BASIC CONCEPTS OF DESIGN AND CONSTRUCTION OF CITY GAS

DISTRIBUTION NETWORK

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

OVERVIEW OF CITY GAS DISTRIBUTION

 CGD IS THE LAST COMPONENT OF THE NATURAL GAS

VALUE CHAIN DELIVERING NATURAL GAS TO END
USERS IN TOWNS AND CITIES TO MEET THE DEMAND
FOR CLEANER, MORE EFFICIENT, ECONOMICAL &
ENVIRONMENTAL FRIENDLY ENERGY SOURCE.

 THE SUPPLY OF NATURAL GAS TO A CITY OR

GEOGRAPHICAL AREA IN INDIA IS GOVERNED BY
PETROLEUM AND NATURAL GAS REGULATORY BOARD
(PNGRB)

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

PETROLEUM AND NATURAL GAS REGULATORY BOARD

PNGRB WAS CONSTITUTED ON 31ST MARCH 2006 TO

REGULATE THE REFINING, PROCESSING, TRANSPORTATION,
DISTRIBUTION AND MARKETING OF PETROLEUM PRODUCTS
AND NATURAL GAS . IT EXCLUDES PRODUCTION OF CRUDE
OIL AND NATURAL GAS.
PNGRB CARRIES OUT THE FOLLOWING ACTIVITIES FOR
LOCAL NATURAL GAS DISTRIBUTION :
 AUTHORIZING ENTITIES TO BUILD, OPERATE OR
EXPAND CITY OR LOCAL NATURAL GAS
DISTRIBUTION NETWORK.
 DETERMINATION OF NATURAL GAS TARIFF
 DEVELOPING ACCESS CODE

CONT…
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 CAPACITY DETERMINATION OF STEEL PIPE NETWORK

 ENSURING INTEGRITY MANAGEMENT SYSTEM

 ENSURE CODE OF PRACTICE FOR QUALITY OF SERVICE

 COMPLIANCE TO TECHNICAL STANDARDS AND

SPECIFICATIONS INCLUDING SAFETY STANDARDS

 ENSURE FAIR PRACTICES AND COMPETITION AMONGST

THE CGD ENTITIES.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

SOME MAJOR GAS SUPPLY SOURCES IN INDIA

 APM (ADMINISTERED PRICING MECHANISM) GAS

FROM TRADITIONAL FIELDS OF STATE PSU (PUBLIC
SECTOR UNDERTAKINGS)

 PMT ( PANNA MUKTA TAPTI ) GAS

 RLNG (RE-GASIFIED LIQUED NATURAL GAS) IMPORTS

 KG (KRISHNA GODAVARI) BASIN GAS FROM PRIVATE

PLAYERS

 CBM (COAL BED METHANE) GAS

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
SOME MAJOR CGD COMPANIES IN INDIA
 MAHANAGAR GAS LIMITED (MGL) : JV OF GAIL (INDIA)
LTD, BG GROUP, (U.K.) AND GOVERNMENT OF
MAHARASHTRA.
 SABARMATI GAS LIMITED (SGL) : JV OF BPCL AND GSPC.
 INDRAPRASTHA GAS LIMITED (IGL) : JV OF GAIL AND
BPCL
 AVANTIKA GAS LIMITED (AGL) : JV OF GAIL AND HPCL
 BHAGYANAGAR GAS LIMITED (BGL) : JV OF GAIL AND
HPCL
 CENTRAL UTTAR PRADESH GAS LIMITED (CUGL) : JV OF
GAIL AND BPCL.
 GAIL GAS : A WHOLLY OWNED SUBSIDIARY OF GAIL
(INDIA) LIMITED.
 ADANI GAS: ADANI GAS IS A WHOLLY OWNED
SUBSIDIARY OF THE ADANI ENTERPRISE LTD (AEL).
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
 GUJARAT GAS COMPANY LIMITED (GGCL):
PROMOTED BY GUJARAT GOVERNMENT AND MAFATLAL
GROUP.
 GUJARAT STATE PETROLEUM CORPORATION LIMITED
(GSPC GAS): A WHOLLY OWNED SUBSIDIARY OF THE
GSPC GROUP.
 GREEN GAS LIMITED: JV OF GAIL AND IOCL.
 HARYANA CITY GAS DISTRIBUTION LIMITED (HCG) : A
COMPANY PROMOTED BY SKN- BENTEX GROUP OF
INDUSTRIES.
 MAHARASHTRA NATURAL GAS LIMITED (MNGL): JV OF
BPCL, GAIL WITH THE GOVT. OF MAHARASHTRA.
 TRIPURA NATURAL GAS COMPANY LIMITED (TNGCL) : JV
OF TIDC LTD. [A GOVT. OF TRIPURA UNDERTAKING],
AGCL [A GOVT. OF ASSAM UNDERTAKING] AND
GAIL.
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

OVERVIEW OF CITY GAS DISTRIBUTION

THE SUPPLY OF NATURAL GAS AS FUEL TO THE

FOLLOWING SEGMENTS IN A CITY OR GEOGRAPHICAL
AREA IS TERMED AS CITY GAS DISTRIBUTION :
 DOMESTIC CONSUMERS- HOUSEHOLDS FOR COOKING
AND WATER HEATING
 COMMERCIAL CONSUMERS-HOTELS, RESTAURANTS,
HOSPITALS, MALLS, BAKERIES, SCHOOLS ETC.
 INDUSTRIAL CONSUMERS - MEDIUM & SMALL
INDUSTRIES USING FUELS LIKE LPG, HSD, LDO,
FURNACE OIL, COAL ETC. ( LIMITED TO 50,000 SCMD )
 AUTOMOBILE CUSTOMERS- CITY AND SCHOOL BUSES,
PRIVATE CARS, TAXIS, AUTO-RICKSHAWS, VANS ETC.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

