Design Basis

GAIL (INDIA) LIMITED

Basic Engineering Design Basis

PIPELINE REPLACEMENT PROJECT IN GUJARAT REGION

Engineering Doc. No. - MEC/23PH/05/28/M/001/001, R-0

MECON LIMITED DELHI - 110092

September - 2014

Prepared by Checked by Approved by

Amit Kumar, DE

A K Bharti, SDE

GV Walimbe, DGM

Copyright MECON Limited All rights reserved. THIS DOCUMENT IS THE SOLE PROPERTY OF MECON AND ISSUED FOR THE SPECIFIC PROJECT MENTIONED HEREIN. THIS IS NOT TO BE COPIED OR USED FOR ANY OTHER PROJECTS UNLESS EXPLICITLY PERMITTED BY MECON.

MECON LIMITED DELHI

Oil & Gas Section Delhi

PIPELINE REPLACEMENT PROJECT IN

GUJARAT REGION

TITLE Basic Engineering Design Basis Engineering Doc. No. Page 2 of 44

MEC/23PH/05/28/M/001/001 Revision - 0

C O N T E N T S

Article No. Description

1.0 Introduction

2.0 Scope of Services

3.0 Pipeline Design Parameters

4.0 Facilities Planned

5.0 Pipeline Construction Methodology and Consumer Connectivity

6.0 SCADA & Telecommunication

7.0 Electrical Facilities

8.0 Civil / Structural Facilities

9.0 Fire Fighting facilities

10.0 List of Standards

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

1.0 INTRODUCTION

GAIL (India) Limited is apublic sectorunder Petroleumministry, intend to strengthensafeoperationof theNaturalGaspipelinesystem includingconnectivity toconsumers.TodosoithasbeendecidedtoreplaceselectedoldpipelinesofNaturalGasDistributionNetworksonthebasisofpresentheathstatusinBarodaregion.Presently,GAILLimitedisplanningtoreplaceabout475kmnaturalgaspipeline.Replacement of the pipeline is to be done on the basis of completion of design life,Thicknesslosses,designcompliancetothePNGRB&piggabilitystatusofthepipeline.Aspercurrentstatusofthepipeline,total74nos.(approx.)ofpipelineistobereplacedwhich includeawiderangeof length from0.1kmto96.6kmanddiameter from2to14.

New pipeline shall be laid in same ROU of existing pipeline with some unavoidablererouting.

2.0 SCOPEOFSERVICES

MECONhasbeenengagedbyGAILLimitedtocarryoutDesign,Engineering,procurement,

inspection& ProjectManagement Consultancy Services required for replacement of oldnatural gas trunk pipeline & pipeline network for supplying the gas to various type ofindustryasperfollowingtable.

A.PipelinesNonPiggable,Thickness25yearsSLNo. PipelineSection

ExistingDiameter(NB)(inch)

ProposedDiameter(NB)(inch)

LengthtobeReplaced(km)

YearofCommissioni

ng PhaseI 1 AnkleshwarBarodaP/L 14 16 96.60 1965

PhaseII 2 CTFGandharDabkaP/L 12 12 47.34 19693 UnderaAlembicP/L 12 12 7.60 19694 8"P/LSection 8 8 43.05 196919805 6"I/CGGSKosambaP/L 6 8 2.20 19856 4"P/LSection 4 4 17.92 19691989

Total 214.71

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

B.PipelinesNonPiggable,Thickness

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

2.0 PIPELINEDESIGNPARAMETERS

Adetailedstudyofexistingpipelineshasbeencarriedoutfortheexecutionoftheproject.Detailedanalysisisgiveninsection03.00ofthisreport.Design of Natural Gas pipeline shall be in accordance with ASME B 31.8andotherapplicable codes. A design life of minimum 25 years for pipeline system shall beconsidered for designing various system and facilities beyond which pipeline systemcanbe considered for abandonment. The life of pipeline can be extended beyondthedesignlifesubjecttosatisfyingthecomprehensivepipeline integritytest.

Analysishasbeendoneofthefollowingbasis

Qualityofgasflowinginthepipeline.MajornaturalgassourceinBarodaregionpipelinesisfromONGCgaswells.Aspernatural gas composition (given in section 3.00 of this report), Baroda regionpipelinesaretransportingwetnaturalgascontainingCO2&moisture.Followingaretherequirementsforthedesignofsournaturalgaspipelines

Gaseous hydrocarbon shall be considered as sour in line with NACEStandardMR0175.At lower concentrationsofH2S, as thepresenceofother constituents in the gas e.g., CO2 and salts inwater etc., can alsocausestresscorrosion,hencetheconcentrationofsuchconstituentsshallalsobeevaluatedingaseoushydrocarbon.

Allmaterials,usedinsourgasservice,shallconformtothematerialrequirements specified in NACE Standard MR0175. Depending uponservice and materials involved, additional tests for Sulphide StressCorrosion Cracking (SSCC) and Hydrogen Induced Cracking (HIC), asspecified inNACEStandardsMR0175andTM0284respectively,shouldalso be conducted for long & short term behaviour of material undercorrosiveenvironments.

ThicknessofthepipelineAsperPNGRBguidelines,Pipewallthicknesslessthan6.4mmshallnotbeusedforcrosscountrypipelines.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

The least nominal wall thickness t for the steel pipe, shall be calculated inaccordancewithASMEB31.8.Thethicknessshallbedeterminedbythefollowingformulaandoptimizedforcostefficiency

PxD t= 2xFxSxExTWheret=Nominalwallthickness,inmm;P=Internaldesignpressure,inN/mm2.D=Specifiedoutsidediameterofthepipe,inmm;S=Specifiedminimumyieldstrength(SMYS)inN/mm2ofpipematerial;F=Designfactorasperlocation;E= Longitudinal joint factor,which for electricwelded (EW), longitudinalseamsubmergedarcwelded(LSAW),helicalseamsubmergedarcwelded(HSAW)andseamlesstypesofpipes,manufacturedinaccordancewithAPIspecification5Landconsideredas1;T = Temperature derating factor based on maximum operatingtemperature;

StationFacilities

Pipeline Dispatch Stations, Intermediate Pigging Stations, Sectionalizing ValveStations, TapOffs & Receiving terminals shall be provided as per requirement.These stations shall be designed as per PNGRB guidelines and relevant designcodes.

Piggabilityofthenaturalgaspipeline

Piggingfacilitiesinthepipelinesshallbeprovidedasperfollowing

Main gaspipelines and feeder lines, spur lines andbranch linesof4and above size and length greater than10 km shallbeprovidedwithpiggingfacilities.

Spacing between consecutive pigging stations shall be determinedbased on the diameterof pipeline, nature of pigging operation andcapabilityof thepigs.

