IGEM-UP-1C Draft For Comment - 2nd Consultation (IGEM-TSP-10-122)

INSTITUTION OF GAS ENGINEERS AND MANAGERS IGEM/TSP/10/122
Founded 1863
IGEM/UP/1C Royal Charter 1929
Communication XXXX Patron
Her Majesty the Queen

STRENGTH TESTING, TIGHTNESS TESTING AND DIRECT
PURGING OF NATURAL GAS AND PROPANE METER
INSTALLATIONS

DRAFT FOR COMMENT

1 This draft Standard IGEM/UP/1C has been prepared by a Panel under the chairmanship
of Dave Blackburn.

2 This Draft for Comment is presented to Industry for comments which are required by
21
st
May 2010, and in accordance with the attached Reply Form.

3 This is a draft document and should not be regarded or used as a fully approved and
published Standard. It is anticipated that amendments will be made prior to
publication.
It should be noted that this draft Standard contains intellectual property
belonging to IGEM. Unauthorised copying or use by any unauthorised person
or party is not permitted.

4 This is a copyright document of the Institution of Gas Engineers and Managers.
Enquiries should be addressed in the first instance to:
Nick Cowling
IGEM
IGEM House
26-28 High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: nick@igem.org.uk
IGEM/UP/1C Draft for Industry Comment (2nd Consultation)
Since IGEM/UP/1C was last issued for Comment (9th March 2009) the Panel has responded to
the Comments received and made changes where appropriate. In addition to this, the Panel
made other amendments to the document including changing the scope. Therefore the
Standard is being re-issued for Industry Comment. To assist with this 2
nd
Consultation, a
summary of the amendments is given below.

Section 2 Scope
Clause 2.1
New. Inclusion of propane meter installations.

Note: Butane is not included as its use is normally limited to cylinders.

Clause 2.3
Amended. Rewording of when Strength/tightness Tests are required.

Clause 2.8
New. IGEM/UP/1C adopts the concept of Gauge readable movement and but accepts that the
concept of No perceptible movement can be used.

Figure 3
New. Inclusion of typical installation diagrams.

Section 4 Strength Testing
Sub-Sections 4.1 to 4.2
New. Guidance on when and how to carry Strength Tests.

Sub-Section 4.3 and Figures 4(a) to (g)
New. Information for testing installations with a pressure break.

Tables 1 to 4
New. Example STP values for Natural Gas and Propane installations.

Table 5 - Selection of Strength test duration
Amended. The values given have been simplified.

Table 6 Safety distances
Amended. The values given have been simplified.

Section 5 Tightness Testing
Sub-Section 5.1
New. Further information on when a tightness test is carried out has been included.

Sub-Section 5.2
Amended. Removal of New and Existing procedures. All installations are now covered by one
procedure.

Sub-Section 5.3 and Figures 6(a) to (c)
New. Information for testing installations with a pressure break.

Sub-Section 5.4 and Tables 7, 8, 9 Tightness test durations
Amended. Test times have been provided. The calculation method for TTD has been moved to
Appendix 4.

Sub-Section 5.5.4
Amended. Removal of existing and new installation procedures, just one procedure provided.

Figure 7 and 8
Amended. Flowcharts given for testing with Fuel Gas and Nitrogen.

Appendix 5
New. Inclusion of risk assessment for purging heavier than air gases.
Organisations to which this Draft for Comment has been issued:
Association of Independent Gas Transporters (AIGT)
Association of meter operators (AMO)
British Standards Institution (BSI)
Chartered Institute of Building Services Engineers (CIBSE)
Chartered Institute of Heating and Plumbing Engineers (CIHPE)
Construction Industry Training Board (CITB)
Council for Registered Gas Installers (CORGI)
Distribution Network Owners
Energy Institute
Gas Industry Safety Group (GISG)
Gas Safe Register
Health and Safety Executive (HSE)
National Grid
National Grid Metering
Northern Gas Networks
Office of Gas and Electricity Markets (OFGEM)
Ofgem MAMCOP Management Board
Scotiagas Networks
Society of British Gas Industries (SBGI)
The Gas Forum
Wales and West Utilities
UKLPG
IGEM Committees and Panels

Founded 1863
Royal Charter 1929
Patron: Her Majesty the Queen

IGEM/UP/1C
Communication XXXX
Strength testing, tightness testing and
direct purging of Natural Gas and Propane
meter installations

Draft for Comment (2
nd
Consultation)

Price Code: XXX
The Institution of Gas Engineers and Managers
IGEM House
High Street
Kegworth
Derbyshire, DE74 2DA
Tel: 0844 375 4436
Fax: 01509 678198
Email: general@igem.org.uk

IGEM/UP/1C
Communication XXXX
Strength testing, tightness testing and
direct purging of Natural Gas and Propane
meter installations

Draft for Comment (2
nd
Consultation)

Copyright 2010, IGEM. All rights reserved
Registered charity number 214001

All content in this publication is, unless stated otherwise, the property of IGEM. Copyright laws
protect this publication. Reproduction or retransmission in whole or in part, in any manner,
without the prior written consent of the copyright holder, is a violation of copyright law.

ISBN 978 1 905903 XX X
ISSN 0367 7850
Published by the Institution of Gas Engineers and Managers

Previous Publications:
There are no previous publications.

For information on other IGEM Standards please visit our website, www.igem.org.uk

IGEM/UP/1C Draft for Comment (2nd Consultation)

IGEM, IGEM House, High Street, Kegworth, Derbyshire, DE74 2DA. Website igem.org.uk.
CONTENTS

SECTION PAGE

1 Introduction 1

2 Scope 4

3 Legal and allied considerations 6

4 Strength testing 7
4.1 Decision whether to strength test 7
4.2 Strength test methodology 7
4.3 Determination of MOP and MIP 8
4.4 Method, pressure, duration and test criteria for strength testing 12
4.5 Procedures 12

5 Tightness testing 16
5.1 Decision whether to tightness test 16
5.2 General 16
5.3 Determination of TTP 17
5.4 Tightness test duration (TTD) 18
5.5 Procedures tightness testing 19
5.5.1 By-passing components 19
5.5.2 Ambient conditions 19
5.5.3 Section and valve isolation 19
5.5.4 Testing 19
5.6 Completion 20

6 Direct purging 24
6.1 General 24
6.2 Planning and supervision 24
6.3 Site precautions 25
6.3.1 Warning notices and labels 25
6.3.2 Electrical and fire 25
6.4 Designing and positioning purge points, hoses and vent stacks 26
6.5 Verification of purge velocity 27
6.6 Identification of purge gas cylinders 27
6.7 Gas detectors, oxygen measuring devices and other
electronic equipment 27
6.8 Determination of the purge volume, minimum purge flow rate
and purge time 28
6.9 Vent gas testing 29
6.10 Purging procedures 29
6.10.1 Direct purging from air to gas i.e. commissioning 29
6.10.2 Direct purging from gas to air i.e. de-commissioning 31

APPENDIX

1 Glossary, acronyms, abbreviations, units, subscripts and symbols 35

2 References 37

3 Indirect purging with nitrogen 39

4 Calculation of tightness test duration 41

5 Purging heavier-than-air gases risk assessment 44

FIGURES

1 Algorithm to select testing and purging standards 2

2 Relative pressure levels 2

3 Typical schematic meter installations 5

4 Pressure breaks. Strength requirements 9-10

5 Flowchart/decision algorithm for strength testing 15

6 Pressure breaks. Tightness test requirements 17-18

7 Flowchart/decision algorithm for tightness testing with air or Nitrogen 21

8 Flowchart/decision algorithm for tightness testing with fuel gas 22

9 Flowchart for direct purging of air to gas 33

10 Flowchart for direct purging of gas to air 34

TABLES

1 Example 1. A low pressure outlet fed from a low pressure network (NG) 11

2 Example 2. A low pressure outlet fed from a
medium pressure network (NG) 11

3 Example 3. A low pressure outlet fed from a low pressure network
(Propane) - BS 3016 regulators 11

4 Example 4. A low pressure outlet fed from a medium pressure network
(Propane) - BS 3016 regulators 11

5 Selection of the method, pressure, duration, and the test
criteria for strength testing 12

6 Safety distances each side of an installation for strength testing
at STP exceeding 1 bar 13

7 Tightness test duration for typical installations and using a
pressure gauge with a GRM of 0.5 mbar 20

8 Calculated tightness test durations (mins) for RD and turbine meters
using a gauge with a GRM of 0.5 mbar (Natural Gas) 23


9 Calculated tightness test durations (mins) for RD and turbine meters
using a gauge with a GRM of 0.5 mbar (Propane) 23

10 Minimum purge flow rate and velocity with recommended minimum
purge point, associated vent and flare stack dimensions 29

11 Flammability limits and safe purge end points 29

12 Minimum quantity of nitrogen per 1 m length of pipe 39

13 Flammability limits and safe purge end points for inert purge 40

14 Installation volume (IV) of meters 41

15 Volume of 1 m length of pipe 42

16 Selection of pressure gauges (typical data) 42

17 Factor F1 to apply when calculating TTD 43


1
SECTION 1 : INTRODUCTION

1.1 This Standard has been drafted by an Institution of Gas Engineers and Managers
(IGEM) Panel, appointed by IGEMs Gas Utilization Committee, and has been
approved by IGEMs Technical Co-Ordinating Committee on behalf of the Council
of IGEM.

1.2 It is necessary to check the scope of referenced standards given below. Figure 1
shows the most suitable Standard for a particular situation.

IGEM/UP/1C deals with strength testing, tightness testing and direct purging of
meter installations (as defined in IGEM/G/1), containing either Natural Gas (NG)
or Propane, of volume not exceeding 1 m
3
and MOP not exceeding 7 bar.

IGE/UP/1 Edition 2 deals with all aspects of strength testing, tightness testing
and direct purging of selected 1
st
, 2
nd
and 3
rd
family gases. For example, for NG,
it covers pipework downstream of the emergency control valve (ECV) of
maximum operating pressure (MOP) not exceeding 16 bar.

IGE/UP/1A Edition 2 deals with strength testing, tightness testing and direct
purging of NG installations of volume not exceeding 1 m
3
and diameter not
exceeding 150 mm, of MOP (and operating pressure (OP)) not exceeding 40
mbar and supply MOP not exceeding 75 mbar.

IGE/UP/1B Edition 2 deals with tightness testing and purging of NG installations
of volume not exceeding 0.035 m
3
, capacity not exceeding 16 m
3
h
-1
, diameter
not exceeding 35 mm, OP not exceeding 21 mbar and supply MOP not
exceeding 2 bar.

Note: At the time of publication, it is anticipated that IGEM/UP/1B Edition 3 will cover LPG.

BS 5482-1 deals with tightness testing of domestic-sized liquefied petroleum
gas (LPG) pipework (volume not exceeding 0.02 m
3
). For greater volume,
IGE/UP/1 Edition 2 applies.

Note: See above regarding LPG in IGEM/UP/1B Edition 3.

If it is preferred (it is not recommended, as it is more complex to follow)
IGE/UP/1 Edition 2 can be used rather than IGE/UP/1A Edition 2, IGE/UP/1B,
IGEM/UP/1C or BS 5482-1.

