GPCOEWG/GAS/D/03
Ref No.
GENERAL PEOPLE’S COMMITTEE OF
ELECTRICITY, WATER AND GAS
Document name: Procedure & Specification for the Design & Construction of
Distribution Systems Operating At Less Than 16 Bar
PREPARED BY:
Name: Phil Winnard
Position:
Date:
Amendment Record
1 30/10/07
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DISCLAIMER
This document is not to be used as design handbook; it does not eliminate the need for a competent
designer or for competent engineering judgement.
All designs prepared by competent designers must be appraised and authorised for issue by a
competent person or authority before any construction works are carried out in accordance with the
design brief.
The requirements of this specification are adequate for safety under conditions usually encountered in
the gas industry. Requirements for all unusual conditions cannot be specifically provided for, nor are
all details of engineering and construction prescribed; therefore activities involving the design,
construction, operation, or maintenance of gas transmission or distribution systems should be
undertaken using personnel having the experience and knowledge to make adequate provision for
such unusual conditions and specific engineering and construction details.
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CONTENTS
Page
1 DOCUMENT INTRODUCTION 10
1.1 Context 10
1.2 Purpose 10
1.3 Responsibility 10
1.4 General Requirements 10
1.5 Primary Design Codes 10
1.5.1 Distribution Mains 10
1.5.2 Services 10
1.5.3 Supplies To High Rise Multi Occupancy Buildings 10
1.5.4 Metering Installations 11
1.5.5 Industrial Meter Installations 11
1.5.6 Other Relevant Standards 11
1.6 Safety And The Environment 11
1.7 Statutory Requirements 11
1.8 Competency And Quality Assurance 12
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List of Tables
List of Figures
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DEFINITIONS
Assets Mean the pipeline and any other installation or apparatus through which natural
gas is intended to flow, including block valves, a structure to be used solely for the
support of a pipe, facilities to launch and receive Pigs, pressure reduction
installations, cathodic protection system, odorisation plant, and, where requested,
the metering installation and flow weighted average calorific value measuring
equipment.
Authorising The Authorising Engineer shall be competent to approve written procedures and
Engineer authorise work instructions and permits to work and documents for undertaking
work on the gas system
Distribution Pipe work normally laid below ground operating at pressures up to 4 bar
main
Distribution Pipework connected to the distribution main and conveying gas to the gas
Service consumers premises terminating at the consumers emergency control valve
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1 DOCUMENT INTRODUCTION
1.1 Context
PB Power has been requested to prepare policies and procedures to ensure that the gas transmission
and distribution system in Libya is operated, maintained and managed safely, securely and to
international standards.
To ensure the appropriate standard of safety and reliability in construction, operation, and
decommissioning it is essential that a system of design exists for assets associated with the
distribution of natural gas.
This document applies to all aspects of design and construction of gas transmission assets, operating
at below 16 barg. Disciplines covered include mechanical engineering, civil engineering, structural
engineering, electrical, instrumentation, gas engineering, safety and environment.
1.2 Purpose
The purpose of this procedure is to ensure that distribution systems are designed to International
standards and using best practice principles.
1.3 Responsibility
The Planning Manager is responsible for ensuring that this procedure is adhered to.
The design must incorporate all reasonably practicable measures to minimise the probability and
consequences of failure.
All new mains and modifications to existing mains shall be designed and constructed in accordance
with the latest edition of IGE/TD/3, Distribution systems less than 16 bar.
1.5.2 Services
All new services shall be designed and constructed in accordance with the latest edition of IGE/TD/4,
Services.
All new installations, and modifications to existing installations, shall be designed and constructed in
accordance with IGE/G/5, Gas installations in flats and other multi-dwelling buildings.
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All new installations, and modifications to existing installations, shall be designed and constructed in
accordance with the following standards:
IGE/GM/6 - Standard diaphragm and RD meter installations. > 6 m3h-1 MOP ≤ 75 mbar
IGE/GM/7 Ed 2 - Electrical connections and hazardous area classification MOP ≤ 100 bar
All new installations, and modifications to existing installations, shall be designed and constructed in
accordance with the following standards:
Other IGE specifications which are relevant to the design of transmission systems include:
Development activities undertaken by the Authority can have an impact on the safety of the general
public, Authority staff and contractors and can affect the local environment. The Authorities policy on
Health Safety and the Environment shall be followed at all times to reduce this impact to a minimum.
The Authority must comply with all relevant statutory requirements in designing the gas transmission
system.
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The primary method of ensuring the design specification is consistently applied is by adoption and
implementation of the IGE/GL/5 - Managing new works, modifications and repairs’. The Authority shall
be responsible for management of the Design and Design Appraisal procedure.
Providers of design services shall comply with and be registered to ISO 9002 – Quality assurance
standards.
The design process should follow the recommendations as detailed in BS 7000: Part 4: 1996 Design
Management Systems, Guide to Managing Design in Construction.
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DESIGN PROCESS
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DESIGN PROCESS
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DESIGN PROCESS
The design and construction process has been divided into four stages. The four stages are listed as
follows:
2. Feasibility Studies for Mains, Pipelines and Installations Operating at less than 16 Bar.
3. Detailed design of Pipelines, Mains, Services and Installations Operating at less than 16
Bar.
The design and construction process includes a review and appraisal of each stage. This appraisal
shall be carried out be a competent and independent organisation with extensive knowledge of the
design technologies being reviewed. This will ensure that design and construction activities meet the
requirements of the Authority procedures, standards and specifications.
Feasibility studies will normally be carried out on gas pipelines operating in the range 2 – 16 bar and
gas installations with inlet pressures in the range 2 – 16 bar. Where the project involves large and
more complex gas distribution mains and services schemes then the Authority may also commission
a feasibility study in advance of detailed design and construction.
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The Authority shall undertake all activities associated with the future planning of gas supplies for
Libya.
Network performance tools such as Graphics Based Network Analysis (GBNA) and Large Integrated
Network Analysis System (LINAS should be used to provide comprehensive planning of the overall
mains distribution system.
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• Network validation by testing the network model against actual pressures experienced in the
network - Recorded pressure measurements are taken at strategic points through the system
& compared with the model pressure. Discrepancies are investigated and the model modified
to more closely match reality.
• Design appraisal and review of feasibility studies and detail design proposal.
Reference shall be made to IGE/GL/1 ‘Planning distribution systems. MOP ≤ 16 bar’, for the planning
of gas distribution systems.
The Authority shall provide a project brief for the organisation that is to carry out the feasibility study.
The project brief will contain the following information:
• Gas flows.
Other constraints that should be included in the project brief are listed as follows:
• Time periods during which a particular construction process must be completed taking
account of Network Outages for Connections.
• Intermediate route points that the pipeline has to connect with or be close to.
• Impact on, or creation of, a site that falls within any specific regulations.
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The Authority Project Manager will be responsible for producing the deliverables required by this
procedure.
This feasibility study will enable informed and cost effective decisions to be taken based on
engineering and environmental constraints.
• Identify possible sites for above ground installations such as pressure reduction and metering
installations etc…
• Identify factors that may limit the scope of the project including potential risks to the overall
project.
• Definition of an area of search to be considered for sites, mains and pipeline routes.
• Review of published information regarding the natural, physical and environment matters, and
the identification of possible constraints which may affect the project.
• Production of a Route Corridor Investigation Report including constraints maps identifying the
possible routing constraints and possible route corridor options for pipelines.
• Production of basic Engineering Line Diagrams (ELDs) and outline General Arrangement
(GA) drawings for the facilities/installations required.
• Consideration of the impact of any regulations that may affect the project.
• Ground conditions should be addressed in a Ground Risk Study in which the geotechnical
impacts on each of the route corridor options should be identified, especially as ground
conditions pose significant risk to the construction phase. The study should consider such
aspects as geology, hydro-geology, ground conditions, mining subsidence, land slip, solution
caverns, the presence of landfill sites and other forms of ground instability.
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The feasibility study report shall be representative of what took place during the design study. The
report shall put emphasis on the decisions made, why they were made and by whom. The report shall
outline the options considered and why, and identify the competency level for named personnel
involved in the feasibility study including details of relevant qualifications, training and experience.
The report shall outline possible design options and explain the rationale behind them. Factors that
may limit the scope of the project and evaluate any anticipated difficulties shall also be detailed.
The feasibility study report shall include, but not be limited to, the following:
Executive Summary
This section should be a brief summary of the need for the project the background to the project, a
brief description of the pipeline route (if applicable), key site names and basic materials.
Pipeline Route
This section shall describe the proposed pipeline route corridor options identified including any
environmental considerations including Route Corridor Investigation.
Design or technical information relating to the options being considered shall be provided as follows:
• Process criteria and design parameters for example, flow and pressure ranges (minimum and
maximum), temperatures, flow meter accuracy, ramp up rates, etc…
• Materials, for example, outline details of pipe material grades and wall thickness
recommended for the proposed pipeline, long lead time items that may restrict the
programme, plant and equipment that is required for any installations etc…
• Confirmation of compatibility with the existing pipeline system and identification of factors that
may affect future operation and maintenance.
Safety Engineering
All legislative requirements that may impact on the project shall be addressed.
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Engineering Line Diagrams (ELDs) and General Arrangement Drawings (GAs) shall be prepared for
the installations, where appropriate, showing the relative size and position of pipework, plant and
equipment. All drawings shall clearly show the relationship between new and existing plant,
equipment and pipework, and identify any modifications necessary.
On pipeline projects this shall include outline details of connecting the start and finish points of the
proposed pipeline into existing or future pressure systems or supply points and identify the land
required.
Recommendations
The recommendation shall include the preferred option, further work and necessary actions to enable
the scope of the Detailed Design for the project to proceed.
An outline project plan (e.g. Gantt chart) shall be provided, showing details of all the major elements
to project completion, typical lead times etc…, so the critical path of the project can be highlighted and
addressed.
For a pipeline the initial routing process will involve a desk top study to identify possible suitable
routing options. Although the shortest route between 'A' and 'B' is normally the most economic, other
criteria have to be considered which will affect possible routing options, such as centre of population,
the location of environmental constraints etc. Careful routing of pipelines is the most effective means
of ensuring protection of the environment, by avoiding sensitive areas wherever possible.
Generally, the alternative courses of action, choices for pipeline start and termination points, and
different routing options, are considered during the feasibility study stage of the project.
Decisions on the range of alternatives to be considered will need to be taken with only a limited
amount of information available, hence the process becomes iterative as more information becomes
available. Environmental matters will influence the decision process and they will have to be balanced
against issues such as engineering, technical, safety, economic and project programme.
Therefore early evaluation of the purpose of the project, the perceived need, possible alternatives and
the assessment of a proposed project is important to identify the direction of the environmental
assessment process.
The aim of pipeline routing is to locate the most cost effective option which satisfies the safety
requirements, whilst minimising the impact on the environment and capital cost.
The issues typically considered as part of the Route Corridor Investigation study include, but are not
limited to, the following:
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• Land use: For example agriculture, mining areas, quarries, mineral extraction, recreational
facilities etc…
• Planning policies.
The route corridors are usually identified as a band of interest up to 1 kilometre in width having taken
into account major constraints, such as conurbations, topography, scheduled sites, major road and
rail crossings. The width of the route corridor(s) will depend on the complexity of the environment
through which it passes. The corridor need not be a uniform width throughout and may alter in size
due to constraints. One of the main objectives of the routing study is to determine route corridor
options and show why some route corridors have not been considered or have been disregarded.
• The shortest distance between the start and finish points, bearing in mind the above criteria
and the implications on project costs.
• The requirements of the design code selected (e.g. IGE/TD/1 or IGE/TD/3 etc.) from the point
of view of the minimum permissible building proximity distances between the pipeline and
occupied buildings are detailed according to pipeline diameter, operating design parameters
It is desirable that the route corridors proposed should, as far as practicable, avoid running closely
parallel to high density traffic routes, railways or overhead high voltage cables. The length of the route
between the start and finish points should be kept to a practical minimum.
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The Detail Design Report shall be a comprehensive design package. The detailed design will
consider and report upon the following parameters:
• Gas Pressures - Max Incidental P, (Safe operating Limit), Max Operating P, and Min
Operating P.
• Methodology - transient, static, (based on Panhandle, Smooth pipe law, Other equation).
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• Route selection.
• Selection of building proximity distance multiplier and section length (rolling circle or other
method).
• Identification of populated buildings both existing and planned (Population density survey).
• Area classification.
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2.3.6 Proximity Distances Based On Pressure, Pipe Diameter, Wall Thickness And Material
Grade
• From roads.
• From railways.
• Field testing (CIPPS, current drain tests etc) specification and requirements.
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• Fitting material certification – bends, tees, valves, flanges, reducers, “O”Lets, gaskets, bolts.
• Standards, specifications, data sheets and Quantities of pipe, valves, fittings and other
materials.
• Pressure vessel requirements and certification (PD 5500 Asme 8, Form X etc).
• Tracks.
• River crossings.
• Drain crossings.
• Ditch crossings.
• Rail crossings.
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• Venting requirements.
• Stress analysis.
2.3.13 Legal
• Wayleave schedule.
• Compensation register.
• Shutdown/isolation requirements.
• Boilers and heat exchanger system, frequency response and control requirements.
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• Pressure systems.
• Site selection.
• Geotechnical assessment.
• Geophysical assessment.
• Hydro-graphic assessment.
• Support design.
• Fencing design.
• Housings for gas equipment indicating ventilation and explosion relief design calculations.
• Support design.
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• Testing schedule.
• P & ID.
• Operational procedures.
• Block diagrams.
• P&IDs.
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• Earthing drawings.
• Cable layouts.
• Cable calculations.
• Welding specification.
• Gauge pig run details – gauge plate thickness and diameter and certification.
• Testing procedure.
• Testing equipment calibration certification including pumps, gauges, hoses, test ends etc…
• Pressure volume plot including hold points and entrained air by volume calculation.
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2.3.20 Drying
• Drying procedure.
• Dryness report.
• Land purchase.
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• Wayleave payments.
• Riser pipe sizes, valve types and locations, construction proposals and materials.
• Lateral off take sizes, lengths, valve type(s) and locations, construction proposals and
materials.
• Architects scaled drawings for all floors in all building types. Drawings to show as required:
• Riser and lateral duct design including expected fire rating, access panels and
proposed panel fire sealing.
• Riser and lateral duct ventilation design, size, sizing calculations and location
ventilation ducts (high & low level).
• Penetration sealing proposals, between floors and into properties (material and
application process).
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This Section provides relevant information on safety matters relating to the design and construction of
gas transmission systems. The following safety aspects are addressed:
To ensure that all work carried out in a safe manner, it is necessary for employees to know about the
occupational safety laws which affect them. This Section provides a resume of the Safety Laws which
are in place in the United Kingdom and provides an effective framework for ensuring work is
undertaken safely in Libya.
3.1.1 Information On The Laws Of The United Kingdom Governing Health And Safety
Everyone has a responsibility for safety and safe working. The Health and Safety at Work, etc. Act
1974 (HASWA) requires everyone to ensure, so far as is reasonably practicable, the health and
safety of themselves and others who may be affected by what they do or fail to do.
a) Everyone who may work with you, including casual workers, part-timers, trainees and
contractors or sub-contractors;
c) Anyone who may be affected by your work (i.e. the public and others).
HASWA 1974 applies to all work activities, and everyone at work at whatever level (e.g. employee,
supervisor, manager, Chairman and Chief Executive) has certain responsibilities under HASWA 1974.
The Gas Safety Regulations 1972 as amended by the Gas Safety (Installation and Use) Regulations
1994 detail statutory requirements regarding the installation of service pipes, service governors,
internal supply pipes, meters and appliances.
Guidance on these Regulations is given in Health and Safety Executive booklet L56.
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d) That a service must be disconnected where the meter has been removed for a period
exceeding 12 months.
It is a statutory requirement that all gas installers are registered. It is the responsibility of the employer
and the duty of the employee to ensure compliance with the requirements of the Regulations
regarding the laying of gas services.
The Management of Health and Safety at Work Regulations 1992 ('the Management Regulations') set
out broad general duties which apply to almost all work activities in Great Britain and offshore. They
are aimed mainly at improving health and safety management and can be seen as a way of making
more explicit what is required of employees under HASWA 1974. Their main provisions are designed
to encourage a more systematic and better organized approach to dealing with health and safety.
a) Assess the risks to the health and safety of employees and of anyone else who may be
affected by their work activity. This is so that the necessary preventive and protective
measures can be identified. Employers with five or more employees have to record the
significant findings of the assessment. (The same threshold is already used in HASWA 1974.