Pigging stations shall be providedwith allweather access road fromthenearestroad

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

Piggingfacilitiesshouldbedesignedtobesuitablefor:

Accesstothepigtraps; Handlingofpigs; Isolation requirements necessary for pig launching and

receiving; Ventinganddrainingofcarriedovermuck/condensateduring

piggingoperation; Directionofpigging includingbidirectionalpigging; Minimum permissible bend radius and the distances between

bends/fittings; Fittings/branch connections and compatibility of line pipe

material; Variation inpipelinediameterandwallthickness

The safetyofaccess routes and adjacent facilities shallbe consideredwhendeterminingtheorientationofpigtraps

Majority of the pipeline is suffering from internal corrosion problems. This is due topresenceofmoistureatsourcestationofthepipeline.SincenaturalgasofGujratregionisalsocontainingasmallquantityofCO2,whichaccelerate the rateof internalcorrosion inpresenceofmoisture.Mitigation of internal corrosion in the natural gas pipeline can be done by removal ofmoistureorwaterfromnaturalgasstream&considerationofhighercorrosionallowancesinthepipelinethickness.

2.1 Removalofmoistureandwaterdroplets

Untreatednaturalgas,whichisflowingfromONGCsourcetoGAILsdispatchterminalshallbeeithertreatedatsourceot itcanbetreatedatdispatchterminalsdependingupontheflowrateofthenaturalgas.MECONwillconsiderthetreatmentfacilitiessuchasinstallationofdehydration system,molecular sieve system and liquid knocking systembasedon thenaturalgassourcestudy.Primereasonof internalcorrosion inthenaturalgaspipelines isavailabilityofmoisture inthe natural gas stream. Removal of moisture from natural gas stream can be done byfollowingsystems:

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

2.1.1 MechanicalliquidknockingSystemsLiquid particles can knocked from natural gas stream by using natural gas flow and itsvelocity in termsofagitation inamechanicalsystem. Itdoesnt requiredanyconsumablematerialsandexternalenergy.Considering flow ofwet gas and formation of condensate in the pipeline, proper liquidknockingfacilitiesistobedevelopedatsourcestationforthepipelineshavinglengthmorethan10kms.Followingwaterknockingfacilitiesmaybeconsidered

Scrubber KnockOutDrum FilterSeparator Combinationofabovethree.

2.1.2 ChemicaldehydrationandsievingSystems

Alsoat someplaceshavinghighermoisture content, it is suggested to installnaturalgasdehydrationfacilitieslike

Molecularsievedehydrationfacilities GlycolDehydrationfacilities AminebaseddehydrationSystem

MolecularSieve

Theseareacrystallineformofalkalimetal(calciumorsodium)aluminasilicates,verysimilartonaturalclays.Theyarehighlyporous,withaverynarrowrangeofporesizes,andveryhighsurfacearea.

Manufacturedby ionexchange,molecularsievesarethemostexpensiveadsorbents.Theypossess highly localized polar charges on their surface that act as extremely effectiveadsorptionsitesforpolarcompoundssuchaswaterandhydrogensulfide.Molecularsievesarealkalineandsubjecttoattackbyacids.Specialacidresistantsievesareavailableforverysourgases.

Sincetheporesizerangeisnarrow,molecularsievesexhibitselectivitytowardsadsorbateson thebasisof theirmolecularsize,and tendnot toadsorbbiggermoleculessuchas the

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

heavyhydrocarbons.The regeneration temperature isveryhigh.Molecular sievesofferameansofsimultaneousdehydrationanddesulfurizationandarethereforethebestchoiceforsourgases.

A typicalmolecular sievedehydrationplant consistsof twoadsorption towers filledwithsoliddesiccant.Oneoftheadsorptiontowers isusedforthedehydrationofwet inletgaswhiletheparallelinstalledtoweraimstoregenerateloaded(watersaturated)desiccant.Ingeneral,all liquidand solid impuritiesare removed from the feed streamofamolecularsieve plant by an inlet separator or scrubber (upstream). As wet gas contacts the soliddesiccantbed,watervapourisadsorbeduntilequilibriumisestablishedbetweenthewatercontentinthegasstreamandonthesoliddesiccantparticles.Driednaturalgasleavesthebed,flowsthroughtheexitswitchingvalve,andfinally leavesthedehydrationunitviathedrygasoutletheader.Whileonebed isondrying,theotherbedhastoberegenerated.Regenerationcanbecarriedoutusingdryproductgasorwetinletgas.Regeneratorgashastobeheatedupstream the regeneration tower.Hot regeneration gasheatsup thebed,drivesthewateroffthedesiccantparticles,andcarriestheresultingwatervapouroutofthebed.The regeneration stream is cooleddownand thewater content is separated in theregenerationseparator.

DehydrationusingGlycol

Scrubbingofwetgaswithglycol isoneof themostapplieddehydration technologies fornatural gas. The glycol is highly hygroscopic, andmost of thewater vapor in the gas isabsorbedby the glycol.Glycol selection fornatural gasdehydration applicationsmaybebasedonanumberoffactorsincludingdehydrationcapability,glycollossesinthecontactorand regenerator, and absorption of volatile organic compounds (VOCs). The mostcommonlyusedglycolistriethyleneglycol(TEG).Diethyleneglycol(DEG)andethyleneglycol(EG)may alsobeused indehydration applications;however,DEG and EG areoftennotconsideredduetodrygaswatercontentrequirements.

Inatypicalglycolunit,thewetgaspassesthroughan inletscrubbertoremovesolidsandfree liquids,and thenenters thebottomof theglycolcontactor.Gas flowsupward in thecontactor,while lean glycol solution (glycolwith littleornowater) flowsdownover thetrays.Richglycolabsorbswaterandleavesatthebottomofthecolumnwhiledrygasexitsatthetop.Therichglycolflowsthroughaheatexchangeratthetopofthereboilercolumn(called still)where it isheatedandprovides thecoolant for the stillcondenser.Then thewarmsolutiongoestoaflashtank,wheredissolvedgasisremoved.Therichglycolfromtheflashtankisfurtherheatedbyheatexchangewiththestillbottoms,andthenbecomesthe

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

feedtothestill.Thestillproduceswateratthetopandaleanglycolatthebottom,whichgoestoasurgetankbeforebeingreturnedtothecontactor.

Type of dehydration system shall be decided further on the basis of Efficiency, Cost,AvailabilityandRequirementofserviceatnaturalgassource.AsperPNGRBguidelines,pipelineswithdesignedwallthicknessof6.4mmistobereplacedtoaminimumwallthicknessof6.4mm.Pig launchingand receiving facilitiesare considered for thepipelineshaving lengthmorethan10.0km.BasedonscopeofworkanddetailofpipelinesattachedasAnnexureIanalysisofthedatahasbeendone.Sincecurrentpopulationdensity indexdata isnotavailable,70%of totallengthofpipeline is consideredunderClassII location,20%of total length is consideredunderclassIIIlocationand10%oftotallengthisconsideredunderclassIVlocation.

AminebaseddehydrationSystem

The amine scrubbing is awashingprocess,whichuses amine aspurifying agent.Carbondioxide (CO2)andhydrogen sulphide (H2S)canalmostcompletelybe removedusing thistechnology.