If IGE/UP/1A Edition 2 or IGE/UP/1B Edition 2 or IGEM/UP/1C or BS 5482-1 are
not indicated, then it is essential that IGE/UP/1 Edition 2 is used. At the time of
publication, neither IGE/UP/1B Edition 2 nor BS 5482-1 require strength testing.


2
START
NATURAL GAS OR
PROPANE METER
INSTALLATION?
YES
NO
NATURAL GAS
INSTALLATION?
MOP 7 bar AND V 1 m
3
AND no
PE included AND isolated at outlet of
the meter installation?
OP and MOP 40 mbar AND supply
MOP 75 mbar AND V 1 m
3
AND
150 mm?
IGEM/UP/1C
IGE/UP/1A
EDITION 2
NO
YES
YES
YES
NO
LPG
INSTALLATION?
Supply MOP 2 bar AND
OP 21 mbar AND 35 mm AND
meter capacity 16 m
3
h
-1
AND
V 0.035 m
3
?
NO
28 mm AND
V 0.02 m
3
?
BS 5482-1
IGE/UP/1B
EDITION 2
YES
YES
YES
NO
NO
NO
IGE/UP/1
EDITION 2

FIGURE 1 - ALGORITHM TO SELECT TESTING AND PURGING STANDARDS

1.3 MOP and other new terms such as maximum incidental pressure (MIP) and
OP have been introduced to reflect gas pressure terminology used in European
standards. IGEM/G/4 defines these terms and IGE/GM/8 Part 1 explains them in
greater detail.

Referring to Figure 2, note how OP is shown to oscillate about the set point
(SP). Note also that MOP can be declared at any value from OP upwards to a
limit below MIP. The strength test pressure (STP) has to be at least 110% MIP
and in many cases (see Table 5) will be greater.

STP = Strength test pressure
MIP = Maximum incidental pressure (for example, as declared by the GT/MAM)
OP = Operating pressure
MOP = Maximum operating pressure
SP = Set point of the regulator.

Note: This is extracted from IGE/TD/13 and simplified for the purposes of IGEM/UP/1C.
FIGURE 2 - RELATIVE PRESSURE LEVELS

3
1.4 This Standard makes use of the terms should, shall and must when
prescribing particular requirement. Notwithstanding Sub-Section 1.7:
the term must identifies a requirement by law in Great Britain (GB) at the
time of publication
the term shall prescribes a requirement which, it is intended, will be
complied with in full and without deviation
the term should prescribes a requirement which, it is intended, will be
complied with unless, after prior consideration, deviation is considered to be
acceptable.

Such terms may have different meanings when used in legislation, or Health and
Safety and Executive (HSE) Approved Code of Practice (ACoPs) or guidance, and
reference needs to be made to such statutory legislation or official guidance for
information on legal obligations.

1.5 The primary responsibility for compliance with legal duties rests with the
employer. The fact that certain employees, for example responsible engineers,
are allowed to exercise their professional judgement does not allow employers
to abrogate their primary responsibilities. Employers must:
have done everything to ensure, so far as it is reasonably practicable, that
responsible engineers have the skills, training, experience and personal
qualities necessary for the proper exercise of professional judgement
have systems and procedures in place to ensure that the exercise of
professional judgement by responsible engineers is subject to appropriate
monitoring and review
not require responsible engineers to undertake tasks which would
necessitate the exercise of professional judgement that is not within their
competence. There should be written procedures defining the extent to
which responsible engineers can exercise their professional judgement.
When responsible engineers are asked to undertake tasks which deviate
from this they should refer the matter for higher review.

1.6 It is now widely accepted that the majority of accidents in industry generally are
in some measure attributable to human as well as technical factors in the sense
that actions by people initiated or contributed to the accidents, or people might
have acted in a more appropriate manner to avert them.

It is therefore necessary to give proper consideration to the management of
these human factors and the control of risk. To assist in this, it is recommended
that due regard be paid to HSG48.

1.7 Notwithstanding Sub-Section 1.4, this Standard does not attempt to make the
use of any method or specification obligatory against the judgement of the
responsible engineer. Where new and better techniques are developed and
proved, they should be adopted without waiting for modification to this
Standard. Amendments to this Standard will be issued when necessary, and
their publication will be announced in the Journal of the Institution and other
publications as appropriate.

1.8 Requests for interpretation of this Standard in relation to matters within its
scope, but not precisely covered by the current text, should be addressed in
writing to Technical Services, IGEM, IGEM House, High Street, Kegworth
Derbyshire, DE74 2DA and will be submitted to the relevant Committee for
consideration and advice, but in the context that the final responsibility is that of
the engineer concerned. If any advice is given by or on behalf of IGEM, this
does not relieve the responsible engineer of any of his or her obligations.

1.9 This Standard was published in June 2010.

4
SECTION 2 : SCOPE

2.1 This Standard applies for any meter installation (as defined in IGEM/G/1 and
IGEM/G/4) or section of a meter installation:
supplying Natural Gas or propane

Note: This Standard does not cover Butane as its use is normally limited to cylinders.
of MOP 7 bar
of volume not exceeding 1 m
3

having a method of temporarily sealing the outlet of the installation/section,
for example a valve, blanking device, etc.
not including polyethylene (PE) pipe or fittings
which is not within scope of IGE/UP/1B.

Note 1: The diversity of meter installations is such that it is inappropriate to provide detailed
guidelines for all types of installation covered by the scope of this Standard. It is recognised
that special circumstances may occur, on a meter installation, for which some of the
requirements in this Standard cannot be applied. In such a case, IGE/UP/1 applies and the
procedure needs to be developed by personnel of adequate competency and experience.

Certain legacy meter installations do not comply with the Standard arrangements given in
IGEM/G/1. The principles of this Standard may be applied to the majority of such legacy
installations.

Note 2: Meter installation or section of a meter installation is hereafter referred to as
installation.

2.2 This Standard covers pneumatic strength testing and tightness testing, and
direct purging. It does not address hydrostatic testing.

2.3 This Standard covers strength testing and/or tightness testing in the following
circumstances:
prior to a new installation being commissioned with gas,
where a leak is suspected to exist on an existing installation,
where a new section has been added into an existing installation,
where there has been a complete loss of pressure, for any reason, for
example component replacement, section replacement, etc.

Typical schematic installations are shown in Figure 3.

2.4 This Standard covers direct purging in the following circumstances:
new installation
alteration to, replacement of, or re-use of, an existing installation
where there has been a complete loss of pressure for any reason

Note: The closure of a valve, for example the ECV, can result in a complete loss of pressure
which necessitates tightness testing and purging before resumption of supply.
where there is the possibility of air being present in an installation
where an installation is to be taken temporarily or permanently out of
service.

2.5 All pressures quoted are gauge pressures unless otherwise stated.

2.6 Italicised text is informative and does not represent formal requirements.

2.7 Appendices are informative and do not represent formal requirements unless
specifically referenced in the main sections via the prescriptive terms should,
shall or must.


5
2.8 IGEM/UP/1C adopts the concept of Gauge readable movement (GRM). When
using a water gauge, it may be possible to reduce the duration of tests by
adopting the concept of no perceptible movement.

M
M
Downstream system kept
pressurised
M
pressurised
M
M
pressurised
M
M
M

FIGURE 3 - TYPICAL SCHEMATIC METER INSTALLATIONS

6
SECTION 3 : LEGAL AND ALLIED CONSIDERATIONS

3.1 This Standard is set out against a background of legislation in force in GB at the
time of publication. Similar considerations are likely to apply in other countries
where reference to appropriate national legislation is necessary.

All relevant legislation must be applied and relevant ACoPs, official Guidance
notes and referenced codes, standard, etc. shall be taken into account.

Where standards are quoted, equivalent national or international standards etc.
equally may be appropriate. Unless otherwise stated, the latest version of the
referenced document should be used.

3.2 Any person engaged in strength testing, tightness testing or purging of pipework
must be a competent person.

Note: Any person carrying out the installation of gas pipework and associated fittings must be
competent to do so. Where gas installation work is carried out in properties covered by the
current Gas Safety (Installation and Use) Regulations (GS(I&U)R), the persons carrying out
that work must be a member of a class of persons as specified by those Regulations.

Persons who are deemed competent to carry out gas work under GS(I&U)R are those who
hold a current certificate of competence in the type of activity to be conducted issued under
aligned SN/NVQ arrangements, or by a certification body accredited by the United Kingdom
Accreditation Service (UKAS) for the Nationally Accredited Certification Scheme (ACS).

3.3 Consideration shall be given to the environmental impact of methane and other
hydrocarbons in the atmosphere.

3.4 In the following situations, any electronic equipment used shall be certified for
use in a hazardous area:
when seeking the source of a known or suspected gas leak, using a gas
detector
when a hazardous area is imposed by another installation, for example an oil
supply, and the equipment is to be used within that area
when a risk assessment indicates that use of uncertified equipment is not
acceptable (see below)
when it is anticipated that the area in which the equipment will be located
will be left unattended at any time during the test/purge.

The decision on whether electronic equipment, for example pressure gauges and
gas detectors, can be of a type not certified for use in a hazardous area, may be
complex and is not an issue that can be developed in IGEM/UP/1C. However,
unless the pipework being tested or purged is known to contain only air and/or
inert gases (in which case equipment that is not certified may be used) any use
of such uncertified equipment shall be subject to a suitable risk assessment
prior to use. Equipment manufacturers instructions may assist in this risk
assessment.
Note 1: For lower pressures, water gauges can always be used if there is any doubt about the use
of uncertified gauges.

Note 2: For MOP 75 mbar, use of uncertified gauges placed in the open air and located at least
150 mm from any potential gas source (a greater clearance may be required) may be
acceptable although it is still possible for a hazardous area to apply, particularly as imposed
by another installation.

Note 3: Further guidance on hazardous area classification is available in IGEM/GM/7B.

7
SECTION 4 : STRENGTH TESTING

Some leak detection fluids (LDFs) have an adverse effect on certain installation materials.
Consequently, any residual fluid shall be washed off thoroughly and subsequently dried. LDFs
containing more than 30 parts per million of halogens shall not be used on stainless steel
components.

If necessary, for example when joints will be broken, temporary electrical continuity bonds
shall be installed before testing.

Where an installation contains fuel gas, it has to be purged to nitrogen or air before strength
testing.

4.1 DECISION WHETHER TO STRENGTH TEST

4.1.1 A strength test shall be carried out on any new or replacement installation (or
part thereof) except for components that have been pre-tested or have been
removed to avoid over pressurisation, for example regulators and meters.

4.1.2 Where the meter installation is pre-assembled and fully tested by the
manufacturer; comes complete with documentation and has not been modified
or altered in any way, there is no need to carry out a strength test on the
assembly. A tightness test shall be carried out (See Section 5).

4.1.3 Where a meter installation is assembled from components (screwed or bolted
together), all of which have been fully tested by the manufacturer; are delivered
complete with documentation and have not been modified or altered in any way,
there is no need to carry out a strength test on the assembly. A tightness test
shall be carried out (See Section 5).

Note: Where a component or sub-assembly (meter installation component, meter skid unit,
etc.) has been pre-tested and not subsequently modified (such as by cutting threads or
welding) and has appropriate certificates of conformity available, the strength testing of
such a component/assembly need not be undertaken but a visual examination of joints,
general condition, suitability, etc. is recommended prior to installing and subsequent
tightness testing as for a new installation. Permanent marking, for example by
manufacturers badging/stamping, may be deemed as certification of conformity.