Employers with five or more employees have to prepare a written health and safety policy);
b) Make arrangements for putting into practice the health and safety measures that follow from a
risk assessment. They will have to cover planning, organization, control, monitoring and
review, in other words, the management of health and safety. Again, employers with five or
more employees will have to record their arrangements;
c) Provide appropriate health surveillance for employees where the risk assessments show it to
be necessary.
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d) Appoint competent people (either from inside their organization or from outside) to help to
devise and apply the measures needed to comply with their duties under health and safety
law;
f) Provide employees with information they can understand about health and safety matters;
h) Make sure that employees have adequate health and safety training and are capable enough
at their jobs to avoid risks; and
i) Provide temporary workers with some particular health and safety information to meet special
needs.
a) Place duties on employees to follow health and safety instructions and report danger.
b) Extend the current law which requires you to consult employees' safety representatives and
provide facilities for them.
These general duties lie side-by-side with the more specific ones in other health and safety
regulations, although that does not mean doing things twice. For example, a risk assessment made to
comply with the COSHH Regulations does not need to be repeated for the same hazardous
substances to comply with the Management Regulations. A specific duty will normally take the place
of a general one that duplicates it.
The Provision and Use of Work Equipment Regulations 1992 are designed to pull together and tidy up
the laws governing equipment used at work. Instead of piecemeal legislation covering particular kinds
of equipment in different industries they:
b) List minimum requirements for work equipment to deal with selected hazards whatever the
industry.
'Work equipment' is broadly defined to include everything from a hand tool, through machines of all
kinds, to a complete plant such as a refinery. 'Use' includes starting, stopping, repairing, modifying,
installing, dismantling, programming, setting, transporting, maintaining, servicing and cleaning.
a) Make sure that the equipment is suitable for the use that will be made of it.
b) Take into account the working conditions and hazards in the workplace when selecting
equipment.
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c) Ensure equipment is used only for operations for which, and under conditions for which it is
suitable.
d) Ensure that equipment is maintained in an efficient state, in efficient working order and in
good repair.
f) Stability of equipment.
g) Lighting.
h) Maintenance operations.
The incorrect handling of loads causes large numbers of injuries and can result in pain, time off work
and sometimes permanent disablement. The Manual Handling Operations Regulations 1992 apply to
any manual handling operations which may cause injury at work. Those operations are identified by
the risk assessment carried out under the Management of Health and Safety at Work Regulations
1992. They include not only the lifting of loads, but also lowering, pushing, pulling, carrying or moving
them, whether by hand or other bodily force.
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2. The way the task is carried out (e.g. the handler’s posture).
Unless the assessment is very simple, a written record of it will be needed. The general
guidance will include some simple guidelines to help assessment.
c) Reduce the risk of injury as far as is reasonably practicable. A good assessment will not only
show whether there is a problem, but will also point to where the problem lies. That is the
starting point for your improvements. For example, if the load is bulky or heavy it may be
possible to use mechanical handling aids or break down the load. If handlers have to adopt
an awkward posture it may be possible to re-arrange the task. Additional training may be
required.
The regulations are supported by general guidance in HSE Publication L23, which includes some
numerical guidelines which help to identify the more serious risks which deserve a more detailed
assessment. More detailed guidance may be developed for individual industries where there are
special needs.
The Workplace (Health, Safety and Welfare) Regulations 1992 cover many aspects of health, safety
and welfare in the workplace. Some of them are not explicitly mentioned in the current law though
they are implied in the general duties of HASWA 1974. The Regulations apply to all places of work
except:
a) Means of transport.
b) Construction sites.
c) Sites where extraction of mineral resources or exploration for them is carried out.
Workplaces on agricultural or forestry land away from main buildings are also exempt from most
requirements. Only the requirements on toilets, washing facilities and drinking water apply. The
Regulations set general requirements in four broad areas, as follows:
a) Working environment
2. Ventilation.
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b) Safety
1. Safe passage of pedestrians and vehicles, (e.g. traffic routes must be wide enough
and marked where necessary, and there must be enough of them).
3. Transparent and translucent door and partitions (use of safety material and
marking).
7. Falling objects.
c) Facilities
1. Toilets.
3. Clothing storage.
4. Drinking water.
5. Rest area (and arrangements to protect people from the discomfort of tobacco
smoke).
d) Housekeeping
2. Cleanliness.
Employers will have to make sure that any workplace within their control complies with the
Regulations. Other people connected with the workplace (such as the owner of a building which is
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leased to one or more employers or self-employed people) also have to make sure that the
requirements falling within their control are satisfied.
The Personal Protective Equipment (PPE) at Work Regulations 1992 set out in legislation sound
principles for selecting, providing, maintaining and using PPE.
PPE is defined as all equipment designed to be worn or held to protect against a risk to health or
safety. This includes most types of protective clothing and equipment such as eye, foot and head
protection, safety harnesses, life jackets and high visibility clothing. There are some exceptions (e.g.
ordinary working clothes and uniforms (including clothing provided inlet for food hygiene), PPE for
road transport (e.g. crash helmets) and sports equipment).
PPE should be relied upon only as a last resort. But where risks are not adequately controlled by
other means employers now have a duty to ensure that suitable PPE is provided, free of charge, for
employees exposed to these risks. The Regulations say what is meant by 'suitable' PPE, a key point
in making sure that it effectively protects the wearer. PPE will only be suitable if it is appropriate for
the risks and the working conditions, takes account of worker's needs and fits properly, gives
adequate protection, and is compatible with any other item of PPE worn with them.
a) Asses the risks and PPE they intend to issue to ensure that it is suitable.
d) Give training, information and instruction to employees on the use of PPE and how to look
after it.
New PPE is also subject to a separate EC Directive on design, certification and testing. PPE
complying with this directive will be marked by the manufacturer with a 'CE' mark. This directive is to
be implemented in the UK by Regulations made by the Department of Trade and Industry (to be
called the PPE (Safety) Regulations).
Work with display screen equipment is not generally high risk, but it can lead to muscular and other
physical problems, eye fatigue and mental stress. Problems of this kind can be overcome by good
ergonomic design of equipment, furniture, the working environment and the tasks performed.
The Regulations will apply to display screens where there is a 'user', that is, an employee who
habitually uses the display screen equipment as a significant part of normal work. Employers will also
have some duties toward the self-employed using display screen equipment in their undertakings.
The Regulations cover equipment used for the display of text, numbers and graphics regardless of the
display process used. There are some specified exclusions though, such as systems on board a
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means of transport, systems mainly for public use, portable systems not in prolonged use, cash
registers and window typewriters.
a) Assess display screen equipment workstations and reduce risks which are discovered.
b) Make sure that workstations satisfy minimum requirements which are set for the display
screen itself, keyboard, desk and chair, working environment and task design and software.
c) Plan display screen equipment work so that there are breaks or changes of activity.
Display screen equipment users are now entitled to appropriate eye and eyesight tests by an optician
or doctor and to special spectacles if they are needed and normal ones cannot be used. It is now the
employer's responsibility to provide tests, and special spectacles if needed.
a) General provisions -specify the requirements for safe working conditions handling and
stacking of material, supervision of work, and welfare facilities.
b) Working places -provide details on fencing and work on roofs, ladders, scaffolds, and
platforms.
c) Lifting appliances -specify the design and construction requirements for lifting appliances
together with details of chains, ropes, slings and winches. They also set down the training
needed for the operators of lifting appliances, and equipment inspection procedures.
The Abrasive Wheels Regulations 1970 were formulated to ensure safe use of grinding and cutting
machines using abrasive wheels, discs, etc. Among other topics covered, there is a requirement to
ensure that only trained and competent persons are permitted to change or mount abrasive wheels
and/or discs.
The use of asbestos is controlled by the Control of Asbestos at Work Regulations 1987, as amended
by the Control of Asbestos at Work (Amendment) Regulations 1992.
If there is any doubt about whether material contains asbestos or not, arrangements shall be made for
a sample to be taken for analysis. If the presence of asbestos is confirmed, the working method given
in Safety Information Note 4/90 shall be followed.
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NOTE -Asbestos boards and cement sheets encountered on customers' premises are often painted
or otherwise treated, making recognition even more difficult.
Any large quantities of asbestos-related materials shall be reported to the Safety Adviser.
The Control of Substances Hazardous to Health (COSHH) Regulations 1988 require all work involving
substances hazardous to health to be fully and sufficiently assessed and all necessary precautions
communicated to persons involved in the work.
Naturally occurring radioactive materials come within the scope of the COSHH Regulations 1988.
Noise at Work Regulations 1989 and Construction (Head Protection) Regulations 1990
General
The Noise at Work Regulations 1989 and Construction (Head Protection) Regulations 1990 have
been introduced to ensure that employees are provided with adequate job/process assessments,
training and personal protection in respect of some basic hazards that may be present on any work
site.
Most of the equipment in use during normal operations can produce dangerous noise levels: such
equipment will normally incorporate a warning label stating that hearing protection must be worn
whilst the equipment is in operation.
In such cases, hearing protection (ear muffs) must be worn at all times, not just by the operator of the
equipment, but by all personnel in the immediate vicinity. This is a legal requirement - the Noise at
Work Regulations 1989 refers.
As a general guide as to the necessity for wearing ear protection, if you have to shout at a distance of
1 m or less to make yourself heard, hearing protection (ear muffs) shall be worn. If you are at all
unsure about the need for personal ear protection, consult the Health, Safety and Environment (H, S
& E) Department.
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The Construction (Head Protection) Regulations 1990 require that persons at work and exposed to
risk of head injury must wear an approved head protector (safety helmet), generally known in the
trade as a 'hard hat'. Typical situations where head protection should be worn include the following:
d) On or near scaffolding.
f) On any site where the person in charge makes rules requiring the wearing of head protection.
General
There are two major parts of the Reporting of Injuries, Diseases and Dangerous Occurrences
Regulations (RIDDOR) 1985. These are detailed in 5.3.14.2 and 5.3.14.3. Guidance is given in
HS(G)23 and HSE 24.
Accident Reporting
Accidents at work which result in an injury and absence from work for more than three consecutive
days (excluding the day of the accident but including any days that would not have been working
days) must be reported to the Health and Safety Executive (HSE), on their official form (F 2508) within
seven days.
Similarly, an accident at work which results in death or a prescribed major injury, or the casualty being
detained in hospital, must be reported to the HSE by the quickest practicable means, but within 24 h.
There is a list of seventeen prescribed 'dangerous occurrences' which must be reported to the HSE by
the quickest practicable means, but within 24 h, and within seven days in writing on Form F 2508.
All sources of a type and strength in the Third Schedule of the Radioactive Substances Act 1960 have
to be registered, the location specified and authority obtained for their disposal. If such a source is
portable, a log shall be kept of its use and locations.
The Public Information for Radiological Emergency Regulations 1992 empowers Fire and Civil
Defence authorities to require information to be supplied for use in the event of a radiation
emergency.
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NOTE - Naturally occurring radioactive materials come within the scope of the COSHH Regulations
1988.
The Ionising Radiations Regulations 1985 are made under the HASWA 1974 and apply wherever the
Act or Regulations made under the Act are in force. They cover the notification and records, basic
principles of protection, radiological and medical surveillance, organization of work and monitoring.
They also cover radiography and other processes and specify in an attached schedule the maximum
permissible radiation doses.
Further guidance on the use of radioactive sources is given in the publication Radiation Safety Site
Radiography prepared by the Oil and Chemical Plant Constructors' Association.
Dangerous substances must be packaged and labelled in compliance with the Classification,
Packaging and Labelling of Dangerous Substances Regulations 1984.
Carriage of dangerous substances must be in accordance with the Road Traffic (Carriage of
Dangerous Substances in Packages etc.) Regulations 1992 or the Road Traffic (Carriage of
Dangerous Substances in Road Tankers and Tank Containers) Regulations 1992, as appropriate.
3.1.2.1 Competence
All persons engaged in the design, construction, commissioning, operating, maintenance and
alteration of mains, services and related plant shall be competent to carry out such work. This may be
achieved by an appropriate combination of education, training and practical experience.
The following represents a general guide to safe working. Certain items are directed particularly to
those employees who have a responsibility for others. Basically you should ensure:
a) that you are familiar with the Health, Safety and Environment Statement, The H S & E
Requirements Manual
b) that your staff are trained and aware of any hazards at their place of work;
c) that your staff know where to find First Aid and fire-fighting equipment, and especially are
aware of its limitations and method of use;
d) that adequate supervision is available at all reasonable times, particularly for younger or less
experienced members of staff;
e) that safety rules are observed at all times and, where required, protective equipment is used;
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f) that safety devices, where provided, are properly adjusted and maintained;
g) that machinery and equipment is frequently inspected to ensure it is properly maintained and
safe to use;
j) that you regularly review working practices to improve Health and Safety aspects at your
place of work.
If there is any doubt, advice should be sought from your Safety Adviser.
Specification
All protective clothing and equipment must, where appropriate, comply with the relevant British
Standards(s) and/or regulations and Certificates of Approval currently in force.
All protective clothing and equipment shall have the approval of the relevant Safety Adviser. If the
introduction of new protective clothing or equipment is proposed (or a variation in use of existing
protective clothing or equipment), the Responsible Engineer shall seek the advice of the Safety
Adviser before introduction.
Provision
The majority of protective clothing and equipment is provided for employees on a personal issue basis
in compliance with statutory regulations (e.g. head protection, ear defenders, safety footwear).
Some protective clothing and equipment may be provided on loan, as and when required, at the
discretion of the Responsible Engineer (e.g. full fire protection suits, chemical and waterproof
clothing). However, in either case, it is essential that adequate supplies of all items are stocked at
local depots, such that they are immediately available for issue. Suitable arrangements shall be made
for access out-of-hours.
Where equipment is issued in compliance with Statutory Regulations, it is essential that replacement
items are issued with the minimum of delay.
The Responsible Engineer shall ensure that proper inspections are carried out on protective clothing
and equipment for which he is responsible within the timescale required by Statutory Regulations.
The Responsible Engineer shall ensure that adequate records are kept of all inspections, and any
subsequent maintenance carried out or replacements issued.
Protective clothing and equipment should be worn whenever necessary. Table 1 gives detail of these
and the hazardous environment for which they are particularly suitable.
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Safety Helmet Head and neck a) Impact from falling or flying objects b) Chemical drips or
splashes c) Adverse climate or temperature NOTE - Some
safety helmets incorporate, or can be fitted with, specially
designed facial, respiratory or hearing protection.
Gloves; gauntlets Hands and arms a) Abrasion. b) Temperature extremes. c) Cuts and punctures.
d) Impact. e) Chemical spillage. f) Electric shock or burns. g)
Skin infection. h) Vibration.
Safety boots and Wellingtons Feet and ankles a) Damp or wet (sometimes frozen) areas. b) Slippery (possibly
(incorporating Transco due to oil or chemical spillage) areas. c) Cuts and punctures. d)
approved steel toe caps) Falling objects. e) Heavy pressures. f) Metal splash. g)
Abrasion.
Disposable respirators; half Respiratory Tracts a) Toxic and harmful dusts. b) Gases and vapours. NOTE - The
masks or full-face mask correct type of respirator filter must be used, as each type is
respirators fitted with filtering effective for only a limited range of substances. Cartridges and
cartridge or canister; powered canisters have a limited life. Where there is a shortage of
respirators blowing filtered air oxygen, or any danger of losing consciousness from fumes, etc.,
to mask, visor, helmet or hood; use only breathing apparatus of the correct type. It should also
fresh air hose equipment; self- be noted that correctly worn breathing apparatus face masks not
contained and fresh air type only provide excellent protection against asphyxiation, but also
breathing apparatus against flesh burns and inhalation of hot gases.
Overalls All-over protection For live gas operations, only overalls which have been ‘Proban’
treated or similar should be worn - these give excellent
protection against flame.
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The use of protection, additional to that given in Table 1, against possible ignition of natural gas
should be largely dependent on the amount of gas likely to be present and the means of egress from
the work area.
The Responsible Engineer, when deciding on the use of full fire protective clothing for the safety of
employees involved on live gas operations, shall take account of the following:
a) fire suits
b) flash hoods
c) gloves
all manufactured from heavy duty 'Proban' treated cotton, or Nomex III or Bristol type.
Fire suits should be of the boiler suit design, close fitting at the wrists and ankles with a heavy duty zip
under a protective flap.
Face and respiratory protection will ideally be provided by breathing apparatus appropriate for the
situation and must always be worn in conjunction with the fire protection clothing.