STEPS IN THE DESIGN OF GAS DISTRIBUTION SYSTEM

 ESTIMATION OF MARKET DEMAND, BASED ON

COMPREHENSIVE FIELD SURVEY OF UNITS COVERING
DOMESTIC, COMMERCIAL, INDUSTRIAL AND TRANSPORT
SECTORS.
 DEMAND FORECAST CARRIED OUT FOR 25 YEARS, CHARGE
AREA WISE.
 RECONNAISSANCE ROUTE SURVEY TO IDENTIFY SUITABLE
ROUTES FOR LAYING PIPELINES, LOCATIONS FOR CITY GATE
STATION, DISTRICT REGULATING STATION & CNG STATION
 PEAK HOUR CONSUMPTION ESTIMATED FOR NETWORK
DESIGN.
 THE SYSTEM IS DESIGNED BASED ON 25TH YEAR DEMAND AT
PEAK LOAD IN A PHASED MANNER.

CONT…
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 NETWORK DESIGN AND OPTIMIZATION OF PIPELINE SIZE IN

SOFTWARE LIKE PIPELINE STUDIO / GAS WORKS / SYNERGY
ETC.
 DESIGN OF MOTHER STATION, ON LINE STATION AND
DAUGHTER BOOSTER STATION FOR CNG SUPPLY TO
AUTOMOBILES.
 NATIONAL / INTERNATIONAL STANDARDS ADOPTED FOR
DESIGN.
 PROJECT IMPLEMENTATION DONE SUBSEQUENTLY.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

CGD - INFRASTRUCTURE
MAJOR CONSTITUENTS OF CGD ARE :

 CITY GATE STATION LOCATED AT OUTSKIRTS OF THE

CITY
 PRIMARY NETWORK
STEEL PIPELINE NETWORK OPERATING BETWEEN 49 – 7
BAR
 SECONDARY NETWORK
POLYETHYLENE PIPELINES OPERATING BETWEEN 7 BAR
TO 100 MBAR
 TERTIARY NETWORK
GI / CU PIPES OPERATING AT LESS THAN 100 MBAR

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 DISTRICT REGULATING STATIONS ( DRS )

 METER REGULATING STATIONS ( MRS )
 SERVICE REGULATORS
 DOMESTIC AND COMMERCIAL REGULATORS AND
METERS
 CNG STATIONS

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
 CITY GAS DISTRIBUTION
CGD PRESSURE REGIMES
SR. NETWORK INLET
INLET FROM OUTLET PRESSURE OUTLET TO
NO. COMPONENT PRESSURE
TRANSMISSION
1 CGS 99 - 60 BARG 26 BARG STEEL GRID
LINE
2 STEEL PIPELINE CGS 26 BARG 26 – 14 BARG DRS / CNG

3 DRS STEEL PIPELINE 26 – 14 BARG 6/4 – 1 BARG MP MDPE PIPELINE

SERVICE
4 REGULATORS MDPE PIPELINE 6 / 4 – 1 BARG 110 MBARG LP MDPE PIPELINE
(SR)
INDL. MRS & COMM.
5 MDPE PIPELINE DRS 6 / 4 BARG 6 / 4 – 1 BARG
CONNECTIONS

REGULATOR OF
MDPE / GI / CU
6 SR 110 MBARG 110 – 50 MBARG DOMESTIC /
PIPELINE
COMM.CONNECTIONS
1.5 BARG OR
INDUSTRIAL MDPE PIPELINE 6 / 4 – 1.5 BARG CUSTOMER SPECIFIC
7 INDUSTRIAL PIPELINE
MRS STEEL PIPELINE 26 – 14 BARG PRESS. WITHIN THE
SUPPLY RANGE
ONLINE/
VEHICLE AT 200
8 MOTHER CNG STEEL PIPELINE 26 - 14 BARG 250 BARG
BARG
STATION
DOMESTIC MDPE / GI / CU
9 110 – 50 MBARG 21 M BARG METER & GAS STOVE
CONNECTIONS PIPELINE
75 MBARG OR
MDPE / GI / CU 110 – 75 MBARG
COMMERCIAL CUSTOMER SPECIFIC
10 PIPELINE 6 / 4 – 500 METER & GAS STOVE
CONNECTIONS PRESS. WITHIN THE
MDPE PIPELINE MBARG MECON LIMITED
SUPPLY RANGE A House of Engineering Excellence
CITY GAS DISTRIBUTION

CITY GATE STATION (CGS)

 CGS IS THE LOCATION OF CUSTODY TRANSFER FROM

TRANSMISSION COMPANY TO DISTRIBUTION COMPANY.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
CITY GATE STATION (CGS)

IT IS THE ENTRY POINT OF NATURAL GAS FROM A SUB-

TRANSMISSION HIGH-PRESSURE GAS PIPELINE TO A CITY /
GEOGRAPHICAL AREA CONSISTING OF.