4.1.4 A strength test should not be carried out on an existing installation unless the
installation has been subjected to repairs involving forming pipes, welding, or
new components that have not been pre-tested separately, or OP is to be
increased to a level not previously covered by strength testing.

4.2 STRENGTH TESTING METHODOLOGY

Where an on-site strength test is required it is recommended that either;
the replacement components are strength tested separate from the
installation,
or,
the strength test is carried out concurrently with the tightness test. This
would mean carrying out the tightness test at STP, applying the greater of
the required stabilization and test times but not both, and applying the
tightness test pass/fail criteria (a pass indicating that both the strength and
tightness tests are satisfactory). However, there will be a minority of
installations that will fail the tightness test that would have passed if the
tests had been carried out separately or simply combined.


8
4.3 DETERMINATION OF MOP AND MIP

4.3.1 The majority of meter installations will incorporate a pressure regulator and, as
such will normally incorporate a pressure break. The pressure break is a point in
the installation defined by the designer, either side of which a different strength
test pressure is applied.

The location of the pressure break will vary depending on the provision of valves
and the characteristics of the upstream Network and downstream consumers
system.

Typically, the pressure break will be the outlet of the first valve downstream of
the pressure regulator, (see Figures 4(a) and 4(b)). However, in a small number
of installations where the consumers system has the ability to subject the meter
installation to a higher reverse pressure under fault conditions (MIP
c
), the
pressure break will be on the inlet to the first safety device (see Figures 4(c)
and 4(d)).

Where the information available on site indicates that the pressure break is not
located as shown in Figure 4, this shall be taken into account.

The values of STP shall be determined for the different sections of pipework to
be tested.

4.3.2 Where different parts of an installation have different DPs, MIPs, etc., the
strength testing requirements of each part of the installation shall be
determined separately and tested accordingly.

Figures 4(e) to 4(g) describe the strength testing requirements (of IGE/GM/8)
either side of the pressure break for different situations.

4.3.3 For consistency with IGE/UP/1, IGE/UP/1A and IGE/UP/1B, the procedures
incorporated in this Standard base STP on a multiple of MOP or MIP. This is
based on the assumption that MOP will always equal DP, but this will not always
be the case. When calculating STP, the following shall be applied:
if DP > MOP, the DP shall be used instead of MOP, and
where available DMIP shall be used instead of MIP.


9

FIGURE 4 (a) - TYPICAL PRESSURE BREAK. FIRST OUTLET VALVE
DOWNSTREAM OF THE PRESSURE REGULATOR (MIV
FITTED)

FIGURE 4 (b) - TYPICAL PRESSURE BREAK. FIRST OUTLET VALVE
DOWNSTREAM OF THE PRESSURE REGULATOR (NO MIV
FITTED)

FIGURE 4 (c) - HIGHER REVERSE PRESSURE. PRESSURE BREAK ON THE
INLET TO THE FIRST SAFETY DEVICE (NO MIV FITTED)

FIGURE 4 (d) - HIGHER REVERSE PRESSURE. PRESSURE BREAK ON THE
INLET TO THE FIRST SAFETY DEVICE (MIV FITTED)

10

FIGURE 4 (e) - DOWNSTREAM PRESSURE BREAK. NO ISSUES WITH
COMPONENT STRENGTH (MIV FITTED)

FIGURE 4 (f) - DOWNSTREAM PRESSURE BREAK. REGULATOR
DIAPHRAGMS NOT CAPABLE OF WITHSTANDING MOP
U

(MIV FITTED)

FIGURE 4 (g) - DOWNSTREAM PRESSURE BREAK, METER NOT CAPABLE
OF WITHSTANDING MIP
U
, REGULATOR DIAPHRAGMS
NOT CAPABLE OF WITHSTANDING MOP
U
(NO MIV
FITTED)

Note: Some of the figures above are reproduced in Figure 6 with emphasise the tightness test
requirements (shown in grey above).

FIGURE 4 - PRESSURE BREAKS. STRENGTH REQUIREMENTS

11
4.3.4 STP shall be determined using a multiple of either MIP or MOP (see Table 5)
Normally, the values of MIP and MOP shall be obtained from the MAM. However,
the majority of meter installations will have standard values as given in
Tables 1 to 4.

Before Regulator mbar After Regulator mbar
DMIP
u
200 MIP
mi
75
DP
u
75 MOP
mi
23
STP
miu
220 STP
mid
82.5

TABLE 1 - EXAMPLE 1. A LOW PRESSURE OUTLET FED FROM THE LOW
PRESSURE NETWORK (NG).

DMIP
u
2700 MIP
mi
50*
DP
u
2000 MOP
mi
23
STP
miu
3000 STP
mid
57.5*

* Figure depends on the set point of the slam shut valve.

TABLE 2 - EXAMPLE 2. A LOW PRESSURE OUTLET FED FROM THE
MEDIUM PRESSURE NETWORK (NG).

DMIP
u
350 MIP
mi
80
DP
u
75 MOP
mi
39
STP
miu
525 STP
mid
97.5

TABLE 3 - EXAMPLE 3. A LOW PRESSURE OUTLET FED FROM A LOW
PRESSURE NETWORK (PROPANE) - BS 3016 REGULATORS

DMIP
u
2700 MIP
mi
80
DP
u
2000 MOP
mi
39
STP
miu
3000 STP
mid
97.5

TABLE 4 - EXAMPLE 4. A LOW PRESSURE OUTLET FED FROM A MEDIUM
PRESSURE NETWORK (PROPANE) - BS 3016 REGULATORS

4.3.5 Where a booster or compressor is included downstream of the installation being
tested, the maximum back pressure (MIP
c
) shall be obtained from its owner.
Where this pressure exceeds MIP
mi
, MIP
c
shall be taken as MIP.


12
4.4 METHOD, PRESSURE, DURATION AND TEST CRITERIA FOR STRENGTH
TESTING

The method, pressure (STP), duration (STD) and criteria for pneumatic strength
testing shall be as given in Table 5.

Where STP is calculated to exceed 3.5 bar for pipework of diameter exceeding
150 mm, or 10.5 bar for diameter exceeding 25 mm, a hydrostatic strength test
shall be carried out in accordance with IGE/UP/1. Pneumatic testing shall not be
carried out in such circumstances.

MOP
(mm)
STP
(greater of)
STABILISE

(mins)*
STD
(mins)
MAXIMUM
DROP
% STP
100 mbar ALL 1.1 MIP and
2.5 MOP
5 5 20
>100 mbar
2 bar
ALL 1.1 MIP and
1.5 MOP

10 5 20
>2 bar
7 bar
150 1.1 MIP and
1.5 MOP
15 30 20

* Where surrounding conditions are stable, the responsible engineer may judge
the installation to have stabilised before the time periods given.

TABLE 5 - SELECTION OF THE METHOD, PRESSURE, DURATION, AND THE
TEST CRITERIA FOR STRENGTH TESTING

4.5 PROCEDURES

4.5.1 A thorough survey of the section to be tested, to detect any major integrity
defect, shall be carried out before testing, including inspection of certificates,
non-destructive testing (NDT), etc.

As far as is reasonably practicable, joints should be exposed during the strength
test to enable the use of LDF following a failed test.

4.5.2 It shall be ensured that all components are inspected prior to testing and have
been designed, installed and anchored to withstand STP.

4.5.3 The following two situations will arise:
where all components within the section to be tested can withstand the
highest STP, (as calculated from the two MOPs or MIPs), the highest STP
should be used to test the whole section.

Note: Normally this will be the case with low pressure sourced metering installations.

or,
where certain components cannot withstand the highest STP of the
assembly, the assembly shall be split so that two separate strength tests can
be carried out, each at the appropriate STP.


13
4.5.4 Before testing, the following actions shall be taken:
ensure all isolation valves are plugged securely or blanked off and the valves
are in the open position to ensure the valve body is tested
where necessary, remove any component that is not to be included in the
test.
Remove any component or sub-assembly that could be damaged by STP
prior to carrying out the strength test. Such a component or sub-assembly
shall be, or be proved to have been, tested separately to an appropriate
standard. Install spool pieces or blanks.

Note 1: Components such as regulators, meters, non-return valves, safety shut-off valves etc,
may need to be removed and replaced with spool pieces or sealed off with an
appropriate fitting.

Note 2: When a removed item(s) subsequently is(are) connected to the installation, it is not
necessary to repeat the strength test for the whole installation before carrying out a
tightness test, provided the connections are inspected carefully during the tightness
test. Such connections, if welded, will need to have been subject to NDT to a standard
equivalent to that used for the rest of the section.
ensure there is a means of pressurising the installation either with dry
compressed air or nitrogen (above freezing point if expanded from bottled
nitrogen)
incorporate (in the connection of the pressurisation medium to the
installation) suitably adjusted regulators and a full flow safety valve(s) to
prevent pressurisation above STP
if the assembly incorporates components that can trap pressure, for example
a pressure regulator, it will be necessary to provide a pressure equalisation
by-pass around such components. Any by-pass shall be suitable to withstand
the pressure.

4.5.5 Appropriate instruments shall be provided to evaluate the test as follows,
duplicated where necessary:
pressure recorders
pressure gauges
temperature recorders.

4.5.6 Gauges and recorders shall be certificated for calibration and, if appropriate,
zeroed before use.

4.5.7 An exclusion zone, in accordance with Table 6, shall be set up around the area
of any installation for which STP exceeds 1 bar. Personnel shall not be within
this distance while pressurising or during the stabilization and test periods.
Note: In general, this will mean that the pressurisation equipment and test instruments are also
outside this area, the latter being piped into the area in small bore pipework. The distances
detailed in Table 5 are based on the centre-line of fittings and components and extend both
sides.
For STP exceeding 7 bar, a suitable risk assessment shall be carried out to
determine the distance required.

STP
(bar)
DISTANCE
(m)
> 1 2 1
> 2 5 2
> 5 7 2.5

TABLE 6 - SAFETY DISTANCES EACH SIDE OF AN INSTALLATION FOR
STRENGTH TESTING AT STP EXCEEDING 1 BAR


14
4.5.8 A final inspection of the section to be tested shall be carried out to ensure that it
is ready for the test (it shall be ensured that any exclusion zone is clear of all
personnel - see Table 6).

4.5.9 If STP exceeds 2 bar, a check for general integrity, for example for open ends,
shall be carried out at a pressure of 350 mbar. The section shall be pressurised
slowly. For STP exceeding 2 bar, after reaching 2 bar, the pressure shall be
increased in 10% stages up to STP leaving a short period between each
increase.

4.5.10 The pressure in the installation should be maintained at STP over the
stabilization period.

4.5.11 At the end of the stabilization period, the pressure source shall be disconnected
from the installation and the strength test duration (STD) (see Table 5) shall
start. The gauge shall be monitored for the full test period.

4.5.12 If the installation fails the strength test (see Table 5 permitted drop), the
pressure shall be reduced to no greater than 1 bar prior to allowing personnel
into the exclusion zone to test joints, glands, etc. for leakage, using LDF.

Before work commences to remedy any leakage, the test pressure within the
pipeline should be reduced to zero, by safely venting to atmosphere.

Once any repairs are complete, a further strength test shall be carried out which
shall be in accordance with the above procedures.