Any person working in or near the highway or visiting such works, must wear the appropriate high
visibility clothing.
The main item of legislation is the COSHH Regulations 1988 which covers virtually all substances
hazardous to health. Only asbestos, lead and materials producing ionizing radiations, which have
their own legislation, are omitted.
The following basic principles of occupational hygiene are embodied in the COSHH Regulations
1988:
a) Assessing the risk to health arising from work and what precautions are needed.
c) Ensuring that control measures are used and that equipment is properly maintained and
procedures observed.
d) Where necessary, monitoring the exposure of employees and carrying out an appropriate
form of surveillance of their health.
e) Informing, instructing and training employees about the risks and the precautions to be taken.
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It is essential that only substances on an approved list are purchased. Any new substances shall be
cleared by the Safety Advisor and an assessment carried out as necessary.
Fire prevention
The formation of a flammable mixture in gas engineering operations may only be avoided by reducing
to a minimum the amount of uncontrolled gas discharged into the atmosphere.
Accordingly, full use should be made of any equipment and working methods designed for 'no gas'
working.
During all engineering operations where escaping gas could be present, regular checks should be
made with approved gas detection instruments, to safeguard anyone affected by the work activities.
Suitable notices shall be displayed to warn and instruct persons affected as follows.
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Good ventilation of all working areas during an engineering operation is necessary to help prevent the
build-up of gas concentrations in the atmosphere.
Any natural ventilation available should be taken advantage of by ensuring, as far as possible, that
the flow of air in working areas is not restricted (e.g. governor kiosks doors are fully opened from front
and rear).
Natural ventilation may not be sufficient to control the concentrations of gas in air, such as
accumulations of gas in a trench or confined space. In these circumstances consideration should be
given to clearing the accumulation by the use of a suitable air mover. It is essential that the air mover
is not a potential source of ignition. It may be driven by compressed air, hydraulic power or approved
electric motor (see 12.1.3.4 regarding certified and non-certified electrical equipment). It shall be
made of electrically conducting materials and it shall have a means of earthing which must prevent a
build-up of static electricity.
Impact between steel tools such as hammers and chisels can cause a spark. Sparks can also easily
be produced by steel tools such as forks, picks, shovels and points striking flints, rock, stones and
concrete, etc.
With all tools, the use of water will reduce the likelihood of sparks occurring. In the presence of
leaking gas, water should be poured on the ground before any potentially spark producing tool is
used.
When pipe is being broken out with a hammer, consideration shall be given to purging the pipe
thoroughly. Both pipe and hammer shall be wetted in areas where impact or friction is likely to take
place. This may be achieved by wetting the pipe with a wet cloth. (The cloth may also reduce the
likelihood of the hammer bouncing off and broken pieces of main being ejected into the air).
Equipment on site employing a naked flame shall be placed at least 5 m from any possible source of
escaping gas, and preferably upwind. If the equipment has to be placed downwind, this distance
should be increased.
In certain circumstances the Responsible Engineer may need to specify that equipment is placed
further away from the work and additional atmospheric monitoring adjacent to the equipment is
necessary (e.g. where gas in atmosphere may be present over a wide area from an open-ended main
as a result of impact damage in a third party excavation or a medium pressure escape).
There shall be no smoking on any site where live gas working is to be/is being carried out.
Suitable warning signs and barriers shall be erected to prevent any unauthorized entry into areas
where gas is being, or will be, discharged into the atmosphere.
Unless specified otherwise by the Responsible Engineer, all electrical equipment which is likely to be
used in a gas-air mixture shall preferably bear the following explosion protection symbol:
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Non-certified equipment used on site shall be suitably located to avoid any possible source of ignition,
but in any case not less than 5 m from any possible source of escaping gas. The ignition system on a
petrol engine is electrical and shall be taken into account when siting equipment.
Immovable and non-certified electrical equipment such as street lighting, illuminated traffic signs or
traffic light switching equipment can be sources of ignition. In the event of a gas escape, the
Responsible Engineer shall, if necessary, contact the people responsible for the equipment, so that
appropriate action may be taken to make the situation safe.
Metal gas pipework acts as a carrier for stray electric currents. These currents can cause sparking
during cut outs and disconnection operations on both mains and services.
Temporary continuity bonds shall be installed before any connection or disconnection work. They
shall be positioned so that they are not disturbed during the progress of the work (see Appendix B).
Dusty gas passing through a main at high velocities can generate large static charges. The charges
can be retained on the dust particles and also on the pipe wall if the pipe is plastics or insulated from
earth.
If an operative is insulated from earth by rubber boots and has to insert a plug in a metallic main, the
plug and operative can become charged from dust in the gas stream coming from the hole. When the
plug is brought close enough to the pipe, the charge collected on the plug and operative may be
discharged to the pipe causing a spark that can ignite the gas.
In this situation the operative and the plug shall be earthed. This can be done by resting the plug on
the metal pipe preferably 350 mm away from the hole and sliding it along the surface of the pipe to
the hole.
High velocity discharges of gas from pipes in mains shall be avoided whenever possible. Pipes used
for venting gas shall be adequately earthed.
Sufficient static charge to cause a spark that can ignite gas can be built up on plastics pipe by
handling and cleaning.
When there is a risk of escaping gas, the pipe shall be covered with a cloth dampened with clean
water and in good contact with earth. This allows the static charge to be discharged safely to earth.
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Sufficient static charge to cause a spark that will ignite gas can be built up on plastics pipe by both
application and removal of stretch wrap and shrink wrap film.
Plastics film should not be applied or removed in areas where potentially flammable or explosive
vapour/air mixtures can exist.
The flow of dusty gas will generate static charge on the internal surface of plastics pipe. Although
polyethylene is generally considered a non-conducting substance, the static charge can be conducted
through the pipe wall to create high potentials on the outside surface.
A damp cloth draped over the pipe and making contact with earth will safely drain the charge and
prevent it building up to dangerous levels.
To avoid the possibility of causing an ignition by static sparks, operatives shall not take off or put on
any clothing where gas is escaping or venting.
Care shall be taken to avoid striking electric cables when excavating and barholing. See A Code of
Practice for Barholing.
Whenever possible, electric cables should be isolated, particularly when embedded in concrete.
The position of electric cables should be established from drawings whenever possible. A cable
locator shall be used prior to and during excavating or barholing. Reference should be made to HSE
publication HS(G)47.
Incidents have been reported of dust glowing red and smoking in sections of pipe cut out from mains
near to old gas works. This dust is pyrophoric and can ignite a gas-air mixture. If a dust from a gas
main begins to heat up, it should be cooled down with water.
Pyrophoric dust is rarely encountered, but all operatives should be aware of its existence.
When it is necessary to weld on to or adjacent to live gas plant, or to carry out other hot work, the
operation shall only be undertaken in accordance with a written routine procedure or a valid Permit to
Work.
The storage and use of other flammable substances (e.g. petrol, fuel oil, liquefied petroleum gas) may
give rise to similar hazards as escaping gas if vapour-air mixtures are allowed to accumulate.
Fire prevention measures to be taken when dealing with these substances are generally the same as
when dealing with gas.
Vapours produced by these substances are usually heavier than air and will not dissipate as easily as
gas. Good low and high level ventilation is essential in storage areas to ensure that any vapours are
adequately removed.
All flammable substances should only be stored in approved, appropriately marked containers.
Minimum quantities only, consistent with effective usage should be stored on site and these in secure
storage.
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Fire protection
In the event of a fire, the protective clothing and equipment worn by an operative should give
sufficient protection to allow time to escape from the incident without injury.
During all engineering operations where there is a risk of escaping gas, appropriate protective
clothing and equipment shall be worn including for hands, head, neck, face and respiratory system as
necessary.
As a minimum during all live gas operations, operatives shall wear full body protection made from
flame retardant materials together with suitable hand protection.
Where conditions require, the Responsible Engineer must also consider the issue and use of
additional protection in the form of full fire protection suits together with head and neck protection.
The Responsible Engineer, when deciding on the use of full fire protective clothing for the safety of
employees involved on live gas operations, shall take account of the following:
Face and respiratory protection will ideally be provided by breathing apparatus appropriate for the
situation.
It shall always be worn in situations where the Responsible Engineer has specified the use of full fire
protective clothing. It shall be worn whenever working in an excavation where the activity is likely to
give rise to a release of gas, or whenever gas readings in the breathing zone are 20% LEL or above.
Additionally, it shall be worn whenever gas readings taken in the atmosphere are equal to or greater
than 20% gas in air (GIA).
Where Breathing apparatus is required to be used there shall be 2 persons trained in its use present
on site and a second fully operational breathing apparatus set is available (for use by the second
person should the need arise).
Breathing apparatus shall be prepared and available for immediate use, easily accessible and
alongside any excavation containing exposed gas mains or services.
During all live gas operations, suitable and sufficient fire extinguishers should be available on site.
At every site where work is being carried out, and where there is the risk of the release of gas, at least
two fire extinguishers shall be conveniently placed for immediate use in an emergency.
Fire extinguishers should be of the dry powder type with a capacity of at least 9 kg.
Every fire extinguisher should be thoroughly examined at least every twelve months by a competent
person.
Each week fire extinguishers should be inspected for external impact damage and replaced if
necessary. At the same time fire extinguishers should be inverted to prevent compaction of the
powder.
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Whenever a fire extinguisher has been primed (whether it has been used or not), arrangements shall
be made to replace it without undue delay. All the remaining dry powder shall he disposed of before
refilling and the hose and trigger equipment cleared of any remaining powder.
It is essential that there is always a means of rapid escape from areas of work in case of fire.
Depending on the circumstances, more than one escape route may need to be provided. Special
precautions are necessary in the case of deep excavations.
In areas where escape would otherwise be difficult, sloping ramps or run-outs should be provided if
possible. Where this is not possible because of site conditions, securely fixed ladders shall be
provided, extending at least 1 m above the level of the excavation or other stepping-off point.
Where an excavation is deeper than 2 m, lifelines shall be provided. They shall be placed ready for
use or worn as the conditions warrant. In this circumstance it is essential that adequate numbers of
personnel are immediately available on site to effect a rescue by lifeline.
Fire fighting
If escaping gas catches fire, it is necessary to decide which is the greater hazard; the fire or the
escaping gas if the fire is extinguished. If the escaping gas would be of the greater hazard, it is
essential that the fire is allowed to burn under close attention until all materials required for sealing the
escape are available or until the gas supply is turned off.
The Responsible Engineer shall attend the site. Representatives from other affected utilities shall be
asked to attend also.
It is essential that the Fire Brigade are requested to work closely with the Responsible Engineer and
are asked not to extinguish the fire until it is safe to do so. In some cases it may be necessary to cool
the surrounding area and exposed pipes.
When it is decided to extinguish a fire, one of the following methods may be used:
a) If the fire is not too large, it may be extinguished by directing dry powder from a fire
extinguisher into its base.
b) The gas supply may be cut off. In some cases valves may be available, but in many cases it
will be necessary to isolate the main either side of the fire. The size of the fire should be
reduced by partially shutting off the supply. The fire should then be extinguished with a dry
powder fire extinguisher and the gas supply immediately shut off completely.
All appropriate engineers and operatives must be trained in basic fire fighting techniques. Practical
refresher training should be given at appropriate intervals.
In the event of an outbreak of an infectious disease such as foot-and-mouth disease an 'infected area'
is imposed covering a minimum radius of 10 miles around the infected premises. This area usually
remains in force for 21 days. Wide publicity is given when outbreaks of disease occur, and the extent
of the 'infected area' can be obtained from the local police station.
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Emergency work may continue, but if such work is necessary on land within five miles of an outbreak,
the Veterinary Officer in charge of the local Control Centre should be informed. The address and
telephone number of the Control Centre is given wide publicity locally, and details of the extent of the
'infected area' will also be available from the Control Centre.
NOTE - Employees who own or attend farm livestock are excluded from working on premises where
disease exists.
Routine work within two miles of the infected premises should be stopped until the 'infected area'
restrictions are lifted.
In the area extending from two miles to five miles from the infected farm, work should be postponed
for seven days after the outbreak, and then continued only if the occupier of the land on which the
work is to be carried out agrees.
On land over five miles from the outbreak to the boundary of the 'infected area' work may continue as
normal.
When work is being undertaken on any farm land within an 'infected area', all boots, equipment and
the outside of vehicles, particularly the wheels and wheel arches, should be cleaned and disinfected
with a disinfectant approved for use against the infectious disease.
All sites should have at least one First Aid box placed at a convenient point and clearly marked with a
white cross ( ) on a green background. Small, travelling First Aid kits should be provided to personnel
working alone, or in small groups, away from the main site.
You may or may not be a qualified First Aider and, if you are not, it would be irresponsible on your
part to assume that you are. However, in the event of an accident involving a colleague, you may be
the only other person present and therefore represent that colleague's only hope between life and
death (e.g. could you stand by and let your colleague bleed to death whilst waiting for a qualified First
Aider to save your colleagues life?).
The advice given in subsequent clauses is intended to provide a few commonsense things to do
should you find yourself in a circumstance similar to that described above. However, such advice
given herein should not be construed as a substitute for proper First Aid training, especially in the
areas of artificial resuscitation and cardiac arrest where a course of practical instruction should be
undertaken.
First Aid boxes and kits are provided for use in an emergency. Do not misuse the contents; it is not
much help if an accident occurs resulting in injury to a colleague and you find that someone has taken
and not replaced the essential bandages, sterile dressings, safety pins, etc.
Vehicles should contain a First Aid kit. This kit should be kept in the space provided or other
prominent position so that whoever is using the vehicle can locate it easily when required.
If a First Aid kit or any of its contents are badly damaged, the kit should be returned to for
replacement.
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Accident reporting
Every accident shall be reported to a responsible person. Details of any injury, and the treatment (if
any) given, shall be entered in the on-site Accident Book as soon as possible after the accident.
In the event of an accident causing injury to personnel, the following course of action should be taken:
a) Get help: that does not mean that you should leave the casualty whilst you go in search of a
telephone. Call out (or shout) to attract the attention of passers-by or other persons in the
vicinity.
b) Take immediate action: do what you can to protect the casualty from further danger or injury.
Attempt to stop any bleeding and, if you know how and the need is evident, give artificial
resuscitation. You are not the doctor and might not be a qualified First Aider, so limit your aid
to the more obvious, commonsense actions until expert help arrives.
c) Comfort the casualty: keep the casualty warm and dry and above all reassure him/her that
help is on the way. Anyone who has been involved in an accident will know how good it feels
to know that someone is at hand to take care of you.
Some of the emergency situations likely to be encountered on and the immediate action/remedies are
given in Table 2.
However, where medical attention is not readily available, especially in the following circumstances:
e) bleeding wounds,
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b) Temporarily protect the wound with a sterile swab (or clean handkerchief) and clean
the skin around the wound, wiping away, not towards, the wound and dab it gently to
dry.
c) If bleeding is continuous, apply direct pressure to stem the flow of blood and, if
possible, raise the injury to reduce the flow of blood.
d) Dress the wound. A small cut can be dressed with a plaster or small bandage; in the
case of a larger wound apply a sterile dressing or a clean pad and bandage firmly.
c) Place the injured part under slow running cold water, or immerse it in a container of
cold water.
NOTE -If cold water is not readily available, any cold, harmless, fluid (e.g. milk, beer,
wine, cold tea) will do.
d) Do not apply an adhesive dressing or any lotions, ointments, fats or oils to the injury
e) Do not break blisters, loose skin, or otherwise interfere with the injured part
b) Get the casualty to the Accident and Emergency Department of a hospital without
delay.
c) If details of the hazardous substance are known and the casualty is unconscious,
advise the medical team accordingly.
Hazardous substances a) If attempting a rescue, ensure you will not be affected.
(Inhalation)
b) Remove the casualty to fresh air; keep him/her warm and at rest.
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Remove the casualty into the fresh air as quickly as possible and seek medical
Carbon monoxide (CO)
a) attention
poisoning
Assess the situation and ensure that you do not carry out any action, which may cause
b)
you also to become a casualty.
If breathing has stopped altogether, apply artificial resuscitation. The most important
e) factor is to endeavour to ensure that breathing continues.
If the casualty is conscious and breathing is regular, keep the casualty warm and lay
f)
him/her in the recovery position (see below).
When the casualty and his/her breathing become stronger, do not allow him/her to
g) move about or exert himself/herself in any way. This applies to anyone who has been
even slightly gassed. Under no circumstances shall the casualty be allowed to walk.