 KNOCK OUT DRUM (KOD) FILTER (CARTRIDGE)

 METERING UNIT (TURBINE / ORIFICE / ULTRASONIC)
 GAS CHROMATOGRAPH (GC)
 PRE-HEATER (IF REQUIRED)
 PRESSURE REDUCTION SKID COMPRISING
ACTIVE & MONITOR REGULATORS WITH MINIMUM
50% REDUNDANCY,
 SLAM SHUT VALVE , OVER & UNDER PRESSURE
PROTECTION, CREEP RELIEF VALVES.
 ODORISING UNIT

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

PRIMARY NETWORK ( underground Steel Pipeline )

Design Parameters :
– Design Pressure : 49 Kg/cm2(g)
– Max. Op. Pressure, kg/cm2(g) : 17 - 32 kg/cm2
– Design Temperature : – 29°C to 60 °C
– Joint Factor : 1
– Population Density Factor : 0.4 (Class IV)
– Design Life : 30 Years
– Corrosion Allowance : 0.5 mm
– Pipeline Efficiency/ Roughness : 0.9 / 45 micron.
– Depth of pipeline laid : 1.0 M below ground level
– SV STATIONS : AT EVERY 3 KM

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

THE TECHNICAL DETAILS OF DRS

SL. TECHNICAL DETAILS PARAMETERS

NO.
1 STANDARD CAPACITY 500, 1000, 2500 & 5000 SCMH
 DESIGN PRESSURE 49 BARG
 UPSTREAM PRESSURE 17 - 32 BARG

2 DOWNSTREAM PRESSURE 6 / 4 BARG

3 DESIGN TEMP (MIN / MAX) 0 OC / +60 OC
4 NO. OF STREAMS 1 + 1 OR 2+1
5 REDUNDANCY MINIMUM 50 %

6 INSTALLATION ABOVE GROUND / UNDER

GROUND

MECON LIMITED
A House of Engineering Excellence
 CITY GAS DISTRIBUTION
DISTRICT REGULATING STATION (DRS)

EXTERIOR VIEW

INTERIOR VIEW

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

DISTRICT REGULATING STATION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

DISTRICT REGULATING STATION

MECON LIMITED
A House of Engineering Excellence
 CITY GAS DISTRIBUTION

MRS COMPONENTS

 INLET & OUTLET ISOLATION

VALVES
 FILTER
 PRESSURE REGULATOR WITH
A BUILT IN SLAM – SHUT
DEVICE
 RELIEF VALVE
 STRAINER
 FLOW METER (RPD, TURBINE,
ETC.)

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MEDIUM DENSITY POLYETHYLENE (MDPE) PIPES

 TECH SPEC: IS 14885:2001 & ISO 4437

 MATERIAL GRADE & COLOR:
INTERNATIONALLY APPROVED RESINS
OF PE 100 GRADE OF ORANGE COLOR
 MINIMUM REQUIRED STRENGTH (MRS)
OF PE 100 GRADE PIPE: 10 MPA
 PIPE THICKNESS – SDR 11
 OPERATING PRESSURE: 6 BAR (G).
 OPERATING TEMPERATURE RANGE: -
10 0 C TO + 40 0 C.
 NOT TO BE INSTALLED IN ABOVE
GROUND PIPING

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
ADVANTAGES OF PE
PIPES
 HIGHER PRODUCTIVITY, I.E., REDUCTION IN
INSTALLATION TIME (15 MIN. FOR PE AGAINST 4 HRS.
FOR STEEL), THEREBY LESSER INCONVENIENCE TO
PUBLIC
 HIGH PERFORMANCE (GLOBALLY PROVEN LEAK FREE
SYSTEM)
 MORE FLEXIBILITY, COIL ABILITY, DUCTILITY, HIGH
ELASTICITY
 LOW DENSITY (LOW WEIGHT, HIGH STRENGTH TO
WEIGHT RATIO)
 HIGH RESISTANCE TO CORROSION
 LOW HEAT CONDUCTIVITY (SMALL THERMAL LOSS)
 SMOOTH SURFACES (LOW PRESS. LOSSES DUE TO LOW
PIPE FRICTION)
CONT…
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 EASY TO TRANSPORT, HANDLE AND LAY

 LONGER LIFE
 EASIER AND SPEEDIER JOINING TECHNIQUES TO
ENSURE LEAK TIGHT JOINTS BY EMPLOYING
ELECTRO FUSION TECHNIQUES
 REDUCED NUMBER OF JOINTS, HENCE SAFER AND
LEAK FREE SYSTEM
 LESS TIME IS CONSUMED TO REPAIR PE DAMAGES AS
COMPARED TO STEEL DAMAGES
 GOOD SQUEEZE OFF PROPERTIES
 LONGER DESIGN LIFE OF PE PIPES (50 YEARS) AS
COMPARED TO STEEL PIPELINE (30 YEARS)
 AVOIDANCE OF NDT TECHNIQUES IN BUILDING
PREMISES, WHICH IS VERY CRITICAL
 SIZE OF TRENCH IS LESS IN CASE OF LAYING OF PE
PIPE AS COMPARED TO STEEL

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MDPE FITTING

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
MDPE FITTINGS

 TECH SPEC: ISO 8085-3

 BAR CODED ELECTRO
FUSION FITTINGS
 MATERIAL GRADE: PE 100
 TERMINAL PIN SIZE: 4 OR
4.7 MM
 VOLTAGE: 39 – 40 VOLTS.
 COLOR: BLACK.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

PE BALL VALVES (TYPICAL)