4.5.13 Following a satisfactory test (see Table 5 permitted drop), the pressure in the
installation should be reduced to OP if a tightness test is to be carried out
immediately. If not, the pressure shall be vented and the installation left in a
safe condition until the tightness test is to be carried out. Any exclusion zone
then can be re-opened for all site personnel.

4.5.14 The strength test shall be documented and included in any site Health and
Safety File. Results should be recorded on a formal certificate, a copy of which
should be given to the MAM of the installation.

STP and MOP shall be recorded clearly and be available for reference by any
party subsequently working on the installation.
Note: IGEM publishes suitable triplicate certificates in pads.

15

Note: This algorithm does not show all necessary steps and the full procedures in Section 4 apply.

FIGURE 5 - FLOW-CHART/DECISION ALGORITHM FOR STRENGTH
TESTING
NO
NO
YES
NO
YES
YES
NO
NO NO YES YES

START

NEW
INSTALLATION?
EXISTING. IS IT
NECESSARY TO CARRY
OUT A STRENGTH TEST?
(4.1)
GO TO
TIGHTNESS
TEST
(5)
YES
FULLY PRE-TESTED,
UNMODIFIED AND
DOCUMENTED?
(4.1.2 and 4.1.3)
GO TO
TIGHTNESS
TEST
(5)
APPLY
PRECAUTIONS
AND TEST
(4.5)
DOCUMENT AND
GO TO
TIGHTNESS
TEST (5)
DO COMPONENTS
OR SUB
ASSEMBLIES
NEED TO BE
REMOVED?
(4.5.3)

IS IT SAFE TO STRENGTH
TEST?
(4.5.1 and 4.5.2)

SELECT METHOD,
STP AND STD
(TABLE 5)
TEST PASS?
(TABLE 5)
DE-PRESSURISE
AND REPAIR

REMOVE AND
REPLACE/SEAL
RE-ASSESS
CONSTRUCTION AND
TEST METHOD.
ELIMINATE
UNACCEPTABLE RISK
OR ELIMINATE NEED TO
STRENGTH TEST.
RETURN TO START.


16
SECTION 5 : TIGHTNESS TESTING

Even if a tightness test result is satisfactory, any smell of gas or a gas detector reading
indicating the presence of gas is not acceptable. However, for an existing installation, the test
may be against isolation valves which could be relatively old and worn, so a defined maximum
level of leakage is permitted.

Some LDFs have an adverse effect on certain installation materials. Consequently, any
residual fluid shall be washed off thoroughly and subsequently be dried. LDFs containing more
than 30 parts per million of halogens shall not be used on stainless steel components.

If necessary, for example when joints are broken, temporary continuity bonds shall be
installed before testing.

5.1 DECISION WHETHER TO TIGHTNESS TEST

Tightness testing is required under the following circumstances:
prior to a new installation being commissioned with gas,
where a leak is suspected to exist on an existing installation,
where a new section has been added into an existing installation,
where there has been a complete loss of pressure, for any reason, for
example component replacement, section replacement, etc.

When repairing/modifying/replacing components on an existing installation
which has resulted in a loss of pressure due to opening the gasways, it is only
necessary to undertake a tightness test on the section that has lost pressure. As
such, particularly on larger installations, as much of the meter installation as
possible should be kept pressurised, along with the consumers system, (see
Figure 3).

Where the downstream installation pipework is being kept live the pressure
should be maintained at OP. It should be ensured that there are no major leaks
on the temporary pipework supplying the gas, by using LDF or a gas detector,
as appropriate.

5.2 GENERAL

5.2.1 A thorough survey of the section to be tested shall be carried out before testing,
to detect and correct any major integrity defect.

5.2.2 For any installation of tightness test pressure (TTP) exceeding 1 bar, either the
safety distances given in Table 6 shall be applied or the test carried out when
the premises are unoccupied.

5.2.3 If an installation contains fuel gas, it should be tested with fuel gas unless a
complete purge to air is carried out (see Section 6) before testing with air.

5.2.4 Where an installation containing air is pressurised with fuel gas, and following a
satisfactory tightness test, it shall immediately be purged to fuel gas.

If the tightness test should fail, the leak shall be traced and repaired. If it is
necessary to open the gasways to do this, the installation shall be depressurised
and purged to air (see Section 6).


17
5.3 DETERMINATION OF TTP

The tightness test is normally undertaken with a TTP of OP.

The majority of meter installations incorporate a pressure regulator, and as such
will normally incorporate a pressure break, and have sections operating at
different OPs, which result in different TTP requirements.

The section downstream of the pressure break shall be tested with a
TTP OP
mi
.

Any section on the inlet side of the pressure regulator(s) that can be tested as a
separate section at OP
u
, shall be tested with a TTP equal to OP
u
.

The section incorporating the pressure regulators and safety devices is more
problematic. The pressure regulators will have to be by-passed and the whole
section tested at either OP
u
or OP
mi
:
where all components within the section to be tested can withstand OP
u
, the
whole section should be tested at OP
u
.
where components may be damaged by pressurising the downstream side of
the pressure regulators to OP
u
, the whole section shall be tested with a TTP
equal to OP
mi
, and all the joints upstream of the pressure regulators
subsequently tested with LDF at OP
u
.

FIGURE 6 (a) - DOWNSTREAM PRESSURE BREAK, NO ISSUES WITH
COMPONENT STRENGTH (MIV FITTED)

FIGURE 6 (b) - DOWNSTREAM PRESSURE BREAK REGULATOR
DIAPHRAGMS NOT CAPABLE OF WITHSTANDING MOP
U

(MIV FITTED)

18

FIGURE 6 (c) - DOWNSTREAM PRESSURE BREAK, METER NOT CAPABLE
OF WITHSTANDING MIP
U
, REGULATOR DIAPHRAGMS
NOT CAPABLE OF WITHSTANDING MOP
U
(NO MIV
FITTED)

FIGURE 6 - PRESSURE BREAKS. TIGHTNESS TEST REQUIREMENTS

5.4 TIGHTNESS TEST DURATION (TTD)

5.4.1 The TTD shall be either:
as specified in Tables 7, 8 or 9 as appropriate
or,
for those installations and gauges not covered by Tables 7, 8 or 9 the TTD
shall be calculated in accordance with Appendix 4.

DESIGNATION
OF METER
TTD (mins)
NG PROPANE
G4/U6
G10/U16
G16/U25
U40
G40/U65
G65/U100
U160
2
2
2
3
4
7
11
2
4
5
9
13
23
See Note 2
RD or turbine up
to 100mm NB and
up to 5 m length
2 5

Note 1: If adopting the concept of NPM, TTD can be calculated by dividing the durations given
above by 2 and rounding up to the nearest minute, with a minimum test time of 2 minutes.

Note 2: TTD would be above 30 mins, and IGE/UP/1 needs to be consulted.

Note 3: Further TTDs for larger installations are shown in Tables 8 and 9.

TABLE 7 - TIGHTNESS TEST DURATION (MINS) FOR TYPICAL
INSTALLATIONS AND USING A PRESSURE GAUGE WITH A
GRM OF 0.5 MBAR


19
5.5 PROCEDURES - TIGHTNESS TESTING

5.5.1 By-passing components

5.5.1.1 If there is any component in the section to be tested that could trap pressure,
for example a regulator, a non-return valve (NRV), etc., the component
concerned shall be by-passed temporarily to equalize the pressure either side of
the component. All valves shall be open, or by-passed.

5.5.1.2 When constructing a by-pass, particular care shall be taken to use
materials/components and security (via anchorage, etc.) suitable for the test
pressure (IGEM/UP/2 provides requirements).

Care shall be taken to avoid damage to regulator diaphragms, filters, etc.

5.5.2 Ambient conditions

5.5.2.1 Where a section to be tested includes exposed pipework, the test shall be
carried out taking account of ambient conditions i.e. when ambient conditions
are stable. Testing shall not be carried out if any part of the installation would
be exposed to direct sunlight during the test period.

5.5.2.2 For an installation in a building, testing should take place when the temperature
will not change over the test period.

5.5.3 Section and valve isolation

5.5.3.1 Testing with nitrogen/air

All valves in the section to be tested shall be spaded off, plugged or capped and
left in the open position, in order that the test will include the valves and will be
made against sealed ends. The ECV shall be spaded off on the downstream side.

5.5.3.2 Testing with fuel gas

A let-by test shall be carried out on the section inlet and outlet valves.

5.5.4 Testing

5.5.4.1 The following tightness test procedure shall be followed:

(a) If testing an installation with fuel gas, a let-by test of the installation
isolation valve(s) shall be carried out, ensuring the valve(s) is/are closed,
by adjusting the pressure to approximately 50% OP.

If, over the same test period as calculated for the tightness test (TTD), a
rise in pressure of more than GRM is observed, the isolation valve may
be letting-by. Any defective isolation valve shall be repaired/replaced
before proceeding to the tightness test. If let-by is confirmed on an ECV,
the Gas Emergency Contact Centre (for Propane, the gas supplier) shall
be notified and the installation made safe, suspending the test until a
repair has been made.

(b) If TTP exceeds 2 bar, a check for general integrity, for example for open
ends, shall be carried out at a pressure of 350 mbar. The section shall be
pressurised slowly. For TTP exceeding 2 bar, after reaching 2 bar, the
pressure shall be increased in 10% stages up to TTP leaving a short
period between each increase.


20
(c) The temperature should be allowed to stabilise for TTD or for 15 mins,
whichever is the longer.

The source of pressure shall then be isolated.

(d) The gauge shall be monitored as necessary for the duration of the test.
Any movement of the gauge shall be less than GRM (Table 16). If greater
movement is detected, the test has failed and the leak(s) shall be located
and rectified and the test repeated.

Note: For the scope of this Standard, correction for atmospheric pressure and
temperature variations is not needed.
(e) If spades, etc. are fitted, the installation shall be de-pressurised, the
spades, etc. removed and any disturbed joints checked with LDF.

5.6 COMPLETION

5.6.1 If testing on air the pressure shall be released in a safe and controlled manner,
and the section may be purged to fuel gas immediately following a successful
tightness test. If purging is not carried out immediately, a further tightness
check must be carried out immediately prior to purging.

5.6.2 Where a section containing air has been tested with fuel gas, following
completion of a satisfactory tightness test, the section shall be immediately
purged to fuel gas. If the test should fail, the leak shall be traced and repaired.
If it is necessary to open the gas ways, the section shall be de-pressurised and
purged to air prior to undertaking repairs.

5.6.3 After proving tightness, any purging shall be carried out as detailed in Section 6.

5.6.4 The tightness test shall be documented and included in any site Health and
Safety File. Results should be recorded on a formal certificate, a copy of which
should be given to the MAM of the pipework tested.

OP shall be recorded clearly and be available for reference by any party
subsequently working on the installation.