Keep the casualty under constant observation and, in the absence of a doctor, the
casualty must be taken, still under observation, to the Accident and Emergency
h) Department of a hospital. If, during the journey, the casualty’s heart or breathing stops,
artificial resuscitation must be applied. On arrival at the hospital advise the hospital
staff of the type of poisoning.
Never attempt to give an unconscious casualty anything to drink - it may choke
i)
him/her. Above all, never administer alcohol as this will worsen the circumstances
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Accidents involving a) Having ensured there is no personal risk, immediately remove the casualty to an
cylinder gases uncontaminated area.
(Inhalation)
b) If the casualty has stopped breathing, check that his/her airways (e.g. remove his/her
false teeth if fitted) are not obstructed and that a pulse is present.
c) Seek expert medical attention, i.e. on site medical centre or local hospital.
Accidents involving a) If practicable, wash the eye out with cold running water or, preferably, a proprietary
cylinder gases (Eye eye wash solution.
contact)
b) Refer the casualty to a hospital.
Eye injuries. Eye injuries shall be regarded very serious. An eye can be cut or bruised from a direct
blow or by fragments of grit, metal or glass. Eye injuries can be very painful and, if the
eye is inflamed or bloodshot, the casualties vision may be seriously impaired
As the only person at hand, your aim should be to protect the casualty’s eye(s) from
further damage, i.e.:
b) Cover the injured eye with an eye pad or sterile dressing. Hold this in place with a
bandage or sticky tape
c) Advise the casualty to keep his/her other eye as still as possible. If necessary apply a
blindfold but, before resorting to this form of action, reassure the casualty beforehand.
d) On no account attempt to remove a foreign body from an eye - leave this to someone
who knows what they are doing.
1. Temporary electrical continuity bonds shall be installed before any connection or disconnection
work is carried out on a main or service. Electrical continuity bonds shall be positioned such that
they will not be disturbed during the progress of the work.
2. Having determined the positions on the main and/or service where the electrical continuity bonds
are to be connected, remove any pipe wrapping, paint or other protective coating and thoroughly
clean the area using a wire brush.
3. The electrical continuity bonds shall be of adequate length, and the end fittings shall be clean,
securely connected to the wire or braid and in good working order.
4. The electrical continuity bonds shall be attached to the main or service pipe as shown in Figure 3
ensuring that good 'electrical' contact is made.
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5. The electrical continuity bonds shall be removed from the main or service pipe only when all
connection or disconnection work is completed and after ensuring that the area is 'gas free'.
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Road Traffic (Carriage of Dangerous Substances in Road Tankers and Tank Containers) Regulations
1992
* Publications in the L (legal) series explain or interpret legislation. They will gradually supersede
existing publications in the HSC COPS series (Approved Codes of Practice) and the HSE HS(R)
Series.
EH36 Work with asbestos cement EH55 -The control of exposure to fumes from
welding, brazing and similar processes
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L24 Workplace (Health, Safety and Welfare) Regulations 1992. Approved Code of
Practice and Guidance
L56 Safety in the Installation and Use of Gas Systems and Appliances. Gas
Safety (Installation and Use) Regulations 1994.
All construction work shall be overseen by a competent Health and Safety supervisor. The person
appointed shall meet the following criteria:
b) Trained to degree level, will be a member of a relevant professional body e.g. UK Nebosh
Certificate or Diploma and be able to demonstrate a substantial track record in a similar role
within the oil and gas sector.
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f) Ensure that suitable HSE management arrangements are in place to deliver performance
standards.
t) Incident investigation.
3.4.1 Handling, Transport And Storage Of Steel Pipe, Bends And Fittings
For information on the handling, transport and storage of PE pipes and fittings reference shall be
made to IGE/TD/3 Edition 4 Supplement 1.
All persons engaged in the design, construction, commissioning, operating, maintenance and
alteration of mains, services and related plant shall be competent to carry out such work. This may be
achieved by an appropriate combination of education, training and practical experience.
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3.5.1 Excavating
For all projects reference shall be made to Libyan Environmental Legislation and the relevance of
Lows (Low 15). Archaeological permission shall be obtained from the relevant local authority.
On projects in the public highway the Responsible Engineer shall walk the route with the team leader
or contractor's representative and a representative of the Highways Authority. Any obvious defects in
the surface of the road or path (e.g. broken flags, building defects) should be noted and confirmed in
writing to the appropriate authority.
Where the works involve land in private ownership, a joint inspection to agree and note any existing
defects in the surfaces along the proposed route shall be made by the owner and/or tenants together
with representatives of the contractor and Transco.
Once the approximate route has been determined, a detailed survey shall be undertaken to establish
the most suitable line on which to lay. During this survey, the position of surface boxes, marker posts
and recent excavations shall be noted.
When laying across infilled sites, the line of the trench shall be surveyed and investigated for the
presence of obstructions or permanent hard spots, so that they may, whenever possible, be avoided.
The location of all obstructions and underground plant should be recorded and, where necessary,
clearly marked before construction plant is allowed to enter the area.
Where it is necessary to lay pipes in close proximity to buildings or other structures, any structural
defects shall be noted and either agreed with the owners of the property or, alternatively,
photographed.
Where reliance is placed on photographic evidence, it is essential to establish that such evidence was
obtained prior to the commencement of the works.
The Engineer or Engineer's representative shall ensure that each team leader or contractor shall be
supplied with all available relevant drawings or information describing the position, size and
capacity/rating of any current carrying cable, for:
a) Planned work; up-to-date information should be obtained on the position of cables before
excavation begins and a hard copy made available on site.
b) Emergency and urgent works; if not readily available on site, relevant information should be
obtained as soon as possible after work starts.
For planned work, drawings giving the cable location should be attached to job instruction cards.
Alternatively, teams may be provided with microfiche plans.
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The team leader or Contractor shall exercise great care in order that existing underground plant is not
damaged. Cable and pipe locators shall be used to confirm the position of existing cables and other
metallic underground plant. Reference should be made to HSE Guidance Note HS(G) 47 for
precautions to be observed.
A clearance of not less than 250 mm should, wherever possible, be kept between gas mains and
fittings and the known position of other Utilities plant, irrespective of whether it is running over,
alongside or under the plant. If the gas pipe crosses other Utilities' plant, this clearance may be
reduced if there is further external protection to either the gas pipe or other Utilities' plant.
Prior to the commencement of the works, agreement shall be reached with the Highway Authorities
and such other persons as may be concerned with the programme of work, methods of construction,
access ways, traffic control, alternative reinstatement specifications, and any road signs.
It is an offence to remove or obliterate any lawfully placed permanent traffic signs. The responsible
highway authority should be consulted where there is a need to remove or severely restrict viewing
access of any such signs, in order that they can make the necessary alternative arrangements. They
should also be advised of the completion of the works so that the signs may be properly replaced.
Special care shall be taken to avoid damage to pressure regulating and gas storage facilities and their
associated control systems.
Where excavations are to be made within 10 m of the perimeter of a pressure reduction station,
governor installation the team leader shall be advised of suitable precautions and, where necessary,
be given the assistance of a person competent to exercise control of the plant.
The Engineer shall ensure that the team is made aware of the accurate position of inlet and outlet
mains and by-passes, and of any impulse pipes or other associated plant. The Engineer may require
the continuous presence of a Responsible Engineer who will ensure that adequate precautions are
taken so as to safeguard gas supplies.
Trenches and excavations can, in some situations, be regarded as confined spaces. Before entering
any confined space a suitable and sufficient risk assessment must be carried out and advice must be
sought as to whether a Permit to Work or written procedure is required, as appropriate.
An approved trench support system should be used in excavations at depths of 1.2m or above
(measured from the bottom of the excavation). Where a trench support system is not used an
alternative safe system of work must be determined e.g. sloping the sides of the trench by at least 45°
from the vertical. The risk assessment must be recorded (written or electronic) with details of the
specified controls as agreed with a supervisor or line manager.
A permit to work must be issued for all excavations where any type of trench support system is used.
The permit will be valid for a period of seven days with a new permit being issued by a Responsible
Engineer following completion of each weekly inspection.
The trench support system must be installed by trained and competent persons (i.e. operatives with
sufficient training and experience of excavation work.
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Work in excavations less than 1.2m deep may also be dangerous, and it may be necessary to provide
support. Risks are greater when bending or kneeling in excavations. If there is any doubt, seek advice
from a Responsible Engineer or Safety Supervisor.
c) Where there are variations in the nature of the soil (e.g. pockets of sand).
d) Where a crane or other mechanical plant is employed in close proximity to the excavation.
The ground conditions will determine the method of support e.g. in moderately stable ground the open
poling board method may be employed, whilst in loose ground close-boarded timbering, sheet piling
or a similar approved method would be required. Staging must be provided if the excavation is deeper
than 2 m. Examples of trench supports are given in figures 5 - 8 inclusive.
All excavations must be inspected each day, before work begins, by a trained (i.e. someone with
sufficient training and experience of excavation work. An inspector must pay specific attention to:
c) Adequacy of supports.
The excavation must also be inspected after any event likely to have affected its strength or stability
e.g. heavy rain, freezing or thawing, and after accidental fall of rock, earth or any other material. A
written report must be prepared for all inspections carried out in these circumstances.
For excavations where a trench support system is in place a Responsible Engineer must undertake
the weekly inspection. The following information must be recorded on the permit to work at the start of
the job and in all subsequent permits after each weekly inspection:
a) Name and address of person on whose behalf the inspection was carried out.
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e) Details of any factor identified that could pose a health and safety risk.
All deficiencies noted in the inspection must be made good; any remedial or other works necessary
must be carried out as soon as possible and, in any intervening period, no other works must be
carried out in the excavation. Where this is the case, or where any other change to the excavation or
the site are apparent the new permit to work must be detail all remedial action, additional risks and
requirements for additional action.
Vehicles and plant shall not be brought alongside excavations unless it is essential and the team
leader has approved the operation. No person shall be under a suspended load.
Special care is necessary when vehicles, plant or equipment, etc., are brought into the vicinity of
overhead power lines. The Responsible Engineer should be consulted regarding precautions to be
taken to prevent accidents involving overhead power lines. Reference should be made to the HSE
Guidance Note GS6.
Vibrating and impact machinery shall be kept well clear of trench sides.
When live gas working is being carried out and tunnelling or undercutting is unavoidable,
consideration should be given to preventing the possibility of gas pockets being formed.
Adequate means of entry and exit shall be provided for all excavations. Ladders or other assistance
shall be provided where entry or exit would otherwise be difficult. Lifelines shall be provided and
placed ready for use where any excavation is deeper than 2 m, and shall be worn when trench
conditions warrant such action.
Special precautions are necessary in the case of deep excavations or those having restricted entry or
exit. Consideration shall be given to the possibility of asphyxiation of personnel working in such
conditions.
For their own safety it is important that all personnel working on or near a highway be readily visible to
all road users. To achieve this, high visibility garments shall be worn.
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High visibility garments must comply with BS 6629, Appendix G. Class A standard jackets/coats shall
be used on 'high speed' road conditions, with Class B waistcoats/tabards as a minimum requirement
for all other situations.
Personnel working in the vicinity of overhead lines and underground services must undertake the
works in accordance with HSE Guidance Notes GS6 and/or HS(G)47 as appropriate.
Where cables are embedded in concrete, a route should be selected for the new pipe, either by
means of tunnelling or diversion, which does not disturb the cable or concrete.
If a new route is not possible, and it is necessary to break out or disturb the concrete, the electricity
supplier (or cable owner) should be consulted first. No further work shall be carried out until the
electricity supplier (or cable owner) agrees an alternative safe method of work or isolates the cable.
Where waterlogged ground conditions are encountered and water removing equipment is required, it
is usually satisfactory to pump from sumps within the excavation (see Figure 9).
Where in-trench pumps are used for prolonged periods, particularly in ground of a sandy or silty
nature, it may be necessary to install suitable filters behind sump linings to prevent loss of ground
which could affect stability. Similar filters may be necessary along the trench sides in extreme
conditions. Trench sumps shall not be excavated to such a depth that they present a hazard.
Alternative water removing methods shall be considered in any of the following circumstances:
b) Where pumping from trench sumps is inadequate to keep trenches free from water.
d) Where excavations are to be present for a considerable period of time in waterlogged ground.
Alternative measures include sumps external to the excavation, well points, electro-osmosis and
consolidation by freezing or by chemical process.
Where it is anticipated that such measures will be needed, the advice of a suitability qualified
engineer experienced in such works shall be sought.
Where excavations are to be made in corrosive ground (i.e. ground with a resistivity of less than 2000
O cm) in order to lay steel pipe or other ferrous materials, or where any pipe is to be laid through
chemically polluted soil, provision shall be made for bringing to site a supply of suitable non-corrosive
material for the pipe bed and surrounding backfill.
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Trenching in conditions in which hard spots may be expected should be avoided as far as possible.
Care should be taken to eliminate hard spots which would place unacceptable bending stresses on
pipes. Where there is reason to believe that hard spots exist, probing to a depth of 300 mm below the
pipe bed should be carried out to identify a suitable route.
Where serious problems are foreseen, the advice of a civil engineer should be sought as to the most
appropriate remedial action.
When excavating trenches parallel to a wall, the stability of the wall, and hence the ability to work
safely in its vicinity, shall be ensured.
Excavation work should not proceed if the wall is leaning, cracked or showing any signs of instability.
Stability check
2) With reference to Figure 11, dig a trial hole to determine depth of foundations or base of
wall, taking care to avoid undercutting any foundation or base.
- provide suitable supports appropriate to the type of structure, soil characteristics and depth
of trench.
Every effort should be made to minimize damage to tree roots during excavations.
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Where necessary, trial holes shall be opened in advance of trench excavations to prove the proposed
route. Trial holes should be excavated to a depth of 250 mm below the proposed trench bed to ensure
that utility plant proximity distances are maintained. These excavations shall be adequately signed
and barriered to ensure the safety of the public and employees.
The Engineer or Engineer's representative should consider whether there is a requirement to lay the
main to a fall and the need to provide water or liquid removal facilities. This consideration should be
based on the risk or possibility of water or liquids entering the system, possibly from interconnected
systems.
Once the line and approximate fall of the proposed main has been determined on the surface,
excavation of a sufficient (determined by the material dimensions) length of trench in advance of
pipelaying should be carried out to ensure that the required depth of cover can be maintained.
For crossings at railways, canals, rivers, etc..., the requirements of the Authority concerned shall be
followed.
Trench edges at the surface should, where possible, be cut and/or delineated by approved saw
cutting methods and equipment.
The trench shall be cut to give a solid, even bed to the correct depth.
Where mains are laid under verges, the depth of cover shall be measured from the kerb level or
surface level, whichever is the lower, having due regard to the likelihood of regrading.
If the correct depth is exceeded, the bottom of the trench shall be backfilled to the correct level with
selected and suitable material.
Where obstructions are encountered it may be necessary to lay a main at depths of cover greater
than those stated below.
Where mains are to be laid across rock, made-up or irregular ground, the trench should be excavated
to 75 mm below the required depth and backfilled with a suitable non-corrosive material to form the
pipe bed.
The normal minimum depth of cover for mains in roads shall be 750 mm and, in footpaths and verges,
600 mm. For mains laid in agricultural or cross country locations the depth shall be not less than 1.1
m.
It may be necessary to select a greater depth of cover after taking into account the following:
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a) Traffic loading.
d) Corrosion control.
f) Known obstructions.
Where practicable, mains laid in close proximity to road junctions should be at a depth of not less than
750 mm to overcome the future likelihood of having to lower mains affected by road junction
improvements.
Where the normal depth of cover in roads of 750 mm cannot be met, the depth of cover may be
reduced to 650 mm cover for all mains, at the discretion of the Engineer. If a further reduction is
deemed necessary, expert advice shall be sought.
For mains in footpaths and verges the minimum depth of cover (600 mm) may be reduced at the
Engineer's discretion. However, additional protection using concrete slabs or steel plates should be
installed.
Trench widths shall be kept to a minimum and should not be greater than the nominal size of the main
plus 30 mm. This recommendation is based on the requirement to ensure that the minimum trench
width should equal the pipe outside diameter plus four times the maximum finefill particle size.
Maximum trench widths shall typically be nominal size of main plus 250 mm.
An allowance should also be made for any necessary trench shuttering. For trenches deeper than 1.2
m, the trench width may be increased.
Trench widths should also allow for safe access and for the use of necessary tools and equipment in
the trench.
