike pointing away from the body.
• Replace the Rubber Cap on the spike after use and tighten the
spike retaining Thumb Screw.
• Hold the Searcher bar away from the body and especially the face
when driving it into the ground.
 • Do not touch the metal spike when is it inserted into the ground – it
may be touching an electrical cable.
• Place the spike end onto the ground over the area where you wish
to discover the leak.
• Ensure feet are well apart and the bar is a comfortable distance
from the body and head.

2. Undo the Spike Retaining Thumb Screw

3. Raise the handle and force down sharply so the top closure plug (inside the
handle) hits the boss head of the spike. The “pile driver” action will drive the
spike into the ground – soil, asphalt or concrete – concrete being the most
difficult to penetrate).

4. When you reach the depth required, remove the spike by means of a reverse
action of lifting the handle STRAIGHT UP so it hits the boss head of the spike
from the underside, so lifting the spike out of the ground in a vertical way.

5. DO NOT MOVE THE SPIKE FROM SIDE TO SIDE AS THIS WILL BEND
THE METAL. ALSO – DO NOT USE THE SEARCHER BAR AS A “CROW
BAR” AS THIS WILL ALSO BEND THE SPIKE.

6. A neat hole is now made in the ground down which the gas testing probe can
be lowered to test for the leak.

7. Retighten the spike retaining Thumb Screw and replace the Rubber
protective foot on the end of the spike when the bar is not in use. Store in dry
conditions.

8. The Searcher bar is only used for making the hole in the ground – not for
measuring gas.
 ANNEXURE – 10

Work Instruction for Line Valve Closure, Depressurization of Section by

Gas venting and Re-commissioning of same

Section Isolation :

1) Review the network drawing and plan the valves to be isolated.

2) Arrange required tools tackles and valve keys for isolation of valves.
3) Get approval / consent of section isolation from GSPC gas Co through O&M
Contractor In charge by conveying / communication following
• purpose for section isolation
• gas supply affected area
• number of domestic & commercial customers affected
• Time duration of supply stoppage to customers
4) Communicate the gas supply stoppage to concerned customers, by
announcing building to building using public address system.
5) Advice customers to keep the gas tap closed till gas supply resumption
message is received / announced.
6) Monitor the gas pressure at upstream and downstream end of section to be
isolated.
7) Carry out isolation first from upstream side by operating valve gradually
8) Monitor the gradual decrease of gas pressure of said section
9) Allow maximum possible gas consumption by downstream gas customers.
10) Close the downstream isolation valve/s gradually one by one and isolate total
section.
11) Monitor the gas pressure stabilization at upstream and downstream end.
Gas Venting :

12) Decide gas venting location based on following criteria

• Remote and less populated place

• Away from residential / commercial buildings
• Away from road traffic area
• Away from overhead electrical line
• Area where least chances of sparking / hot work

13) Install the vent pipe of ½” (or adequate size) of height more than three meter
from ground on vent valve/s to allow gas dispersion above human nose level
on ground
14) Post the operator / technicians in downstream wind direction with calibrated
gas detector/s to monitor the gas concentration in atmosphere
15) Carry out gas venting by gradually opening vent valves and ensure following
safety precautions
• Open vent valve gradually & intermittently to prevent accumulation of gas
• Coordinate with technicians, monitoring gas concentration in atmosphere
in down wind direction, to control / to stop gas venting
• Never allow gas concentration above 20% of LEL in atmosphere
• Stop gas venting if it is so to allow gas to disperse
• Ensure that gas does not ingress in buildings
• Observe and ensure no sparking near gas venting area
• Monitor the gas pressure of section

16) Monitor the gas pressure on pressure gauge/s and on vent pipe and confirm
that gas is fully vented.
17) Close the valve/s and isolate the section. Check and ensure that indicator /
pointer of valve/s is in CLOSE position.
Re-commissioning :

18) After completion of job, monitor the gas pressure, installed on upstream and
downstream point of isolated section.
19) Communicate the gas supply resumption in few minutes to concerned
customers, by announcing building to building using public address system.
20) Advice customers to keep the gas tap closed till gas supply resumption
message is received / announced.
21) Open gradually upstream valve. Open the valve till the gas flow sound is
heard and stopped there.
22) Communicate the valve opening to technicians posted in downstream valves
for monitoring of gas pressure.
23) Open the valve further gradually and monitor the gas pressure at upstream
and downstream point.
24) Once gas is pressure is stabilized, open downstream valve/s and resume the
gas supply to customers.
25) Communicate the gas supply resumption to concerned customers, by
announcing building to building using public address system.
26) Communicate to GSPC Gas Co and O&M Contractor In charge through
control room about resumption of gas supply
27) Check the indicator / pointer of all valve/s is OPEN condition.

ANNEXURE – 11
Work Instruction for PE Pipe Squeezing
1. Dig an trench of a size sufficient to carry out the work safely
2. Clean the pipe with a clean cloth to remove dirt and dust particles
3. Install pressure points both side of the squeeze off points to monitor pressure
during operation. See sketch below.
4. Place a water damped cloth on the pipe either side of the leakage point
5. Lift the pipe gently and place a rubber gasket, along with the bottom roller, at
bottom of the pipe at a distance of at least 600mm downstream from the point
of damage
6. Place the second gasket onto the pipe and insert the upper body of the
squeeze off tool (consisting of integral roller, screw and handle) into the lower
roller
7. Rotate the handle in a clockwise direction, so as to move the upper rollers
towards the wall of the pipe. Continue until the pipe is compressed between
the two rollers.
8. Lift the pipe gently and place a rubber gasket, along with the second bottom
roller, at the bottom of the pipe at a distance of at least 600mm upstream from
the point of damage
9. Repeat Steps 5 and 6
10. The ring of the PE pipe inside each squeeze off tool is tested by soap solution
and if leakage is detected the squeeze off is re-tightened further until no
further leakage is observed.
11. A third squeeze off tool is applied 600mm further upstream from the second
squeeze off tool
12. Repeat Steps 5 & 6
13. The damaged section of pipe is repaired
14. The squeeze off tools are released in reverse order in which they were
applied
15. The repaired section and the squeeze off positions are checked for
soundness
16. Apply warning tape and marker pen on the location of the squeeze offs to
ensure no re-application of squeeze offs at the same points in future
17. Collect scrap / burrs/ dust particles and return to a designated scrap yard for
disposal.
Sketch

Pr Point Pr Point
SQ 4 SQ 1 SQ 2 SQ 3
 ANNEXURE – 12
Work Instruction For Electrofusion Reinforcement Clamp Welding

1. Dig an trench of a size sufficient to carry out the work safely

2. Stop the flow of Gas by either squeeze off as per Annexure 11 or by closing
valves Annexure 10

3. Remove any burrs from the puncture on the surface of the pipe. Clean the
pipe surface with isopropyl alcohol or acetone using a clean & dry cloth

4. Prepare the pipe surface by using appropriate tooling to remove a uniform

layer of the PE oxidized surface over an area slightly greater than the fusion
footprint of the fitting

5. Install the two halves of the clamp, place one over the puncture and one
underneath the pipe

6. Insert a bolt in the first hole of the top half of the clamp in such a manner that
it passes through the first hole of the second half of the clamp

7. Insert a nut over the bolt and tighten by turning it in a clockwise direction and
securing the nut by an appropriate spanner

8. Repeat the process for the hole diagonally opposite the first hole. Similarly
tighten all the other bolts, this will bring the two halves of the clamp tightly
together against the pipe wall

9. Connect the Electrofusion unit to a power supply either through a mains

connection or via a generator

10. Activate the main switch & connect the fusion plug firmly to the contact
terminals of the fitting. Ensure that the contact faces of the fusion connector &
the fitting are free of coatings & deposits

11. Read the bar code with the wand by holding the wand at a slight angle and
moving it briskly left to right of the label
12. If the wand is used correctly and the bar code is matched then this is
confirmed by the emittance of an audible “beep”

13. On the screen the following is displayed:

FRIA, <diameter of fitting>, <temperature measurement> & <START indication>

14. Press the START button and the automatic fusion will take place, with the
required fusion time shown

15. At the end of the fusion process, STOP indication is displayed on the screen
16. Allow the joint to cool for at least 30 minutes
17. Re-commission the line with natural gas. Check & ensure that there is no
leakage using a soap solution
18. Remove the un-fused second half of the clamp
19. Collect the scrap/ burrs/ dust particles and deliver them to a designated waste
yard.
 ANNEXURE – 13

Work Instruction for Pipe Jointing using

Electrofusion Couplings

1. Both ends of the pipe to be joined shall be cut square and perpendicular to
the axis of the pipe. All burrs shall be removed
2. Remove any burrs from the puncture on the surface of the pipe. Clean the
pipe surface with isopropyl alcohol, using a clean & dry cloth
3. Prepare the pipe surface using appropriate tooling to remove a uniform layer
of the PE oxidised surface over an area slightly greater than the fusion
footprint of the fitting
4. Insert both ends of the pipe into the coupler so that they meet at the centre
mark
5. Connect the electrofusion control box to a power supply – either mains
electricity or a generator
6. Activate the main switch and connect the fusion plug to the contact terminals
of the fitting. Ensure that the contact faces of the fusion connector and of the
fittings’ terminals are free of coatings & deposits.
 ANNEXURE – 14

Work Instruction for Use of Electrofusion Welding Machine

Operate and maintain, Electrofusion Welding Machine as per manufacturer

instruction.

[A] Electrofusion welding using the Friatec (FF) unit

1. Read the bar code with the wand by holding the wand at a slight angle &
moving it briskly from left to right of the label

2. If the wand is used correctly and the bar code is matched then this is confirmed
by the emittance of an audible “beep”

3. On the screen the following is displayed

FRIA, <diameter of fitting>, <temperature measurement> & <START indication>

4. Press the START button and the automatic fusion will take place, with the
required fusion time shown

5. At the end of the fusion process, STOP indication is displayed on the screen

6. Allow the joint to cool for at least 30 minutes

7. Re-commission the line with natural gas. Check & ensure that there is no
leakage by using a soap solution & a Combustible Gas Indicator

8. Collect the scrap/ burrs/ dust particles and deliver them to a designated waste
yard for onward disposal
[B] Electrofusion welding

1. After switching on, all the displays show “0000” on the screens.

2. The fusion time is to be found on the fitting itself

3. Depress the “+” button for approximately 1 second

4. The numerical display of the stage to be programmed shall blink

5. Depress the “+” button several times until the desired number of seconds is
displayed on the screen

6. The next stage is reached by depressing the “+” button for another 1 second

7. Repeat Steps 5 & 6 until all 4 stages are input

8. Press the “I” key. The continuous fusion process is indicated by the time display
running backwards

9. When fusion process has been completed successfully, display shows “0000”

10. Disconnect the power supply and remove adapter

11. Allow the joint to cool to ambient temperature & check for leakage with soap
solution or a Combustible Gas Indicator

12. Collect the scrap / burrs / dust particles and deliver them to a designated waste
yard for onward disposal.
 ANNEXURE – 15

Guidelines for Earthing Of Installation While Carrying Out Maintenance

Activity on GI Gas Pipelines

There are all probabilities that while carrying out maintenance activity on the GI
installation some stray current passing through the pipe may electrocute the person
carrying out maintenance.