21
START
STRENGTH TEST CARRIED
OUT OR PRE-TESTED AND/
OR ALL EXISTING
EQUIPMENT CERTIFICATED?
STRENGTH TEST, PASS?
DO NOT TIGHTNESS TEST,
RECONSTRUCT
FIT TEMPORARY BY-PASSESS
FOR COMPONENTS THAT
WILL TRAP GAS
FIT SPADES/PLUGS TO ALL
VALVES AND TEST IN OPEN
POSITION
IS THE SITE SURVEY
SATISFACTORY?
COMPLETE REMEDIAL WORK
SELECT TTD (5.4) OR
CALCULATE TTD
(APPENDIX 4)
ADJUST PRESSURE TO TTP
ALLOW TO STABILISE
CARRY OUT TIGHTNESS
TEST, TOTALLY GAS TIGHT?
COMPLETE
DOCUMENTATION (5.6) AND
PURGE (SECTION 6)
GAUGE READING DROP LESS
THAN PERMITTED DROP AND
NO SMELL OF GAS?
CAN LEAK BE TRACED AND
REPAIRED WITHOUT
DE-COMMISSIONING?
DE-PRESSURISE
REPAIR AND RE-TEST
TRACE LEAK, REPAIR AND
RE-TEST
NO NO
NO
NO NO NO
YES
YES
YES
YES YES
YES


FIGURE 7 - FLOW CHART/DECISION ALGORITHM FOR TIGHTNESS
TESTING WITH AIR OR NITROGEN


22
START
STRENGTH TEST CARRIED
OUT OR PRE-TESTED AND/
OR ALL EXISTING
EQUIPMENT CERTIFICATED?
STRENGTH TEST, PASS?
DO NOT TIGHTNESS TEST,
RECONSTRUCT
FIT TEMPORARY BY-PASSESS
FOR COMPONENTS THAT
WILL TRAP GAS
FIT SPADES/PLUGS TO ALL
VALVES AND TEST IN OPEN
POSITION, EXCEPT SECTION
ISOLATION VALVES
IS THE SITE SURVEY
SATISFACTORY?
COMPLETE REMEDIAL WORK
SELECT TTD (5.4) OR
CALCULATE TTD
(APPENDIX 4)
CARRY OUT LET-BY TEST ON
SECTION ISOLATION
VALVE(S), SATISFACTORY?
REPAIR VALVE OR ISOLATE
SECTION BY OTHER MEANS
(5.5.4.1 (a))
ADJUST PRESSURE TO TTP
ALLOW TO STABILISE
CARRY OUT TIGHTNESS
TEST, TOTALLY GAS TIGHT?
COMPLETE
DOCUMENTATION (5.6) AND
PURGE (SECTION 6)
GAUGE READING DROP LESS
THAN PERMITTED DROP AND
NO SMELL OF GAS?
CAN LEAK BE TRACED AND
REPAIRED WITHOUT
DE-COMMISSIONING?
DE-PRESSURISE AND PURGE
TO AIR OR NITROGEN
REPAIR AND RE-TEST
TRACE LEAK, REPAIR AND
RE-TEST
NO NO
NO
NO
NO NO NO
YES
YES
YES
YES
YES YES
YES


FIGURE 8 - FLOW CHART/DECISION ALGORITHM FOR TIGHTNESS
TESTING WITH FUEL GAS

23

LENGTH
(m)
DIAMETER
(mm)
1 2 3 4 5 6 7 8 9 10
40 2 2 2 2 2 2 2 2 2 2
50 2 2 2 2 2 2 2 2 2 2
80 2 2 2 2 2 2 2 2 2 2
100 2 2 2 2 2 3 3 3 3 4
150 2 2 3 3 4 5 5 6 7 7
200 2 3 4 5 6 8 9 10 11 12
250 2 4 6 8 9 11 13 15 16 18
300 3 5 8 10 13 15 18 20 23 25

Note: If adopting the concept of NPM, TTD can be calculated by dividing the durations given

TABLE 8 - TIGHTNESS TEST DURATIONS (MINS) FOR RD AND TURBINE
METERS USING A GAUGE WITH A GRM OF 0.5 MBAR
(NATURAL GAS)

LENGTH
(m)
DIAMETER
(mm)
1 2 3 4 5 6 7 8 9 10
40 2 2 2 2 2 2 2 2 2 2
50 2 2 2 2 2 2 2 3 3 3
80 2 2 2 3 3 4 5 5 6 6
100 2 2 3 4 5 6 7 8 9 10
150 3 5 7 9 12 14 16 18 20 23
200 4 8 12 16 20 24 28
Note
2
Note
2
Note
2
250 6 12 18 24 30
Note
2
Note
2
Note
2
Note
2
Note
2
300 9 17 25
Note
2
Note
2
Note
2
Note
2
Note
2
Note
2
Note
2

Note 1: If adopting the concept of NPM, TTD can be calculated by dividing the durations given

Note 2: TTD would be above 30 mins, and IGE/UP/1 needs to be consulted.

TABLE 9 - TIGHTNESS TEST DURATIONS (MINS) FOR RD AND TURBINE
METERS USING A GAUGE WITH A GRM OF 0.5 MBAR
(PROPANE)

24
SECTION 6 : DIRECT PURGING

This section deals with direct purging with air or fuel gas. If, for any reason, the purge is not
complete, it will be necessary to carry out an indirect purge using nitrogen (N
2
), guidance on
which is provided in Appendix 3 (see also clause 6.1.2 and Sub-Section 6.8).

This Standard assumes that the installation will be pressurised during purging.

6.1 GENERAL

6.1.1 The environmental impact of releasing methane into the atmosphere shall be
considered and the volume of any vented gas should be minimised, for example
by minimising the section to be purged through the use of appropriate isolation
valves, only purging the section being worked on and not significantly exceeding
the calculated purge volume.

6.1.2 For propane, reference should be made to the advice contained in Appendix 5
when assessing safety.

If the assessment indicates that safety would be compromised, the
heavier-than-air gas shall be purged indirectly seeking specialist advice if
necessary.

Heavier-than-air gases shall be flared.

6.1.3 A tightness test must be carried out immediately prior to any purge admitting
gas. Vent points shall be leakage tested.

Note: This equally applies when admitting N
2
to be followed by NG/Propane (see Appendix 3).

6.1.4 The pressure created during purging shall not exceed MOP of any component
being purged.

6.1.5 If compressed air/nitrogen from a cylinder is used for purging, the air shall be
supplied through high capacity regulators, appropriate precautions being taken
for example pressure gauges, safety devices and multi stage regulation.

Note: This is to prevent icing of regulators and excess pressure being applied.

6.1.6 Where an installation is to be taken permanently out of use, it shall be isolated
physically, for example by spading or removing a component and sealing the
ends.

Any de-commissioned installation shall be left purged to air.

6.1.7 Where an installation is to be taken temporarily out of service for repairs or
alterations, a let-by test shall be carried out on any valve(s) to be used to
isolate the installation (see clause 5.5.4.1(a)). Where an installation is left
unattended, it shall be isolated physically, for example by spading or, where not
practicable, by reliably locking off to prevent unauthorised operation.

6.2 PLANNING AND SUPERVISION

6.2.1 The meter installation shall be checked to ensure that it has all necessary valves
and sufficient access points to allow the purging operation to take place safely.

6.2.2 Purging of a meter shall be carried out only with the agreement of its owner
prior to the purge.


25
6.2.3 Purging shall be planned carefully and the following procedures shall be
undertaken as appropriate:
determine the required number of gas operatives
survey the installation to establish that it is in a satisfactory condition. Any
defect shall be corrected before any purging is undertaken, unless de-
commissioning
for complex purging operations, prepare a written procedure for the
operation. If it is anticipated that cutting or welding of any part of the
installation may take place after completion of purging, consideration shall
be given to the use of a permit to work system.

6.2.4 During the purging operation, all other work on the installation being purged
shall be prohibited.

6.2.5 The complete purge procedure shall be continuous and the minimum purge flow
rate, and hence the minimum velocity, given in Table 10 shall be achieved.

Note 1: This is to prevent stratification and, hence, low or zero flow of one of the contained gases.

Note 2: It is not a requirement to purge at OP. In general, if purge points are sized adequately, the
minimum required velocity will be achieved more easily at lower pressures (see Table 10,
column 5).

If it becomes immediately apparent that a direct purge will not achieve the
required flow rate, the restriction may be removed and the purge re-started.
Otherwise, an indirect purge using N
2
shall be carried out (see Appendix 3).
Consequently, planning shall take into account the need for sufficient quantities
of N
2
to be available.

6.2.6 Purge points shall be located at the remote ends of the section to be tested.

6.2.7 Purge points shall be located as close as possible to the extremities of the
installation to enable a complete purge.

6.2.8 When purging with air, it must be ensured that air will not enter the GTs or any
other distribution network.

6.3 SITE PRECAUTIONS

6.3.1 Warning notices and labels

6.3.1.1 Appropriate No smoking and/or No naked lights signage shall be displayed
prominently around any vent and the overall area where purging will take place.

6.3.1.2 Any valve to or from the installation to be purged shall be labelled clearly, for
example Do not operate purging in progress.

6.3.2 Electrical and fire

6.3.2.1 Where appropriate, due regard shall be paid to the intrinsic safety of any
electrical equipment used in the vicinity of the vent points.

6.3.2.2 Any fitted electrical continuity bonds shall be maintained throughout the purging
operation.

6.3.2.3 Sufficient and appropriate fire extinguishers should be situated near the vent
point(s).


26
6.4 DESIGNING AND POSITIONING PURGE POINTS, HOSES AND VENT
STACKS

6.4.1 Precautions shall be taken to reduce, as far as possible, the hazards associated
with venting, for example by avoiding venting close to property air intakes, or to
any potential sources of ignition such as street lamps and electrical plant. If
there is any doubt about the minimum clearance to ignition sources, reference
should be made to IGE/SR/23. Any electrical switch or isolator in the vicinity of
the vent outlet shall not be operated during purging.

Consideration shall be given to potential complaints of smell arising from any
purging operation and prior notice should be given to any persons identified as
liable to notice purged gas by smell.

6.4.2 Purge points, associated vents, hoses and vent stacks shall be sized to permit
sufficient flow in order to maintain the required purge rate/velocity, Table 10,
columns 4 and 5 should be used.

Note: Where the minimum required size of purge hose and vent stack cannot be achieved,
multiple vents may be used. These may be operated simultaneously, provided each point is
supervised and communications are adequate to enable a safe purge.

Any valve used in the purge process should be full bore, where possible.

6.4.3 Any vent stack should terminate with a suitable flame arrestor.

Note: Where the purge velocity can be guaranteed, it may not be necessary to fit an arrestor but
suitable additional precautions are required.

6.4.4 Any vent stack shall incorporate a full bore control valve and sample point.

6.4.6 The purge hose shall be:
suitable for containing the fuel gas
gas tight
secured firmly to the purge point

Note: Unsecured push-on connections are not acceptable.
earthed suitably to avoid sparking, if necessary, for example for externally
armoured hose.

Hose materials that may generate static electricity, for example PE, shall not be
used.

Note: The possibility of generating static electricity increases as the purge velocity increases.

6.4.7 Any vent outlet should be located in open air, terminate at least 2.5 m above
ground and be located at least 5 m downwind of any potential ignition source.

6.4.8 Precautions shall be taken to prevent vented gas drifting into buildings.

6.4.9 When purging small volumes, purging may be carried out directly into a well
ventilated internal area without the use of a purge hose, vent stack or flame
arrestor, but only if all the following criteria are satisfied:
OP of the section being purged shall not exceed 21 mbar
the total volume of the pipework to be purged shall not exceed 0.02 m
3

with the exception of an external purpose built meter house, the volume of
the internal area shall not be less than 30 m
3

Note: The exception for purpose built meter houses is only applicable where there is no
means of gas entering the building from the housing.