• STANDARD: ASME B 16.40, EN 1555-4

PRESSURE CLASS: SDR 11.
• DESIGN PRESSURE: 7.0 BAR (G).
DESIGN TEMPERATURE: 45 0 C.
• END CONNECTIONS: PE MATERIAL
(SPIGOT TYPE)
• STEM EXTENSION: INTEGRAL STEM
EXTENSION REQUIRED (MINIMUM 690
MM FROM THE TOP OF PIPE)
• VALVE DESIGN: ONE PIECE
CONSTRUCTION.
• BALL POSITION INDICATOR: OPEN /
CLOSE LIMITS REQUIRED.TO BE
STRATEGICALLY LOCATED IN MDPE
PIPELINE NETWORK

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

TRANSITION FITTING (TYPICAL SPECIFICATION)

 USED TO CONNECT U/G PE PIPES WITH A/G GI PIPES

 OPERATING PRESSURE: UP TO 6 / 4 BAR (G)
 OPERATING TEMPERATURE: 40 0 C
 HYDROSTATIC TEST PRESSURE: MINIMUM HOLD
PRESSURE OF 10 BAR (G), FOR 1 HOUR DURATION
 PNEUMATIC TEST PRESSURE: MINIMUM PRESSURE OF 8
/ 6 BAR (G), FOR 1 HOUR DURATION
 PULL OUT TEST:
 SHALL NOT FRACTURE WITHIN THE JOINTED
ASSEMBLY
 SHALL WITHSTAND THE PNEUMATIC PRESSURE
LEAK TEST
 SHALL NOT LEAK

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
TYPICAL REQUIREMENTS OF PRESSURE REGULATORS USED
FOR DOMESTIC AND SMALL IND.&COMM. CUSTOMERS
 MAX. INLET PRESS.: MAX. : 6 / 4 BAR (G)
 NOMINAL OUTLET PRESS. : 500 / 100 MBAR (G)
 FLOW CAPACITIES: 50, 80, 150, 200, 250 SCMH
 END CONNECTIONS: THREADED (& TAPERED)
AS PER BS 21
 OPERATING AMBIENT TEMP.: UP TO 45 0C
 LOCKUP: MAX. PRESS., UNDER NO-FLOW
CONDITION
 CREEP RELIEF VALVE: TO PROTECT AGAINST
DOWNSTREAM OVER PRESS. AT LOW FLOWS OR
IN THE EVENT OF VALVE SEAT MALFUNCTION.
 OVER PRESS. SHUT OFF (OPSO): DEVICE TO
PROTECT AGAINST DOWNSTREAM OVER PRESS.
 UNDER PRESS. SHUT OFF (UPSO): DEVICE TO
PROTECT AGAINST DOWNSTREAM UNDER
PRESS.
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
REGULATOR SELECTION

INFORMATION REQUIRED TO SELECT A

REGULATOR:
 MAXIMUM AND MINIMUM INLET PRESSURE
 REQUIRED OUTLET PRESSURE
 MAXIMUM FLOW RATE
 TOLERANCE ON OUTLET PRESSURE
 SIZE OF PIPE WORK
 TYPE OF GAS
 SAFETY FEATURES REQUIRED
 OPSO, UPSO & RELIEF SETTINGS
 INSTALLATION INDOORS OF OUTDOORS
 ORIENTATION OF REGULATOR

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
SERVICE REGULATORS

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

METER REGULATOR

 GAS FLOW RATE : 2.5 M3/H

 NOMINAL INLET PRESSURE : 100 MBAR (G)
 MAXIMUM INLET PRESSURE : 160 MBAR (G)
 NOMINAL OUTLET PRESSURE : 21 MBAR (G)
 LOCK-UP PRESS. : SHALL NOT EXCEED 30 MBAR (G)
 LOW PRESS. CUT-OFF : AT INLET PRESS. OF 11.5 TO 15
MBAR (G).

RE-PRESSURIZATION SAFETY DEVICE IS FITTED WHICH

PREVENTS THE REGULATOR FROM RE-OPENING WHEN
THE INLET PRESSURE IS RESTORED UNLESS THERE IS A
DOWNSTREAM BACK PRESSURE, I.E., ALL CONNECTED
APPLIANCES HAVE BEEN TURNED OFF.
 END CONNECTIONS: RIGHT ANGLED INLET AND OUTLET
CONNECTIONS OF ¾”X ¾” NPT (FEMALE)
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

GAS METERS

THE MOST COMMON TYPES OF METERS USED

ARE:
 DIAPHRAGM

 ROTARY POSITIVE
DISPLACEMENT (RPD)

 TURBINE

A TYPICAL DOMESTIC
GAS METER (DIAPHRAGM
TYPE)

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

DIAPHRAGM GAS METERS (DOMESTIC)

 TECH SPEC: BS 1359 / BS 4161

 CAPACITY: 2.5 M3/HR

 RANGEABILITY OR TD RATIO: 1:150 OR BETTER

 NOMINAL WORKING PRESSURE: 21 MBAR (G)

 END CONNECTIONS: ¾”, AS PER BS 746 (MALE)

 CENTER TO CENTER DISTANCE: 110 MM BETWEEN

INLET AND OUTLET CONNECTIONS

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

ROTARY POSITIVE DISPLACEMENT (RPD) METERS

 TECH SPEC: EN 12480

 VOLUMETRIC METER
 APPROPRIATE FOR MEDIUM
SIZE LOAD
 TYPICAL TURNDOWN 35:1 TO
50:1
 ACCURACY ±1%
 LARGE MEASURING RANGE
 NOT SENSITIVE AGAINST
DISTURBANCES
 NOT SENSITIVE AGAINST FAST
CHANGES IN FLOW RATE
 NEEDS LUBRICATION
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