The activity may also be affected due to electrostatic current produced during the
activity.

In order to avoid such instances the following guidelines must be followed.

(Refer Figure on next page)

1. Check whether there is any stray current on the pipeline with the help of the
tester. Ensure that the tester is in contact with bare pipe and not the coating.
2. If it is found okay, connect the earthing system as per the attached drawing.
a. Insert the Earthing rod into the soil (Minimum one foot). Pour the water
nearby area of rod for good earthing.
b. Connect the earth cable to the pipeline with the help of crocodile type
clamp. Before connecting the clamp remove the coating for better
contact.
3. Wherever the pipe is cut in two pieces or an installation is dismantled from
the in between portion use a jumper wire to ensure the continuity of the
earthing on all the portions of the installation.
4. Ensure the earthing rod is properly inserted in the ground.
5. To have better earthing make the ground wet at the portion where the
earthing rod is to be installed.
 ANNEXURE – 16

Work Instruction for Evacuation of Building/s In Case Of Gas

Accumulation

1. Evacuate where:
• Gas concentrations are 40% LEL or above inside the properties.
OR
• Person/ s is / are exposed to gas or products of combustion
OR
• Occupant’s safety is at risk.

2. Get approval / consent of building/s evacuation from GSPC Gas Co through

O&M Contractor In charge by conveying / communicating following

3. purpose for evacuation

4. number of buildings / residences affected

5. Communicate (personally or through public announcement) to customers /

public of risk of exposure to gas and ask them to evacuate the home / building
slowly

6. Communicate (personally or through public announcement) to customers to

ensure safety precautions as per safety advice of Annexure 01

7. Check gas concentration in all surrounding building / residences and evacuate

all affected buildings / residences

8. Locate the suitable safe place nearby and allow public to gather there

9. Keep traffic and pedestrians well clear of site.

10. An evacuated building should not be reoccupied until:
• The source of leakage is isolated and gas concentration is confirmed
zero in affected buildings / residences.
• The leakage, from outside the building prevented from entering the
building and accumulated gas is ventilated.
• Site is restored to safe level.

11. Communicate (personally or through public announcement) to customers /

public about safe to occupy buildings and allow them to go

12. Inform GSCP Gas Co and O&M Contractor In charge through Control Room
 ANNEXURE - 17

PE Damage / Fire / Explosion

Incident Report

Incident
Reason
Location
Date/Time

Activity Carried Out By :

Call / Response Information :

Observation /Action Taken :

Other Information of Damage:

Size of Pipe Damaged

Damaged by
Customer Affected
Squeezing Time
Period of Gas Supply Affected
For O&M Contractor,
(O&M Contractor
(Shift In charge)
In charge)

Remarks / Comments (GSPC Gas):

 3.6 Customer Complaint And Request Handling

Procedure and facilities shall be established for receiving and handling various
complaints related to network / installation of city gas distribution system from the
customers, public and employees. The receipt and handling of complaints shall be
managed through control room manned for 24 x 7 (round the clock) by experienced
and trained O&M team.

The complaints from various agencies may be categorized in to (a) Technical (b)
Non-technical and (c) Emergency Complaint such as

Emergency Complaint (Gas

Non technical
Technical Complaint smell / leak / escape / fire /
Complaint
explosion)
Low flame / pressure Change of name Fire / Explosion
Temporary disconnection Bill not received Gas Leakage (U/G)
Reconnection Change of address PE Damage
Meter Complaint / Meter fast Improper address,
Joint Failure
name
Stove Complaint Higher gas bill Rat Bite
Alteration of gas piping Cheque related issue Gas Leakage (A/G)
No proper restoration / repair
Delay in gas connection Transition Fitting Leakage
at premises
Delay in charging of gas
GI Pipe / Fitting Leakage
connection
Audco Valve Leakage
Regulator (Adaptor / Bush)
Meter (Adaptor / Hex Nut)
Gas Tap
Rubber Tube
No Gas Complaint
SSV Shut OFF (OPSO)
Saddle Drilling
3.7 CPRS & DRS

Content :

1. General Information

2. Procedure for preventive maintenance of Service Regulator

3. Work Instruction

1) Functional checking / testing and resetting of PRVs, SSV and SRV

of a CPRS, DRS

2) Cleaning / Replacement of Filter Elements of a CPRS, DRS

3) Routine Maintenance of CPRS, DRS

4) Pressure Monitoring report for CPRS, DRS

5) Report for Maintenance of CPRS, DRS

1. General Information

The distribution system of CGD, includes a number of appropriately located above

ground Common Pressure Reduction Station (CPRS) and Domestic Regulating
Station (DRS). The function of CPRS / DRS is to reduce the pressure of 15-19 bars
to 4-5 bar, supplying to MP PE distribution network. There is a Knock Out Drum &
Filter Separator provided at the inlet of the CPRS / DRS. It is twin stream installation
of regulation with active & monitor, safety device like Slam Shut Valves (SSV) and
safety Relief Valve (SRV) along with manual isolating valves provided to isolate the
stream for servicing / repair maintenance. There is redundant regulation stream,
hence in case of failure of any valve of active gas stream, it can be repaired /
rectified without shutdown.

The pressure monitoring of all CPRS / DRS across the network is carried out
regularly, on daily basis, by visiting individual site and remedial measures taken as
required.

The operation and maintenance plan containing activities, frequencies and schedule
for CPRS / DRS shall be prepared based on manufacturer’s recommendations,
various statutory & code of practice / guidelines, conditions and year of service. And
it shall be executed / implemented and monitored. Below table suggests O&M
activities and their frequencies.
Sr.
Activity Frequency
No.
01 Monitoring of Pressure (Inlet / Outlet) Daily
02 House Keeping in and around Fenced Area Quarterly
03 Leak check / testing Quarterly
04 Draining / Venting Quarterly
05 Preventive Maintenance of CPRS / DRS, Yearly
On line testing / resetting of active, monitor, SSV &
SRV
Cleaning of filter elements
Isolation Valve operation
Leak check
House Keeping
Fencing & cabin
Paint Touch-up
Display of Asset Name & Tag
Display of Emergency Contacts
06 Pr Gauges (Inlet, outlet, differential) Yearly
07 Hydro Testing OR Internal Inspection of filter body Five Yearly
08 Attending gas leak / over pressure / under pressure / gas As when required
stoppage
2. Procedure for preventive maintenance of CPRS / DRS

Sr.
No. Activity Steps Responsibility
1 Based on O&M frequency of CPRS / DRS, Annual O&M Contractor
In charge
Maintenances Plan covering all CPRS / DRS shall be
prepared and submitted to GSPC
2 As per Annual Maintenances Plan, spares / material O&M Contractor
In charge
required shall be checked for availability. If required, new
spares / material shall be procured / arranged in
coordination with GSPC Gas.
3 Required staff / engineers shall be trained and educated for O&M Contractor
In charge
O&M activities for CPRS / DRS
4 Based on Annual Maintenances Plan, Monthly Preventive O&M Contractor
In charge
maintenance schedule for CPRS / DRS shall be prepared.
5 On scheduled date work permit shall be obtained. Work In Charge
6 On reaching the site, process of initial observation of CPRS / Work In Charge

DRS installation, its working parameters, and site hazard

identification along with control measures shall be carried
out.
7 Pressure regulating valve, slam shut off valve, Safety relief Work In Charge
valve of CPRS / DRS shall be opened / checked /
overhauled and shall be reset for normal functioning &
passing, as per Work Instruction -01
8 The working pressure of Pressure regulating valve, Slam Work In Charge
shut-off valve & Safety relief valve are set as per specified
parameters and shall be reported as shown in “Report for
Maintenance of CPRS / DRS”
9 Filter elements of CPRS / DRS shall be replaced / cleaned, Work In Charge
as required Work Instruction - 02.
10 Routine Maintenance, especially cleaning, leak check of all Work In Charge
joints and painting, if required, shall be carried out, as per
Work Instruction - 03.
11 Site supervision by trained / experienced personnel of O &M O&M Contractor
In charge
team shall be ensured to see that routine maintenance and
on line functional checking / testing of valves of CPRS / DRS
is carried out as per various work instructions and according
to requirements of work permit.
12 Intimation about job completion shall be given to control Work In Charge
Room. Logbook and history card (in computer) shall be
updated.
13 Scrap / garbage from above activities shall be collected from Work In Charge
the site & kept at designated scrap yard.
14 Monitoring of maintenance schedule of CPRS / DRS shall O&M Contractor
In charge
be done and in case maintenance is not carried out as per
schedule it shall be re-planned & carried out.
15 Spares / Material consumption statement shall be prepared O&M Contractor
In charge
and submitted to GSPC Gas in charge for material
reconciliation and inventory management.
16 Report submitted to GSPC Gas and records shall be O&M Contractor
In charge
updated.
3. Work Instruction

Work Instruction - 01
Functional Checking / Testing and Resetting
of PRVs, SSV and SRV of a CPRS/DRS