When mechanical excavators (or machine powered surface breakers) are to be used, it is essential
that the integrity of all underground plant is maintained through location and exposure by hand
digging in advance of the machine.
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For mains operating at pressures in excess of 2 bar, mechanical excavation shall not be permitted
within 3 m and the use of hand held power tools shall not be permitted within 500 mm, of the
previously exposed position, unless approved by the Responsible Engineer.
For mains operating below 2 bar, mechanical excavation and hand held power tools shall not be
permitted within 500 mm, unless approved by the Responsible Engineer.
When mechanical excavators are to be used in the vicinity of gas pipelines operating above 7 bar or
in the vicinity of Third Party plant, the owner shall be consulted for the proximity distance to be
applied.
To ensure the safer use of any mechanical excavator, consideration should be given to the use of a
banksman.
Should any damage be caused to underground plant, it shall be reported to the Engineer or
Engineer's representative as soon as possible.
Excavated material shall normally be placed along the side of the trench.
Care shall be taken to prevent the weight of excavated material contributing to excess loading and
collapse of the trench side.
To provide adequate working space and to avoid the danger of debris falling into the trench, sufficient
space (preferably 600 mm to 1.2 m, but not less than 300 mm) shall be left between the trench and
excavated material.
If the material is to be placed in a gutter, suitable channels or covered drainage pipes shall be left for
surface water drainage. Where conditions permit, consideration should be given to placing the
excavated soil so as to form an additional barrier against traffic. In all cases, excavated material shall
be placed so as to cause least nuisance and inconvenience to traffic.
Where the excavated material is to be re-used, the surface materials shall be kept separate from the
sub-soil, so that suitable layers may be replaced in the proper order during reinstatement. This is
particularly important when pipelaying in agricultural land.
If the excavated material is to be re-used, it should be protected against adverse wet weather
conditions or excessive drying out and consideration should be given to covering the excavated
material in order to maintain the moisture content.
The bottom of the trench shall be prepared to provide a bed for the pipe. The bed should be levelled
and suitably compacted so as to provide a firm support under the pipe and should be free of
hardspots or sharp stones which are potentially damaging to PE pipe or the protective coating on
other pipe materials.
Where the trench excavation crosses poor ground conditions, i.e. rock or irregular consistency, then
the trench should be excavated to 75 mm below the required depth and replaced.
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The Responsible Engineer shall determine the line of the main or service, paying due regard to the
locations of existing gas plant and other Utilities' plant and shall indicate this on the line of proposed
excavation works.
After the location of adjacent plant has been established by hand excavation, consideration may be
given by the Responsible Engineer to the use of mechanical excavators. A minimum of 500 mm
should be maintained between the excavator and plant wherever possible, this distance may be
reduced at the discretion of the Responsible Engineer.
When giving advice regarding the use of mechanical excavation equipment, consideration should be
given to the hazards which may be caused if the plant becomes damaged.
Where major excavation works are being carried out adjacent to pipelines, full specification for the
works covering the method of construction, type of support system, timing of support, backfill
materials and their methods of placement should be obtained from the initiating party. If considered
necessary, arrangements should be made to continually or regularly monitor the site works to ensure
that the agreed specification is adhered to.
The following factors should be recognised as those likely to give rise to damage:
a) The nature of the soil, which can be such that it is difficult to excavate without causing
substantial movement.
b) Ground water and methods of lowering the ground water table which, if carried out carelessly,
increase the risk.
NOTE - Information on factors a) and b) can be obtained from borehole records and/or the site
investigation works from the initiating party.
c) Depth and width of excavation and its relationship to the affected main.
e) Backfill material and its consolidation, particularly the failure to compact in stages.
f) The time during which the side of the excavation is not fully supported. This can occur during
excavation and during backfill, if the supports are not installed and removed in stages.
g) Loads imposed on the sides of the excavation by plant and stored spoil/backfill materials.
h) Increased impact forces from traffic due to irregularities in the restored surface.
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It may be necessary to bridge excavations temporarily (e.g. to provide access to premises, or to make
the full carriageway available when work in roads subject to considerable traffic is closed down at
night, at weekends or during peak traffic periods).
NOTE - When bridging footways for pedestrian access, materials other than those normally used for
road plates may be used at the Responsible Engineer's discretion, i.e. suitable purpose-built
wooden/composite structures.
When road plates are used the following precautions shall apply:
c) The plate should be of sufficient length to be firmly supported for at least 600 mm on each
side of the trench and of a width sufficient to provide a distance of at least 250 mm from the
wheels of vehicles to the edge of the plate.
d) The thickness of the plate should be sufficient to support the range of traffic encountered (If
further advice is deemed necessary, expert advice should be sought).
e) Ramps should be formed of a suitable material where the roadplate is proud of the road
surface.
f) When the site is not attended, or when subject to frequent use by heavy vehicles,
consideration should be given to securing the roadplate(s) by pinning or sinking into the
roadway.
All road plates on unmanned sites should be submitted to visual inspection on a regular basis.
Excavation for services shall be carried out employing the general principles laid down for mains.
Wherever possible, services shall be laid in a straight line between the main and the service entry
position.
The normal depth of cover in private property shall be 375 mm with, wherever possible, an even
gradient towards the main. Where it is necessary to lay at less than 375 mm cover, the approval of the
Responsible Engineer should be sought as protective measures may be necessary.
The requirements for public roadways shall be applied where pipes in private property are subjected
to surface loading comparable with normal roadways (e.g. factories, hospitals).
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The normal minimum depth of cover in public roadways shall be 450 mm. However, the depth of
cover shall be increased to ensure that there is 75 mm of fine fill between the bottom of the road
foundation and the top of the service pipe, or other precautionary measures should be taken (e.g.
sleeving).
Services in proximity to road junctions should be laid at 450 mm minimum depth or at a depth
sufficient to provide 75 mm of fine fill between the top of the service and the bottom of the adjacent
road structure.
The trench width shall be kept to a minimum and should not exceed 300 mm.
The trench shall be excavated to the correct depth and the service pipe fully supported throughout its
length on firm ground, free from stones or projecting rock. Wherever possible, the trench bed should
have a continuous downward gradient towards the main.
Prior to placing fine fill reinstatement materials around the pipe, all coating and wrapping shall be
completed, where applicable. Care shall be taken not to damage any coating or wrapping during the
reinstatement procedure.
If necessary (mandatory in the case of PE pipe) the subsoil shall be clean, moist and free from sharp
stones greater than 18 mm in size, to prevent damage. Certain soils can be riddled to remove sharp
stones and produce a fine backfill material. If this is not possible it will be necessary to import suitable
material. Cementitious materials shall not be used as finefill material around the pipe. The fine
material should be packed firmly around the pipe or fittings to give a minimum compacted thickness of
75 mm.
When placing fine fill around pipelines and mains, particularly those greater than 250 mm nominal
size, or where the side gap between the wall of the excavation and the main is greater than 75 mm,
special care should be taken to ensure firm compaction of the fine fill especially around the lower half
of the pipe. This provides good side support, prevents ovality in the main, and gives adequate support
to the reinstatement structure (see Figure 12).
When undertaking insertion work using PE pipes of wall thickness less than SDR 17, care should be
taken when backfilling at unsupported tie-in or launch receive pits. Fine backfill should be used that is
well compacted around the pipe to provide adequate support. Consideration may be given to the use
of a structured backfill material such as foam concrete in this instance.
The required thickness of the backfill, sub-base and roadbase layers (as shown in Figure 12) will
depend on the type of carriageway or footway, etc., in which the reinstatement is carried out.
Where reinstatement is carried out to a permanent standard, the following guidelines shall apply:
a) Excavated materials may be suitable for re-use at backfill level or a suitable granular or
cementitious material may be imported.
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c) Roadbase materials will always be imported. They may be unbound granular materials,
cementitious materials or bitumen/asphalt bound materials.
When foamed concrete is used for reinstatement purposes, adequate safety measures shall be
employed to ensure that members of the public and employees are prevented from becoming trapped
in an uncured layer. These safety measures may include some form of heavy duty mesh or plastic
sheeting fixed over any open excavation containing foamed concrete.
All unbound materials at backfill, sub-base or roadbase levels shall be placed in layers within the
trench and firmly compacted using approved mechanical compaction equipment.
Excavated material may be suitable for re-use as backfill material provided that the material is moist,
does not contain any particles larger than 75 mm and is not uniformly graded i.e. is not single-sized.
The following materials shall not be used for backfill under any circumstances:
c) Corrosive or combustible materials including coal or coke dust, clinker and ashes.
f) Materials with high plasticity; typically certain clays or silts or mixtures thereof.
Excavated pavement materials may be suitable for re-use at sub-base level provided that the material
is moist, well graded, does not contain any particles larger than 75 mm and is not contaminated with
materials.
3.5.3.3 Reinstatement
Reinstatement shall be carried out to the standard prescribed Local Authority specification.
The surface of all interim reinstatements shall be laid in accordance with the Local Authority
specification and shall be maintained in that condition during the period before that reinstatement is
made permanent.
A 75 mm minimum cushioning layer of consolidated clay/soil/sand should be left between the top of
the pipe, or of the service tee if applicable, and the base of the road foundation. This distance may be
reduced at the Responsible Engineer's discretion provided compliance with the Local Authority
specification can be achieved.
The reinstatement of the surface layers of a flexible carriageway or footway, etc., will require the use
of bitumen/asphalt bound material. The type of material will be prescribed in the Local Authority
specification.
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Reinstatement of rigid carriageways and footways, modular footways and other paved surfaces shall
be carried out in accordance with the Local Authority specification.
All surplus materials shall be removed from the site on completion of works.
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NOTE - If steel sheet piling is driven into the ground the lower walings and struts may be omitted.
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1) Name and address of person for whom inspection was carried out.
2) Site address.
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SECTION 4
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This Section provides relevant information for the detailed design of gas distribution systems including
main and service laying.
Pipelines are defined as bulk feeder systems operating at pressures greater than 4 bar and below 16
bar.
Mains are defined as pipes supply more than two consumers operating at pressures up to and
including 4 bar.
Services are defined as pipes supplying up to 2 consumers. Service pipes are described as pipes
between the distribution main and the outlet of the first emergency control valve downstream from the
distribution main.
This document covers construction design, construction planning, construction, connection, testing,
commissioning and decommissioning of pipes used for the distribution of natural gas.
The end of the distribution system is defined as the outlet of the emergency control valve. The
emergency control valve is used by the gas consumer to close of the gas supply to the installation
pipe-work in the event of an emergency.
Before undertaking the design or construction of gas services the minimum ventilation requirements of
any appliances to be installed within a building must be considered.
Technical competence is established through training, assessment, knowledge and experience for a
particular role. A job title is not in itself a measure of competence.
• Gas Network Safety Passport qualification (GNSP) which sets out the basic gas safety needs
for persons employed on gas related activities.
The Authority will establish a competency framework for all persons employed on gas
systems.
A fundamental requirement is to demonstrate that the personnel employed to design and construct
the gas assets are competent to do so. Therefore sufficient current, valid, credible and authenticated
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documentary evidence shall be provided to satisfy the authority that the individuals designing,
installing and administering the process are competent. This may be a combination of qualifications,
training, experience, aptitude and fitness for the job.
Design Engineers.
Persons engaged on the design of gas infrastructure should be able to provide evidence of both
competence and knowledge and understanding of the design phase. This may be achieved by an
appropriate combination of education, training and practical experience relating to the design activity
undertaken. Formal qualifications shall include Chartered or Incorporated Engineer through a
professional body such as The Institution of Gas Engineers and Managers.
Construction Engineers
A Gas Networks Operations qualifications structure should be in place to ensure persons employed
on the construction of the gas network or competent to carry out the activities they have been
delegated to undertake.
If at any time a person becomes aware of or suspects there is a gas escape or other emergency any
person employed by the Authority or its contractors must record:
• Name, address and telephone number of the person reporting the gas escape
• Turn off the gas at the meter, unless the meter is located in a cellar or basement – in which
case, advise them not to enter the cellar / basement.
• Turn off all gas appliances and do not use until they are checked by the engineer.
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• If there is a smell in the cellar or basement, you must advise the consumer/s to evacuate the
building.
The minimum requirement for PPE equipment for all personnel engaged on distribution work include
reflective jackets, safety clothing and foot-wear and other task specific equipment must be deployed
and used at all times.
Operatives involved in gas operations must wear gloves and flame retardant overalls along with all
other relevant protective clothing.
A live gas operation is one where gas is not physically controlled by a closed valve or physical
disconnection. These operations can range from routine minor live gas operations, such as changing
a meter control valve to failure of a main due to third party interference. It is possible to further sub-
divide live gas operations into controlled and uncontrolled.
• Flow-stopping.
For the above tasks the element of the live gas operation is controlled by a technique or procedure,
which eliminates the release of gas wherever practical or to such an extent that the release is so small
and controlled that it does not constitute a risk. Where gas is released, it will be vented to a position
away from the working or public area.
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• Plugging steel long radius bends or long screw service connections to mains.
The amount of gas present during each of these tasks will vary as will the exposure time/duration of
individual working on each task. The concentration levels of gas will be dependant on a number of
factors such as pressure, diameter of the pipe/service connection to main, what natural ventilation is
available, etc…
However, there can still remain an uncontrolled release of gas and control measures must to be
adopted which reduces the risk of exposure to the absolute minimum.
The risks associated with working with natural gas are the occurrence of fire/explosion or oxygen
deficiency, which can cause asphyxiation at high concentrations or cause narcotic effects,
headaches, dizziness or nausea at lower concentrations.
Asphyxiation caused by natural gas deprives the brain of oxygen, causing confusion and irrational
behaviour. The brain can last without oxygen, under good conditions, for about 4 minutes before
definite damage appears. Once asphyxiation commences judgement is markedly affected and it
becomes very difficult for individuals to make sensible decisions, such as getting out of a trench and
putting on breathing apparatus. Sudden collapse can be followed within minutes by permanent brain
damage and death.
If escaping gas ignites and is inhaled, serious and lasting damage can be caused to the lungs.
Breathing apparatus will offer respiratory protection and limited face protection when working in a
gaseous atmosphere.
From the table it can be seen that the initial risk is that of being burnt from the ignition of a flammable
gas/air mixture, with asphyxiation occurring once you have passed through the explosive range of
natural gas. However, the dispersion of gas will always result in the explosive range being present
somewhere in the gas cloud and therefore the risk of being engulfed within an ignited gas cloud is
always present if you work in an atmosphere above the lower explosive limit (L.E.L.).
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Suitable warning signs and barriers must be erected to prevent any unauthorised entry into areas
where gas is, or will be discharged into the atmosphere. These notices must be displayed at
appropriate distances to warn and instruct persons affected of the hazard and to ensure that there will
be no smoking on any site where live gas working is to be/is being carried out.
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Ventilation of the working area should be so that the flow of air in the working area is not restricted.
The following is a list of sources of ignition which should be eliminated from the working area:
• Electric cables
• Electric equipment
• Tools
• Naked flames
• Personnel
• Plastic pipes
• Dusty gas
• Hot works
• Pyrophoric dust
Impact between steel tools such as hammers and chisels can cause sparks, which can ignite a gas-
air mixture. Sparks can also be easily produced when the steel tools (e.g. forks, picks shovels and
points) strike flints, rock, stones, concrete, etc. ‘Spark reducing’ tools may be used, but they do not
provide a guaranteed spark –free operation.
With all tools the use of water will reduce the likelihood of sparks occurring.
In the event of a fire, the protective clothing and equipment worn by an operative should give
sufficient protection to allow time to escape from the incident without injury.
At least two 9 kg dry powder fire extinguishers must be placed in a convenient position next to the
location of operations and within easy reach of the operatives on site for immediate use in an
emergency.
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The fire extinguisher must be inspected for external damage, maintenance date and replaced if
necessary.
The fire extinguishers must be turned upside down to prevent compaction of the powder as part of the
initial checks.
Wherever a fire extinguisher has been primed, whether or not it has been used, arrangements must
be made to replace it immediately.
Always check the atmosphere for gas before entering the excavation and continue to monitor during
and on completion of work. Some non routine operations may require atmospheric checks to be
recorded. Safe and unaided egress to a firm and clear position must be made available.
Breathing apparatus must be assembled and ready for use when any work is to be undertaken on live
gas mains or services in excavations or other such confined spaces as follows:
• Connections.
• Flow stopping.
Breathing Apparatus must be worn under the following conditions to safeguard persons from
asphyxiation or internal damage to lungs:
• If gas in the breathing zone is above 20% LEL and continues at that level following ventilation.