ROTARY POSITIVE DISPLACEMENT (RPD) METERS

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
GI ERW PIPES
 TECH SPEC : IS 1239 (PART 1)
 TYPES USED : MEDIUM CLASS AND HEAVY
CLASS
 PIPES SHALL BE SCREWED WITH TAPER
THREADS
 THREADS: TAPERED AND CONFORMING TO BS
21
 GALVANIZING : IS 4736
COATING REQUIREMENTS: MASS OF
COATING IS 400 GMS / M2
 POWDER COATING :
POWDER MATERIAL : PURE POLYESTER
APPLICATION : ELECTROSTATIC SPRAYING
(40 – 90 KV, MANUAL / AUTOMATIC)

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

FORGED FITTINGS (WROUGHT STEEL IRON)

 TECH SPEC: IS 1239 PART 2

 MATERIAL: IS 1387
 DIMENSIONS & TOLERANCES: IS 1239
PART 2
 THREADS: IS 554
ALL INTERNAL & EXTERNAL
THREADS SHALL BE TAPERED
CHAMFER SHALL HAVE INCLUDED
ANGLE OF 900 +/- 50 FOR INTERNAL
THREADS & 700 +/- 100 FOR
EXTERNAL THREADS
 GALVANIZING: IS 4759
COATING REQUIREMENTS: MASS OF
COATING IS 700 GMS / M2.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
RUBBER HOSE (FLEXIBLE AND STEEL WIRE BRAIDED)

 USED TO CONNECT THE

APPLIANCE, INSIDE THE HOUSE OF
DOMESTIC CUSTOMER
 TECH SPEC: TYPE IV OF IS 9573
 SIZE: 8 MM NB
 MATERIAL: IT CONSISTS OF
Hose
A. LINING: SYNTHETIC RUBBER LIKE
NITRILE BUTADIENE RUBBER (NBR)
OR CHLOROPRENE RUBBER (CR)
B. REINFORCEMENT: WIRE
REINFORCED IN BRAIDED FORM IN
BETWEEN THE LINING AND THE
COVER
C. COVER: CONSOLIDATED BY
WRAPPING, AND UNIFORMLY
VULCANIZED TO GIVE GOOD
ADHESION
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
RUBBER HOSE (FLEXIBLE AND STEEL WIRE BRAIDED)
 MECHANICAL PROPERTIES:
TENSILE STRENGTH: MIN.10 MPA FOR
LINING AND COVER
ELONGATION AT BREAK: MIN. 200% FOR
LINING AND 250% FOR COVER
 SALIENT FEATURES:
STRONG (STEEL WIRE REINFORCED) HENCE
RATS CAN'T BITE THROUGH STEEL WIRE
FLAME RESISTANT
ABRASION, OZONE AND WEATHER
RESISTANT, HENCE NO CRACKS
LOW TEMPERATURE FLEXIBILITY
MINIMUM BURST PRESS. OF 0.5 MPA
LONG LIFE (5 YEARS)
GRIP STRENGTH (TO NOZZLE OF
APPLIANCE) MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
VIRTUAL PIPING

MECON LIMITED
A House of Engineering Excellence
 CNG STATIONS
IN
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CNG MEGA STATION

MECON LIMITED
A House of Engineering Excellence
 MECON LIMITED
A House of Engineering Excellence
 MECON LIMITED
A House of Engineering Excellence
 MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
CNG ADVANTAGES

PROPERTIESOCTA UNIT PEROL DIESEL LPG CNG

NE NO.O
RELATIVE WATER = 0.74 0.84 0.55 -
DENSITY 1
RELATIVE AIR = 1 - - 1.285 0.64
DENSITY
AUTO IGNITION 0C 360 280 374 540
TEMP.
FLAMMABILITY % IN AIR 1-8 0.6 – 2.2 – 5 - 15
RANGE 5.5 9.0
FLAME TEMP. 0C 2030 1780 1983 1900

OCTANE NO. - 87 - 93 127

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
CNG ADVANTAGES

 SAFER FUEL
 NARROW FLAMMABILITY RANGE
 NO THREAT TO LAND OR WATER ON SPILLAGE
 DISPERSES RAPIDLY, MINIMIZING IGNITION
RISK

 BETTER COMBUSTION QUALITY

 HIGHER OCTANE NUMBER MAKES IT SUITABLE
FOR SPARK IGNITION ENGINE
 CNG ENGINES RUN MORE EFFICIENTLY,
ENHANCING VEHICLE LIFE

 CHEAPER THAN PETROL

CONT…

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

EMISSION REDUCTION IN CNG BUS

TYPICAL EMISSION REDUCTION IN CNG BUS COMPARED

TO A DIESEL BUS HAS BEEN SHOWN IN THE TABLE
BELOW:

EFFLUENT PERCENTAGE REDUCTION

CARBON MONOXIDE 56
HYDROCARBONS 55
PARTICULATE MATTER 86
NOX 56

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

MOTHER STATION - SCHEMATIC

STORAGE CASCADE

MOTHER
COMPRESSOR

CNG VEHICLE

CNG
CNG
Dispenser

Gas Supply

LCV - MOUNTED
CASCADES

MECON LIMITED
A House of Engineering Excellence
 CNG - Mother Station
The units envisaged in Mother Station are :