The amine flows in a closed circuit and is continuously regenerated. TheCO2 andH2Sloadedamineneedstoberegeneratedcontinuously.Therefore,asecondcolumnisneeded,wheretheamineisregeneratedbyreboiling.ThesourgasisexportedtotheClausprocess,where elementary sulphur will be recovered. With this technology and MEA(monoethanolamine)aspurifyingagentCO2canberemovedup to less than50ppmandH2Suptolessthan3ppm.Presently based on data received, MECON proposes to install Natural Gas Dryer(MolecularSieveBased)alongwithRefrigeration/ChillingandHeatingfacilityatfollowingsources.

1. SouthGujratRegion CTFAnkleshwar(0.25MMSCMD) GNAQ(0.35MMSCMD)

2. AhmedabadRegion GGSRamol(0.250.50MMSCMD)3. MehsanaRegion GGSNandasan(0.025MMSCMD)

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

2.2 Considerationofhighercorrosionallowances

Majorityof thenatural gaspipelines inBaroda region are interconnected.Also, it is noteconomicaltoinstalldehydrationsystematallthesourcesparticularlyatsmallernaturalgassources. To keep the design effective and safe operation of the pipeline in future, it isdecided toconsiderhighercorrosionallowances in thenaturalgaspipelinesconnectedtowetgassources.Foradesign lifeof25years,a total corrosionallowancesof3.00mm is consideredatacorrosionrateof0.12mmperyear.

2.3 PipelineDesignLocationClass

Thisproject isbeing implementedon thebasisofalreadyexistingpipeline facilities, freshsurvey has not be done.Majorityof pipelines are located in population dense industrialareas,ithasbeendecidedtolaythenaturalgaspipelinebyconsideringlocationclassIV.PopulationdensityintherouteofpipelinefromGandhartoDabkaseemstobeless,soithasbeenconsideredunderlocationclassIII.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.0 PIPELINEDETAIL

Detailedstudyof thecurrentstatusofallpipelineshasbeendoneandnewpipelineshasbeendesignedasfollows:

3.1 AnkleshwarBarodaP/L CurrentStatus: PipelineSize : 14NB TotalLength : 96.60km. Yearofcommissioning : 1965 Piggability : NonPiggable No.ofSVStation : 9 DesignClass : 150# OperatingPressure : 19kg/cm2 CPSystem : PCP Coating(External) : CTL Coating(Internal) : None SourceGas : Ankleshwar/CPFGandhar/RLNG TypeofGas : WetGas PipeThickness : 6.35mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 16NB TotalLength : 100.60km.(approx.) DesignClass : 300# DesignTemperature : (29C)to(+65C) OperatingPressure : 19kg/cm2 PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : NaturalGasDehydrationSystem Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : PDIdata(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.2 CTFGandhartoDabka CurrentStatus: PipelineSize : 12NB TotalLength : 47.34km. Yearofcommissioning : 1989 Piggability : NonPiggable No.ofSVStation : Tobeconfirmedfromsite DesignClass : 400# OperatingPressure : 30kg/cm2 CPSystem : PCP Coating(External) : DensoType Coating(Internal) : None SourceGas : Ankleshwar/CPFGandhar/RLNG TypeofGas : WetGas PipeThickness : 6.35mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 12NB TotalLength : 47.34km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 30kg/cm2 PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : AsperPDIdata(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.3 GNFCtoNTPCPipeline CurrentStatus: PipelineSize : 12NB TotalLength : 16.0km. Yearofcommissioning : 1994 Piggability : NonPiggable No.ofSVStation : Toconfirm DesignPressure : 42Bar OperatingPressure : NonFunctioning CPSystem : PCP Coating(External) : PE Coating(Internal) : None SourceGas : NonFunctioning TypeofGas : NonFunctioning PipeThickness : 6.35mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 12NB TotalLength : 16.00km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : Asperrequirement PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.4 UnderaGIPCLPipeline CurrentStatus: PipelineSize : 12NB TotalLength : 6.23km. Yearofcommissioning : 1990 Piggability : NonPiggable No.ofSVStation : DesignPressure : 64Bar OperatingPressure : 30kg/cm2 CPSystem : PCP Coating(External) : DensoType Coating(Internal) : None SourceGas : RLNG TypeofGas : DryGas PipeThickness : 6.35mm CompliancetoPNGRB : No ProposedFacilities PipelineSize : 12NB TotalLength : 6.23km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 30kg/cm2 PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : PDIdata(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.5 DabkatoDhuvaranPipeline CurrentStatus: PipelineSize : 12NB TotalLength : 37.62km. Yearofcommissioning : 1990 Piggability : Piggable No.ofSVStation : Toconfirm DesignPressure : 64Bar OperatingPressure : 30kg/cm2 CPSystem : PCP Coating(External) : PE Coating(Internal) : None SourceGas : RLNG TypeofGas : DryGas PipeThickness : 6.35mm CompliancetoPNGRB : No ProposedFacilities PipelineSize : 12NB TotalLength : 37.62km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 30kg/cm2 PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.6 ChokaritoUnderaPipeline CurrentStatus: PipelineSize : 12NB TotalLength : 25.96km. Yearofcommissioning : 1990 Piggability : Piggable No.ofSVStation : Toconfirm DesignPressure : 64Bar OperatingPressure : 30kg/cm2 CPSystem : PCP Coating(External) : PE Coating(Internal) : None SourceGas : RLNG/ONGC TypeofGas : Dry/WetGas PipeThickness : 6.35mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 12NB TotalLength : 25.96km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 30kg/cm2 PipeGrade : API5L,X60 CorrosionAllowances : 3.0mm PipeThickness : 9.5mm StationFacilities : AsperP&ID(AfterverificationfromSite) Coating(External) : 3LPE Coating(Internal) : InternalEpoxy SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.7 GNAQtoJambusarPipeline CurrentStatus: PipelineSize : 8NB TotalLength : 13.00km. Yearofcommissioning : 1989 Piggability : Piggable No.ofSVStation : Toconfirm DesignPressure : 64Bar OperatingPressure : 40kg/cm2 CPSystem : PCP Coating(External) : Coldappliedtape Coating(Internal) : None SourceGas : GNAQ TypeofGas : WetGas PipeThickness : 4.78mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 8NB TotalLength : 13.00km.(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 40kg/cm2 PipeGrade : API5L,X56 CorrosionAllowances : 3.0mm PipeThickness : 8.7mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.8 DabkatoSarsawaniPipeline CurrentStatus: PipelineSize : 8NB TotalLength : 16.60km. Yearofcommissioning : 1986 Piggability : Piggable No.ofSVStation : DesignPressure : 48Bar OperatingPressure : 12kg/cm2 CPSystem : PCP Coating(External) : PE Coating(Internal) : None SourceGas : Dabka TypeofGas : WetGas PipeThickness : 5.56mm CompliancetoPNGRB : Yes ProposedFacilities PipelineSize : 8NB TotalLength : 16.60km.(approx.) DesignClass : 300# DesignTemperature : (29C)to(+65C) OperatingPressure : 12kg/cm2 PipeGrade : API5L,X56 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm(ClassII) StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.9 JOLWAtoGACLPipeline CurrentStatus: PipelineSize : 8NB TotalLength : 7.80km. Yearofcommissioning : 2004 Piggability : NonPiggable No.ofSVStation : DesignPressure : OperatingPressure : CPSystem : None Coating(External) : None Coating(Internal) : None SourceGas : JOLWA TypeofGas : WetGas PipeThickness : CompliancetoPNGRB : No ProposedFacilities PipelineSize : 8NB TotalLength : 7.80km.(approx.) DesignClass : 150# DesignTemperature : (29C)to(+65C) OperatingPressure : kg/cm2 PipeGrade : API5L,X56 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : None CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.10 8PipelineSections(300#,CarbonSteel) CurrentStatus:

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

CP Source PNGRB

3.11.1 KalolGGSIFFCO(NG) 2.51 8 5.56 1974 PCP Abandoned No3.11.2 KADI GMSSK CTF

NKCTF16.85 8 5.56 1980 PCP CTFSKADI Yes

3.11.3 Motera GCSRelianceCompressorSugad

3.72 6 4.77 1997 SacrificialAnode

Motera No

Piggability : NonPiggable No.ofSVStation : DesignPressure : 48Bar OperatingPressure : 046kg/cm2 Coating(External) : Coaltar Coating(Internal) : None TypeofGas : WetGas ProposedFacilities PipelineSize : 8NB TotalLength : Asperabovetable(Existing)(approx.) DesignClass : 300# DesignTemperature : (29C)to(+65C) OperatingPressure : 0406kg/cm2 PipeGrade : API5L,X56 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.11 8PipelineSections(150#,CarbonSteel) CurrentStatus

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE

Source PNGRB CoatingType

3.12.1 Shobhasan CTF Dudhsagar

9.20 8 5.56 1975 Wet MEHSOBCTF

No Coaltar

3.12.2 Alembic to Dineshmill

3.50 8 5.56 1969 Dry RLNG No Coaltar

3.12.3 I/C GGSKOSAMBAP/L

2.20 6 6.35 1985 Wet No CTE

3.12.4 GACLP/L 11.25 6 4.78 1996 Dry RLNG Yes PE3.12.5 GUJRATGLASSP/L 2.70 6 4.78 1992 Wet Ankleshw

arNo CTE

Piggability : NonPiggable No.ofSVStation : DesignPressure : 10.019.0Bar OperatingPressure : 0312kg/cm2 Coating(Internal) : None CPSystem : PCP ProposedFacilities PipelineSize : 8NB TotalLength : Asperabovetable(Existing)(approx.) DesignClass : 300# DesignTemperature : (29C)to(+65C) OperatingPressure : 0312kg/cm2 PipeGrade : API5L,X56 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.12 4PipelineSections(600#,CarbonSteel) CurrentStatus

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE

Source CoatingType

CPTYPE

3.13.1LaxmipuraWestern 2.05

4 4.78 1978 Wet RLNG /DABKA

CoalTar PCP

3.13.2LaxmipuraRotomould 1.25


CoalTar PCP

3.13.3RotomouldBanco 3.20


CoalTar PCP

3.13.4BancoTranspek 3.83


CoalTar PCP

3.13.5 GACLTapoffGACL 4.80 4 4.80 1990 Dry RLNG CoalTar PCP3.13.6 NadeswariTpt.Dipak

Nitrate 2.974 6.40 1996 Dry RLNG PE Sacrifi

cial3.13.7 VaghodiaComp.ApolloTyre 1.70

4 6.40 2004 Dry RLNG PE PCP

3.13.7 BarsadacharrastaFlorochem 7.024 6.40 2004 Dry RLNG PE PCP

Piggability : NonPiggable No.ofSVStation : DesignPressure : 6492Bar OperatingPressure : 1290kg/cm2 Coating(Internal) : None PNGRB : No ProposedFacilities PipelineSize : 4NB TotalLength : Asperabovetable(Existing)(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 1290kg/cm2 PipeGrade : API5L,X42 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID CPSystem : PCP3.13 4PipelineSections(300#,CarbonSteel) CurrentStatus

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE

Source CoatingType

CPTYPE

3.14.01 RANASANTPOINTRELIANCE 2.85

4 4.77 1989 Wet Kalol /Ramol

CoalTar PCP

3.14.02 SchottGlassBancoProducts 0.75

4 6.40 1988 Dry RLNG PE Sacrificial

3.14.03 RANASANTPOINTRELIANCE 2.88


PE PCP

3.14.04 RANASANTPOINTSHYAMIND. 1.30


PE PCP

3.14.05 EPSWASNAUNIVERSALMETAL

0.614 10.00

(MDPE)

2002 Wet Wasna

3.14.06 GGS5BAGWATIGLASS 1.954 5.00 1993 PipelineAbandoned

3.14.07 EPSNANDASANNIRMA 4.97

4 4.36 1995 Wet Nandasan

PE PCP

3.14.08 EPSNANDASANSTERLING 2.84


PE PCP

3.14.09 EPSNANDASANTOSTERLING(k) 0.52


PE PCP

3.14.10EPSWADUPIONEER 0.35

4 4.36 1996 Wet Wadu PE Sacrificial

3.14.11 SANANDGGSJALARAM 1.17

4 4.36 1996 Wet SANNDJLRA

PE Sacrificial

3.14.12 SHOBHASANCTFSAHJANAND 3.28

4 4.36 1996 Wet MEHSOBCTF

PE Sacrificial

3.14.13 SAHJANANDP/LT/OASHOK/RAMESH 0.3594 4.36 1996 Wet MEH PE Sacrifi

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE

Source CoatingType

CPTYPE

SOBCTF cial3.14.14 SAHJANANDP/LT/O

STANDARD 0.14 4.36 1996 Wet MEH

SOBCTFPE Sacrifi

cial3.14.15 Ankhi(Tap)Schott

Glass 3.24 4.36 1995 Dry RLNG PE Sacrifi

cial3.14.16 EkalbaraBelgium

Glass 74 2000 Dry RLNG PE Sacrifi

cial3.14.17

Chitral(Tap)HNPL 5.24 5.36 1996 NonFunctional PE Sacrifi

cial3.14.18 Masar(Tap)SavanaCeramic 2.752

4 4.36 1996 Dry RLNG PE PCP

3.14.19 SavanaCeramicGujaratGlass 0.124 4.36 1996 Dry RLNG PE PCP

3.14.20DabkaJantaGlass 1.96

4 4.80 2004 NonFunctional PE Sacrificial

3.14.21 Gavasad(Tap)BellGranito/HaldyanGlass 0.9

4 4.80 1995 Wet Dabka /RLNG

PE Sacrificial

3.14.22 Gavasad(Tap)SourashtraSolid 0.55

4 6.40 2006 Wet Dabka /RLNG

PE Sacrificial

3.14.23 DabkaGGSHaldynGlass 0.9

4 1995 NonFunctional PE Sacrificial

3.14.24KanawaraGEAPAR 13

4 6.40 1996 NonFunctional PE Sacrificial

3.14.25 AsterSilicatetoPrabhat 0.15 4 4.78 3.14.26 LIMBODARAEPSAKASH 0.2

Piggability : NonPiggable No.ofSVStation : DesignPressure : 6492Bar OperatingPressure : 1290kg/cm2 Coating(Internal) : None PNGRB : No