A Voltstick is a device for detecting the presence of an AC voltage. When an AC voltage above 50v
AC is detected a red indicator in the plastic tip illuminates. The Voltstick must be used in the following
situations:
• Disconnecting meters
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All operatives and staff working in the Highway must be suitably qualified and have sufficient signs,
lights and barriers to enable work to be undertaken safely.
Underground plant must be identified before any work is undertaken. The following must be borne in
mind:
• Iron and steel water pipes and gas pipes will look very similar. If uncovered they must be
treated as a gas pipe.
• Other pipelines e.g. Oil, gas pipelines, chemical etc. may be present.
Construction design and planning includes: route selection; lay technique; materials specifications for
mains. The specification for services is contained in Section 3.3 however certain information
contained in this Section is also relevant to the laying of gas services.
• Medium Pressure (MP) - Pressure > 75 mbar but not exceeding 2 bar
• Intermediate Pressure (MP) - Pressure > 2 bar but not exceeding 7 bar
Pipelines operating at pressure above 4 bar may be located in cross country routes to ensure the
minimum proximity distance to occupied buildings is achieved.
Mains operating at pressures below 4 bar should be located within a service strip or public roadway to
ensure unrestricted access for maintenance and installation purposes. PE pipe shall be used unless
the pipe encroaches within the defined proximity distance, special crossing, locations of shallow cover
and other situations determined by a risk assessment. Where steel is to be used as part of a PE
system, the designer shall identify this on the project drawing.
The design shall ensure that the minimum mains design pressure at the system extremity remains
above 21mbar at the design flow rate and 23mbar at the normal flow rate.
New mains should have a minimum diameter of 63 mm. This is so that temporary bypasses can be
installed in the event of flow stopping.
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• Effective Diameter
• Material
• SDR
• Grade of steel
• Fittings; –
• In line or branch
• UPT or cut-out
• Cap-end or flanged
• Grade of welds
For system operating at pressures greater than 2 bar a design appraisal shall be carried out in
accordance with the recommendations made in IGE/GL/5.
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Application of the procedure will ensure that material specifications are fit for purpose, that Safe
Operating Limits are specified, that a suitable pressure system schematic is provided and that the
system maintenance regime is initiated.
For relatively simple main laying schemes, e.g. single diameter, 355 mm diameter and below of 100 m
length, it is likely that a route will be chosen from area plans, with attention being taken to avoid, if
possible, locations having, for example, electricity sub-stations, culverts or bridge crossings and
heavily trafficked routes. Where these cannot be avoided, additional information may be needed at an
early stage.
For more complex schemes, a more thorough route planning exercise shall take place. Site visits will
take place and information will be gathered on other utilities plant and third party pipelines.
Consultation with other parties, consumers and others affected by the scheme should be made. If
necessary, these will be supplemented by trial holing to find a route and determine ground conditions.
Dependent on the proposed main laying technique to be use trial holes must reflect the recommended
minimum main laying depths, as shown in Table 4 or depths increased as appropriate.
Trial holes should be carried out at strategic locations e.g. proposed connection points, road
crossings, and approaches to bridges and along the proposed route in the highway.
Factors, which may affect the future safety of the pipe, include:
• Physical obstructions: typical examples are waterways, railways and major roadways,
structures from below ground foundations, bridges, tunnels and trees;
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• The location and age of other underground plant: in particular, indications of settlement of
trenches should be investigated.
• The route should be selected so as to avoid areas of possible future settlement which may be
caused by deep trenches for sewers or other plant laid by open cut method which can give
rise to unstable ground.
• Areas already congested with underground plant that will not allow sufficient clearance for
flow stopping equipment or repair techniques.
• Proximity distances between the potential line of the main and existing buildings or
unventilated voids See Reference IGE/TD/3 – Section 5.8 -Table 5 for building proximity
distances for PE and steel mains.
• The presence of traffic factors such as bus lanes, pedestrian crossings, school, hospital or fire
station entrances and exits, for which special provision may have to be made in planning the
work.
• Topology of site – Where hydrostatic testing is required water inlet and outlet discharge points
must be identified.
• The presence of above ground structures: these may become unstable as a result of
construction work close by.
• Landfill sites.
• For long lengths of steel pipelines an adequate electrical supply for cathodic protection (CP);
for short lengths anodes should be installed.
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• The existence of street furniture: typical examples are traffic control kiosks, telephone kiosks,
lamp columns, and traffic signs.
• Areas of sand, gravel or flood risk, (where anti-dewatering devices may be deployed).
• Trees and tree roots: damage to trees or their roots may have an environmental impact.
• Contaminated ground.
Where the recommended depths cannot be achieved on of the following shall be adopted:
• Additional protection over the pipe for shallow depths, e.g. use of concrete slabs, steel plates
or reinforced marker tape.
The result of the risk assessment must be recorded within the project documentation and ‘as laid’
drawing marked up accordingly indicating the protective measures taken, e.g. depth.
A detailed design proposal must be prepared and consultation with relevant authorities shall take
place where the following is encountered. These situations are also applicable to gas services;
• Rail Crossings
• Water Crossings
Buried crossings are preferred to overhead and bridge crossings. Wherever possible the use of ducts
or sleeving should be avoided for such crossings. Auger boring, thrust boring and horizontal
directional drilling can be employed.
If it is necessary to design and construct an overhead crossing then the following factors must be
taken into account:
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• The crossing must be designed to withstand the stresses and environmental conditions
imposed on the pipe, carrier system and supports.
• It must be high enough to avoid damage from both vehicular traffic and river traffic etc…
• Anchorage requirements.
• The effectiveness of cathodic protection either side of the crossing must be safeguarded.
• Burial in the road deck which relies on sufficient depth of road construction.
• Insertion through an existing above ground pipe, thermal expansion and contraction
must be allowed for.
Where laying a pipeline, main or service under a ditch, a depth of cover (below the true bed of the
ditch) of not less than 1.1 metres must be maintained. This will minimise the risk of interference
damage when cleaning of the ditch is carried out. In addition concrete slabs or concrete filled bags
should be placed 300mm above the crown of the pipe. Marker posts must then be installed on both
sides of the ditch to indicate its presence.
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• PE 80 polyethylene
• PE 100 polyethylene
The choice of material is dependent upon the desired Maximum Operating Pressure (MOP),
environmental factors, laying technique and safety factors, such as proximity to buildings and
susceptibility to damage, or above ground for special crossings such as bridges.
GIS/PL 2-1 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 1 - General & PE compounds for use in PE
pipes and fittings.
GIS/PL2 Part 2 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 2 - Pipes for use at pressures up to 5.5 bar
GIS/PL2 Part 4 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas. Part 4 - Fusion fittings with integral heating
element(s)
GIS/PL2 Part 8 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 8 - Pipes for use at pressures up to 7 bar
GIS/F9: Part 1 Specification for Metric and Imperial Carbon and Stainless Steel Single
Ferrule Compression Fittings for Tubes. Part 1 - General Requirements.
GIS/F9: Part 2 Specification for Metric and Imperial Carbon and Stainless Steel
Compression Fittings for Tubes. Part 2 - Evaluation Procedure
Service pipes are supplied in SDR 11, with the exception of 16mm diameter and 20mm diameter,
which are supplied in SDR 7 and 9 respectively.
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There are two types of colour coded PE 100 pipe, orange and multi layer - (Profuse) yellow with
brown stripes. Multi layer pipe was introduced in 2003 as an alternative pipe for diameters from
250mm upwards and excludes close fit pipe diameters. The different SDRs and their pressure
limitations can be found in IGE/TD/3 – Section 5.6 – Table 4. It should be noted that due to ongoing
development in materials and SDR’s manufacturers recommendations must be consulted to ensure
the latest specification is applied.
This utilises PE100 SDR 21 pipe to provide a system, which maximises capacity via the thinner wall,
provides greater flexibility than SDR 11 PE 100 and permits a higher maximum operating pressure
than PE 80. The pipe diameters range from 250mm to 630mm operating at pressures up to 2 bar. The
peel off polypropylene skin provides a surface which requires no scraping prior to jointing, thus saving
considerable time and improving joint quality. The contrast between the pipe colour of the skin and
the core pipe provides clear evidence of any surface damage, occurring during delivery, storage,
handling and during the pipe laying process. The brown strip on the skin of the pipe identifies the pipe
as a multi-layer.
This material has significant strength and crack resistance advantages over PE 80. It can be used for
both direct burial and insertion applications. Manufactured in SDR 11, it is used for systems operating
between 2 and 7bar, and is orange in colour.
Note: Further information on maximum operating pressures with respect to the ambient temperature
range, refer to manufacturers’ recommendations.
Fusion fittings with integral heating elements are fused to polyethylene (PE) pipes using electrical
energy supplied to a heating element integral with the fitting. The energy is supplied via a control box,
which operates for a selected time depending upon the fitting type and size.
Fittings are classified as class B (suitable for use at operating pressures not exceeding 5.5 bar) or
class C (suitable for use at operating pressures not exceeding 7 bar). It is essential that the pipe be
supported to prevent it being moved during the heating, fusion and cooling phases. Long pipes should
be supported to avoid misalignment due to sagging.
Pressure testing must not be carried out until the complete system has cooled down to ambient
temperature. Each fitting is marked as follows:
• Fusion time(s)
• Cooling time
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Steel pipe is available in a variety of wall thickness, and is used in systems where polyethylene is not
suitable. These include:
• Building proximity
• Pressure range
• Exposed locations
• Special crossings
Steel pipe for use at below 7bar must comply with BS1387 and API 5L.
For information on grades of steel pipe and minimum wall thickness refer to IGE/TD/3 – Section 5.6 –
Table 1 and Table 2.
Whenever steel service pipes are laid, they must be protected by suitable wrapping and the
application of sacrificial anodes.
GIS/L2 Technical specification for steel pipe 15mm to 450mm inclusive nominal size for
service at pressures up to 7 bar (Supplementary and amending specification to BS
3601) + Amendment no.1 (September 1994)
For threaded joints, taper-to-taper, or taper (male) to parallel (female) threads may be used. Pipe
threads must comply with BS 21. All such threaded joints must be assembled using an approved
jointing material.
Threaded joints should not be used on main and service laying working where operating pressures
exceed 2bar.
The welding of pipes in nominal sizes up to 50 mm must be carried out using fillet welding in
conjunction with fittings to BS 3799. Pipes and fittings in nominal sizes above 50 mm must be butt
welded, using full penetration welding.
The permissible proximities to normally occupied buildings vary depending upon construction material
and operating pressure.
See Reference IGE/TD/3 – Section 5.8 -Table 5 for building proximity distances for PE and steel
mains.
To facilitate repair, maintenance or extensions to the mains system a minimum clearance of 250mm
should be maintained between gas pipes, fittings and the known positions of other utilities’ plant.
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This distance is for plant running in parallel. For plant crossing the main this distance, may be
reduced, as long as protection is provided in the form of concrete tiles, concrete sleeves or heavy-
duty marker tape.
There are a number of protective measures available which may be used for PE/steel pipes. Some
measures will only provide a warning that a pipe is present whilst others provide a protective barrier.
Their advantages and disadvantages are summarised in Table 5 as follows
Warnings
Protective Measures Advantages Disadvantages
Warning marker tape Easy to install and can be used Only used as a warning
in conjunction with other does not provide
protections measures protection to the pipe
Marker posts Easy to install and used as Only used as a warning
above ground identification of a does not provide
pipeline route protection to the pipe
Detectable – tracer wire – marker Provides identification for Only used as a warning
tape persons using detecting does not provide
equipment protection to the pipe
Barriers
Protective Measures Advantages Disadvantages
Concrete/PE slabs or tiles above the Provides protection and Use over short lengths
pipeline identification when used with
warning tape
Concrete or steel sleeving Provides protection and Installation problems, CP
identification when used with requirement and provides
warning tape track for any escaping gas
High tensile netting / mesh Provides protection and Use over short lengths,
identification when used with can be penetrated by
warning tape, does not affect excavators
drainage
Increased depth of cover Reduces frequency of No warning of presence of
interference damage pipe. Increases installation
cost
Ducting – perforated (small diameter Used on new build construction Offers limited protection
service application) works utilising pre installed
service ducting
Where concrete tiles or concrete sleeves are used marker tape should be placed above the tile/sleeve
for future identification purposes and the ‘as-laid’ drawing marked accordingly.
If there is a need to protect other underground services, contact should be made direct to the
appropriate utility company. Further guidance can be found in HSG 47 ‘Avoiding danger from
underground services’ published by the UK Health and Safety Executive.
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When open cut techniques are employed, suitable marker tape with an appropriately marked legend
must be laid above mains of all sizes and all services, to minimise the risk of interference damage.
This should be placed at a convenient depth between the backfill and sub-base layers in road or
footpath constructions, or 250 mm above the crown of the main in open ground.
When laying PE 100, SDR 11 pipe for use at pressures up to 7bar, the use of marker tape
incorporating a single insulated tracing wire should be installed. This will enable the position of the
main to be determined using a cable locator during pre-excavation surveys, and provide a visual
indication of the presence of a buried main during excavation.
For additional protection, in the public highway, a yellow 3.5 mm thick PE strip, of width not less than
the diameter of the PE100, SDR 11 pipe, should be installed 75 mm above the crown of the main.
Marker posts should be installed to provide access to tracer wires and to indicate branches, changes
in direction of the main and location of valves. In the case of cross-country pipelines the installation of
aerial markers should be installed. Reference to IGE/TD/1 Edition 4 should be made for information
on marker posts.
Reference should also be made to IGE/TD/3 Section 5.9 Figure 3 for additional information on
protection measures.
4.2.7 Valves
Valves should be installed on new connections to the existing network or to maintain or safeguard
supplies during maintenance or for management of a supply emergency.
Plastic bodied valves may be installed on pipe diameters up to and including 180mm at a pressure up
to and including 2bar. Plastic bodied valves must not be used as a construction valve.
GIS/V7 Part 2 Specification for Distribution Valves - Part 2 plastic bodied valves of sizes up to
180mm suitable for operation at pressures not exceeding 5.5 Bar
GIS/V7 Part 1 Technical specification for distribution valves Part 1 - Metal-bodied line valves for use
at pressures up to 16 bar and construction valves for use at pressures up to 7 bar
Valves on services are installed for the purpose of emergency control valves, service isolation valves,
tamper proof valves, additional emergency control valves and excess flow valves.
• For main > 180 mm/150 mm rider/purge diameter = 63mm (2” steel).
• For main > 180 mm/150 mm rider/purge diameter = 32mm (1” Steel).
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• Valve body vent sealed with plugged valve. Not normally piped to surface.
• The top of the valve spindle extension or pressure / rider points should terminate 100mm
below the underside of the surface box lid.
• Where there is more than one valve between off takes on any section of main, unless the
main is two-way fed.
For pipelines subject to hydrostatic pressure testing the valve must be full bore to allow the passage
of a pigging device.
For off- take valves a valve must be installed on the valve supplying the off-take and valves must also
be installed either side of the off-take. Pressure points must be installed either side of each valve.
Strategic valves must be of double block and bleed construction. The valve spindle must be extended
to a surface box. Pressure points and rider/purge vent points must also be installed and extended to
surface boxes.
Slide valves must not be used as strategic valves or as a method of retaining gas in a pipeline. In
such cases the pipeline must be physically capped.
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Construction valves are used solely for the purpose of aiding the process of connecting systems, i.e.
under pressure tee connections. For low pressure mains, where the tee outlet does not exceed 300
mm (12 in.) diameter, a slide valve of the self-sealing type may be used. For low pressure mains
above 300 mm (12 in.) tee outlet diameter and all medium and intermediate pressure tees a double
block and bleed valve must be installed. Where a double block and bleed valve is to be used as a
strategic valve, pressure and riser points must be installed, otherwise the valve must be buried and its
control mechanism should not be accessible from the surface.
• Marker Plate - marker plate must have the diameter, valve number, pressure and distance,
which are attached to a marker post or wall.
• Valve covers/marker disc - the valve cover should be marked “gas”. Alternatively a marker
disc should be fitted over the valve spindle.
A record card/sketch must be prepared for each valve on which the following information should be
recorded:
• Date fitted
• Function of valve
• Maintenance history
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Care must be taken to place pipes so as to cause the minimum possible interference with, or
obstruction to, traffic, pedestrians or other plant/structures. Pipes must be wedged to prevent
accidental movement and where necessary, barricades must be erected and warning signs and
lamps positioned. Before pipes are positioned in the trench, pipe bores must be checked to ensure
that they are free from obstructions and debris. Care must be taken during pipe laying and jointing
that pipe bores are kept clean.