• Electric / Gas Engine Driven Reciprocating

Compressor Capacity : 1200 SCMH along with
auxiliaries
• Electric Power Consumption of Compressor : 180 KW
• Dispensers for buses - 75 Kg/min
• Dispensers for cars and three-wheelers – 15 Kg/min
• Loading Facility for Mobile Cascades – 3000 WL
Capacity
• Stationary Cascades - 4500 WL Capacity
• Electrical Control Panel
• Instrument Air and Water Facilities
• Fire Fighting equipment and safety sign
• Office-cum-Control Room and other facilities

MECON LIMITED
A House of Engineering Excellence
CNG ON-LINE STATION - SCHEMATIC

Storage
Cascade

On-line
Compressor

CN Vehicle

CNG
CNG

Dispenser

Gas Supply

MECON LIMITED
64
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
CNG - ON-LINE STATION

THE UNITS ENVISAGED IN ON-LINE STATIONS ARE:

 ELECTRIC / GAS ENGINE DRIVEN RECIPROCATING

COMPRESSOR CAPACITY : 1200 / 750 SCMH ALONG
WITH AUXILIARIES.
 ELECTRIC CONSUMPTION OF COMPRESSOR : 180 / 120
KW
 DISPENSERS FOR BUSES (AS REQUIRED) - 75 KG/MIN
 DISPENSERS FOR CARS AND THREE-WHEELERS – 15
KG/MIN
 STATIONARY CASCADES OF 3000WL / 2200 WL.
 ELECTRICAL CONTROL PANEL
 INSTRUMENT AIR AND WATER FACILITIES
 FIRE FIGHTING EQUIPMENT AND SAFETY SIGN.
 OFFICE-CUM-CONTROL ROOM AND OTHER FACILITIES
MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

DAUGHTER BOOSTER STATION

STORAG
E
CASCAD
LCV FILLING E
BOOSTER

CNG
VEHICLE

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

DAUGHTER BOOSTER STATION

THE UNITS ENVISAGED IN DAUGHTER BOOSTER STATIONS

ARE:
 BOOSTER COMPRESSOR OF 250 SCMH CAPACITY
ALONG WITH AUXILIARIES
 ELECTRIC CONSUMPTION OF COMPRESSOR : 22 KW
 DISPENSERS FOR CARS AND THREE-WHEELERS : 15
KG/MIN
 STATIONARY CASCADES – 2200 WL
 ELECTRICAL CONTROL PANEL
 INSTRUMENT AIR AND WATER FACILITIES
 FIRE FIGHTING EQUIPMENT AND SAFETY SIGN
 UNLOADING FACILITY FROM MOBILE CASCADES
 OFFICE-CUM-CONTROL ROOM IF REQD.
MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
OPERATIONAL SAFETY OF CNG STATIONS

SAFETY FEATURES - LAYOUT

 CLEAR AND SAFE PASSAGES FOR VEHICLES FROM
INGRESS AND EGRESS TO DISPENSER
 SAFE TURNING RADIUS FOR VEHICLES AND PARKING
DURING FILLING
 LCV FILLING POINTS LAID SEPARATELY TO MINIMIZE
INTERFERENCE WITH REGULAR TRAFFIC
 HEIGHT CLEARANCES FOR BUSES AND SAFE HEIGHT
FOR GAS VENTING
 FENCING OF EQUIPMENT AREA AND SAFETY GUARDS
AROUND DISPENSER ISLAND
 ENVIRONMENT FRIENDLY DESIGN WITH ADEQUATE
GREEN TURFING

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

SAFETY FEATURES - COMPRESSOR

 EMERGENCY SHUT DOWN (ESD) SYSTEM IN CONTROL

ROOM

 FAIL SAFE SYSTEM INCORPORATED TO STOP

COMPRESSOR, ISOLATE CASCADE, DISPENSER &
COMPRESSOR SUCTION LINE, GROUND IGNITION AND
CUT OFF FUEL GAS SUPPLY TO ENGINE ON
ACTIVATION OF ESD SWITCH

 TWO L.E.L DETECTORS AND TWO ULTRA VIOLET (UV)

DETECTORS FOR COMPRESSOR ENCLOSURE

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

 TWIN CYLINDER CONFIGURATION, AUTOMATIC CO2

FLOODING SYSTEM TO EFFECTIVELY COVER THE
ENTIRE ENCLOSURE (ONE CO2 CYLINDER INLINE AND
SECOND STANDBY)

 PULSATION SUPPRESSION DEVICES AT SUCTION AND

DISCHARGE AS PER API-618

 MAXIMUM VIBRATION LEVEL AT CYLINDER LIMITED

TO 7.5 MM/S

 ACOUSTIC ENCLOSURE TO RESTRICT NOISE LEVEL

BELOW 65 DB WITH FLAME PROOF LIGHTING WITH
PROPER VENTILATION

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

SAFETY FEATURES - ALARMS AND TRIPS

 COMPRESSOR

 LOW LUBRICATING OIL PRESSURE / LEVEL

 LUBRICATION FAILURE
 HIGH DISCHARGE TEMPERATURE AT EACH STAGE
 HIGH DISCHARGE PRESSURE AT EACH STAGE
 LOW AND HIGH SUCTION PRESSURE
 HIGH BLOW DOWN VESSEL PRESSURE
 HIGH VIBRATION

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

SAFETY FEATURES - DISPENSER

 DESIGNED FOR HAZARDOUS AREA : CLASS-1,

DIVISION-1, GROUP-D

 NGV1 FILL NOZZLE DESIGNED FOR 100,000 CYCLES

 DISPENSER AUTOMATICALLY AND IMMEDIATELY

SHUTS-OFF CNG SUPPLY TO FILL INDIVIDUALLY IN
CASE OF POWER FAILURE, LOSS OF DISPLAY,
FAILURE OF METERING LOW FLOW, OVERFILL