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

ProposedFacilities PipelineSize : 4NB TotalLength : Asperabovetable(Existing)(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 1290kg/cm2 PipeGrade : API5L,X42 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID(Retaincurrent,ifpossible) CPSystem : PCP3.15 4PipelineSections(150#,CarbonSteel) CurrentStatus

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE


CPTYPE

3.15.1KalolCollectorLineBVM

1.704 4.78 1974 Wet Kalol No CoalTar PCP

3.15.2 BIGS P/L toBIGSIndus 3.044 4.78 1969 Dry RLNG No CoalTar PCP

3.15.3Vijapur U/GValve PT GMGB

0.134 4.78 1990 Wet MEH_S

OB_CTFNo CoalTar Sacrifi

cial

3.15.4TPointDudhsagar Santosh

2.254 4.78 1990 NotWorking No NotWorking

3.15.5BorosilP/L

13.104 4.78 1994 Wet ANK /

CPFGandh./RLNG

Yes PE PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE


CPTYPE

3.15.6VNGLP/L

0.804 4.78 1996 Wet CPF

Gandh./RLNG

No CTE PCP

3.15.7 PragatiGlassP/L 1.504 6.35

1992 Wet Anklshw

arNo CTE PCP

3.15.8 NeutralGlassP/L 1.104 6.35 1992 Wet Ankls. No CTE PCP

3.15.9 GSFCP/L 2.30 4 6.35 1992 Wet Anklsh. No CTE PCP3.15.10 CYA.&CHEM.OlpadP/L 1.20

4 4.78 2006 Wet Olpad No CTE Sacrificial

3.15.11 NaharP/L 0.854 6.35 2002 Wet Nahar No PE Sacrifi

cial

3.15.12TPointDudhsagar Ronak

0.502 4.78 1993 Wet MEH

SOBCTFNo CoalTar PCP

3.15.13 EPSWasna Sterling

3.904

10.00(MDPE)

1997

Wet Wasna No

3.15.14NandasanEPS AkikTiles

2.434 10.00

(MDPE)

1997 Wet Nandasan

No

3.15.15PaliyadTPSBhawani &Ajita

0.234 10.00

(MDPE)

1997 Wet PALLIYAD

No

3.15.16ShobhasanCTF VimalOil

3.824 10.00

(MDPE)

1997 Wet LIMBODARA

No

3.15.17Vimalterminal GMGB2

1.504 10.00

(MDPE)

1997 Wet MEHSOBCTF

No

3.15.18 Tpoint MLC2

0.284 10.00

(MDPE)

1997 NotWorking No

3.15.19 EPS AkoljoniSapnaChe.

3.404

(MDPE)

2003 NotWorking No

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

P/LSl.No.

Name Length(Km.)

Size(NB)

Thick.(mm)

Comm.Year

GASTYPE


CPTYPE

3.15.20 HaryanaSheetGlass

12.004 4.78 2003 Wet ANK /

CPFGAN/RLNG

Yes

PE PCP

3.15.21 KIM EPSP/L

1.203

(MDPE)

2004 Wet KIMEPS No

3.15.22MotwanP/L

3.202

(MDPE)

2003 Wet Motwan No

Piggability : NonPiggable No.ofSVStation : DesignPressure : 10.019.0Bar OperatingPressure : 0312kg/cm2 Coating(Internal) : None ProposedFacilities PipelineSize : 4NB TotalLength : Asperabovetable(Existing)(approx.) DesignClass : 600# DesignTemperature : (29C)to(+65C) OperatingPressure : 0312kg/cm2 PipeGrade : API5L,X42 CorrosionAllowances : 3.0mm PipeThickness : 7.1mm StationFacilities : AsperP&ID Coating(External) : 3LPE Coating(Internal) : None SVNos.&Locations : AsperP&ID CPSystem : PCP

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

3.14 CharacteristicsofNaturalGas

When handled properly Natural Gas is a safe fuel. It is a nonpoisonous, nontoxiccombustible sourceofenergy.NaturalGas iscomposedessentiallyofmethanewithminorquantitiesofethane,propane,carbondioxideandtracesofhigherhydrocarbonsandoxygen.Ithasaspecificgravityof0.598whichmeansitisonly59.8%asheavyasairanditrisesundernormalatmosphericconditions.

NaturalGascanbehazardousinthefollowingways

From asphyxiation through overexposure to natural gas, usually in a confinedspace, caused by inadequate ventilation or mechanical or accidental failure ofequipment.

Fromexplosionthroughanaccumulationofescapinggas,alsousuallyinaconfinedspace,beingignitedwhenmixedwithair.

Fromfirethroughtheuncontrolledburningofgas,usuallyafteranexplosion.

From overpressure through submitting gas facilities such as regulators, valves,gauges,etc,topressuresinexcessoftheirmaximumworkingpressure.

The Gas Quality Characteristics for above said Natural Gas Pipelines are shownbelow

KadiSource

ComponentsofNaturalGas Mole%

MethaneC1H4 80.0%

EthaneC2H6 5.00%

PropaneC3H8 5.00%

ButaneC4H10 2.00%

PentaneC5H12 2.00%

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

Hexane+C6H14+ 3.00%

CarbonDioxideCO2 2.00%

NitrogenN2 1.00%

UnderaSource


MethaneC1H4 72.1%

EthaneC2H6 9.16%

PropaneC3H8 9.62%

ButaneC4H10 4.14%

PentaneC5H12 0.75%

Hexane+C6H14+ 0.26%


NitrogenN2 0.10%

MehsanaSource


MethaneC1H4 70.080.0%

EthaneC2H6 5.008.00%

PropaneC3H8 2.007.00%

ButaneC4H10 3.005.00%

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

PentaneC5H12 0.002.00%

Hexane+C6H14+ 0.000.50%

CarbonDioxideCO2 4.008.00%

NitrogenN2 0.001.00%

BharuchSource


MethaneC1H4 96.93%

EthaneC2H6 1.35%

PropaneC3H8 0.50%

ButaneC4H10 0.23%

PentaneC5H12 0.00%

Hexane+C6H14+ 0.33%


NitrogenN2 0.11%

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

4.0 FACILITYPLANNED4.1 PipelineMaterial

Pipeline&itsappurtenancesshallbeprovidedwithcarbonsteelmaterialsuitablefortheintendedserviceasindicatedabove.

LinePipe

LSAW/ERW,LinepipeshallconfirmtoAPISpecification5L,PSL2Quality. ThegradeoflinepipeshallbeAPI5LGr.X70/60/42.PipewallthicknessshallconfirmtoASMEB31.8and shallalsomeet the requirementofOISD226/PNGRBRegulation. At rivercrossinghigherwallthicknessshallbeused.