• Close the drain valve and fit the mmwc pressure gauge, at the drain point after
SRV, and open the valve after fitting pressure gauge.
• Check / record the initial inlet, outlet, and monitor regulator valves’ flowing and
locked pressures, along with the time of recording.
• Close the inlet and outlet isolation valves of the service regulator and
depressurise the system by operating vents / drains, of filter body, near SSV,
between PRVs and after SRV.
• Release the spring tension of the valve by unscrewing the pressure setting
screw after Measuring / recording the initial setting of pressure setting screw
and releasing the lock nut.
• Unbolt and open the actuator bonnet of the SSV and do oiling/ greasing of
valve and actuator parts for easy movement of parts. Keep the SSV closed.
• Open the bonnets of active regulator valve and check the condition of rubber
diaphragm and internals. Ensure that there is no puncture / hole / crack on the
diaphragm, it has retained its elasticity and that there is no foreign part / dust
etc inside.
• Assemble the bonnet back, if everything found satisfactory, ensuring the
breather hole in the bonnet is clean and clear.
• Repeat the above steps for monitoring and SRV valves.
• The Pressure setting screw of Active, Monitor valve should be fully unscrewed
to ensure the closing of both the valves at initial stage. The setting screw of
SRV should be set near to earlier recorded setting.
• Diaphragms, spring rubber seats and other parts should be replaced, if found
damaged, worn out.
• Wherever pilot regulators are given for large flow capacity service regulators,
the pilot regulators, their tubing should be checked for effective working and if
 required their diaphragm, spring, rubber seat and other parts should be
changed.
• Ensure that SSV actuator and valve are working effectively, by frequently
operating the same to open / close position, with the use of gas supply and
lever, before assembly.
• If found ok, assemble the SSV’s actuator on valve.
• Close the drain and vent points, crack open the inlet valve of SR and allow the
pressure to go up to max operating figure.
• Carry out leak check of all joints once again, especially the bonnet and tubing
joints by soap solution.
• Check that the active monitor valves are not passing, as shown by zero
pressure on the drain point after SRV.
• Set the pressure of the monitor regulating valve by screwing down the setting
screw and observing the pressure in the gauge. It should be as per CPRS /
DRS Supplier.
• Similarly set the pressure of the active regulator by screwing down the setting
screw and observing the pressure in the gauge. The pressure of the active
regulating valve should be as per CPRS / DRS Supplier.
• Observe the system for 10 / 15 minutes for effective working of valve in locked
position, the set pressure should not rise.
• If found o.k. open the downstream low pressure isolation valve of CPRS / DRS
• Observe the system and do the fine tuning of required gas pressure for the
downstream network.
• The system should be observed for pick and non pick hours for minimum and
maximum pressure.
• System should be monitored for working pressure as mentioned above, for 2
days.
 Work Instruction – 02
Cleaning / Replacement of Filter Elements of CPRS / DRS

• Ensure that filter body is depressurised by opening drains and top gauge
connection. Venting is done under controlled condition with all safety
precautionary measures as per work permit system
• Before starting venting operation, ensure that CPRS / DRS inlet and outlet
valves are closed.
• Unbolt bolts of Top cover of filter & Remove Filter top cover, carefully.
• Remove filter element carefully, after removing the nut on element guide rod.
• Observe / check the inside of filter body and element fixtures for any
abnormality, and finally clean inside of the filter body.
• Clean the faces of faces of filter cover and body
• Similarly clean and reuse the old element, if possible.
• If required, replace the element with new element.
• Refit the element by screwing down the nut, washer and rubber packing, on
guide rod.
• Use the old gasket if the condition of the same is good. If not replace the
same, by new gasket.
• Refit the top cover by bolting down equally on all sides.
• Carry out the leak check of cover joint by soap solution, when the filter is
pressurised after completion of all other jobs on CPRS / DRS.
• Check and record the final DP, if available.
• Prepare the report and update the record including, spares / material
consumption statement and submit to GSPC Gas in charge for material
reconciliation and inventory management.
 Work Instruction - 03
Routine Maintenance of CPRS / DRS

• Check CH4 % with gas detector and carry out leak test with soap solution &
Cosmos meter, of all pipe, valve and tube joints.
• Clean all valves, drains vents, pressure gauges, pipe spools and pilot
regulators and filter, with dry clean cloth.
• Grease plug valve with grease stick till all valves becomes free in operation.
• Operate l valves in clock-wise/anti clock-wise direction frequently to make all
them free in operation.
• If found necessary paint all plug valves and audco valves with blue colour,
pipe, vent pipe with yellow colour, Filter with silver colour , S.R.V. with red
colour , P.R.V. & S.S.V. with sky blue colour.
• If Regulator No. / Equipment No. is not visible, required marking is done with
appropriate paint.
• Collect and deposit the scrap / garbage from above activities, at designated
scrap yard.
• Close the cabin and fencing gate and lock it.

Pressure Monitoring report for CPRS / DRS

Work
SR
Sr. Upstream Downstream Differential In
Date Time Tag Location
No. Pressure Pressure Pressure Charge
No
Sign

_____________ ________________
Checked By O&M Contractor In-charge
 Report for Maintenance of CPRS / DRS

SR Tag No: Location:

Date of maintenance:

Setting Before & After Maintenance

Sr. Before
Valve setting pressure After Maintenance
No. Maintenance
01 SSV set pressure
02 Active Regulator set pressure
03 Monitor Regulator set pressure
04 SRV Set Pressure
05 Isolation Valves Operation
06 Vent Drain Valves Operation
07 Filter Element Condition
Final Inspection Status
08 Leak Check of all joints
09 SSV Impulse Line valve
10 Filter Drain Plug
11 Low Pressure Drain Plug
12 Valve Chamber Valve Plug
13 Odorant Smell Checked
14 Dewatering from Valve Chambers
15 SSV Indicator Working
16 House Keeping
17 Up Stream Pr Reading
18 Down Stream Pr Reading
19 Filter Differential Pressure
Remarks:

_____________ ________________
Work In Charge O&M Contractor In-charge
3.8 Industrial Connection

General Information :

In a city gas distribution business, gas connection to industry is a major activity and it
consists of variety of gas equipment from simple furnace to complex thermo pack or
boiler. PE pipeline carrying pressure at 4 -5 bar, is laid underground from
downstream of CPRS and connected to MRS which is installed in industrial premises
for metering and regulating purpose.

The selection of site for installation of Metering and Regulating Station (MRS) in the
premises of industry is key to safety & integrity of gas installation and public. It
should be installed in well ventilated area away from buildings or major installation
having easy approach and access.

Commissioning of Industry:

Before charging the gas in the industry, pre-commissioning safety checks of that
industry should be carried out by concerned work in charge so that commissioning
can be done in time with all safety measures.

This safety checks will not only show the status of various sections / equipments, but
will also indicate the requirements of tools, gauges, sizes of valve keys etc. to be
kept ready at site.
Safety checks / precautions to be observed before and during commissioning

• Ensure that all items like pipes, valves, fittings are of standard quality having
proper test certificates.
• Ensure that standard fabrication, welding, inspection and installation methods
are followed.
• Check / Review pressure testing reports of all sections / equipment.
• After ensuring pressure testing, take leak test by locking 1 to 2 bar pressure of
N2 in all section. Use soap solution to find out the gas leak and repair / rectify
gas leak if it is found.
• All sections / equipments must be N2 purged to remove air (Oxygen) from the
installation to minimum 2% by volume.
• After N2 purging & testing, the whole installation should be pressure locked, at
0.5 bar of N2.
• Finally, close the following valves.
1. MRS gas filter outlet valve.
2. MRS gas filter by pass valve.
3. MRS outlet valve.
4. Gas train inlet valve.
• The healthy functioning of sequence controller for burner operation is of vital
importance and it should be checked, first in the laboratory by sequence
controller tester and then at site after installation.
• All safety interlocks and Audio visual alarms should be checked twice for their
functioning.
• Special attention should be given to the proper functioning of block and bleed
valves.
• Bleed valve’s outlet should never be plugged. Ensure that leak indicating
water bottle is fitted on it and if needed, in congested space the bleed valve
outlet may be guided out in the open atmosphere by providing rubber tubing /
piping.
• DCP type fire extinguisher should be located near the site.
• Other safety checks, like electrical hazard, position of flue gas damper access
valves, valve keys, overall housekeeping etc should be carried out to ensure
overall safety.
• All measuring instruments like Pressure Gauges, O2 analyzer, Gas Detectors,
etc should be calibrated and their batteries fully charged to remain operative
throughout N2 purging and gas charging.
• Wireless communication is very vital for saving the time and in case of
emergency during gas charging in the industry.

Gas Charging In the Industry

From safety point of view gas should be taken to the burner, section wise, namely.

1. Gas Charging in the PE Network.

2. Gas Charging in MRS.
3. Gas charging in internal piping.
4. Gas charging in gas train burner.
 GAS CHARGING IN PE SUPPLY LINE

SR. ACTIVITY PRECAUTION

1. Confirm the closure of MRS inlet valve Carefully read closing mark.
is closed
2. Crack open the tapping valve and Keep the valve key on position
raise the section pressure from zero with one man having walky-
to 4-5 bar. talky.
3. Take the gas through temporary Never inhale N2, to confirm of
strainer / filter, Natural Gas, by nose. Ensure
no spark / no naked flame. NG
concentration in atmosphere
should not increase more than
2%. If required do venting /
draining intermittently.
4. Measure CH4 (Methane) % it should Check functioning of Gas
be more than 90%. Do this twice. Detector before use. Ensure no
spark / no naked flame during
venting / draining.
5. Close drain valve completely. Check complete closure of valve
by soap test.
6. Open the tapping valve fully, observes
/ record and section pressure and
observe the line for 5 minutes.
 GAS CHARGING IN MRS

Sr. ACTIVITY PRECAUTION

1. Confirm the closure of MRS outlet Observe carefully the closing
valve. mark on valve.
2. Crack open the filter outlet valve OR Keep valve key on position with
MRS inlet valve and raise system one man stand by.
pressure to line pressure.
3. Vent out N2 from pressure gauge Do not inhale N2 for confirming
tapping near PRS outlet valve. incoming Methane. Ensure no
spark / no naked flame. If
required do venting / draining
intermittently.
4. Measure Methane (CH4)%, it should Check Gas Detector before use.
be more than 90% Ensure no spark / no naked
flame during venting / draining.
5. Close the venting valve completely Check leak test by soap test.
and fit pressure gauge on it.
6. Open the MRS inlet valve fully.
7. Check / observe the function of –
- Pressure regulating valve.
- Slam – shut off valve.
- Pressure relief valve and
record their settings.
Observe the system for 5 minutes.
 GAS CHARGING IN INTERNAL PIPING:

SR. ACTIVITY PRECAUTION

1. Confirm the closure of gas train inlet. Observe carefully closing mark.

2. Crack open the MRS outlet valve and Keep valve key on position and
raise the section pressure to 1 or 2 a man with walky talky.
bar.
3. Crack open the pressure gauge Do not inhale N2.
tapping valve near gas train inlet valve
and vent out N2. Ensure no spark / no naked
flame. Methane concentration in
atmosphere should not increase
more than 2% If required do
venting / draining intermittently.
4. Measure CH4 (Methane) %. It should Observe No spark / no naked
be more than 90%. flame: If required do Venting
intermittently.
5. Close the pressure gauge tapping
valve completely.
6. Open the MRS outlet valve fully and
observe the system for 5 minutes.
 GAS CHARGING IN GAS TRAIN BURNER:

SR. ACTIVITY PRECAUTION

1. Slowly open the gas train inlet valve Keep valve key on position.
and record the pressure.
2. Switch on the electrical panel.
3. Switch on sequence controller and
observe the sequences like

Pre-fire purging Note timing of purging.

