Overview of City Gas Pipe lines PSC 2018 08th March 2018 By K. Mukharji Ch. Manager-Projects and O&M & G.Venkatesh Dy. Manager-Projects and O&M Bhagyanagar Gas Limited

Overview of City Gas Pipe lines

BHAGYANAGAR GAS LIMITED Content: Overview of BGL CGD infrastructure Network Design Steel Projects PNG projects PNG O&M Safety

BHAGYANAGAR GAS LIMITED ( A Joint venture of GAIL (I) & HPCL) M/s. Bhagyanagar Gas Limited (BGL) is a joint venture of GAIL (India) Limited and Hindustan Petroleum Corporation Limited, was incorporated in August 2003 as a City Gas Distribution (CGD) in the states of Telangana & Andhra Pradesh. Received Authorizations from PNGRB to develop and operate CGD Networks in the year 2009 for Hyderabad, Vijayawada and Kakinada cities.

The main objectives of Company are To provide safe , convenient and reliable natural gas supply to it’s customers in the domestic and industrial customers. To provide a cleaner, eco friendly alternative as auto fuel to Telangana and Andhra Pradesh residents, this will considerably bring down the pollution levels.

BGL BUSINESS SEGMENTS CNG Industrial Commercial Domestic

Type of Gas required for different sectors: Transport Sector Compressed Natural Gas (CNG) Domestic Sector Commercial Sector Piped Natural Gas (PNG) Industrial Sector

Areas of operation & infrastructure details: Sr.no. Details Nos. or KM 1 Length of steel pipe line  107.28 Km 2 Length of MDPE pipe line  521.57 Km 3 No. of DRS  12 nos. 4 No. of Domestic customers  20784 nos. 5 No. of commercial customers  63 nos. 6 No. of Industrial customers  06 nos. 7 No. of CNG stations  45 nos.

CITY GAS DISTRIBUTION NETWORK INFRASTRUCTURE Primary Network above 7 bar & below 49bar Secondary Network above 100 mbar & below 7bar Tertiary Network Less than 100 mbar

CGD NETWORK Consists of City Gate station (CGS) Steel pipe line CNG stations MDPE Pipe lines PNG installations

Typical layout of CGD Network:

City Gate Station (CGS):

Pressure Reduction station (PRS): BGL

District Regulating Station (DRS): Safety valves Slam shut off valves Pressure gauge Safety relief valves Active regulator Hot standby stream Filters 19 bar inlet Outlet 4 bar

The various challenges in city gas distribution network can be categorized under two broad heads as below Setting up the Network Operation & Maintenance of the Network

Codes & standards: Area Codes & Standards Overall CGD Project Project PNGRB regulations 2008 – Technical Standards CGS AGA3, AGA7 – metering IGE / TD/13 Steel Grid line, Fittings ASME B 31.8 ASME B 31.3 T4S API 1104- API 6D ASTM A 370 MSSP ASME B 16.5 CNG API- 11p, API 616, ISO 13631 NFPA MDPE Steel pipeline PNGRB technical standards IGE /TD/03 ANSI B 31.8

CGD Network Design: Pipeline Modeling in Software. Locate Demand Centers Define Boundary Conditions (Pressure Limits). Define Gas Demand at each Demand Center Define Velocity Limitations Define Gas Composition & Calculate Gas Properties. Define Design Temperature & Ambient conditions Perform Pipe Sizing and Simulation Network Optimization What-if analysis to evaluate alternative options. Ensure that all Pressure requirements are met with.

Challenges in Laying city gas pipe lines: No separate corridors or ROW Existence of other utilities (Parallel or crossing) Permissions from Govt. Authorities Opposition from Local people

Steel Pipe line laying activities:

Display of caution boards:

PNG- A Typical Gas supply Scheme

Safe practices:

Domestic connection:

Comparison of Steel and MDPE Pipelines: STEEL PIPELINE MDPE PIPELINE Steel pipelines can be operated at very high pressures MDPE pipelines can be operated up to 4 bar in case of PE 80 grade and up to 10 bar PE 100 grade. Prone to corrosion and requires Cathodic Protection and coating to protect the pipeline from corrosion. No corrosion problem and almost negligible maintenance cost. Not flexible and requires more fittings. Flexible and easy to lay in city like conditions Expected life of 25 years. Expected life of 50 years Cannot be squeezed. Can be squeezed and regains original shape after removing the squeezer.

O&M Activities: Network Integrity Maintenance Activities Third Party Digging Emergency Handling Leakage Survey ,Detection and Rectification Odourization Maintenance Activities Regulator & TF testing Internal testing MDPE Testing Attend customer complaints Maintenance of FRS/MRS/DRS Condition Monitoring of valve chambers Work permit issue ISO documents Maintaining MDPE fittings ,meters ,regulators and other o& m stock

Network Integrity: 1. Third party digging One of the biggest challenges for a CGD is to mitigate the chances of damage due to ‘Third Party’ diggings. The steps taken to ensure pipeline safety are: A. Increasing Awareness:- Installation of Pipeline Markers at a distance of 50 Meters against the T4S requirement of 100 meters 24x7 Patrolling over pipelines by Ex Army Biker Guards with Guards being monitored using ‘Vehicle Tracking System’ SMS is sent & Stickers are pasted over JCB/HDD/Earthmovers/Boring Machines in Hindi & English with information of BGL Emergency Contact Numbers.