PipelineFittingandFlanges

All pipeline materials such as pipe, valves, flanges and fittings etc. shall be of class600#/300#/150#asperrequirement.

MainlineValves/StationValves

AllmainlinevalvesarefullboreAVtypeanddesignedasperAPI6DandAPI6FA/API607firesafedesignrequirements.TheStationvalvesarereducebore/fullboreanddesignedasperAPI6DandAPI6FA/API607firesafedesignrequirements.

Isolationvalveinmainlineshallbebuttweldedtype. Flanges,TerminalPipes&Fittings

All aboveground piping system shall be seamless pipes of equivalent grade to match600#/300#/150#pressureand temperature ratingasper requirement. All fittingsshallconformtoANSI600#/300#/150#asperrequirement.

BallValves

Allballvalvesforterminalsshallbefullbore/reduceboretypeandshallbedesigned inaccordancewith API 6D.Underground ball valve shall havewelded configuration andabovegroundstationvalvescanbeaboltedconfiguration.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

FlowTees

Allbranchconnectiononthemainline,whicharegreaterthan40%ofmainlinewouldbeprovidedwith flow tees toallow smoothpassageofpigs.Flow teesmaterialwouldbesameasthatoflinepipe.

InsulatingJoint Insulating joints would be provided at transition point of aboveground & underground

portionofpipelineforelectricalisolation.Thesewillbemonoblocktypesuitableforbothabove/undergroundinstallations.

LRBends

Coldfieldbendsshallbeinaccordancewithcodesbutinnocasewitharadiusbelow40timesdiametersfor24NB&notradiusbelow30timesdiametersfor16NBpipeline&21timesdia.For8NB&4NBpipeline.

Induction bend shall only be used wherever space constraint is there. However atstationsitcanbeused.

4.2 PipelineExternalCorrosionProtection

ThreelayersofPECoatingshallbeprovidedforthepipeline. Temporary Cathodic Protection shall be provided to take care during construction

period. ImpressedCurrentbasedpermanentCathodicProtectionSystemshallbeprovided. Plotsforanodebedforaservicelifeof30yearsshallbeprovidedbytheclient.

5.0 PIPELINECONSTRUCTIONMETHODOLOGYANDCONSUMERCONNECTIVITY

Pipelineshallbeconstructedasperrelevantstandardandcodes.

IsolationValveshallbeprovidedateach2.5kmdistance,sothatifanyconsumercomesgascanbeprovidedandpartiallyconstructedpipelinecanbecommissionedbyclosingtheisolationvalve.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

5.1 MainPipeline

Incaseofsoftsoil,conventionaltrenchingandbackfillingcanbeconsideredforlayingofpipeline.

Incaseof sub surfaceencounteredbeingweathered rock,aminimumof150mm thicklayerofsoftbackfillmaterialshallbeprovidedallaroundthepipelinepriortobackfillingthe trenchwithexcavatedmaterial.Whereblastingcannotbecarriedoutdue tocloseproximityofexisting facilities,mechanicalequipment for rockexcavation canbeused.Conventionaltrenchingandbackfillingusingtrenchingmachinehasbeenconsideredforlayingofthepipelineinthesoftsoilareasotherthandescribedabove.

The type of corrosion coating selected (PE) for the pipeline has adequatemechanicalpropertiestowithstandthehardsurfacefeatures.Atypicalcoverofone(1)meteroverthetopofpipelineisconsidered.

5.2 PipelineCrossings

a) Rail

Railway linesshallbecrossedbyboringmethod. Approvalofdesignsandconstructionmethodologyshallbeobtained fromconcerned railwayauthorities. Pipelineat railwaycrossing shall be providedwith casing pipe. The carrier pipe shall be installed insidecasingpipe. Thecasingpipeshallbe threenominalsizes larger thancarrierpipe. Theminimumclearcoverat thecrossingabove topofpipelineshallbe1.7m. Thecrossingangle shall be as close to 90 as possible. The railway crossing shall complywith therequirementofAPI1102and IndianRailwayauthorities.Casing insulatorandsealsshallbeprovidedtoisolatecarrierandcasingpipes.

b) Road&Canal Roadcrossing shallcomplywith the requirementofAPI1102and requirementsof the

concernedroadauthorities. PipelineatNationalHighwaysandStateHighwaysCrossing

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

(whereverrequired)shallbeprovidedwith thecasingpipe. Metalledroadsother thanthenationalhighwaysandstatehighwaysshallbecrossedbyopencutmethod.Howeveratlocationswhereitisnotpossibletocrosstheroadbyopencutmethodboring/jackingmethodshallbeused.Nocasingpipeshallbeconsideredatsuchlocations.Allthecarttracks crossings shall be carried out by open cutmethod. The road crossing shall beprovidedwithminimumcoverof1.2mmeasuredfromtopofthecarrierpipe.

Irrigation land canals shall be crossed by boring method wherever required by the

statutoryauthorities.Allotherminorcanalsandnalacrossingsshallbecarriedoutwithconventionalopencutmethodunlessdirectedotherwisebyconcernedauthorities.Thecanal/drain/nalaandditchescrossingsshallbeprovidedwithaminimumclearcoverof1.5m.

c) RiverCrossing Allriverscrossingareproposedtobecrossedbyconventionalopencutmethodexcept

for the rivers specifically proposed to be crossed by HDD Method. Pipeline shall beinstalledapprox.1.5m (for rocky) /2.5m (fornormal soil)below the lowestbed level.Lowestbedlevelshallbecalculatedaftergivingdueconsiderationtoscourdepthofsuchwatercrossings.

Thelinepipeshallbeconcretecoated,ifrequiredtosufficientnegativebuoyancy.

Atallmajorcrossingtwonos.ofHDPEconduitsshallbe laid insteelcasingpipetotakecareoffuturerequirement.

6.0 SCADA&Telecommunication TheobjectiveofSCADA&Telecommunicationsystem istoensureeffectiveandreliable

control, management and supervision of the pipeline from centralized location usingRemote Terminal Unit (RTU) at different location of the pipeline section. Dedicated

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

Telecommunicationsystemshallbeimplementedforoperation,monitoring,controlandmaintenanceofthepipeline.

GAILhasdesire to replace inphasemannerapproximately460KmofGaspipeline for

safeoperation inGujaratRegionconsistingofnetworkforconsumersconnectivityfrom4to16spreadallacrossGujarat.

The existing pipelines are having dedicated SCADA system for effective and reliable

Control, Management and Supervision of pipelines. Dedicated OFC basedTelecommunication network implemented for Voice & Data connectivity of thesepipelines.GAIL ispresentlyMonitoring&Controlmostof thesepipeline&oldpipelinethroughCentralisedSCADAsystemsupplied&Commissionedby M/sYokogawahavingMasterControlStations(MSs)locatedatGAIL,NoidaandBackupControlStation(BCS)atJaipur.SomeofthepipelinenotmigratedincentralizedSCADAsystemispresentlyhavingitsowndedicatedSCADAsystemandlikelytobeconnectedtoCentralisedSCADAsysteminphasemanner.