Pilot flame ‘ON” Note L.P. gas pressure in water
Main flame ‘ON” column.
4. Switch off the sequence controller and Functioning of block and bleed
note. valve.

Post fire purging.

5. Again switch on the sequence
controller and check all safety
devices, interlocks, alarms
modulation, if any.
6. If alarm is observed and system is
going after switching controller on.

Find out the cause of alarm, rectify,

reset the system and switch on again.
7. Observe the system for 30 minutes
after successful start-up.
Work Instructions for Shutdown Jobs in MRS

SR.
ACTIVITY PRECAUTION
NO
1. Close industry’s tapping valve. Do greasing of MRS inlet / outlet
valve, check closing mark on valve
& use proper valve key.
2. Close MRS inlet valve and at Do greasing of MRS inlet / outlet
downstream joint of this valve fit valve, check closing mark on valve
blank / spade or separate flange joint. & use proper valve key.
3. Close MRS outlet valve. Do greasing of MRS inlet / outlet
valve, check closing mark on valve
& use proper valve key.
4. De – pressurize MRS by opening Smoking, Sparking to be avoided.
filter drain venting of pipe section Check over head electric wires.
after PRV & venting of standby Methane concentration in
stream. atmosphere should not increase
more than 2%.
5. Purge the whole MRS with N2. Check N2 cylinder before use.
Check condition of gas detector
before use.
6. Measure methane% (less than 2%) It should be 0.00% for ideal
twice. condition.
7. Do the repair / maintenance job. Take all necessary safety
measures as mentioned above.
8. Do visual inspection of all joints /
work.
9. Purge the system again with N2 and As per No. 5. Ensure no leakage in
test system with N2 pressure. MRS after repairing / maintenance.
10. Check O2% (less than 2%) twice. Check condition of O2 Analyzer
before use.
11. Recharge NG by slowly operating.
- Tapping valve.
 - MRS inlet valve.
12. Finally open the MRS outlet valve.
13. Observe the installation for at least Ensure that nothing left-out inside
10 minutes after successful PRS after the completion of job.
recharging of system.

Work On Charged Gas Network of Industry:

Whenever any pipe or equipment that has been installed on gas service is to be
opened, it is the duty of work in charge to obtain the necessary safety work permit
along with appropriate planning / preparations to carry out the job effective.
Communications is very important. The set steps of carrying out the jobs are as
follows:

• Isolation of section / equipment.

• De – pressurizing of section / equipment.

• Opening of the flange joint.

[A] Isolation Of Section / Equipment:

When a section or equipment is to be opened for repairs or maintenance work, the

upstream and downstream isolation valves must be closed fully. The closing mark
should be checked by the engineer in charge before de – pressurizing. Whenever

possible, double isolation should be done. Valves should be greased for perfect

sealing before closing and also after closing to ensure that it is not leaking / passing.

Once the valves are satisfactorily closed valve key should be removed from valves
or valve wheel to be tagged or locked to avoid unauthorized operation and thereby to
avoid accident.
[B] De – Pressurizing Of Section / Equipment:

Once the valves are fully closed and greased, the de – pressurizing of the section
can be done by venting out the gas at, atleast 3 meter height with adequate safety
precautions especially observing no smoking, no sparking and no gas concentration
above 2% of LEL.

De-pressurizing should be confirmed by opening another vent (if any) or pressure

gauge if fitted.

Venting area should be cordoned off and man with gas detector should be posted at
the down wind direction to measure the methane in atmosphere. The methane in
atmosphere should never increase more than 2.0%. If required, venting should be
done, intermittently to give more time for gas dispersion. Similarly, gas venting
should be stopped when some vehicle is passing near the spot, if operation is being
done on traffic roads.
[C] Opening Of Flange Joint:

• The opening of equipment or pipe section / valve, filter, etc… pose a special
safety problem and unless proper precautions are taken, mishap may occur.
The problem gets magnified if the section to be opened is pressurized with
natural gas.

• To ensure safety, in job of opening equipment / pipe section, it is good

practice to treat the equipment / section, as if it is still under considerable
pressure even though all steps have been taken to relieve the pressure.

• Similarly, it is good practice to treat the equipment / section, as if it still

contains inflammable Natural Gas, even though N2 purging has been done to
remove inflammable gas completely from the system.

• In opening flanges, or cover plates, employees shall first loosen the bolts on
the far side away from the man doing the job, with a sufficient number of bolts
allowed to remain tight on the near side until the connection can be wedged
open. Any anticipated, entrapped pressure / gas will then be dissipated in a
direction away from the man doing the work.

• During the course of work, any unsafe condition, if noticed, report promptly to
the permitting authority for taking corrective actions.
Industrial Complaints and Remedial Measures :

Sr. Nature of complaint /

Cause Action to be taken
No. Sources
Leakage
A
1 Flange joint leakage 1. Loose bolt 1. To Tighten the bolt
2. Gasket not provided on 2. To provide gasket on
both sides of filter cloth both the side of filter
3. Gasket provided without clothes.
3. To clean the surface and
cleaning of surface.
replaced the gasket.
4. Dust / Dirt on surface. 4. To fit proper size of bolt.
2 Threaded Connection 1. Loose connection 1. To tighten the
2. Teflon Tape not wound connection
3. Improper fitting 2. The wound the Teflon
tape and retighten the
same.
3. To do proper fittings.
3 ½” dia valve 1. Cracked due to over 1. To replaced the valve
tightening
4 Drain Valve of F/S 1. Heavy passing 1. To provide the sealant
2. Plug not fitted 2. To provide the plug
3. Loose plug 3. To tighten the plug
5 Valve gland 1. ½” & 1’ dia glad bolt 4. To tighten the bolt and
loose operate the valve 5
2. Sealant not provide times
5. To filled the sealant
6 UG Pipeline 1. Due to corrosion 1. Immediate isolation of
2. Damage of pipeline valve if methane % found
in atmosphere. If methane
% not found, then detect
the location by bar hole
methodology. Excavation
to be carried out if
possible leak clamp to be
fit.

2. Immediately isolation of
valves and to replace the
damaged portion.
B
FLAME & FLOW

1 Low gas pressure at 1. Filter cloth choked 1. Replaced the bolting

equipment 2. Strainer / filter choked cloth
2. Cleaned the strainer /
filter
2 Low Gas pr. at all 1. Carry out PRV setting
equip. 1. PRV setting disturbed 2. Drain F/S or check /
2. F/S choked replace filter element
 3. PRV under capacity 3. Replace PRV
4. Internal pipeline 4. Check design of pipeline
capacity low and PRS & take
5. Main line pr low necessary modification /
6. PRS Under capacity replacement.
2 1. PRV setting more 1. Carry out regulator
High Gas Pressure 2. PRV passing setting
2. Repair or replace
regulator

3 PRV problem 1. PRV setting disturbed 1. Repair or replace

2. PRV diaphragm damage regulator
3. PRV diaphragm sticked
4. PRV passing
5. PRV plunger jammed
4 SSV 1. Tripped 1. Reset SSV and check
2. Passing PRV for setting / passing
2. Repair / Replace the
SSV
5 SRV 1. Passing 1. Repair / Replace the
2. Not operated SRV
6 Burner Problem 1. Flame not established 1. Check gas percentage /
2. Burner tripped quality
2. Check gas pressure
3. Call burner supplier

C 1. Gas Leakage resulting in 1. Immediate isolate the gas

Fire & Explosion to fire or explosion supply of particular
2. Other fire equipment If approach is
3. Burner panel fire not clear than isolate
supply from PRS or valve
chamber
2. Evacuate the site / area
3. Isolate electrical supply
4. Intimate to higher / GSPC
Gas
D Miscellaneous
a. Water with gas 1. Hydro test water from 1. Drain water from F/S.
b. Isolation valve line Clean the line with air
passing 2. Sealant / Greasing not flushing
done 2. Filled the sealant
E False
a. Smelling 1. Other chemical smell 4. Checked the hole line for
b. No gas supply 2. Operate fault leakage if any
c. Low pressure 3. Error to read pr. gauge 5. Educate the operator
6. Educate the operator
3.9 Annual Maintenance of Customer Connections

Content

1. General Information

2. Procedure for Annual Service of Domestic Connection

Annexure – 01 Service Card

Annexure – 02 Work Instructions for Annual Service of

Domestic Customer

Annexure – 03 Reports for Annual Service of Domestic

Customers
1. General Information

Domestic gas connection is very critical asset which need regular maintenance to
ensure integrity of asset and safe installation. Domestic gas connection is operated
by house wife / family which are not knowledgeable / expert in maintenance of gas
installation.

Many a times tampering / improper use found with gas installation like illegal
extension, use of non-standard or long rubber tube, use of pipeline for hanging
cloths or other house items etc. Many a times, joints of gas pipeline found loose
overtime due to undue stress / use of pipeline as above. All these might results in
leakage/s of gas in house causing fire and explosion, if it is not inspected and
repaired / maintained properly & in time.