27
the internal area shall be well ventilated, for example with windows and
doors open and any mechanical ventilation in operation
the purge point(s) shall be located in a well ventilated section of the internal
area and shall not exceed 25 mm
there shall be no potential ignition sources within 3 m of any purge point
the valve used to control the purge shall be in the same internal area as the
purge point(s)
the gas concentration in the area shall be monitored and, as far as is
possible, it shall not be permitted to exceed 10% lower flammability limit
(LFL). If it does, the purge shall be stopped immediately and the system
purged to outside.

6.5 VERIFICATION OF PURGE VELOCITY

6.5.1 A method of verifying that the required purge velocity (Table 10) is achievable
shall be available and shall be one of the following:
a suitably sized volume meter (used in conjunction with a timer to enable
the flow rate to be calculated) already fitted in the section of pipework to be
purged
a suitably sized rate of flow meter, i.e. capable of passing well in excess of
the purge flow rate or other suitable flow measuring device fitted
downstream of the purge point(s), such as an independent positive
displacement or turbine meter.

Note 1: Usually, the meter being purged will fulfil this function. However, for short purge times, the
purge gas passed may not register.

Note 2: Provided there is confidence (see also clause 6.2.5) that the required purge velocity
(Table 10) will be achieved, a timed passage of purge gas (see clause 6.9.4) may be used
at the discretion of a responsible, competent person.

6.5.2 A test of the vent gas shall always be carried out (see Sub-Section 6.10).

6.6 IDENTIFICATION OF PURGE GAS CYLINDERS

When the purge gas for example, air/nitrogen is supplied from a cylinder,
special care shall be taken to ensure that the cylinder does not contain the
wrong gas, for example oxygen. Cylinders shall be checked in this respect,
before use.
Note: This can be achieved, for example by using an oxygen detector or by confirmation of the
contents of the cylinder by the supplier, etc.

6.7 GAS DETECTORS, OXYGEN MEASURING DEVICES AND OTHER
ELECTRONIC EQUIPMENT

Any gas detector, oxygen measuring device or other electronic equipment shall:
comply with Sub-Section 3.4
be operated in accordance with the manufacturers instructions and by a
trained competent person capable of interpreting the results obtained
have its batteries tested prior to use
be zeroed at the commencement of each test and have its zero checked at
the finish of each test
be tested, overhauled and calibrated in accordance with the manufacturers
instructions.


28
6.8 DETERMINATION OF THE PURGE VOLUME, MINIMUM PURGE FLOW RATE
AND PURGE TIME

6.8.1 The purge volume (PV) of the installation and purge hose/vent pipe shall be
calculated as follows:
Note: The volume of the purge hose may be significant in relation to small volumes of installation
and this needs to be taken into consideration.

PV of a diaphragm meter
= 5 x cyclic volume (Table 14)
Note: The cyclic volume (capacity per revolution) is shown either on the index plate of
modern meters or, on older tin case meters, on the badge plate.
PV of a RD, turbine or ultrasonic meter
= 1.5 x volume of an equivalent length of pipe (see Table 14)
PV of the remainder of pipework and components within the installation
= 1.5 x (IV
p
+ IV
f
) (see Appendix 4)
PV of a purge hose/vent pipe
= 1.5 x volume of hose/pipe (Table 14).

The total purge volume (PV) is the sum of the above.

6.8.2 It should be confirmed that the velocity of the purging medium through the pipe
is above a minimum level, to ensure that the effect of stratification does not
impair the purging.

Note: Although velocity is not easily measured in such a situation, it can be related to purge flow
rate which can be monitored with a flow meter or a timing method.

6.8.3 The minimum purge flowrate (Q) shall be determined from Table 10. For an
installation including significant volumes of pipe, the largest diameter pipe shall
be used to determine Q.

Note: If Q is not achieved, the purge time and volume of purge gas required will be excessive
and, even then, a satisfactory purge may not be achieved as the minimum velocity
required, the key factor, will also not be achieved.

6.8.4 Where necessary (see clause 6.5.1), the maximum purge time (PT
max
) shall be
calculated as follows:

Note: This is the maximum time (purge time) it will take before a vent gas test should indicate a
sufficient quantity of fuel gas or air as appropriate to indicate completion of the purge.

Example:

A single filter and regulator within a section of 80 mm pipe of total length 0.8 m.
An RD meter with no by-pass, fitted in a section of 100 mm pipe of total length 1.2 m.
6 m long purge hose of 40 mm diameter.

PV = (1.5 X 0.8 X 0.0054) + (1.5 X 1.2 X 0.009) + (1.5 X 10 X 0.0015)
PV = (0.00648) + (0.0162) + (0.0225)
PV = 0.0452 m
3

Minimum purge flow rate from Table 10 for 100 mm pipe is 0.33 m
3
/min
PT
max
is therefore 0.0452/0.33 0.137 mins = 9 secs.

3
3 1
PV(m ) x 3600
Q(m h )

PT
max
(secs) =

29
1 2 3 4 5
NOMINAL
PIPE
DIAMETER
TO BE
PURGED
MINIMUM
PURGE
VELOCITY

MINIMUM PURGE
FLOW-RATE
(Q)
PURGE HOSE/
VENT STACK
NOMINAL BORE

FLAME
ARRESTER
NOMINAL
BORE

mm m s
-1
m
3
min
-1
m
3
h
-1
mm mm
20
25
32
40
50
80
100
125
150
200
250
300
400
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.6
0.7
0.8
0.9
1.0
0.01
0.02
0.03
0.05
0.08
0.19
0.33
0.5
0.7
1.32
2.35
3.6
7.9
0.7
1.0
1.7
2.5
4.5
11
20
30
38
79
141
216
473
20
20
20
20
40
40
40
50
50
100
100
150
150
20
20
20
20
50
50
50
50
50
200
200
200
200

TABLE 10 - MINIMUM PURGE FLOW RATE AND VELOCITY WITH
RECOMMENDED MINIMUM PURGE POINT, ASSOCIATED VENT
AND FLARE STACK DIMENSIONS

6.9 VENT GAS TESTING

The criteria given in Table 11 shall be used when testing the vent gas.

Note: Table 8 is intended to ensure safe conditions, but not necessarily efficient combustion
performance.

FLAMMABILITY
LIMITS
SAFE PURGE END POINTS
FUEL TYPE
(GAS OR
VAPOUR)
SPECIFIC
GRAVITY:
AIR = 1
(See Note 1)
LOWER
LIMIT %
GAS IN
AIR
UPPER
LIMIT %
GAS IN
AIR
DIRECT
PURGE FROM
AIR TO GAS
DIRECT
PURGE FROM
GAS TO AIR
(see Note 4)
NATURAL GAS 0.6 4.5 15.5 90% fuel gas 1.8% gas
PROPANE 1.5 2.1 10.1 See Note 2 See Note 2

Note 1: Specific gravity of gases in relation to air, <1 being lighter-than-air and >1 being heavier-
than-air.

Note 2: It is recommended that these gases be purged using N
2
rather than air due to their low
LFLs or high specific gravity. Refer to Appendix 3 for N
2
purging.

Note3: Gas detectors used for differing gases need to be calibrated for the particular gas being
tested. For NG, most instruments are calibrated for methane which, normally, forms well
over 90% of NG.

Note 4: This end point is at 40% LFL.

TABLE 11 - FLAMMABILITY LIMITS AND SAFE PURGE END POINTS

6.10 PURGING PROCEDURES

6.10.1 Direct purging from air to gas i.e. commissioning

The procedure assumes that, prior to purging, any purge point and any valve on
any connected vent stack is closed, that the installation isolation valve(s) is/are
closed and that any other valve within the installation is open.


30
Throughout the purge operation, steps should be taken to ensure that any
upstream pipework or appliance will not be affected by the purging operation.

Note: On larger installations at higher pressures, for example exceeding 2 bar, it may be
necessary to use a valved rider to bypass the installation isolation valve, in order to enable
a satisfactory level of control of pressurisation.
It also may be necessary to introduce a pressure regulator into the rider to control the
supply pressure to prevent overpressurisation of attached purge hoses and vents.

The following procedure shall be carried out:

(a) Ensure that a satisfactory tightness test (Section 5) has been carried out,
immediately before starting the purge.

(b) Open all purge points and open valves on connected vent stacks and the
installation isolation valve to admit gas. Simultaneously, start the chosen
method of measuring the flow of purge gas (see clause 6.5.1), i.e.;
start a timer and
read the in-line meter or read the flow meter rate.

Note: If using a flow meter, it will be immediately apparent if the minimum required
purge volume rate is not being achieved. In this case, it may be possible to stop
the purge, rectify the reason for the incomplete purge and re-start the purge (from
the beginning) without resorting to an indirect (N
2
) purge (see (d) below).

(c) After half the estimated purge time (see clause 6.9.3) has elapsed (or
earlier if desired which may limit the wastage of gas), start testing the
concentration of fuel gas in the vent gas using a suitable gas detector.

Note: For an RD meter, the purge time could be very short and it may not be practical to
start testing so early in the purge.

(d) Stop the purge by closing the vent stack valve(s) (and record the in-line
meter reading, if applicable) when a level of fuel gas, as indicated in
Table 11 for safe purge end point, is achieved, or the metered purge
volume has passed.

Note: Any method has to be verified by a satisfactory vent gas sample.

If Table 11 concentrations are not achieved within the purge time (or by
the time the purge volume has passed) an incomplete purge is indicated.
In this case, close the installation isolation valve(s) and immediately
purge the section with N
2
in accordance with Appendix 3. Before
repeating steps (a) to (d), identify and rectify the reason for the
incomplete purge.

Note 1: For any "partially complete" purge, the pipework will contain a mixture of gas and
air that is potentially hazardous. If it is possible to rectify the problem without
opening the gasway, then it may be acceptable to so rectify and re-start the purge
from the beginning. In the intervening period, it is imperative that the gasway is
not opened, that any installation isolation valve is not opened, that the installation
is not left unattended and that site precautions (see Sub-Section 6.3) remain in
place. An overall risk assessment is required which, if sufficient assurance of safety
is not indicated, will lead to an indirect purge using N
2
(see Appendix 3).

Note 2: The reason for an incomplete purge is likely to be insufficient velocity of the NG.
Check the purge time recorded against any meter reading/ flow rate recorded. Any
metered reading less than PV is suspect (see clause 6.9.1). Any flow rate less than
PV expressed as a flow rate is also suspect (see clause 6.9.2). If both are
satisfactory, re-check the calculations (see Sub-Section 6.9). If no problem is
found, it is likely that the actual design of the section is not as assumed when
calculating PV.

Note 3: In conjunction with a stopwatch for metered flow, all the above methods will serve
to confirm that the purge velocity is the minimum required (see Table 7).


31
(e) Close all purge points, disconnect vent stacks, remove all purge
equipment and plug or cap the open ends with an appropriate fitting.
Test any disturbed joints with LDF or a gas detector.

Note 1: A gas detector is not permitted to move from zero or 0% LFL on the 0% to 10%
LFL scale.

Note 2: Disconnected purge equipment (hoses, meters, etc.) will need to be purged of NG.

(f) Rectify the cause of any detected escapes or smell of gas.

(g) Seal with an appropriate fitting the outlet of the installation and label to
indicate that gas is turned on and purged up to that point.

(h) Complete an appropriate purging certificate.


