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

2. Overview of City Gas Pipe lines

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

4. 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.

5. 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.

6. BGL BUSINESS SEGMENTS
CNG
Industrial
Commercial
Domestic

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

8. Areas of operation & infrastructure details:
Sr.no.
Details
Nos. or KM 1
Length of steel pipe line
  Km 2
Length of MDPE pipe line
  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.

9. 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

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

11. Typical layout of CGD Network:

12. City Gate Station (CGS):

13. Pressure Reduction station (PRS):
BGL

14. 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

15. 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

16. 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

17. 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.

18. 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

19. Steel Pipe line laying activities:

20. Display of caution boards:

21. PNG- A Typical Gas supply Scheme

22. Safe practices:

23. Domestic connection:

24. 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.

25. 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

26. 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.

27. 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

28. Pipe line markers :
TLP station

29. 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

30. 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.

31. 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.

32. 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

33. 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

34. 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.

35. 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

36. 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.

37. 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

38. 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

39. 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

40. 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

41. 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.

42. 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

43. MDPE Electro fusion machine
MDPE SQUEEZER

45. MDPE PIPE CUTTERS

46. CNG STATION:

47. Safety awareness programs
BHAGYANAGAR GAS LIMITED
Safety awareness programs

49. Thank you