Annual maintenance of domestic connection is for checking the overall installation

integrity and to make necessary repair / replacement for long term safe service.
2. Procedure for Annual Service of Domestic Connection

Sr.
Activity Steps Responsibility
No.
01 O&M Contractor shall take over the list of domestic
O&M
connections, it’s area and planning of annual service from Contractor
In Charge
GSPC Gas
02 A Service Card as per Annexure – 01 shall be prepared and O&M
Contractor
maintained for each customer. In Charge
03 Annual Service shall be executed as per Annexure – 02 O&M
Contractor
In Charge
04 Any leakage observed by the technician / contractor during O&M
Contractor
the execution of Annual service shall be attended. In Charge
05 After completion of annual service, service card shall be filed O&M
Contractor
and customer signature shall be obtained. In Charge
06 If any house is found closed, customer shall be
communicated by affixing a sticker at his premises. Also a O&M
Contractor
letter requesting the customer to fix time for availing service In Charge
shall be sent through post.
07 Customer clearance / Complaints regarding annual service
O&M
shall be received and same shall be attended on priority Contractor
In Charge
basis.
08 O&M Contractor shall submit signed off Service Card/s and
O&M
“Report for Annual Service of Domestic Customer” as per Contractor
In Charge
Annexure-03 to engineer in charge of GSPC Gas for review.
09 Findings of Annual service shall be analyzed, reviewed
O&M
during the meeting with GSPC Gas & corrective & Contractor
In Charge
preventive actions shall be initiated for future improvement.
10 O&M Contractor shall invite GSPC Gas to randomly check O&M
Contractor
quality of the Annual Service at various domestic customers In Charge
11 On the basis of measurement sheets, contractor bills shall O&M
 Sr.
Activity Steps Responsibility
No.
be finalized and payment shall be made Contractor
In Charge
12 Monthly material consumption & reconciliation report shall
O&M
be prepared and submitted to GSPC Gas for review and Contractor
In Charge
approval.
13 After completion of contract, all Service Cards shall be O&M
Contractor
handed over to GSPC Gas or it’s designated contractor In Charge

Annexure – 01
Service Card

Annual Service Card

Customer Address
No
Name of Contact Nos
Customer
Date of Leak Clamps Paint Tube Cap Sign of Sign of
AMC Atten Replac Touc Replac Replac Technician Customer
ded ed h Up ed ed
Nos of Repair / Replace
 Annexure – 02
Work Instruction for Annual Service of Domestic Customer
1. Before starting the service, obtain permission from the customer.
2. Clean the pipe thoroughly using wire brush at corroded pipeline area and paint the
pipe with two coat with specified paint
3. Fix additional clamps where line is found hanging.
4. Tight / Refit / Replace the clamps where it is loose / damaged.
5. Replace neoprene / surksha tubes at points where it is in use.
6. Check for leakage:

i) Using calibrated gas detector

ii) Using soap solution
7. Attend the leakage in consultation with customer and note down the
material used for attending the leakage
8. Any disrupt activity on gas line like
• Illegal extension by using material not conforming to our standards.
• Extension carried out without Company's permission.
• Using neoprene tube greater than 1.5 meter length.
• Booked as Domestic / Non-commercial Connection and using for
commercial purpose.
• Line dismantled without informing to Company.
• In all the above cases intimate the concerned supervisor immediately.
9. After completion of the work inform the customer regarding the activities carried
out and get the customer's signature on service card.
10. The scrap neoprene rubber tube, scrap clamp and paint container shall be
collected and submitted to Scrap Yard for further disposal.
 Annexure – 03

Report for Annual Service of Domestic

Customers

Sr. Customer Neoprene

Gas Leak Paint Clamps Neoprene Cap
No. No. Tube
Nos of Repair / Replacement
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

________
O&M Contractor In-charge GPSC Gas Engineer In-charge
3.10 Calibration, Testing & Certification

Content :

1. General

2. Procedure for calibration and testing of items and equipments

Annexure: 01 Calibration Mater List

Annexure: 02 Annual Calibration Schedule

Annexure: 03 Monthly Calibration Schedule

Annexure: 04 Monthly Calibration Report

Annexure: 05 Calibration History Card

3. Procedure for external examination / thickness test and hydro test of

knock out drum / filter separator

Annexure: 06 Format for Equipment History card

1. General

There are many items and equipments of City Gas Distribution System, which need
to be periodically calibrated, tested for ensuring their functioning, working accuracy
and complying the laws and statutory requirements. Periodic calibration of
measuring, detecting items and testing of pressure vessels and valves, not only
ensure the integrity of whole system but also enhance the safety of the facility

The Gujarat factory act says that pressure gauges and safety relief valves on
pressure plants / piping should be calibrated every year. Similarly as per SMPV,
there are various periodical inspection and test requirements for pressure vessels
like knock out drum, filter / separators, etc installed at city gas station (CGS) of gas
distribution system. Items and equipment to be calibrated are identified, the
frequency of calibration is decided as per manufacturer’s recommendations or as per
requirements of law, statutory compliance or their criticality of function or if they are
found susceptible in their function and accuracy. For proper documentation of
reports and history records the numbering and tagging of the items and equipments
identified for calibration is very important, hence before preparing and finalizing the
Mater Calibration List and Annual Calibration plan, proper numbering and tagging
should be done . For assigning the calibration jobs to any internal / external agency,
it must be ensured that the adequate calibration facility is available and trained
persons are engaged. Similarly it must be ensured that master calibrator is within
calibration period and the agency posses the tractability proof for the same. The
process of identification, numbering, tagging and calibration, is carried out as per the
following procedure and work instructions, reports and records.
2. Procedure for Calibration and Testing of Instruments & Equipments

Sr. Activity Steps Responsibility

1 Required scope, activity and frequency for calibration / testing GSPC GAS
of items and equipments are determined on the basis of law, Location in
statutory requirements and service life, and condition. charge
2 Instruments & Equipments to be calibrated are identified & GSPC GAS
Calibration Master List is prepared as per Annexure-01 Location in
charge
3 Instruments and equipments are numbered and tagged. O&M
Calibration / Testing History Card is prepared as per Contractor In
Annexure -05 based on the overall Master list. Charge
4 Based on the frequency mentioned in calibration master list,
O&M
no. of equipment’s to be calibrated during the year is listed
Contractor In
and annual calibration schedule is prepared as per Annexure -
Charge
02.
5 Calibration details for various assets are collected compiled O&M
and a consolidated annual calibration schedule is prepared Contractor In
Charge
6 Monthly Calibration Schedule as per Annexure -03 is
prepared as per the following:
• Annual Calibration Schedule O&M
• Pending Calibration if any Contractor In
• The equipment that has been skipped from Annual Charge
Calibration Schedule and identified through verification of
calibration history card
7 Items and equipments are calibrated as per method of O&M
calibration specified in the calibration master mostly through Contractor In
external competent agencies. Charge
8 Verification -Calibration O&M
The calibration of inspection, measuring and test equipments Contractor In
(like voltmeter, ammeter) that are being verified at a regular Charge
 interval by more precise equipments (Millimeter /Clip-on
Meter) is required only when the difference of readings
between verifying equipment and measuring equipments
exceeds deviations beyond acceptable limit specified in
calibration history card. These equipments are also calibrated
at defined frequency and other steps are followed as above.
The verification reports of these equipments are maintained
9 Calibration Report is prepared or collected from calibrating
agencies, if calibration is performed in-house, its status O&M
(containing Equip. No., O.K, calibration date and next Contractor In
calibration due date) is tied up/ pasted on the equipment. Charge
Calibration Report is filed with the equipment history card.
10 Calibration History Card is updated based on the calibration O&M
report. The necessary actions for repair or replacement of Contractor In
equipments if any are taken. Charge
11 Instruments and equipments are calibrated at laboratory /
agencies having national / international traceability O&M
(Government Approved laboratory / Certifying agencies) and Contractor In
Calibration Status Reports are collected and filed with history Charge
card.
12 Detecting, measuring & test equipments are handled carefully
O&M
to ensure its accuracy and fitness for use. Adjustment of
Contractor In
instruments is safeguarded from manipulation, fiddling /
Charge
tempering.
13 On the basis of individual Instrument's calibration reports,
O&M
Monthly calibration Report as per Annexure – 04 is prepared.
Contractor In
And attached with monthly review and plan report submitted
Charge
to GSPC GAS every month.
14 Calibration status report received for various assets is
compiled and the same are verified against their monthly O&M
calibration schedule. In case of repetitive deviation for a Contractor In
particular asset, it is communicated to concerned person / Charge
agency for further action.
15 It is ensured that all critical instruments are calibrated as per O&M
schedule and also after every maintenance that affects the Contractor In
performance of the instrument. Charge
16 Calibration master list is updated as per the following
™ any new inspection, measuring & test equipments are
introduced;
™ there is a change in the permissible limits of the
O&M
calibration;
Contractor In
™ Obsolescence of any specific inspection, measuring and
Charge
test equipments
™ Change in the responsibility for performing the calibration.
The updated calibration master list is circulated to all
concerned.
 ANNEXURE ; 01
Calibration Mater List

Sr. Specification / Scope /

Particulars Range / Capacity Unit Qty. Frequency
No. Make / Vendor Activities

A. CGS
Nos. Calibration
Nos. Calibration
Nos. Calibration
1 Pressure Gauge Yearly
Nos. Calibration
Nos. Calibration
Nos. Calibration
2 SRV Nos. Resetting Yearly
UT,
3 KOD Nos. Certification Yearly
External
Yearly,
Temperature
4 Nos. Calibration as required
Transmitter
Yearly,
Pressure
5 Nos. Calibration as required
Transmitter
Differential
Yearly,
6 Pressure Nos. Calibration
as required
Transmitter
Differential
Yearly,
7 Pressure Nos. Calibration
as required
Transmitter
Temperature
8 Nos. Calibration Yearly
Gauge
UT,
Yearly
9 Filter Separator Nos. Certification
External Yearly
Hydrotest /
10 BA Set Set Yearly
Refill
Refill /
11 Fire Extinguisher Nos. Yearly
Inspection
B CPRS / DRS

Nos. Calibration

1 Pressure Gauge Nos. Calibration Yearly

Nos. Calibration
Nos. Calibration
 Nos. Calibration
2 SRV Nos. Resetting Yearly
UT,
3 KOD Nos. Certification Yearly
External
UT,
4 Filter Separator Nos. Certification Yearly
External
Refill /
5 Fire Extinguisher Nos. Yearly
Inspection

C. Service Regulator

1 Pressure Gauge Nos. Calibration Yearly

D. Emergency Vehicle
Refill /
1 Fire Extinguisher Nos. Yearly
Inspection
E. Control Room
Refill /
1 Fire Extinguisher Nos. Yearly
Inspection
F. Gas Detectors
Methane Meter
1 Nos. Calibration Yearly
(CH4)
Leak Surveyor
2 Nos. Calibration Yearly
Instrument
Oxygen Analyzer
3 Nos. Calibration Yearly
(O2)

Note: While preparing annual calibration schedule, hydro test of KOD, Filter
separator, Air Tank, BA Set, BDV, Fire Extinguishers etc to be considered after 5
years.
 ANNEXURE ; 02

Annual Calibration Schedule

Year: Page: _____ of_______

Number Of Instruments Planned Per Month

Instrument /
Sr. J F M A M J J A S O N D
Equipment Location
No. A E A P A U U U E C O E
Name & Tag
N B R R Y N L G P T V C

Prepared By Authorized By

O&M Contractor In-charge

 ANNEXURE ; 03

Monthly Calibration Schedule

Instrument /
Sr. Instrument Date Of Responsibility
Equipment
No. Location Calibration For Calibration
Name & Tag