 OVERFILL PROTECTION THROUGH ELECTRONICALLY

PROGRAMMED HOSE TO TERMINATE THE FILL AFTER
200 KG/CM2(G). PRESSURE RELIEF VALVE PROVIDED
TO AVOID OVERFILLING

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

SAFETY FEATURES - CASCADE

 CYLINDER MATERIAL IS SEAMLESS ALLOY STEEL (CR-

MO) AND APPROVED BY CHIEF CONTROLLER OF
EXPLOSIVES (CCOE)

 FUSIBLE BURST DISC (IS:3224) WILL RUPTURE AT 360

KG/CM2 PRESSURE

 ALL VALVE FITTINGS LIKE QUICK RELEASE COUPLING

PRESSURE GAUGES, SHUT OFF VALVES AS PER
NORMS

 CASCADE FRAME STRUCTURE DESIGNED TO 4G

IMPACT TEST

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
FIRE PROTECTION SYSTEM AT CNG STATIONS

FIRE FIGHTING ARRANGEMENTS AS PER OISD-179:

EQUIPMENT DCP-75KG. DCP-10 KG. CO2- 4.5

KG.

COMPRESSOR 1 1 -
(ONLINE & MOTHER)

DISPENSER - 1 -

CASCADE - 1 -
LCV POINT - 1 -
ELECTRICAL PANEL - - 1

AS PER CCOE GUIDELINES: 6 NOS. FIRE BUCKETS AT EACH CNG

STATION.

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
FIRE PROTECTION SYSTEMAT CNG STATIONS

VIEW OF A CNG STATION WITH FIRE FIGHTING ARRANGEMENTS

MAINTENANCE AND TESTING OF FIRE FIGHTING SYSTEMS ARE

REGULARLY CARRIED OUT TO CHECK THE AVAILABILITY.
MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

CO2 FLOODING SYSTEM

 THE COMPRESSOR PACKAGE IS

PROVIDED WITH A CO2
FLOODING SYSTEM, WHICH IS
TRIGGERED BY SIGNAL FROM
THE UV/IR FLAME DETECTORS.

 ON DETECTION OF FLAME, CO2

IS DISCHARGED TO EXTINGUISH
THE FIRE.

 ADDITIONAL CO2 CYLINDER

(100%) IS PROVIDED FOR
BACKUP.

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY
GAS (% LEL)/FLAME (UV-IR) DETECTOR INSIDE THE CNG
COMPRESSOR

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

MECON LIMITED
A House of Engineering Excellence
INSTALLATION OF CNG FACILITY

MECON LIMITED
A House of Engineering Excellence
 CODES & STANDARDS
IN
CITY GAS DISTRIBUTION

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

SOME IMPORTANT CODES & STANDARDS

PETROLEUM & NATURAL GAS REGULATORY BOARD
 GSR 612(E) TECH. STDS. & SPECNS. INCLUDING SAFETY
STANDARDS FOR CITY OR LOCAL NATURAL GAS
DISTRIBUTION NETWORK.
 GSR 720(E) CODE OF PRACTICE FOR QUALITY OF
SERVICE FOR CITY OR LOCAL NATURAL
GAS DISTRIBUTION NETWORK.
 GSR196(E) AUTHORIZING ENTITIES TO LAY, BUILD,
OPERATE OR EXPAND CITY OR LOCAL
NATURAL GAS DISTRIBUTION NETWORK.
 F. NO. INFRA/IMP/CGD/1/2013
INTEGRITY MANAGEMENT SYSTEM FOR
CITY OR LOCAL NATURAL GAS
DISTRIBUTION NETWORK.

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

OIL INDUSTRY SAFETY DIRECTORATE STANDARDS ( OISD )

 OISD-226 NATURAL GAS TRANSMISSION PIPELINES &

CITY GAS DISTRIBUTION NETWORKS
 OISD- 141 DESIGN AND CONST. REQUIREMENTS
FOR CROSS COUNTRY HYDROCARBON
PIPELINES
 OISD-118 LAYOUTS FOR OIL AND GAS
INSTALLATIONS
 OISD-115 GUIDELINES ON FIRE FIGHTING,
EQUIPMENT AND APPLIANCES IN
PETROLEUM INDUSTRY
 OISD 179 SAFETY REQUIREMENTS FOR
COMPRESSION, STORAGE, HANDLING AND
REFUELLING OF CNG FOR USE IN
AUTOMOTIVE SECTOR.
 OISD 113 CLASSIFICATION OF AREAS FOR ELECTRICAL
INSTALLATIONS AT HYDROCARBON
ROCESSING AND HANDLING FACILITIES
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

BUEAREU OF INDIAN STANDARDS.