When pipe laying is in progress, pipe ends must be temporarily capped, e.g., using an expanding
stopper, dust cap or sealed to prevent ingress of foreign bodies during construction work.
The use of rollers should be used to prevent pipe coating damage. On steel pipelines the use of pull
through should be used to clear the pipe. Pipes must be lowered into the trench using approved
equipment and during lowering operations no person must be allowed to stand underneath the
suspended pipe.
PE gas pipe must not be used as a duct for another gas pipe or any other utility.
PE pipes should not be installed in locations where the temperature of the ground surrounding the
pipe exceeds 200C. Jointing tents must be used when the air temperature is below – 50C or above
400C.
All pipes and fittings must be inspected for cuts, deep scratches or other damage before use. PE pipe
can sustain damage on site of up to 10% (including circumferential gouge and longitudinal scores etc)
of the pipe wall thickness and still perform satisfactorily over its design life. A depth gauge must be
used to determine the depth of any gauge. Damaged pipe exceeding these criteria must not be used.
For most main laying projects, it will be necessary to provide a suitable area for storage. Care must be
taken that the chosen location is:
• Sited to cause the minimum interference with or obstruction to traffic and pedestrians.
Stacks of pipes must be no more than 2 metres high for steel, no more than eight layers high for PE
up to (and including) 125mm diameter and for larger diameters pipe must not be stored greater than
four layers high. Pipe coils 63mm and above must not be stacked more than 2 coils high.
When offloading pipes from the delivery vehicle, mechanical handling of pipes should only take place,
using slings for PE pipes or slings/chains for steel pipe but only slings for PE, which have been
inspected and are covered by appropriate certification, confirming suitability for use. Chains must not
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be used on coated steel pipe. Under no circumstances must pipes or fittings be dropped from
vehicles.
Upon delivery, pipes and fittings must be checked for any obvious damage and if necessary marked,
to facilitate return to the supplier.
Reference should be made to IGE/TD/1 supplement 1, Handling, transport and storage of steel pipe,
bends and fittings and IGE/TD/3 supplement 1, Handling, transport and storage of PE pipe and
fittings.
Coil trailers should be used to dispense coiled pipe. Correct sequences for cutting of coils’ security
bands must be adopted. Only sufficient bands should be cut to provide the required length of pipe.
For coils of 125mm diameter or greater provision must be made for at least three operatives on site.
Particular care should be taken, before lifting coils into and out of trailers to avoid overhead cables.
• Displacement
• Open cut
• Open trench
4.2.10.1 Displacement
Impact Moling, using either unguided or directionally guided machines can be employed to lay pipes
up to and including 180mm PE. Unguided moles have limited use and require significant prior
investigation to avoid damage to adjacent buried plant.
Horizontal directional drilling is a steerable system for the installation of pipes, in which usually a fluid
(Bentonite) filled pilot bore is drilled and enlarged by back reaming to the size required and through
which is drawn back the new pipe
• Inside or within 10m of the boundaries of Above Ground Installations and Pressure Reduction
Sites.
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• Within 10m of oil cooled electric cables and electric stations/sub-stations where their
underground plant exits.
• Landfill sites.
• Known areas of underground mines, voids, cavities, natural caverns which are close to the
surface.
A detailed safety plan must be produced at the project planning stage, covering the following areas:
• Information on all buried services/structures along the proposed route including details from
their owners of their requirements for the avoidance of damage and precautions to be
observed.
• Details of any special engineering difficulties, e.g. road/rail/water crossings, industrial plants.
Mole ploughing is carried out on cross country pipe laying and it enables long lengths of pipe to be
buried very effectively in agricultural land without the need for top soil stripping.
Disadvantages of the technique are the possible destruction of land drains and substantial ground
heave, which will require rectification.
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By mechanical excavator
For general work in the highway, excavators provide a reasonable level of productivity. Mini
excavators are available to carry out work in confined spaces, where a full size machine cannot be
used.
Hand Excavation
Hand excavation must be used for trial holing in areas of known buried plant and for excavation in
close proximity to plant.
Mechanical trenchers can provide extremely high levels of productivity, but the route must be very
carefully chosen to avoid damage to underground plant.
Open Trench
Where the excavation work is undertaken by a third party and the trench left open to allow the pipe to
be laid.
Prior to any excavation taking place, the route of the main should be walked and a visual record
(either photographic or video evidence) made of any damage to roads or structures and any other
potential on site complications e.g. mature trees, crossings, etc. Where existing damage is identified
the extent of the damage should be notified to the owners in advance of work.
Information on utility plant, third party pipelines and other buried structures must be collated and
located on site as necessary. Precautions must be taken to avoid damage to overhead plant by
vehicles or mechanical excavators.
When planning to excavate parallel or in close proximity to adjacent boundary walls, a stability check
must be made.
Cathodic protection must be applied to buried steel pipelines to provide protection from corrosion. In
order that protection can be satisfactorily achieved the pipe must have a very high quality coating and
the pipeline system must be electrically isolated from above ground installations and pipelines of other
materials. Either impressed current or sacrificial anode cathodic protection should be used.
For impressed current, an electric current is applied, which makes the pipe more negative than the
surrounding ground. Impressed current is, more suitable for protecting long lengths of cross-country
pipelines, where danger of electrical interaction with other buried metallic structures is low.
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Sacrificial anodes are generally used in populated areas, where they provide corrosion resistance
over short distances, and are unlikely to interact with other plant.
In order to provide the required corrosion protection, the pipe to soil potential, with respect to a
copper/copper sulphate reference electrode, should be –0.85 volts (-0.95 volts in the presence of
sulphate reducing bacteria in the soil).
On completion of the pipeline, the cathodic protection system should be validated to ensure that the
pipeline is adequately protected over its total length.
To ensure satisfactory protection of steel pipes and fittings high performance coatings should be
applied in addition to cathodic protection.
Tapes must be applied to all bare sections of pipe to give a 55% overlap in all cases. Particular
attention must be given to fittings, such as valves, flanged joints, service tees and other items where
tapes need to be moulding to the profile of the fitting during application.
Where metallic fittings are connected to polyethylene pipes, they should be wrapped to prevent
corrosion. Bolts on fittings, such as under pressure tees may be anodic to the rest of the fitting or to
the parent main and, hence, these must also be wrapped to prevent corrosion.
Site wrappings must not affect the integrity of the PE system e.g. the petrochemical properties of
‘denso’ wrapping has a long term degrading effect on PE pipe.
Wrapping of joints and fittings must not be undertaken until after a successful pressure test(s).
4.2.14 Jointing
When carrying out pipe jointing if the air temperature is below -5°C or above 40°C precautions must
be taken to bring the air temperature within limits.
Pipes made from dissimilar polymers should only be joined by electrofusion joints. Where
electrofusion couplings are used to connect sections of thin walled pipe (e.g. SDR 26), steel inserts
must be fitted to prevent pipe wall collapse during the fusion operation.
Pipes must be supported using proprietary clamps which allow the pipe to move back and forward
within the butt fusion machine and remain still when using electrofusion, during the heating, fusion
and cooling phases.
Electrofusion is the recommended option of jointing mains up to and including 90mm diameter. Above
this diameter butt-fusion should be used.
PE mains must not have any unrestrained mechanical joints during pressure testing.
Restraining clamps must be used when using electrofusion fittings and for larger diameter mains the
use of re rounding clamps must be used to remove the ovality from the pipe.
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Should the fusion process be interrupted the joint must be discarded or cut out and a new fitting used.
Re-heating of the fitting must not be carried out.
• That the fusion indicators have risen and that no melted material or wire has exuded from the
ends of the fitting
• That the area around the joint is clean and there is evidence of scraping
When using multi layer pipe the outer skin must be removed creating a uniform circumferential peel,
to allow the electrofusion joint to take place.
Fully automatic butt fusion machines must be used. All machines should have the facility for printing
records or electronically downloading the data from the jointing process. The use of aluminium
cleaners or scouring powders is permitted for cleaning excessive deposits on the heater plate. For the
first joint of the day or when changing the pipe diameter, the fusion cycle must be aborted to ensure
that the heater plate is clean. The cycle must then be restarted.
All external weld beads must be removed with an approved tool and inspected. (IGE/TD/3 Section
6.8.3.4. - 7 and Appendix 7)
Removed beads must be kept for inspection and must be numbered with its corresponding joint
number.
A bead gauge must be used to confirm the bead width is within the specified size range.
Where the bead inspection identifies a faulty joint, or where indications show that an electrofusion
joint has failed, the joint must be cut out and the jointing operation repeated. The reason for the joint
failure must be investigated to determine the mode of failure. Common failures include:
• Equipment Failure
• Fitting Failure
• Human Failure
Mechanical joints are generally used for the transition between a PE system and metallic systems.
Flanged joints i.e. ‘pecat’ adaptors can be used at valve interfaces as well as connections on to steel.
Pipework must be fabricated so that mating flanges are aligned and abutted squarely. The type of
flanges to be used must be to PN16 specification for operating pressures up to 7 bar. For operating
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pressures above 7 bar refer to specification for flanges detailed in the appropriate design code
IGE/TD/1, Steel Pipelines for High Pressure Gas Transmission or; BS 8010 Codes of practice for
steel pipelines or; ASME 31.8 Gas Transmission and Distribution Piping systems. In the case of PE
flanges the sealing faces must be protected against damage prior to assembly.
Bolts should be tightened in the correct sequence and a sufficient number of circuits undertaken to
ensure that the specified bolt torques are. It must be noted on flanged joints using elastomeric
gaskets some relaxation of the gasket will be experienced.
• Use only 3mm thick, one piece, 80 hardness Nitrile rubber gaskets to EN681-1 and to suit
flange rating.
• Hold the gasket in correct position on clean flange face until flanges meet.
• Lubricate bolt threads and all mating surfaces of nuts, washers and flanges using an
automotive grade of oil or grease.
80 8 M16 65 70 19 160
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Gaskets should be stored in a cool dark place in black polyethylene sacks which exclude light,
especially ultraviolet. Store away from sunlight, electrical discharges and sparking electric motors.
Storage temperature should be below 20 deg. C. Always store gaskets in an unstressed condition –
never hang on hooks, nails, handrails, etc. even for a short time.
Gaskets should be lubricated prior to fitting. Failure to apply lubricant can cause gasket creep under
load. This may cause bolt torques to drop, thus necessitating re-tightening.
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Screwed joints must only be used on steel pipe up to and including 50mm dia and a maximum
pressure of 2 bar. Other joints must be either welded or flanged.
The transition from steel to other metallic mains and to non-cathodically protected steel mains is
undertaken using an insulating joint. Insulation joints shall be manufactured to an appropriate
standard such as UK standard:
GIS/E17 Part 2 Technical specification for insulation joints Part 2 - Joints operating at pressures not
greater than 7 bar
Following removal of the coating and cleaning of the steel main, ultrasonic and magnetic particle
examination should be carried out to confirm satisfactory wall thickness and freedom from flaws in the
area where the fitting is to be located.
If the wall thickness is found to be less than 4mm, connections must be made using mechanical
fittings where practicable and be limited to maximum operating pressures of less than 2 bar. Any
service tees or pressure points must be fitted using a saddle or split collar. These fittings must be
checked to ensure that they are approved for the maximum operating pressure of the main.
On mains greater than 2 bar where the wall thickness is found to be less than 4mm an alternative
position for the connection must be found.
A branch saddle is electrofused to the main and tested prior to drilling. In the event of a test failure,
the saddle must be abandoned, cut off as near to the main as possible and a new fitting electrofused
more than 250mm away. The drilling must be carried out through a valve attached to the branch
saddle.
The design for the welding of steel pipe must address the following criteria:
• Welding specification
• Welding procedure
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Welding shall be carried out to an appropriate standard such as BS 2971 Arc welding of carbon steel
pipework.
Full penetration butt-welding is used for jointing of steel pipes. Saddles and fittings must be fillet
welded. When pipes are to be jointed by welding, the welding operation must, whenever possible, be
carried out above ground, barriers and screens erected to protect members of the public and those
not involved in the welding operation from arc flashes. The maximum length of pipes, which can be
welded in this manner, will depend on road traffic conditions and the nature and frequency Where ‘in
ground’ welds are required, additional localised excavation will be required at the joint positions.
Sufficient ground must be excavated to permit the welder to gain access to the full joint
circumference.
Welding of joints must not be carried out when prevailing weather conditions are such that the quality
of the weld could be impaired, unless adequate weather protection is used. Pipes and fittings should
not be welded when they are at a temperature below 00C, pre-heating of pipe and fittings will be
required in these conditions.
Fillet welds – 100% visual examination- 100% radiography – 100% magnetic particle examination.
GIS/F7 Technical specification for steel welding pipe fittings 15mm to 450mm inclusive
nominal size for operating pressures not greater than 7 bar.
• IGE/GL5 approval is required for connections to mains operating at pressures above 2 bar.
• A correctly sized bypass determined by Network Analysis must be installed around every
section of pipe to be cut or connected unless its omission can be specifically justified.
• A low resistance electrical continuity bond must be fitted across all sections of ferrous pipe to
be cut or connected. Vent pipes must be included in cross bonding or earthed. When non-
metallic gas pipes are encountered cloths soaked in water must be wrapped around the
position of the remaining pipe ends and draped down to the ground to form a low resistance
electrical path to earth.
• Where impressed current cathodic systems are installed the system should be isolated.
• Pressure gauges and/or recorders must be installed either side of the operation.
Flow stopping equipment shall only be used when other means of mains isolation e.g. valve closure,
cannot be achieved.
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For PE 80 mains over 500 mm diameter, no squeeze off is currently available; flow stopping must be
achieved by closing a line valve.
For PE 100 SDR 11 mains squeeze-off must only be used for pipe sizes up to and including 315 mm.
For pipe sizes 250 mm and 315 mm, a stainless steel wrap around clamp must be subsequently fitted
the squeeze-off position to remove hoop stress from the PE100 pipe wall.
On completion of a squeeze-off operation, the pipe must be re-rounded and a tape marked ‘Squeeze-
off applied’ affixed to the pipe. The same squeeze-off position must not be used again and at least six
pipe diameters distance must be allowed between squeeze-off positions on the same pipe.
The minimum distance between squeeze off bars or beams is calculated as a percentage of twice the
minimum wall thickness.
For 250mm pipe the limit is 80% of twice the minimum wall thickness.
For 315mm – 400mm pipe the limit is 90% of twice the minimum wall thickness.
Refer to manufacturers instructions for detailed information on the positioning and application of
squeeze offs.
A welding procedure should be prepared for any work is undertaken on steel mains.
Pipe may be cut using rotating wheel cutters, mechanical rotary cutters, flame cutters or hacksaws.
Flame cutters must not be used on mains, which have contained gas, or in a gaseous or potentially
gaseous atmosphere.
When welding to a stopped main is unavoidable, a constant bleed of inert gas must be maintained
and the distance between the stopper and the ignition source maximised as far as is practically
possible.
Having excavated around the main at the cut out position, the main should be thoroughly cleaned and
examined for damage.
The cut out should be made, after earthing the pipe either side of the cut, using a damp cloth around
the main and touching the ground.
4.2.19 Anchorage
Anchorage is required to prevent movement of pipe work and/or fittings that could cause a joint to be
disturbed or a fitting to be displaced. Anchorage is not normally required for all welded steel or fusion
jointed polyethylene (PE) pipelines. However, when these systems are connected to new or existing
pipe work by flexible compression joints, temporary thrust restraints and permanent anchor blocks
must be used.
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Between the boundary of each pressure tier a pressure reduction station shall be installed. For the
design of pressure reduction stations reference shall be made to IGE/ TD/13 Pressure regulating
installations for transmission and distribution systems. Pressure regulating modules shall be
purchased to an appropriate standard such as UK standard:
4.2.21 Metering
All new installations, and modifications to existing installations, shall be designed and constructed in
accordance with the following standards:
IGE/GM/6 - Standard diaphragm and RD meter installations. > 6 m3h-1 MOP ≤ 75 mbar
IGE/GM/7 Ed 2 - Electrical connections and hazardous area classification MOP ≤ 100 bar
All new mains must be pressure tested. Any part of the supply system, which is diverted, altered or
renewed, must be pressure tested. Joints, which cannot be included in such a pressure test, must be
tested at operating pressure using an approved leak detection fluid.
A pneumatic pressure test must be applied to mains operating at less than 2 bar.