6.10.2 Direct purging from gas to air i.e. de-commissioning

The following procedure assumes that, prior to purging, any purge point and
any valve on any connected vent stack is closed, that the installation isolation
valve is closed and that any other valve within the installation is open.

Any appliance attached to the section shall be turned off.

Throughout the purge operation, steps should be taken to ensure that any
upstream pipework or appliance will not be affected by the purging operation.

The following procedure shall be carried out:

(a) Carry out a let-by test on the installation isolation valve(s), to prove
its/their integrity (see clause 5.5.4.1 (a)).

(b) Ensure the installation isolation valve(s) is/are turned off.

(c) Ensure OP of the section will not be exceeded.

Note: This will require a suitable pressure gauge to be fitted as close as practicable to
the air inlet point. Limiting the pressure can, normally, be achieved with the use of
a low-pressure air blower(s) or, in the case of refillable cylinder(s)/tank(s), with
the use of a suitable regulator that can be accurately set to a pressure at or below
OP. Low-pressure air blower(s), cylinder(s)/tank(s), and regulator(s) need to be
sized to pass the required purge flow rate.

(d) Open all purge points and valves on connected vent stacks and admit air.
Simultaneously, start the chosen method of measuring the flow of air
(see clause 6.5.1) i.e.
start a timer and
read the in-line meter, or read the flow meter rate.

Note: If using a flow meter, it will be immediately apparent if the minimum required
purge volume rate is not being achieved. In this case, it may be possible to stop
the purge, rectify the reason for the incomplete purge and re-start the purge (from
the beginning) without resorting to an indirect (N
2
) purge (see (f) below).

(e) After half the estimated purge time (see clause 6.9.3) has elapsed (or
earlier if desired) start testing the concentration of air in the vent gas
using an appropriate instrument.

Note: For an RD meter, the purge time could be very short and it may not be practical to
start testing so early in the purge.

(f) Stop the purge by isolating the air supply (and record the in-line meter
reading, if applicable) when a level of air, as indicated in Table 11 for

32
safe purge end point, is achieved or the metered purge volume has
passed, whichever occurs first.

Note: Any method has to be verified by a satisfactory vent gas sample.

If Table 11 concentrations are not achieved within the purge time (or by
the time the purge volume has passed) an incomplete purge is indicated.
In this case, close the installation isolation valve(s) and immediately
purge the section with N
2
in accordance with Appendix 3. Before
repeating steps (a) to (d), identify and rectify the reason for the
incomplete purge.

Note 1: For any "partially complete" purge, the installation will contain a mixture of fuel
gas and air that is potentially hazardous. If it is possible to rectify the problem
without opening the gasway, then it may be acceptable to so rectify and re-start
the purge from the beginning. In the intervening period, it is imperative that the
gasway is not opened, that any installation isolation valve is not opened, that the
installation is not left unattended and that site precautions (see Sub-Section 6.3)
remain in place. An overall risk assessment is required which, if sufficient
assurance of safety is not indicated, will lead to an indirect purge using N
2
(see
Appendix 3).
Note 2: The reason for an incomplete purge is likely to be insufficient velocity of NG. Check
the purge time recorded against any meter reading/ flow rate recorded. Any
metered reading less than PV is suspect (see clause 6.9.1). Any flow rate less than
PV expressed as a flow rate is also suspect (see clause 6.9.2). If both are
satisfactory, re-check the calculations (see Sub-Section 6.9). If no problem is
found, it is likely that the actual design of the installation is not as assumed when
calculating PV.
Note 3: Provided there is confidence (see also clause 6.2.5) that the required purge
velocity (Table 10) will be achieved, a timed passage of purge gas (see clause
6.9.4) may be used at the discretion of a responsible, competent person.

(g) Close all purge points, disconnect vent stacks, remove all purge
equipment and plug or cap the open ends with an appropriate fitting.
Test any disturbed joints with LDF. Seal or disconnect pipework from the
gas supply, sealing all ends with an appropriate fitting.

Note: Disconnected purge equipment (hoses, meters, etc.) will need to be purged of NG.

(h) Label all pipework to show that it has been de-commissioned.

(i) Complete an appropriate purging certificate.


33
AIR TO GAS
Commissioning

FIGURE 9 - FLOWCHART FOR DIRECT PURGING OF AIR TO GAS

Ensure that a satisfactory tightness
test has been carried out
Carry out all preparation work
(6.2, 6.3, 6.4, 6.6, 6.7)
Calculate: purge volume
purge flow rate
purge time
(6.9)
Isolate potential ignition sources
and erect warning signs (6.3)

Open vent point valve(s)
Immediately admit fuel gas at
correct flow rate (6.11.1 (b))

Monitor gas pressure
Monitor gas flow rate
Sample at vent point after purge
time

After satisfactory vent gas test,
close vent point valve and remove
purge hose from vent
Test all disturbed joints and joints
in ducts for leaks. Seal all outlets

Complete records and inform
responsible person of position

Vent stacks and hoses correctly
located. Notices, barriers, fire
extinguishers available and checked.
Test meters and gas detectors
checked.
If correct flow rate cannot be
achieved, abandon purge and use
indirect method (Appendix 3)
Check purge is complete
(Table 11)

34
GAS TO AIR
De-commissioning

FIGURE 10 - FLOWCHART FOR DIRECT PURGING OF GAS TO AIR
Carry out all preparation work
(6.2, 6.3, 6.4, 6.6, 6.7)
Calculate: purge volume
purge flow rate
purge time
(6.9)
Isolate potential ignition sources
and erect warning signs (6.3)

Open vent point valve(s)

Immediately admit air at correct
flow rate (6.11.2(d))

Monitor pressure
Monitor air flow rate
Sample at vent point after purge
time

Complete records and inform
responsible person of position

Vent stacks and hoses correctly
located. Purge gas (air) supply
available. Notices, barriers, fire
extinguishers available and checked.
Test meters and detectors checked.
If correct flow rate cannot be
achieved, abandon purge and use
indirect method (Appendix 3)
Check purge is complete
(Table 11).
Do not allow to exceed original
operating pressure.
After satisfactory vent gas test,
close purge gas (air) inlet valve
vent and remove purge hose from
vent. Seal all outlets

35
APPENDIX 1 : GLOSSARY, ACRONYMS, ABBREVIATIONS, UNITS,
SUBSCRIPTS AND SYMBOLS

GLOSSARY

All definitions are given in IGEM/G/4 which is freely available:
as a CD, with the purchase of any IGEM Standard, upon request
by downloading a printable version from IGEMs website www.igem.org.uk.

Recommended and legacy gas metering arrangements are given in IGEM/G/1 which is freely
available:
with the purchase of any IGEM Standard, upon request
by downloading a printable version from IGEMs website.

Downloading from the website ensures access to the latest version.

ACRONYMS AND ABBREVIATIONS

ACS Nationally Accredited Certification Scheme
ACoP Approved Code of Practice
DMIP design maximum incidental pressure
DP design pressure
ECV emergency control valve
GB Great Britain
GM gauge movement
GRM gauge readable movement
GS(I&U)R Gas Safety (Installation and Use) Regulations
GT gas transporter
HSE Health and Safety Executive
IV installation volume
IGEM Institution of Gas Engineers and Managers
LDF leak detection fluid
LFL lower flammability limit
LPG liquefied petroleum gas
LR leak rate
MAM meter asset manager
MIP maximum incidental pressure
MIOV meter installation outlet valve
MOP maximum operating pressure
MOV meter outlet valve
MPLR maximum permitted leak rate
NDT non-destructive testing
NG Natural Gas
NRV non-return valve
OP operating pressure
PT purge time
PV purge volume
RD rotary displacement
PE polyethylene
SG specific gravity
SN/NVQ Scottish National/National Vocational Qualification
SP Set point
st standard
SSV slam-shut valve
STD strength test duration
STP strength test pressure
TTD tightness test duration
TTP tightness test pressure
UKAS United Kingdom Accreditation Service.


36
UNITS

in inch
m metre
mbar millibar
min minute
mm millimetre
m
3
cubic metre
m
3
h
-1
cubic metre per hour

SYMBOLS

Q flow rate
> greater than
less than or equal to
nominal diameter
V volume
is valve (normally open)
valve (normally closed)
regulator
safety device
appliance
` meter
filter
blanking device
d diameter
L length
N
2
nitrogen

SUBSCRIPTS

c consumer
f fittings, etc
m meter
mi meter installation
p pipe
t total
u upstream
A
M

37
APPENDIX 2 : REFERENCES

Care needs to be taken to ensure that the latest editions of the relevant documents are used.

A2.1 LEGISLATION
Gas Act 1986 (as amended by the Gas Act (1995)
Health and Safety at Work etc. Act 1974

Note: This applies to all work activities. It places general duties on employers to ensure, so far
is reasonably practicable, the health safety and welfare of their employees and the
health and safety of members of the public who may be affected by the activity.
Petroleum Act 1962
Confined Spaces Regulations 1997
Construction (Design and Management) Regulations 2007
Control of Substances and Hazardous to Health Regulations 2002
Dangerous Substances and Explosive Atmospheres Regulations 2002
Electricity at Work Regulations 1989
Gas Safety (Installation and Use) Regulations 1998

Note: These apply to domestic and commercial premises. For industrial premises, the
requirements of these Regulations could be considered relevant in any investigation
under the Health and Safety at Work etc. Act. The Regulations set out detailed
requirements for gas installation work. In particular, they require that anyone carrying
out such work must be competent to do so. They also prescribe circumstances in which
a tightness test and purge must be carried out.
Management of Health and Safety at Work Regulations 1999
Manual Handling Operations Regulations 1995
Personal Protective Equipment at Work Regulations 1992
Pressure Equipment Regulations 1998
Pressure Systems Safety Regulations 2000

Note: For cylinders etc., Carriage of Dangerous Goods (Classification, Packaging and
Labelling) and Use of Transportable Pressure Receptacles Regulations 1996 (as
amended), the Transportable Pressure Vessel Regulations 2001 may also be relevant.
Provision and Use of Work Equipment Regulations 1998.

A2.2 HSE ACOPS AND GUIDANCE NOTES

HSG48 Human factors in industrial safety. Guidance.
HSL56 Safety in the installation and use of gas systems and
appliances. ACoP and Guidance.

A2.3 BRITISH STANDARDS (ABBREVIATED TITLES)

BS 5482-1 Domestic butane and propane gas burning installations
BS EN 60079 Electrical apparatus for explosive gas atmospheres.


38
A2.4 IGEM STANDARDS

IGE/UP/1 Strength and tightness testing and direct purging of
Edition 2 industrial and commercial gas installations
RWA
IGE/UP/1A Tightness testing and direct purging of small low pressure
Edition 2 industrial and commercial gas installations
RWA
IGE/UP/1B Tightness testing and purging of Natural Gas installations
Edition 2
IGE/UP/2 Gas installation pipework on industrial and commercial
Edition 2 premises
IGE/SR/22 Purging operations for fuel gases in transmission,
distribution and storage
IGE/SR/23 Venting of Natural Gas
IGE/SR/24 Risk assessment techniques
IGEM/G/1 Defining the end of a network, meter installation, and
installation pipework
IGEM/G/4 Definitions for the gas industry
IGEM/GM/7B Electrical connections and hazardous area classification for
gas metering equipment.