 IS 14885 SPECIFICATION FOR ANUFACTURE

OF POLYETHYLENE PIPES
 IS 1239 (PART-I) SPECIFICATION FOR
MANUFACTURE OF CARBON STEEL
PIPE.
 IS 1239 (PART-II) SPECIFICATION FOR
MANUFACTURE OF CARBON STEEL
FITTINGS.
 IS 5572 CLASSIFICATION OF HAZARDOUS
AREAS (OTHER THAN MINES) FOR
ELECTRICAL INSTALLATIONS
 IS 5571 GUIDE FOR SELECTION OF
ELECTRICAL EQUIPMENT FOR
HAZARDOUS AREA
MECON LIMITED
A House of Engineering Excellence
 CITY GAS DISTRIBUTION

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

 ASME B31.8 GAS TRANSMISSION AND DISTRIBUTION

PIPING SYSTEM
 ASME B16.25 FLANGES & FITTINGS WITH BUTT WELDED
ENDS
 ASME B16.9 FACTORY – MADE WROUGHT IRON STEEL
BUTT-WELDING FITTINGS
 ASME B16.11 FORGED STEEL FITTINGS, SOCKET
WELDING AND THREADED
 ASME B16.25 BUTT WELDING ENDS
 ASME B16.5 PIPE LINE FLANGES AND FLANGED
FITTINGS
 ASME BOILER AND PRESS. VESSEL CODE SECTION-
IX QUALIFICATION STD. FOR WELDING &
BRAZING PROCEDURES, WELDERS, BRAZERS,
AND WELDING & BRAZING OPERATORS
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
AMERICAN PETROLEUM INSTITUTE (API)

 API - 1104 WELDING OF PIPELINES AND RELATED

FACILITIES
 API – 607 FIRE TEST FOR SOFT SEATED QUARTER
TURN VALVES
 API - 6FA SPECIFICATION FOR FIRE TEST FOR
VALVES
 API - 5L SPECIFICATION FOR LINE PIPE
 API - 6D SPECIFICATION FOR PIPELINE VALVES (
GATE, PLUG, BALL AND CHECK VALVES)
 API – 1102 SPECIFICATION FOR STEEL PIPELINE
CROSSING & HIGHWAYS.
 API – 500 RECOMMENDED PRACTICE FOR
CLASSIFICATION OF LOCATIONS FOR
ELECTRICAL INSTALLATIONS AT PETROLEUM
FACILITIES CLASSIFIED AS CLASS I,
DIV.AND2
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
COMPRESSED NATURAL GAS (CNG)

CODES & STANDARDS - COMPRESSORS

 API- 618 RECIPROCATING COMPRESSORS
 NFPA-37, STANDARDS FOR CNG VEHICULAR FUEL
NFPA-52:1992 SYSTEMS
 NFPA-70 STANDARD FOR ELECTRIC DEVICES &
WIRING
 OISD 179 SAFETY REQUIREMENTS FOR COMPRESSION,
STORAGE, HANDLING AND REFUELING OF
CNG
FOR USE IN AUTOMOTIVE SECTOR
 OTHERS INDIAN ELECTRICITY RULES, INDIAN
EXPLOSIVES ACT

MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

CODES & STANDARDS - DISPENSERS

 NFPA 52 STANDARDS FOR CNG VEHICULAR

FUEL SYSTEMS
 NGV 4.1 REQUIREMENTS FOR CNG DISPENSING
AGA 2-92 EQUIPMENT FOR VEHICLES
 NGV 4.2 REQUIREMENT FOR HOSES FOR NGVS
OF AGA 1-93 FUEL DISPENSERS

 ANSI COMPRESSED NATURAL GAS FUELING

NGV1 CONNECTION DEVICES

 NGV4 REQUIREMENTS FOR BREAKAWAY

DEVICES AGA FOR CNG VEHICLES,
FUELING DISPENSERS AND FUELING
HOSES
CONT…
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 IS:5572 CLASSIFICATION OF HAZARDOUS AREAS

(OTHER THAN MINES) FOR ELECTRICAL
INSTALLATIONS
 IS:5571 GUIDE FOR SELECTION OF ELECTRICAL
EQUIPMENT FOR HAZARDOUS AREA
 OISD 179 SAFETY REQUIREMENTS FOR
COMPRESSION, STORAGE, HANDLING AND
REFUELING OF CNG FOR USE IN
AUTOMOTIVE SECTOR
 OISD 113 CLASSIFICATION OF AREAS FOR
ELECTRICAL INSTALLATIONS AT
HYDROCARBON PROCESSING AND
HANDLING FACILITIES
 OTHERS GAS CYLINDER RULES - 1981, INDIAN
EXPLOSIVES ACT, AUSTRALIAN / NEW
ZEALAND REFUELING STANDARD - AG901
/ NZS 5425
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION
CODES & STANDARDS - CASCADES

 NFPA 52 STANDARDS FOR CNG VEHICULAR

FUEL SYSTEMS
 OISD 179 SAFETY REQUIREMENTS FOR
COMPRESSION, STORAGE, HANDLING
AND REFUELING OF CNG FOR USE IN
AUTOMOTIVE SECTOR
 GAS CYLINDER STANDARDS FOR CNG STORAGE
RULES : 1981 AND GAS CYLINDER RULES

STATIC AND MOBILE PRESSURE VESSELS (UNFIRED )

RULES, SMPV - 1981

 CNG CYLINDER DESIGN CODE, IS : 7285 – 1988

CONT…
MECON LIMITED
A House of Engineering Excellence
CITY GAS DISTRIBUTION

 IS:3224 – 1979 CNG CYLINDER VALVES

(AMENDMENTS 1983, 84,85,86,89,92,98)
 IS:5844 – 1970 HYDROSTATIC STRETCH TEST
 IS:5903 -1970 AFETY DEVICES OF GAS CYLINDERS
 INDIAN EXPLOSIVES ACT
 AUSTRALIAN / NEW ZEALAND REFUELING STANDARD -
AG901 / NZS 5425

MECON LIMITED
A House of Engineering Excellence
THANK
YOU

MECON LIMITED
A House of Engineering Excellence