AtpresentMS&BMSbe interlinkedwithRemoteTelemetryUnits(RTUs) locatedalong

the pipeline by dedicated optical fiber communication system (24 fibre Optical FiberarmouredCable asper ITUTG652 (18 fibre)&asper ITUTG655 (6 fibre)andSDHbased telecomequipmentandLeased line link.Similarphilosophywillbe implementedforallpresentaswellasfuturepipelines.

As Most of the terminal facilities are not included in the present replacement, the

existingequipmentsforSCADA&TelecommunicationSystemwillbeusedformonitoring&controlofthereplacedpipelinesandifrequiredforoldpipelinefacilities(tobedecidedby GAIL). However the dedicated Optical Fibre Cable (OFC) shall be laid by blowingtechniqueinHDPETelecomDuctforVoice&Dataconnectivity.

Foranynewpipeline/spurpipelinesimilarphilosophywillbeadoptedandimplemented.

Allnew terminal /SV locationsRemoteTelemetryUnits (RTU) shallbeconsideredand

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

interfaced with Centralised SCADA system of GAIL. For Telecom connectivity of newpipeline / spur pipeline apart from laying of dedicated OFC, new SDH equipment(minimumSTM1equipmentstoSTM4/16asperrequirements)shallbeprovidedandhookupwiththeexistingOFCbasedTelecomnetworkforVoice&Dataconnectivity.Asper present design philosophy alternate SV will be consider for remote operationhoweveralltheSVwillhaveactuatorsforremoteoperationsinfuture.

Present existing Centralised SCADA system is based on the concept of Open system

Interconnect (OSI)architecturemaximizing theuseof internationalstandard interfaces.Each functional server is redundant and connected to both systems LANs in a hotstandbyconfiguration.TheSCADAsystemcommunicatestoindividuallyIPaddressedRTU/DeviceondedicatedOFCnetwork.Backupcommunication linkbetweenMS,RWSandBCSareprovidedbyIndependentleasedline.TheMShavethecompleteSCADAdatabaseincludingtherealtimedatabaseandintegratedalarm/eventmanagementsummaryforoveralloperationsmanagement&controlfortheentirepipelinenetwork.

TheSCADAsystemiscompletelyredundantindesign,builtofdualredundantmodulesor

sub systems, like servers, networks,workstations, communication equipment, printersand storage devices. The HMI workstations at BCS and other RWS provide completeSCADAHMIcapabilityand access the MS as remote clients. Each RTU of remotelocationswillhavedualEthernet communicationports (configurable independently) tointerfaceon TCP/IP communication with SCADA system on multidroppedenvironment.ThatmeansRTUcancommunicate toSCADAatsame timewithboth theports independently.

APPSSystem ExistingAPPSsystemshallbeextendedfornew/replacementpipeline/spurpipeline.All

necessaryhardware&softwareshallbeprovidedbyGAILthroughexistingOEM.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

DataCommunicationatRemoteConsumerNotHavingControlRoomBuilding: At remoteconsumerendwherecontrol roombuildinghasnotenvisagedand required

real time process data to Centralised SCADA system, following philosophy will beimplemented:

At remote smallormedium consumerswillhavemetering skidwith FlowComputers;

processdata from FlowComputers connected to nearestRTU receiving stations / SVstation / IP stations using IP Ethernet to serial to OFC connectivity. If power is notavailablesmallsolarpowerwithbatterybankshallbeconsidered.

Telecommunication To facilitate the operation, monitoring, control and maintenance of the pipeline,

dedicated telecommunication system/ network is proposed to be installed along forpipeline.TheexistingTelecommunicationsystemcomprisesofSDH/PDH/IPbasedOFCnetworksystemalongwiththepipelineto facilitateproperoperational&managementcontrolofthepipeline.

OpticalFiberCable24FiberarmouredasperITUTG652(18fibre)&asperITUTG655

(6 fibre) is laid by Blowing Technique in 40 mm PLB HDPE Telecom duct in samepipelinetrench.Atcrossingadditionalductareprovidedforfutureuse.ThisOFCnetworkisintegratedwithexistingPipelineOFCNetworkofGAILforSCADA&Telecommunicationconnectivityatinterfacingstations.

AdedicatedEPABXSystemavailabletomeettheoptimumoperation,maintenanceand

safety requirementsofpipeline.Thiswillprovides various facilities suchas voice,dataandvideocommunicationfacilitiesamongthevariousattendedandunattendedstationsof the pipeline. The terminal facilitieswill have EPABX systemwithMDF including allgateways and telephones such as ordinary, explosion proof, digitalwithWork station(NetworkManagementCenter), screens,all softwareandaccessories,printer installed.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

Acoustic Telephone Booth with beacon, Weather proof Telephones are installed atselectivelocationasperrequirements.PhonesinstalledatReceiving,Despatch,SVandIPstations.

Similarphilosophyshallbeimplementedforthenew/replacedpipelinesandinterfaced

withexistingfacilities. Presently CCTV System not installed in any of the present lines considered for

replacement. If decided byGAIL, new CCTV systemwill be implemented subjected toavailabilityofbandwidth.

7.0 ELECTRICALFACILITIES Theworkwillinvolvethesupplyofpowerforthefollowingactivities.

a. TCPb. Telecommunicationload.c. Instrumentationd. Indoor&Outdoorlighting&othernoncriticalload&utilities.e. Firedetectionandalarmsystem

8.0 CIVIL/STRUCTUREFACILITIES

i) Controlroombuilding.ii) Geotechnicalsurvey.iii) Civilworkatdispatchterminal,SVstation&DRSwhich includesboundary

wall,Areafencing&gates,pipessupport&equipmentfoundation,canopyforfieldmountedinstrumentsetctobecarriedout.

9.0 FIREFIGHTINGFACILITIES

New firefighting facilities such as static firefighting equipment (HandAppliances),DCP/CO2/Cleanagent type fireextinguisheratDespatchTerminalandDRSshallbeinstalled.AllremoteoperatedunmannedstationshallbeprovidedwithCO2floodingsystemandallmannedstationshallbewithFM200firesuppressionsystem.