39
APPENDIX 3 : INDIRECT PURGING WITH NITROGEN

An indirect purge is to be carried out only and if:
the direct purge has been unsuccessful
a direct purge is unlikely to be achieved successfully for example where inadequately-sized
purge points are fitted
a risk assessment indicates that heavier-than-air gas has to be purged indirectly.

A3.1 If a direct purge has been unsuccessful, make the installation and the
surroundings safe, before implementing fallback plans.

Check the calculations, survey the installation and inspect equipment to
endeavour to identify the cause of failure to direct purge.

If the cause is identified and can be rectified, (for example following calculation
error, block hose, closed valve, restrictive purge points etc.), the direct purge
can be repeated.

Note: Take additional care at purge gas vent point due as a flammable mixture may occur at a
different stage in the operation.

A3.2 Ensure the indirect purge is a complete displacement purge using volume -
based measurement of inert gas and vent gas testing. Pay particular attention
to any dead-legs.

Take precautions to prevent asphyxiation, especially in basements and confined
spaces.

Take precautions to prevent the purge gas entering the GTs or any other
distribution network.

A3.3 Start with the largest diameter pipe and progress to the smallest.

Ensure a minimum volume of N
2
(equal to 1.5 x IV) of the installation is
available (see Table 12 and Appendix 4).

PIPE NOMINAL
SIZE (mm)
MINIMUM QUANTITY OF NITROGEN
GAS PER 1 m LENGTH (m
3
)
100
150
200
250
300
350
0.013
0.03
0.05
0.08
1.12
2.16

TABLE 12 - MINIMUM QUANTITY OF N
2
PER 1 m LENGTH OF PIPE

A3.4 As a guide, a standard 1.5 m long nitrogen bottle usually has a capacity of 6.5 m
3
.
The maximum flow rate through a high capacity single-stage regulator is,
typically, 60 m
3
h
-1
.

A3.5 The criteria given in Table 13 apply when testing the vent gas.

A3.6 Following the indirect purge, if hot work is to be undertaken, take care in case
small pockets of gas remain in the pipe due to the effects of stratification or due
to the effect of dead-legs.

A3.7 When undertaking any work following an indirect purge, take suitable
precautions to account for the presence of nitrogen.

40

FLAMMABILITY LIMITS SAFE PURGE ENDS POINTS
FUEL TYPE
(GAS OR
VAPOUR
SPECIFIC
GRAVITY
AIR = 1
LOWER
FLAMMABLE
LIMIT % IN
AIR
UPPER
FLAMMABLE
LIMIT % IN
AIR
INDIRECT
PURGE FROM
FUEL GAS TO
NITROGEN
SAFE END
POINT
% GAS IN N
2
INDIRECT
PURGE FROM
NITROGEN
TO FUEL GAS
SAFE END
POINT
% GAS IN N
2
Natural Gas 0.6 4.5 15.5 7.5% gas in N
2
90% Fuel Gas
Propane 1.5 2.1 10.1 3.5% gas in N
2
90% Fuel Gas

TABLE 13 - FLAMMABILITY LIMITS AND SAFE PURGE ENDS POINTS FOR
INERT PURGE

A3.8 Once the purge to nitrogen is complete, it is advisable to then purge to air and
ensure the oxygen level is at least 20%.


41
APPENDIX 4 : CALCULATION OF TIGHTNESS TEST DURATION

A4.1 INSTALLTION VOLUME (IV)

A4.1.1 General

The estimation of IV involves surveying the whole of the section to be tested.

Note has to be taken of the relevant dimensions of all components including
any:
meter
pipe
fitting, including any regulator, bend, tee, etc .
pipework exposed to direct sunlight or high temperature

Note: The tightness test result is valid only if the temperature of the section remains stable
throughout the period of the test.

A4.1.2 Calculations

A4.1.2.1 The following formula can be used to calculate the total installation volume (IV
t
)
(m
3
) of the section to be tested:

IV
t
= IV
m
+ IV
p
+ IV
f

Note: The IV
t
(m
3
) needs to be calculated to two significant figures with rounding being upwards
only.

It is not advisable to round the calculations of IV of individual parts of a section as this may
cause the test to be more onerous than necessary.

A4.1.2.2 IV
m
, IV
p
and IV
f
can be calculated as follows:

(a) IV of meters (IV
m
)

Use Table 14 or consult the meter manufacturer for any other meter.

DESIGNATION
OF METER
IV
m
(m
3
) CYCLIC
VOLUME
BADGED RATING
m
3
ft
3
m
3
h
-1
ft
3
h
-1

G4/U6
G10/U16
G16/U25
U40
G40/U65
G65/U100
U160
0.008
0.025
0.037
0.067
0.100
0.182
0.304
.002
.006
.01
.02
.025
.057
.071
0.071
0.2
0.35
0.71
1.11
2.0
2.5
6
16
25
40
65
100
160
212
565
883
1412
2295
3530
5650
RD or turbine 0.79d
2
L* N/A N/A N/A N/A

* or equivalent length of pipe
d = diameter, i.e of meter connection (m)
L = length, i.e flange to flange dimension (m).

TABLE 14 - INSTALLATION VOLUME (IV) OF METERS


42
(b) IV of pipe (IV
p
)

For a 1 m length of pipe, obtain the volume of the particular pipe from
Table 15. Multiply the value given by the length of the pipe in the
section.

NOMINAL SIZE OF
PIPE
(mm) (in)
VOLUME OF 1 m
LENGTH OF PIPE
(m
3
)
25 1
32 1
40 1
50 2
65 2
80 3
100 4
125 5
150 6
200 8
250 10
300 12
350 14
.00064
.0011
.0015
.0024
.0038
.0054
.009
.014
.02
.035
.053
.074
.089

Note: For sizes not shown, go to the next larger size given.

TABLE 15 - VOLUME OF 1 m LENGTH OF PIPE

(c) IV of valves, fittings, pressure vessels, accumulators, etc. (IV
f
)

Add any additional volume caused by such components.

In the event that IV
f
cannot be calculated, add an additional 10% of the
pipe volume (IV
p
).

A4.2 TIGHTNESS TEST PRESSURE (TTP)

TTP is equal to OP, see Sub-Section 5.3 for more information.

A4.3 SELECTION OF PRESSURE GAUGES

A4.3.1 The sensitivity of any pressure gauge determines the gauge readable movement
(GRM).

The gauges listed in Table 16 are typical of the instruments used for tightness
testing and have to be used (for the gauges listed) to determine GRM. The list
does not preclude the use of other types or ranges of gauge but the gauge used
needs its GRM specified.

Note: If an inferential gauge is used then, to ensure accuracy, care needs to be taken regarding
rounding errors caused by using the last decimal place.

TYPE OF GAUGE TYPICAL
RANGE
(mbar)
TYPICAL
READABLE
MOVEMENT
(GRM)
(mbar)
TYPICAL
MAXIMUM TTD
(mins)
Water (SG 1.0) 0 120 0.5 30
High SG (SG 1.99) 0 200 1 45
Electronic (1 decimal place) 0 - 200 0.5 30
Electronic (2 decimal places) 0 200 0.1 15
Electronic (1 decimal place) 0 2,000 0.5 30

Note: Longer tightness test durations (TTD) are possible if an absolute gauge is used.

TABLE 16 - SELECTION OF PRESSURE GAUGES (typical data)

43
A4.3.2 When using a gauge, the following shall be undertaken:
for all gauges, refer to the manufacturers instructions for details but, in the
event that no manufacturers instructions are available, calibrate the gauge
at an interval not exceeding 12 months. A calibration certificate shall be
available for any instrument used for tightness testing
ensure that any gauge is suitably ranged for the installation being tested
ensure an adequate level of accuracy of any gauge
ensure that, where necessary, any electronic gauge is certified for use in a
hazardous area (see Sub-Section 3.4) and operated within the
manufacturers specification with regard to ambient temperature
stabilize any electronic gauge at the temperature of the area where it is to
be used for 30 mins, or as specified by the gauge manufacturer, prior to the
test being carried out

Note: Electronic gauges are prone to drifting due to changes in ambient temperature
changes.
if appropriate, zero any gauge at the start of the test at atmospheric
pressure.

Note: Any movement from zero at atmospheric pressure at the end of the test invalidates the
complete tightness test which then needs to be carried out again.

A4.4 MAXIMUM PERMITTED LEAK RATE (MPLR)

A4.4.1 An MPLR of 0.0014 m
3
h
-1
applies irrespective of the location of the installation.

Note: In the interest of simplification and taking account of the size of metering installations, new
and existing installations have been treated the same.

A4.5 TIGHTNESS TEST DURATION (TTD)

A4.5.1 To calculate TTD, use the formula as given in A4.5.3. GRM and the factor F1 can
be obtained from Table 16 and Table 17 respectively.

A4.5.2 TTD needs to be rounded up to the next full minute and not less than 2 mins.

A4.5.3 Table 16 specifies the maximum TTD for particular gauge types, which minimise
the effect of normal variations in barometric pressure and ambient temperature.

TTD = GRM x IV x F1

F1 = as derived from Table 17

FACTOR F1
GAS TYPE TEST USING FUEL
GAS AT OP
TEST USING AIR OR
NITROGEN AT OP
NATURAL 42 67
PROPANE 102 221

TABLE 17 - FACTOR F1 TO APPLY WHEN CALCULATING TTD

44
APPENDIX 5 : PURGING HEAVIER-THAN-AIR GASES RISK
ASSESSMENT

A9.1 FLAMMABILITY RANGE

Differing fuel gases have very different flammable ranges and, when working
with these various gases, it is essential that the range is understood as well as
having gas detection equipment suitable for the gas being monitored.

A9.2 DENSITY (SPECIFIC GRAVITY)

The densities of gases vary dependant on their temperatures, so it is normal to
refer to density relative to air. Air has a density of 1. Gases with lower density
are lighter-than-air and gases with a higher density are heavier-than-air.

A9.3 PROPERTIES OF LPG

The most common of the heavier than air gases in use are known as Liquefied
Petroleum Gas, or LPG, (3rd family gases). BS 4250 is the specification for
commercial butane and propane, but gases outside this specification are often
used for special purposes.

They are stored in the liquefied state under pressure. The actual pressure in the
storage container, known as the vapour pressure, is dependent upon the
specification of the actual LPG and the temperature of the stored liquid.

These procedures apply only to the pipework downstream of the first stage
pressure regulator in a vapour system. They do not apply to the storage tank,
the high pressure pipework feeding the first stage regulator, or to any part of a
system containing LPG in the liquid phase.

LPG vapour is, normally, used for gas supplies to gas fired equipment. This
vapour may be generated by natural vaporisation of the liquefied LPG, or for
large industrial offtakes by the use of an in line vaporiser where the latent heat
required is provided from an external source.

Some LPG may contain small quantities of heavy hydrocarbons that do not
readily vaporise, often described as "heavy ends". Where they are present,
these heavy ends will concentrate in the bottom of storage vessels used for
natural vaporisation systems, or in the base of external vaporisers. In abnormal
situations, or where the plant operators fail to drain the system regularly, they
may be carried over into the gas supply pipework.

Where heavy ends are found in downstream pipework specialist advice is
required to ensure that they are removed and disposed of in a safe manner. A
permit to carry out such work is required to be issued by an authorised
competent person.

Note: Heavy ends are, normally, only associated with LPG produced from refinery operations and
are not present in LPG produced from natural gas liquids.

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