Regular visit to JCB/HDD /Earthmover/Operators to Sensitize them regarding pipeline safety. Regular coordination meetings with ‘Third Party Agencies’, other Utility agencies like water Board, Electricity Companies etc. to sensitize them on Pipeline safety. Public awareness through SMS to customers. ( future planning) General awareness through Radio advertisements. Liaison with Civic agencies/LOA’s/Administration/Police- Suraksha Liaison meetings with Resident Welfare Associations and Safety Awareness Letters to them Safety awareness trainings to All the societies

Pipe line markers : TLP station

2. EMERGENCY HANDLING EMERGENCY HANDLING IS ONE OF THE MAJOR CHALLENGES IN CGD INDUSTRY. EMERGENCIES CAN BE CATEGORISED AS: Gas leak due to pipeline damage Fire due to gas leak FRS tripping causing stoppage of gas supply The Challenges in handling above situations are as under: Passing Information to Customers Isolation of affected network Traffic Conditions in Hyderabad, Vijayawada and Kakinada. Overcrowded areas

To Mitigate the challenges, following actions have been taken: Implementation of Toll Free number through which Customer’s/Passerby’s can inform about any leakage etc. Walky-Talky are being procured to ensure uninterrupted communication. In case of interruption in PNG Supply, information to customers is passed on by calling them with expected resumption time. Creating awareness to the public to close the valves on the directions of BGL in case of emergency.

Control room has been provided with Emergency Vehicles which is equipped with all the emergency handling tools and tackles and are self sufficient to handle any emergencies. In case repair time is expected to exceed abnormally Domestic customers are fed from LCV’s using Pressure Reduction Skids.

3. Leakage survey , Detection and rectification Objective: To ensure leak-free underground CGD infrastructure Summary: Conducting extensive leakage surveys to determine leakages.     A leakage survey, using suitable gas detection apparatus, or pressure tests shall be conducted annually in principal business districts and the area surrounding schools, hospitals and similar community installations. The survey shall include tests of the atmosphere at utility manholes, other collection points and at openings (cracks) in pavement. LEAKAGE SURVEY Operation Excellence Processes Leakage Surveys Survey of pipelines Conducting pressure tests Determining leaks Rectifying leaks

4. Odorization: FIRST INDICATOR OF GAS LEAKAGE Natural gas being a colorless and odorless gas, optimum odorization is required for identification of leak. ODORIZATION IS FIRST AND FORMOST INDICATOR OF GAS LEAK. odorization is being done by BGL at city gate station. Automated Odorant Injection based on Real Time Flow in CGS. Implementation of Automation for Remote Monitoring (Real time Monitoring) of Odorizer. Odorant using Ethyl Mercaptan Smell survey is done on Monthly basis

Maintenance activities: Regulator and TF testing Regulator and transition fitting testing is a continuous process through out the year. It is done with the help of soap solution. The leakage found is rectified the same day.

2.Internal Testing: It includes testing of PNG installation inside customer house. The installation is tested by holding an air pressure of 100 mbar for 15 minutes. An internal testing iso format is filled along with customer signature. We also check whether meter is working or not . We also do the load testing of meter

3.MDPE testing Mdpe testing of a particular area is carried out once in a Year In MDPE testing we hold the pressure of underground pipeline Between isolation valve and valve chamber of society for at least 4 hours. An ISO document , MDPE test certificate is filled for the same.

4. Attending Customer compliant: General Emergency MDPE Pipe line Major PE modification EMERGENCY CALL (MAJOR LEAKAGE MDPE) PE Plugging PIPELINE DAMAGE BY THIRD PARTY GI INSTALLATION RELATED   TEMPORARY DISCONNECTION (RENOVATION/ PERSONAL REASON/ DEFAULTER) EMERGENCY CALL (MINOR LEAKAGE FROM RUBBER TUBE/ GI PIPE) GI MODIFICATION NO GAS SUPPLY COOKING APPLIANCE RELATED FLAME PROBLEM NEW STOVE CONVERSION RE-CONVERSION TO LPG

5. Work permit system: A permit-to-work is a document which specifies the work to be done and the precautions to be taken There are three types of permit Hot work permit:- Issued when the work require involvement of natural gas and height. Cold work permit:-Issued when the work do not require involvement of natural gas Laying and testing permit:- Issued when laying of pipeline take place

6. VALVE CHAMBER MONITORING Monitoring of valve chambers is done on monthly basis The check point of VC monitoring are:- Accessibility Cleanliness Proper sand availability Paint Construction

7. MAINTENANCE OF DRS/MRS: The maintenance of FRS/MRS is done quarterly The check points during maintenance are:- Cleaning & Painting of FRS/MRS Operating pressure Valve operational Leakage testing UPSO/OPSO Meter oil Filter cleaning

Geographical Information System(GIS) Activities planned after GIS mapping in BGL: Outage Management and Real Time Patrolling Monitoring with alarm for any deviation PE and Steel pipe network designing and simulation using gas network analysis and design software. GIS shall have an interface with the gas network analysis and design software. Load forecasting and planning using external data sources to find out where new loads may materialize. Reduce the response time in attending the emergency calls through accurate location identification and accurate pipeline connectivity details of the problem site. Carry out downstream network tracing to find out customers affected due to closure of valve. Carry out shortest path analysis between Emergency crew locations and Emergency/fault location.

Emergency Response and Disaster Management Plan: Description & details of the city gas pipeline network Identification and definition of Roles, Responsibilities and Authorities Procedures for Emergency Handling, Shutdowns and Evacuations Emergency contact numbers Mutual aid agencies and their roles  Important Do’s and Don’ts List and location of Emergency tools and spares Training requirements and plans

MDPE Electro fusion machine MDPE SQUEEZER

MDPE PIPE CUTTERS

CNG STATION:

Safety awareness programs BHAGYANAGAR GAS LIMITED Safety awareness programs

Thank you