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

10.0 LISTOFSTANDARDSAmericanSocietyOfMechanicalEngineers ASMEB31.8 : GasTransmissionandDistributionPipingSystemASMEB31.8S : ManagingSystemIntegrityofGasPipelinesASMEB31G : ManualfordeterminingtheremainingofcorrodedpipelinesASMEB31Q : PipelinePersonnelQualificationASMEB16.25 : GasTransmissionandDistributionPipingSystemASMEB16.9 : FactoryMadeWroughtIronSteelButtWeldingFittingsASMEB31.3 : ProcessPipingASMEB16.5 : PipeFlangesandFlangedFittingsASMEB16.9 : FactoryMadeWroughtSteelButtWeldingFittingsASMEB16.10 : FacetoFaceandEndtoEndDimensionsofValvesASMEB16.11 : ForgedFittings,SocketWeldingandThreadedASMEB16.20 : MetallicGasketsforPipeFlangesRingJoint,SpiralWoundandJacketed.ASMEB16.21 : NonMetallicFlatGasketsforPipeFlangesASMEB16.25 : ButtWeldingEndsASMEB16.28 : WroughtSteelButtWeldingShortRadiusElbowsASMEB16.34 : ValvesFlanged,Threaded&WeldingEndsASMEB16.36 : OrificeFlangesASMEB16.47SeriesA : LargeDiameterSteelFlangesNPS26throughNPS60ASMEB18.2.1 : SquareandHex.BoltsandScrewsASMEB18.2.2 : SquareandHex.NutsASMEB31.3 : ProcessPipingASMEB36.10M : WeldedandSeamlessWroughtSteelPipeASME Boiler &Pressure VesselCodeSectionIX

:

Qualification standard forweldingandBrazingprocedures,welders,brazes,andweldingandbrazingoperators

ASME Boiler &Pressure VesselsCode SectionII PartC

: SpecificationsforWeldingRods,Electrodes,andFillerMetals

ASME Boiler &Pressure VesselCodeSectionV

: NondestructiveExamination

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

ASME Boiler &Pressure VesselCodeSectionII

: MaterialsPartAFerrousMaterialsSpecifications

AmericanPetroleumInstitute(API)

APISpec5L : SpecificationforLinePipe

APIRP1102 : RecommendedPracticeforLiquidPetroleumPipelinesCrossingRailroadsandHighwaysAPIStd1104 : StandardforWeldingPipelineandRelatedFacilitiesAPIRP1110 : RecommendedPracticeforthePressureTestingofLiquidPetroleumPipelinesAPIStd607 : FireTestforSoftSeatedQuarterTurnValves

APIRP500 : RecommendedpracticeforclassificationoflocationsofElectricalinstallationsatPetroleumFacilitiesclassifiedasClassI,Div.1and2.

API6D : Specificationforpipelinevalves(Gate,Plug,Ball,andCheckvalves)Spec6FA : SpecificationforFireTestforValvesSTD590 : SteelLineBlanksSTD594 : CheckValves,Wafer,WaferLugandDoubleFlangedTypeSTD598 : ValveInspectionandTestingSTD600 : SteelGateValvesFlangedorButtWeldingEnds,BoltedandPressureSealBonnetsSTD602 : CompactSteelGateValvesFlanged,Threaded,WeldingandExtendedBodyEnds.STD607 : FireTestforSoftSeatedQuarterTurnValves

BritishStandardInstitute

BS1868 : Steel Check Valve (Flanged and ButtWelding Ends) for Petroleum, PetroChemicalandAlliedIndustries

BS1873 : SteelGlobe,GlobeStopandCheckValves (FlangedandButtWeldingEnds)forthePetroleum,PetrochemicalandAlliedIndustries

BS5154 : CopperAlloyGlobe,GlobeStopandCheck,CheckandGateValves

BS5351 : SteelBallValvesforPetroleum,PetrochemicalandAlliedIndustries

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

BS5352 : SteelWedgeGate,GlobeandCheckValves50mmandSmallerforPetroleum,PetroChemicalandAlliedIndustries

BS6755PartI : TestingofValvesPart1:ProductionPressureTestingRequirements

BS6755Part2 : TestingofValvesPart2:SpecificationforFireTypeTestingRequirements.

EN2889 :Specificationandapprovalofweldingproceduresformetallicmaterialspart9.Weldingproceduretestforpipelineweldingonlandandoffshoresitebuttweldingoftransmissionpipeline

NDBEN1594 : Gassupplysystemspipelineformaximumoperatingpressureover16barFunctionalrequirements

NBNEN102082 : SteelpipesforpipelinesforcombustiblefluidsTechnicaldeliveryconditionsPart2

ISO155901 : InternationalStandard forPetroleumandnaturalgas industries Inductionbends,fittingsandflangesforpipelinetransportationsystems

DIN30672 : Coatings of corrosion protection tapes and heatshrinking products forpipelinesforoperationaltemperaturesupto50C

SEL0721stEdition : UltrasonicallytestedheavyplateDIN20670 : PolyethylenecoatingsforsteelpipesandfittingsDIN2413PartII : DesignofsteelbendsusedinpressurepipelinesISO/TR5168 : MeasurementoffluidflowEvaluationofuncertainties

OilIndustrySafetyDirectorate(OISDStandards)

OISDGDN115 : GuidelinesonFireFighting,EquipmentandappliancesinPetroleumIndustryFire ProtectionManual: : FireEngines,TrailerPumpsandHydrantSystems

OISDStandard141 : Design and construction requirements for cross country hydrocarbonpipelinesOISDStandard118 : LayoutsforoilandgasinstallationsOISDStandard226 : NaturalGasPipelinesandCityGasDistributionNetworksOISDSTD105 : WorkPermitSystem

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

OISDStandard138 : InspectionofcrosscountrypipelinesOnshoreOISDStandard113 : Classification of Area for electrical installations at Hydrocarbon processingandhandlingfacilities

OISDStandard117 : FireProtectionFacilitiesforPetroleumDepots,Terminals,PipelineInstallationsandLubeOilInstallations

OISDStandard142 : InspectionofFireFightingEquipments&Systems

OISDStandard189 : StandardOnFireFightingEquipmentForDrillingRigs,WorkOverRigsAndProductionInstallations

OISDStandard163 : Processcontrolroomsafety

OISDStandard192 : SafetyPracticesDuringConstruction

OISDStandard207 : ContractorSafetyDuringConstructionOISDStandard233 : GuidelinesoninspectionofNonpiggablepipelines AmericanSocietyforTestingandMaterials(ASTM)

ASTMA82 : StandardSpecificationforSteelWire,Plain,forConcreteReinforcement

ASTMA185 : Standard Specification for Steel Welded Wire Fabric, Plain, for ConcreteReinforcementASTME92 : StandardTestMethodforVickersHardnessTestingofMetallicMaterialsASTME94 : StandardPracticeforRadiographicTestingASTME165 : StandardPracticeforLiquidPenetrateInspectionMethodASTME709 : StandardGuideforMagneticParticleExaminations

ManufacturersStandardizationSociety(MSS)

MSSSP75 : SpecificationforHighTestWroughtWeldingFittingsMSSSP6 : StandardFinishesforContactFacesMSSSP9 : SpotFacingforBronze,IronandSteelFlangesMSSSP25 : StandardMarkingSystemsforValves,Fittings,FlangesandUnion

MECON LIMITED DELHI



GUJARAT REGION


MEC/23PH/05/28/M/001/001 Revision - 0

AmericanGasAssociation(AGA)StandardsAGA7 : MeasurementofNaturalGasbyTurbineMeterAGA8 : CompressibilityFactorofNaturalGasandRelatedHydrocarbonGasesAGA9 : MeasurementofGasbyMultipathUltrasonicMeters

Design Basis

Documents

Transcript of Design Basis