Prepared By Authorized By

O&M Contractor In Charge

 ANNEXURE : 04

Monthly Calibration Report

Instrument /
Sr. Calibration Calibration
equipment Location
No. Done By Remarks
Name & Tag

Prepared By Authorized By

O&M Contractor In-charge

 ANNEXURE : 05

CALIBRATION HISTRY CARD

LOCATION:
Name of the Instruments: Instrument Tag No.:
Range: Acceptance Limit: Upper –
(Unit) Lower –
Instrument Location: Calibration Frequency:

Sr. Date of Calibration Calibration Work In Charge

Remarks
No. Calibration Detail done by Signature
3. Procedure for external examination / thickness test and hydro test of
knock out drum / filter separator

Sr. Responsibili
Activity steps
No. ty
1 Case 1: External Examination O&M
Contractor
It is ensured that every half yearly external examination of F/S, In Charge
KOD & LDS are carried out and report is received from
Competent
competent person as per Factory Act. Agency
2 Case 2 : Thickness Test O&M
Contractor
It is ensured that every half year Thickness of F/S & KOD Drum In Charge
is checked by Ultrasonic Instrument & report is received from
Competent
Competent person as per Factory Act. Agency
3 Case 3 : Hydro Test O&M
Contractor
It is ensured that every four years stability test of F/S KOD is In Charge
taken by hydro test & report is received from Competent person
Competent
as per Factory Act. Agency
4 For case of hydro test the job is carried out as per following O&M
In charge
steps.
5 As per Work Permit Coverage, Work Permit is obtained & O&M
In charge
Control room is informed about starting of job.
6 Appropriate PPEs are arranged and ensured wearing by O&M
In charge
working crew.
7 The section / line where F/S & KOD are installed are fully O&M
Team
isolated.
8 Gas of the isolated section is vented to depressurize the O&M
Team
section. Venting is carried out intermittently in a controlled
manner to prevent the accumulation of Methane beyond
20 % of LEL. The same is monitored in the downwind direction.
9 Nitrogen purging is done in that section to reduce methane O&M
Team
percentage to zero.
10 Top cover, inlet pipe piece & outlet pipe piece of F/S and KOD O&M
Team
 are unbolted and removed.
11 In case of KOD or LDS, internal cleaning is carried out, and O&M
Team
cleaning or replacing the filter element as required
12 Top cover is refitted after cleaning and checking of faces and O&M
Team
gaskets.
13 The connecting pipes are fitted back after unbolting the blind O&M
Team
flanges on the inlet, outlet and drain valves.
14 System is checked for leakage by pressure testing at 10 kg/cm2 O&M
Team
with N2 and applying soap solution at all the joints. If leak is
observed. It is arrested by tightening the bolts
15 N2 purging is again carried out to ensure oxygen percentage is O&M
Team
less than 2%.
16 If system is OK, N2 is removed and system is commissioned O&M
Team
with N.G.
17 All the joints are checked by soap solution once the pressure O&M
Team
rises to maximum operating pressure and ensured that there is
no leakage.
18 Waste material generated during maintenance work is collected O&M
Team
as per the following:
Š If waste is in the form of liquid, the same is collected in the
plastic container/barrel depending upon the quantities of
waste and the same is given back to the supplier;
Š If the waste is in the form of dust, the same is collected in
dustbin and disposed off at designated place.
19 Control Room is informed for completion of job. O&M
In charge
20 Work permit is signed off. O&M
In charge
21 Records are updated in Equipment History Cards (Refer O&M
In charge
Annexure -06 )
 ANNEXURE : 06

EQUIPMENT HISTORY CARD

NAME OF EQUIPMENT : EQUIPMENT NO:

LOCATION :
OTHER DETAILS:

Critical Work In
Date Of Maintenance
Sr. Pending Remark charge
Maintenance Activity Detail
Action Signature
3.11 Festival / Occasional Activity

1. General Information

2. About Diwali Festival Safety

3. About Holi Festival Safety

4. Action Plan for Diwali Festival Safety Activities

5. Action Plan for Holi Festival Safety Activities

1. General Information

Various festival and occasion celebration, by the customers and society have safety
impact on the installation / network of city gas distribution system.

The main festival that require more safety measures are Diwali holidays, and Holi
lighting. Burning of various type and size of crackers, poses fire and explosion
hazard in the domestic premises and distribution network located in the population
zones, if there exists a unnoticed gas leak. Even throwing burning / red hot crackers
on the transition fitting installed behind RCC guard, can damage the PE part of TF
causing gas leak, which may result into fire and explosion. Also primary fire due to
crackers on grass and dry vegetation around leaking gas can cause secondary fire
on installation / network.

Similarly during Holi festival, the spot where holi is lighted / burnt may cause damage
to underground PE pipe line, depending up on the spot location from underground
PE, size and time duration of Holi burning.

Hence for ensuring safety and integrity of people and network, special festival safety
drive is taken up, in advance, just before the festival. And special, petrol and survey,
including the public announcement for safety precautions are carried out during the
days of actual celebrations. Special safety and security watch are also provided for
critical and vital installations, by a dedicated team of persons.
2. About Diwali festival safety

As shown below, for Diwali Festival, such drive mainly includes the leak survey of
installation , network, lock pressure test of network, likely to be affected, customer
education through various media, and ensuring readiness of emergency vehicle,
along with gas detectors, communication means, fire fighting equipments, public
address system, and tools tackles. Even it is ensured, that competent O &M persons
and responsible management persons as per Emergency Response Team are
available during such festival holidays.

3. About Holi festival safety

For Holi Festival, pre Holi survey is carried out by visiting all the known spots of Holi
Burning. For old spot locations previous years’ records are referred and every time,
new spots are added in the list as found during visits and survey. In some cases of
suspicion of likely damage to underground PE, society / street leaders are requested
for shifting the spot to a safe place. Similarly some doubtful / vulnerable spots are
revisited for leak survey, next day after holi burning.
 Action Plan For Diwali Festival safety activities.
days from -------------

Sr. Responsibi
Activity Detail Date Remarks
No. lity
A Pre Diwali Activities
Identify the competent persons and
1 prepare the action plan to carry out the
activities on scheduled date and time.
Review / recall of previous years’ records
and experience, in handling festival and
2
modify / update the current year’s
planning / procedure accordingly
3 Organize Tool Box training for all O&M,
persons, for explaining every one’s role &
responsibility in the various activities and
safety precautions during Diwali holidays.
Carry out lock pressure test of the PE
4
network.
Carry out leak detection survey on PE
5 network, especially, on critical and
vulnerable section / network.

Carry out Leak check and cleaning /

6 removing combustible material like paper,
rags, grass, etc... In and around CGS,.

Carry out Leak check and cleaning /

removing combustible material like paper,
7
rags, grass, etc... In and around valve
chambers and service regulators
 Confirm, adequacy of smell in the gas
supply, by sending the persons, for smell
8
check, in different sectors and studying
the no. of smell complaints received.

Ensure that wireless equipments and gas

9 detectors are in working condition and
their batteries are charged.
If possible, arrange to issue notification
from Police Commissioner, for 100 meter
restricted area, for fire cracking around

10 CGS / CNG station.

Similar notification issued by Surat Police

commissioner as printed in Gujarat Mitra,
news paper dated 06/10/2006
Provide 2 nos. of water buckets, mug,
plastic barrel, full with water for
11 extinguishing burning fire crackers
accidentally falling in the CGS fenced
area.
Provide a wireless hand set or mobile to
12
security guard at CGS.
Carry out Inspection / Servicing of fire
13 extinguisher provided at CGS /
Maintenance van, to ensure their working.
Train /educate the security guards posted
at CGS, during Diwali days for,
1. Watch in and around CGS,
2. Wireless operation,
14
3. Extinguishing burning fire crackers / fire
rockets with the help of water buckets.
4. Operation / use of fire extinguishers.
5 How to contact / whom to contact, in
 case of emergency.

Preparation and submission of shift

15 schedule, of O&M manpower planned,
during Diwali days.

Ensuring availability of company senior

16
person, as per ERP team. during holidays

Preparation and circulation of telephone

nos. of essential persons of O&M
17
Contractor and GSPC Gas available
during Diwali days.
Leak check of all flange / tube joints of
CGS.
18 Cleaning / removing of all combustible
material like grass, paper, rags, etc...In
and around CGS.
Diwali Mubarak / Nutan Varsha
Abhinandan letter /News paper insert, in
Gujarati may be written to customers,
19 which may cover, apart from Diwali and
new year wishes, general gas related
safety and special precautions during
Diwali days, while using crackers.

Display on local TV cable network for

20 message for Diwali Mubarak / Nutan
Varsha Abhinandan along with gas safety.

Pre Diwali announcement to the

21 customers, where PNG network exists, for
safety precautions, while burning crackers.

Co-ordination / liasioning with other

22 utilities / local authorities for halting
excavation activities during festival days.
 Planning of food / snack, for O&M persons
23 and retirement facility, for persons working
for stretched hours, during holidays.

B Activities during Diwali days

Patrolling on network, especially on critical

and vulnerable section / area, along with
public announcement, during fire cracking
24
hours, i e, 20:00 hours to 24:00 hours on
Diwali days from Dhan Teras, Kali
Chaudas, Diwali, New year, Bhai Bij.

Checking and security / safety at CGS at

25
regular intervals, during fire cracking days.

C Post Diwali activities

Preparing report and updating records,

along with near miss, hazard reporting,
26
and lesson learning, if any for sharing with
others.
 Action Plan
for Holi Festival safety ON--------

Sr.
Activity Detail Date Responsibility Remarks
No.

A Pre Holi Activities

Identify the competent persons and

1 make a Task Force for carrying out the
various Holi festival activities,
Review / recall of previous years’
records and experience, in handling
2
festival and modify / update the current
year’s planning / procedure accordingly
Prepare the action plan to carry out the
activities on scheduled date and time.
3 Including arranging food / snacks for
persons busy working on Holi burning
day.
Organize Tool Box training for all O&M,
persons, for explaining every one’s role
4
& responsibility in the various activities
and safety precautions.
Carry out the pre Holi survey to confirm
old spots and identifying and adding
new spots of Holi burning, along with
briefing residents about safety
5
precautions and emergency contact
nos.
At some spots, requesting residents to
shift the spot away to a safe place.
 Ensure that senior management person
6 is available as per ERP team, on the
Holi burning day.

Ensure that wireless equipments /

mobile phones and gas detectors are in
7
working condition and their batteries are
charged.

B Activities on the day of Holi burning

Patrolling on the network population,

especially on critical / vulnerable spots,
and briefing residents about safety
precautions and emergency contact
8
nos. and remain alert and ready to
handle the emergency, if it occurs,
during the Holi burning hours from 18
hours to late night.
During patrolling, remain in contact with
9 control room, for receiving smell / leak
complaints from customers.

C Post Holi Activities

Next day or day after, carry out the post

Holi survey for leak detection on critical /
10 vulnerable spots, for confirmation that
no damage has occurred to our
underground PE pipe.
Prepare the report and update the
records, along with near miss and
11
hazard reports and lesson learning, if
any.
3.12 Safe Guarding Of Pipe Lines from Third Party

The intent of this chapter is to give working guidelines for those who are engaged in
safeguarding of gas pipe lines. Natural gas supplied through the network of city gas
distribution, is highly inflammable and gas escape from the damaged pipe may pose
the potential hazards of asphyxiation, fire and explosion. The PE pipes used for
underground gas network are softer, delicate and highly susceptible, vulnerable to
damage when hit by excavating tools used during manual and / or mechanical
excavation. Similarly, the excavation carried out by mechanical equipments like, JCB
and sometimes manual excavation may damage the underground steel gas
pipelines, or it’s corrosion protection coating, which in turn, leads the pipe failure due
to corrosion, with the lapse of time, if coating is not repaired in time.

Hence it is quite safe and economical to prevent the damage to the pipe lines, rather
than repairing the damaged / leaking pipe. Hence the safe guarding of underground
gas pipe lines from damage is very important activity, considering safety of public at
large and for ensuring safe and uninterrupted gas supply to the customers.

The excavation activities are mostly carried out by other utilities, mainly, water
department, drainage department, road and building departments of Municipal
Corporation of the city or Nagarpalika of a town, BSNL, OFC cable layers, electricity
power supplier, and sometimes by customers.

Various pipe lines safe guarding activities are planned based on, the size and
spread of the underground pipeline network, current & planned infrastructure
developmental activities by all listed utilities, and past experience & records, and
They are executed by deploying competent persons after imparting trainings.
The training tropics mainly focus on,
• Natural gas and it’s properties,
• Hazards of gas escape,
• Causes of pipe line damages,
• Pipe line net work and geography of network spread,
• Understanding as built network drawing
• The site supervision and liasioning,
• Oral instructions and written communication with other utilities.
• Issuing warning notice and damage recovery to excavating agencies, in case
of damage and gas escape.
• Name and contact nos. of excavating agencies and their area of work
• Future excavations plan by other utilities.

Liasioning and coordination with other utilities, for providing gas pipeline network
drawing, company’s emergency contact nos. and providing assistance and site
supervision in safe guarding gas pipe line while they carry out the excavation

The safe guarding of gas pipe lines from damage by manual excavation is easy and
safe, where as safe guarding pipelines during mechanical excavation needs extra
precautions and preparedness and continuous site supervision. It is therefore
advisable to request the excavating agency to carry out the manual excavation in
close proximity of gas pipe lines and critical areas.

Special instructions should be given to the excavating contractors and labours for
reporting the incidental damage / gas leak and warned / penalized for hiding the
damage and gas leak. The hidden leak can become the hazard any time.

Rerouting, shifting and lowering and supporting the hanging pipelines / section are
the activities sometimes associated with safeguarding.

If required the awareness program should be arranged for excavating contractors,

especially for those who have mass excavation and frequently damaging the
pipeline.
3.13 Modifications / Up-gradation

The intent of this chapter is to explain the terms and provide minimum guidelines.

Modification is a term used for the activity of changing the existing plant layout,
process and equipment. Modification may be carried out during initial installation, in
the running plant, after certain experience of operation and maintenance, to meet the
intended output and performance, to enhance quality and safety, to improve process,
layout, operation and maintenance.

Modification should be planned after considering various pros and cons. Cost /
benefits, visible safety and quality improvements. Modification should be decided,
planned and executed by a team of experts drawn from concerned departments.

Modification carried out should be reviewed to understand and study deviation from
intended performance / output. The intended performance of modification carried out
must have reasonable period of validity and should not become non operational
before time.

Modification in gas charged network should be carried out as per safe procedure and
safe practices, after obtaining work permit.

Up gradation is the activity of adding / replacing the existing material / components/

pipes / fittings, with new, better material / item to improve the current level of
performance of whole system with ref. to time / safety and quality, based on the
operation and maintenance experience and review of network performance and
integrity.

After a period of operation, in the city gas distribution network, certain material /
items are found failed or about to fail or obsolete. Hence they need to be replaced by
new substitute item to upgrade the whole network / system.
Upgradation should be planned after considering various pros and cons like cost /
benefits, asset & operation integrity, safety & quality improvements. Upgradation
should be decided, planned and executed by a team of experts drawn from concern
departments.

Upgradation carried out should be reviewed to understand and study deviation from
intended performance / output. The intended performance of Upgradation carried out
must have reasonable period of validity and should not become non operational
before time.

Upgradation in gas charged network should be carried out as per safe procedure
and safe practices, after obtaining work permit. For mass or large up gradation job,
separate competent contractor should be engaged for completing the Upgradation in
scheduled time with safety and quality.
 Typical Up-gradation format

Network up-gradation

Sr. Proposal Reason / Activity need to be Cost of

Benefit
No. detail Purpose carried out activity

Justification and Costing of Network Up-gradation Points

Material requirement:

Sr. Qty. Cost Total

Item Description Remark
No. (Nos.) (Rs.) Cost
3.14 Inspections / Audits

General Information :
In a City Gas Distribution system, various operation and maintenance activities have
being carried out by Company and Contractors on regular bases, to ensure safe and
uninterrupted gas supply to customers and safety, security and integrity of network.
However the safety audit and inspections by third eye like safety engineer /
professional should be planned and executed regularly to know the availability
adequacy, compliance and effectiveness of control programs for ensuring safe
conditions and safe practices. The audit, inspection should be planned with special
focus on HSE, Integrity of system and statutory, legal Compliance. These kinds of
program facilitate to identify the unsafe conditions and unsafe practices, the causes
for accidental losses, and thus ensure incident free operations and healthiness of
distribution system.

There are two type of Safety Audit & Inspection, External and Internal. External audit
are carried out mainly for statutory requirements. Internal audit are carried out on
need base or as planned. Need base audit & inspection is normally carried out after
incident, mishaps or malpractices during day to day activities.

Audit & Inspection has long been an accepted management practices to ensure that
critical business operation are performed in an efficient and profitable way.

Inspection is defined as monitoring function conducted in the organization to locate

and report existing and potential hazards which have the capacity to cause accidents
in the workplace.
The objectives of safety inspection are,

• To find out hazards, accidents causes (unsafe conditions and actions)

losses and appropriate remedial measures for their prevention and control

• To maintain safe work environment, operational profitability and control

unsafe actions of people

• To check statutory provisions of the factories act and similar other safety
status

• To check the effectiveness of the existing systems and to find

improvement if required for the purpose of Total Loss Control

• To check the quality control, product safety good manufacturing practice,

wear & tear, corrosion, tests and also personnel selection

• To gain workers confidence in organized human activity and factory life

Safety Audit is a critical examination of all or part, of a total operating system with
relevance to safety. Safety audit is a more systematic and detailed safety
inspections. It is used to assess the overall standard of safety performance or to
evaluate the safety implications of the inspections and test. A Safety Audit concerns
each area with the object of minimizing the losses. The objective of safety audit is to
assess & ensure safety and integrity of overall CGD System and O&M.
2. Procedure for Safety Inspection and Audit of City Gas Distribution System

Sr. Activity Steps Responsibility

1 At the beginning of year, planning shall be carried out as O&M Contractor
per Annexure – 01, for Safety Audit and Inspection and In charge
consent shall be taken from GSPC Gas. Monthly Audit &
Inspection schedule shall be prepared for execution.
2 Safety Inspection of Domestic / Commercial Connection Safety Engineer
shall be carried out as per format shown in Annexure - 02
3 Safety Inspection of Service Regulator shall be carried Safety Engineer
out as per format shown in Annexure - 03
4 Safety Inspection of Valve Chamber shall be carried out Safety Engineer
as per format shown in Annexure - 04
5 Safety Inspection of Emergency Vehicle shall be carried Safety Engineer
out as per format shown in Annexure - 05
6 The findings of safety inspection shall be discussed with Safety Engineer
Work In charge in presence of O&M Contract In Charge
and copy of reports shall be submitted for actions
7 Action shall be initiated to close the findings of Safety Work In Charge
Inspection. The Action Taken Report and Status of Safety
Inspection Finding shall be submitted to GSPC Gas
through O&M Contractor In Charge. This can be
incorporated in Monthly Activity Report.
8 Joint Audit of City Gas Distribution O&M with GSPC Gas O&M Contractor
shall be carried out as per Annexure -06 annually to In charge
identify safety and integrity issue of CGD System.
9 The need base audit & inspection shall be carried out O&M Contractor
based on the requirement of the incident happened and In charge
improvement needed.
 ANNEXURE - 01
Annual Planning for
Safety Inspection and Audit

Safety Inspection
Joint
Safety Emergency CPRS / Dom / Comm Valve
Month Audit Vehicle DRS Connections Chambers
Nos.
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
 ANNEXURE - 02

Safety Inspection Report for

Domestic / Commercial Connections
Customer No. : Report No. :
Customer Name & Address : Date of Audit :

Sr. Description Observation

No.
1 LEAKAGE
2 GROUND CONNECTION
2.1 Exposure of PE pipe
2.2 Fixing / clamping of RCC guard
2.3 Damage to RCC guard
2.4 Buried RCC guard
3 ISOLATION / CONTROL VALVE
3.1 Valve operation (Smooth / Hard)
3.2 Sign of corrosion on body
3.3 Condition of lever of valve.
3.4 Fixing of lever ( Loose / tight )
4 REGULATOR
4.1 Corrosion on Adapter
4.2 Corrosion on body
4.3 Corrosion on fasteners / sealing band.
5 GAS METER
5.1 Corrosion on Boss
5.2 Corrosion on adopters
5.3 Corrosion on body
5.4 Corrosion on fasteners / sealing band
 Safety Inspection Report for
Domestic / Commercial Connections

Sr. Description Observation

No.
6 G.I. PIPE
6.1 Paint coverage (on length of pipe)
6.2 Dis-bonding of coating
6.3 Post installation construction above pipe.
6.4 Condition of pipe at wall crossing
6.5 Corrosion on pipe
6.6 Corrosion on fitting
7 PIPE SUPPORT
7.1 Condition of clamp
7.2 Clamp fixing on wall
7.3 Adequacy of clamp quantity (pipe hanging
without clamp)
7.4 Fixing of top clamp with chease head screw.
8 GAS TAP
8.1 Gas Tap operation ( Smooth / Hard)
8.2 Overall condition of Gas Tap (Black / Shining –
if brass material)
8.3 Fixing of lever ( Very loose / Tight )
8.4 Condition of Lever (Good / Corroded)

Inspected By: Name & Signature

 ANNEXURE - 03

Safety Inspection Report for

Service Regulator
Date of Inspection:

SR No Location

Sr. Description Observation

A Outside Condition
1 Approach / Encroachment
2 Fencing & Security
3 Display of Emergency Contact
Numbers Caution Board
2 Vent Pipe Location
3 Painting Condition
4 Any Damage
B Inside Condition
1 Gas leak
2 Cleaning
3 Painting
4 Valve Operation
5

Inspected By : Name & Signature

 ANNEXURE - 04

Safety Inspection Report for

Valve Chambers
Date of Inspection :

V / C No Location

Sr. Description Observation

A Outside Condition
1 Encroachment
2 Damage to Cover, Corner
3 Painting
4 Tag Nos.
B Inside Condition
1 Gas leak
2 Cleaning
3 Painting / White Wash
4 Tag Nos.
5 Valve Operation

Inspected By : Name & Signature

 ANNEXURE - 05

Safety Inspection Report for

Emergency Vehicle

Observation of
Sr. DESCRIPTION SIZE Nos.
Nos. & Condition
1 Base Wireless in Vehicles 1
Intrinsically Safe Portable
2 Wireless 1
DCP TYPE FIRE
3 EXTINGUISHER 5.0 kg 2
L.C
Calibrated GAS DETECTORS 1%
4 LEL 2
1/2
Public Announcement System 1
5 MILE
6 Gum Boot PAIR 2
7 Fire Retardant Suit 2
8 Reflactory Jacket 2
9 Industrial Safety Helmet 2
10 First Aid Box with listed items 1
Overall Network Drawing With
1
11 All VALVE CAHMBER Details
12 Flameproof Torch 1
13 Normal Torch 1
Valves of all size valves
(Prepare list as per type & size
14 of valves) 1 set
Pipe Pieces For Leverage to
15 Operate Valve 2
Vent Pipe 3 meter long (Review 1/2" x
16 based on size of vent valves 3m 1
 and outlets)

Leak Clamps (Set) ( Prepare list

17 3 set
as per type & size of pipes)
Squeeze Tools ( Prepare list as
18 3 set
per type & size of pipes )
19 Hydraulic Squeeze Tools 2 set
Tool Box (Review List base on
20 requirement)
21 Spanners SET 1
22 Brass Hammer 1 KG 1
23 Brass Wedges 1
Brass Wire Brush 6" x 1" 1
Screw Spanner 6" , 8" 2
8" ,
Pipe Wrench
12" 2
Hacksaw with blade. 1
Chisel 8" 1
24 PE Pipe Cutter/saw. 1
25 Teflon Tape ROLL 5
0 - 4,
Calibrated Pressure Gauge 0-14
26 bar 1 each
Welding Mirror Set with
27 controller. 1
28 Electrofusion welding Unit 1
Electro Fusion Couplers /
saddles & supporting clamps (
Prepare list as per type & size of
29 pipes ) 1 set
30 Screw Jack With Tomy Bar 1
 Pipe Thread Dye set with 1/2",
31 wrench. 3/4",1" 1
6, 10
Gas Tap
32 mm 3
33 NP Cap 5
34 Neoprene Rubber Tube 1
35 CAF -Full Face Gasket - 3 Mm 1" 4
36 CAF - Ring Gasket - 3 Mm 1" 4
37 Grease Stick Box Set 1
Regulator Adapter
2 each
38 (Dom & Com.)
O ' Ring For Meter cap and
39 liner 6
40 O' Ring For Regulator 6
41 Excavation Appliances
Trikam, Pawda, Tagara 1 set
PE Pipe / Fittings (Prepare
list as per type & size of
42 pipelines / network)
Each
0.5 Meter Long Pipe pieces.
Size 01 set
Each
Equal Tee
Size 01 set
Each
Transition Fittings
Size 01 set
Each
Coupler
Size 01 set
Each
Electrofusion Reducer coupler
Size 01 set
Each
90 Deg. Elbow coupler
Size 01 set
 G.I. Pipe / Fittings (Prepare list
as per type & size of pipelines /
43 network)
Hex Nipple 1/2 '', 1” 3 each
Equal Tee 1/2 '', 1” 3 each
Elbow 1/2 '', 1” 3 each
Union 1/2 '', 1” 3 each
Ball Valve / Plug Valve 1/2 '', 1” 3 each
Cap 1/2 '', 1” 3 each
Plug 1/2 '', 1” 3 each
Coupling 1/2 '', 1” 3 each
1'' X
Tee
1/2'' 1
1” X 1/2
Reducer
'' 1
½” X 3”
Nipple
6”' 3

Inspected By : Name & Signature

 ANNEXURE – 06
SAFETY AUDIT REPORT

Rating Description
1. Dangerous- against compliance with standards. Urgent attention required.
2. Unsafe - does not comply with standards. Remedial action required.
3. Minimum compliance with standards. Need's modification.
4. Exceeds minimum compliance with standards with further improvement possible.
5. Best practice - no further improvement possible.

CGD Area / Location : _________________________

Name of O&M Contractor : _________________________

Sr.
Description
No.

A Safe Procedures & Practices 1 2 3 4 5

Written Procedures for O&M Jobs

Compliance with “Work Permit System”
Nearmiss, Hazard and Accident / Incident reporting
system and it’s compliance
Accident Investigation and Lesson Learnt /
Implemented
Use of Safety items like gas detectors, fire
extinguishers & it’s condition
Use of appropriate PPEs & it’s condition
Use of communication equipment like cell phones,
flameproof wireless handset, public address system
and it’s condition
Use of Barricades & Safety Signage
B Employee Competency 1 2 3 4 5

Induction / Course Training.

Effective Communications.
Knowledge of NG and CDG activities
 Knowledge of HSE aspects of Job
Knowledge of respective jobs
Knowledge of Emergency Procedure.
Knowledge of First Aid
Nos of training program conducted
Certification of participants
C Safe Work Place 1 2 3 4 5

Clean / tidy work areas.

Clean / tidy offices.
Clean / tidy store.
Clean / tidy lunchroom.
Clean / tidy toilet facility.
Adequate washing facilities.
Noise levels.
Safe access to the site.
D Safe Tools & Equipment 1 2 3 4 5

Appropriate for job.

Sufficient for all jobs.
Adequately maintained.
Record of maintenance in serviced / log books
Handling of defective / damaged tool

E Security 1 2 3 4 5

Office security
Office Lighting.
After duty hours security.
Security of stores / sheds
Security of tools / equipment.

_______________________ ____________________
O&M Contractor In-charge GSPC GAS O&M In Charge
3.15 Preparation / Preservation / Updating Drawings / Records

Preparation / preservation / updating Drawings / Records

Drawings and records preparation and preservation have their own importance for
site reference during normal and emergency repair maintenance and safe guarding
efforts. Many a time’s drawings and records are demanded for statutory and legal
compliance. Following procedure is suggested for drawings and records

New Drawings
On the basis of measurement / specification, drawings are prepared and their
numbers are given as per Drawing Codification Scheme.

Drawings are verified against specified requirements and approved.

Approved drawing list for the department is prepared and sent to concerned persons.

“Controlled Copy” Stamp is put on the drawing as well as on the approved drawing
list and the list is returned back to concerned persons.

The approved & controlled drawing is given to the concerned user department

Approved Drawing List for the location is updated.

Modification / change in the drawings

In case of modifications in network, the necessary changes in the existing drawing
are made.

Changed drawing is verified for specified requirement and approved.

The Revision No. in the drawing is incremented and approved drawing list is updated
and forwarded to concern person for taking necessary actions.

“Controlled Copy” Stamp is put on the drawing and also on the approved drawing list
and the same is returned back to the concerned person.

If the entire drawing is changed then obsolete copies are destroyed or obsolete copy
stamp is marked on drawing.

Approved Drawing List for the location is updated. (Ref. Doc. GEN449)

If any person related to the organisation needs drawing for their reference then copy
of such drawings are marked with “Uncontrolled Copy” stamp and the same is issued
to concerned person and uncontrolled drawing register is updated.
 CHAPTER – 3 B
CRITICAL TASKS

3.15 Handling Gas Leak / Network Damage

3.16 Attending Gas Smell / Leak Complaint In
Domestic Connection
3.17 Commissioning & De-Commissioning Gas
Pressurization / Depressurization, Venting,
Draining & Purging
3.18 Valve Chamber Maintenance
3.19 Patrolling & Surveys
3.20 On Line Functional Test of Gas Stream Valves
3.21 On Line / Repair Maintenance of Service
Regulator Valves
3.22 Odorant Handling – Storage, Local
Transportation & Disposal
3.23 Odorant Transfer from Barrel To Storage Tank
General Information

3.15 Handling Gas Leak & Network Damage

3.16 Attending Gas Smell / Leak Complaint In Domestic Connection

3.17 Commissioning & De-commissioning Gas Pressurization /

Depressurization, Venting, Draining & Purging

3.18 Valve Chamber Maintenance

3.19 Patrolling & Surveys

3.20 On Line Functional Test Of Gas Stream Valves,

3.21 On Line / Repair Maintenance Of Service Regulator Valves

3.22 Odorant Handling - Storage, Local Transportation & Disposal

3.23 Odorant Transfer from Barrel to Storage Tank

1. General Information :

In City Gas Distribution System, there are certain activities, which have the potential
to produce major loss to people, property, process and / or environment, if not
performed properly. Hence to control and mitigate the risk associated with such task,
as shown below, the whole task is carried out by established procedures and safe
practices, by the competent person having gone through proper training and
education,

1. Listing / inventory of task / activities,

2. Identify the critical Tasks,
3. Analyze the critical tasks,
• Break task down into steps,
• Pinpoint loss exposure, ( people / equipment / material / environment)
• Make an efficiency check, (Loss Control/ production / quality )
• Develop controls, (procedures / safe practices / PPEs / motivation)
4. Write procedures and practices,
5. Put to work,
6. Update and maintain records.

For our City Gas Distribution System, following are the critical activities identified as
critical task.