For mains operating at more than 2 bar a preliminary pneumatic pressure test at 350 mbar must be
applied prior to a hydrostatic test being carried out - followed by a pneumatic pressure test.
For PE mains that have been subjected to a hydrostatic pressure test, a relaxation period of 3 hours
at atmospheric pressure must be allowed for creep to relax before commencing pressurisation for a
pneumatic pressure test.
Where PE pipe is subjected to a pressure test, the pressure will drop initially owing to creep (see
Appendix 4 – Creep Effects – Table 12 IGE/TD/3) of the pipe wall. This is not normally an issue during
less than 75 mbar operating pressure mains testing, or for mains with small test volumes where the
stabilisation period allows the majority of the creep to occur. However, for pneumatic pressure tests
on greater than 75 mbar operating pressure mains, the effects of creep must be taken into account
prior to commencing the actual pressure test.
Steel mains must not have any unrestrained mechanical joints during pressure testing.
IGE/TD/3 – Section 7 provides guidance on selection of the appropriate test specification for
pneumatic and hydrostatic tests.
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For IP mains it is advisable to raise the pressure in stages (i.e. 1bar, 4bar 7bar) to allow any tie-in
joints to be progressively tested, using leak detection fluid.
For LP and MP systems, the effect of plant and equipment failure must be taken into consideration
when pneumatic pressure testing. If the consequences of failure during the pressure test are high, a
hydrostatic test should be performed using the appropriate test pressure. The hydrostatic test should
be conducted prior to a pneumatic test.
The same, calibrated, test instrument must be used for the initial, intermediate (if any) and final
pressure readings. The test instrument used on pressure tests between 2 and 10.5 bar must have an
absolute accuracy of 3 mbar (for an instrument with a range 0-10.5 bar the accuracy required will be
0.0285%) or greater and have a resolution of 0.1mbar.
Mobile telephones, radios, etc. should not be operated in the vicinity of digital test instruments, as the
pressure indications may become erratic.
For all pneumatic pressure tests of longer than 2 hours duration, gauge pressure readings must be
corrected for barometric pressure. Barometric pressure readings should preferably be taken at the
test site or alternatively at a point within 15 km of the site. Test instruments providing absolute
pressure readings should be used where available to remove the need to apply correction. Absolute
pressure measurements include atmospheric pressure.
For IP mains (i.e. operating above 2 bar), a hydrostatic pressure test must be applied followed by a
pneumatic pressure test.
Where PE pipe is subjected to a pressure test, the pressure drops initially owing to creep of the pipe
wall. For pneumatic pressure tests on MP & IP mains, the effects of creep should be considered. An
extra pressure drop allowance for creep during the test period may be added to the 3 mbar allowable
drop.
Where the pipework system under test contains flanged or (threaded joints only below 2 bar),
pressure testing must be undertaken prior to wrapping the joints.
The full number of appropriate studs or bolts provided for blanking flanges must always be used. Any
studs or bolts with worn or damaged threads must be replaced.
Pressure relief valves of adequate size, set at the appropriate setting (10% above maximum test
pressure), sealed and marked with the set pressure and within the calibration date, must be installed
in the test supply line to prevent the test pressure from being exceeded (testing of low-pressure
services with a water gauge fulfils this purpose.). Pressure relief valves must be fitted during
pressurisation or during any subsequent pressurization of the pipe work, but may be removed for the
test period.
Interchangeable pressure test components (used in applications above 2 bar) such as blank flanges,
pressure gauges, safety valves, temperature gauges and flexible connections should be the subject of
an annual examination by the Competent Person. Pressure test components should be properly
stored, and labelled and registered to assist correct selection and use for the purpose intended. Their
issue must be recorded.
A Permit to Work must be raised for the pressure testing of all Intermediate Pressure mains with a
diameter greater than 2” (63mm). A site-specific risk assessment must determine the requirement to
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issue a Permit to Work for the pressure testing of MP mains, taking cognisance of volume, location
and any other circumstance.
Non Routine written procedures must be prepared for the testing of all Intermediate Pressure mains
and services with a diameter greater 2” (63mm). A Routine Operation written procedure must be
prepared for the testing of Intermediate Pressure services with a diameter of 2” (63mm) or less. A site
specific risk assessment should determine the requirement to prepare a Non Routine Operation
written procedure for the testing of MP mains and services with a diameter greater than 2” (63mm),
taking cognisance of volume, location and any other circumstance. In circumstances where a Non
Routine Operation is not used, a Routine Operation written procedure should be prepared.
• The test pressure, the test duration and testing medium to be used
• Where the testing medium supply line is to be attached to the plant to be tested
• The position and specification of safety valves, pressure gauges and other test components
All employees engaged on any work associated with testing should be are aware of the possible
consequences of pipe or test fitting failure under pressure test conditions. The site specific risk
assessment must be completed to include the test procedure, and consideration must be given to
how and where pressure tests ends and test equipment are located, so as to minimise hazards
resulting from a potential pipe or test fitting failure. Warning of the hazards associated with the energy
stored within a pipe under test and, in particular, the energy stored within a pipe containing both water
and air, must be given to personnel.
There is a risk of injury from particles of dirt and high velocity jets at the time of pressure testing.
Personal protection equipment (PPE), including eye protection must be worn by all persons required
to work within the test area.
All new welded steel and fused PE systems must not incorporate flexible joints whilst pneumatic or
hydrostatic pressure testing is being carried out. Such joints are permitted for connection purposes on
LP or MP systems only
To reduce the risk of failure, flexible air inlet pipes and their connections should be visually examined
prior to use to ensure they are fit for their intended purpose. They must be secured and anchored by a
secondary restraining device (e.g. whip-check or similar) to prevent movement as a precaution in the
event of failure.
The Site Engineer must ensure that all precautions are taken:
• Before pressurisation
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• During pressurisation
The impact of noise generated during pressurising and de-pressurising must be minimised by the
controlled introduction and release of air.
For mains operating at MP or higher, notices warning that pressure testing is in progress must be
prominently displayed where the main is exposed and accessible to the public and viewed from all
access points.
Before pressurisation commences, a final visual check should be made that the test section is secure
for pressurising. The introduction and release of air must be carried out whilst all personnel are
outside the trench.
Whilst the pressure is being raised, no un-authorised person must enter the designated test area or
interfere with the pipe work.
Throughout the duration of the test, particularly in the case of MP and IP mains, the system should be
examined at intervals to ensure that all anchorages are secure and that no hazard exists. It may be
appropriate, in some cases, to maintain a presence on site at all times to minimise the impact of
failure. A site-specific risk assessment should determine whether or not this is necessary. This will
depend on factors such as location, pressure and diameter.
Mains must not be subjected to any form of shock loading or work of any description whilst a pressure
test is ongoing.
The pneumatic pressure test is a leakage test that demonstrates the soundness of a main, requiring
the system under test to be pressurised with air. The application of this test, which simulates the
system operating at its maximum operating pressure under gas conditions, will allow all detectable
leakage to be identified.
The maximum permitted leakage rate is 0.0028m3/h of natural gas at the maximum operating
pressure. This is irrespective of material, size, operating pressure or length. Any leakage in excess of
this rate should be detectable, if occurring at one point.
Note: Physically isolated means; the main to be tested must not be connected to the existing systems.
Closed valves must not be used as end caps. All valves must be tested in the open position. Valves
fitted at the extremity must be securely blanked using a correctly designed blank flange. The insertion
of a correctly designed spade at a flange acts as a physical isolation.
The main must be tested at the pressures and durations calculated in accordance with IGE/TD/3 –
Section 7
Immediately upon satisfactory completion of any sectional tests, the whole of the main must be
subjected to a pneumatic soundness test at maximum working pressure (in stages of 1bar, 4bar and
7bar for an IP system) held while the interconnecting joints between sections are proved with leak
detection fluid. Any pipe-work or fittings used in connecting sections must be pre-tested to the
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appropriate pressure test specification. If pre-testing of all the fittings used in the connection is not
possible, spades must be fitted between the last joint (s) and a pressure test to the appropriate
pressure for ten minutes should be conducted, this will act as a strength test. On satisfactory passing
the strength test all joints must be tested using leak detection fluid.
Following the satisfactory completion of the final tests, the main must be purged and the tie-in joints
tested under maximum operating conditions with leak detection fluid.
Following the completion of final tests, where hydrostatic tests have bee undertaken drying operations
must be carried out before commissioning.
Sections of tested main should be left at a reduced pressure (350 mbar maximum) until
commissioning is undertaken. Details of the partial pressurisation should be indicated on the pressure
test certificate. A recorder should be used to indicate the condition of the pipe during this period.
The pipe must be checked before commissioning to ensure that the positive pressure has been
maintained. Before any further work is carried out on the pipe, the pressure must be reduced to
atmospheric pressure.
Consideration should be given to insulating the pressure test instrument and hose to avoid the effect
of localised temperature variation. When testing mains, the standpipes should be located at all
extremities of the new main and incorporate a relief valve set to lift at a pressure 10% above the
specified test pressure.
Test instruments must be fitted so that they can be read and operated without entering the trench or
standing in line with the end of the main.
Closed valves must not be used as end caps. All valves must be tested in the open position. Where a
valve is fitted at the extremities of the main under test, the valve must be securely blanked and
anchored against movement.
The Project Engineer must be in attendance at the commencement of pressurisation and during the
pressurisation period, to ensure that the necessary safety requirements are met, and the time of
commencing pressurisation must be recorded on the test certificate.
Where creep allowances are to be applied to PE mains tests, it is important that the exact
conditioning time is established by recording the time of commencing pressurisation and the time at
which the first test reading is taken. Conditioning time includes the effects of the 2 h stabilisation
period referred to above. Alternatively, the APT procedure (see Specialist Techniques Chapter) may
be used to log and diagnose the entire test.
Air must be introduced under controlled conditions into the main until the appropriate test pressure is
reached. Care must be taken not to over pressurise the pipework. A single or twin tool compressor
(80 cfm to 100 cfm) will be adequate for pressurising the majority of pipe systems. Where larger
capacity compressors are used, the stabilisation or conditioning time must still be adhered to.
No work must be carried out on a main under test other than any necessary leakage testing or
operation of the valves on the test standpipe.
Before the start of the test period, the temperature of the air in the main should be allowed to stabilise
before the test period is commenced.
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For metallic mains and low-pressure PE mains, this will normally occur within 2 hours, and will be
indicated by a stable pressure reading.
For MP/IP PE mains, the effects of creep must be taken into account and the conditioning period
allowed.
All exposed mechanical joints must be tested for leakage upon initial pressurisation with an approved
leak detection fluid.
Following the period of the temperature stabilisation, the initial pressure reading must be taken. For
PE mains at MP/IP (where the effect of creep is being considered) the first test reading must be taken
at the end of the conditioning period.
A further pressure reading must be taken at the end of the test period. Where a long duration
pressure test period (i.e. over 24 h) is to be undertaken, intermediate pressure readings must be
taken so that the test may be assessed and aborted at an early stage if there is an indication that the
test will ultimately fail.
When the test has been completed to the satisfaction of a competent person, the air pressure must be
released through suitable vents. One vent point must be situated at each extremity of the system and
depressurised in a controlled manner until the whole of the main is at atmospheric pressure.
Appropriate PPE, including ear protection, must be worn.
The Project Engineer must confirm, by checking the gauges installed at all extremities, that the
pressure within the whole of the main has been reduced to atmospheric. The Project Engineer must
record this information on the test certificate before authorising further construction work to proceed.
Where a pressure loss greater than the total allowance has occurred, having accounted for any
variation in barometric pressure and the effects of creep in a PE system, investigations must be
carried out to find the source of leakage. All connections, plugs and external fittings must be re-
examined for possible leakages by leak detection fluid. In the event of discovering leaks, they may be
repaired with appropriate tools without excessive force but the pressure should be reduced in order to
minimise hazards resulting from a potential pipe or fitting failure.
Where no obvious cause can be attributed to a pressure test failure and the test conditions have not
altered the test may be undertaken, using the final or an intermediate test reading as the starting point
for the new test period. In the case of pressure tests on MP/IP PE mains, the revised creep allowance
should be established following calculation of the new conditioning time.
Halogen detector (this methods method involves specialist mains equipment): A small quantity of
sulphur hexafluoride (SF6) must be inserted into the main at the point and time of introduction of air
for testing, and a check made to ensure permeation along the length of the main. When handling SF6
care must be taken to avoid contact with skin and inhalation of fumes. The pneumatic pressure in the
main must then be raised to the appropriate test pressure and the atmosphere at the bar holes
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sampled with an approved halogen detector which gives an audible warning when SF6 is present at
the bar holes.
The main may be divided into sections, each being tested separately, and the section failing the test
must be further subdivided until the location of the leakage is determined.
4.2.23 Commissioning
To ensure the safe commissioning of gas mains, it is essential when purging that certain velocity rates
are maintained. This will ensure that a sharp interface exists between gas and air / inert gas. If the
velocity is too low, it is possible that there will be a layering of gases, with that having the lowest
density, remaining at the top of the main rather than being swept out. This situation could result in an
explosive mixture developing.
Direct purging is the preferred option for commissioning or de-commissioning mains. If the criteria for
direct purging cannot be achieved (i.e. correct velocity), then indirect purging should be used.
Wherever possible, complete displacement is preferred, using an inert gas. However large volume
purges will often necessitate the use of air/inert gas slugs. Indirect and slug purging is classified as a
specialist technique and specialist operatives will be required to carry it out.
Care must be taken to avoid the interruption of purging operations, which can result in gas and air
becoming mixed, potentially resulting in explosive mixtures.
For all purging operations there are a number of general factors to be taken into account. These
include:
• Purging operations must be carried out in accordance with an authorized written procedure as
stipulated in the requirements of GPCOEWG/GAS/OP/03 – Safe Control of Operations.
• Pipelines and mains that have been hydrostatically pressure tested must be thoroughly dried
before commissioning.
• Riders should be constructed from metallic tube, approved flexible steel pipes/hoses or
polyethylene (PE). An on-site risk assessment, which identifies the potential impact on the
rider of mechanical damage, interference or fire hazard, should be used to determine rider
construction.
• Plastic pipes to be cut or separated must be earthed to prevent static build up.
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• Dividing the length of the main by the proposed purge velocity should provide an assessment
of the purge duration.
• Once a purge has started, it should continue without interruption until complete.
• For all commissioning operations, a system of communication must be organised and tested
for personnel operating the riders and vents
• For major purging operations, it may be necessary to inform the Gas Control Centre, the local
authority environmental officers, the Civil Aviation Authority (CAA), the local Police, Fire
Brigade, local residents and any other affected parties, as identified within the written
procedure and on-site risk assessment, to discuss noise, smell and flammability.
• During a purging operation should the pressure in the source main fall below the specified
minimum pressure stated in the NRO/RO the purging operation must stop immediately, the
gas in the new main vented and the reason for the drop in pressure investigated.
When direct purging, low-pressure PE mains not greater than 180 mm diameter the main may be
isolated by a single faced valve or squeeze off. Checks must be undertaken to confirm that the
isolation is sound.
Mains of greater pressure and diameter must be isolated from the parent main by a double block and
bleed system. This system may be a valve with a double block and bleed facility or, alternatively, a
double squeeze-off system with an intermediate vent.
The minimum rider and vent sizes required to prevent stratification, are shown in Table 7. For mains
operating at pressures greater than 2bar, purge velocities should not exceed 20 m/s.
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(mm)
21 mb 30 mb 75 mb 350 mb 2 bar
0-150 32 32 32 32 32
150-200 63 63 63 32 32
200-250 63 63 63 63 63
250-300 90 90 63 63 63
300-450 90 90 90 63 63
• Rider connections to the pipeline or main should be full bore. (It is recommended that saddles
are used to connect the pipeline or main, not service tees).
Vent pipes should be fitted at the far end of the main to be purged and should be manned whilst
venting.
• Discharge vertically into the open air not less than 2.5 m above ground level.
• Be sited where possible not less than 5 m downwind of possible sources of ignition.
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• Be firmly supported.
• Be metallic.
Where the minimum velocity given in the above table cannot be achieved, the mains must be
commissioned using indirect purging methods.
When direct purging it is permissible to purge without riders in the following circumstances:
• With agreement of the Project Engineer, sections of pipelines and mains above 2”/63mm
diameter may be commissioned, using direct purging only, by the controlled release of a
squeeze-off, if the release of the squeeze-off can be controlled to a position corresponding to
the required rider size for achieving the minimum purge velocity.
• At the discretion of the Project Engineer sections of mains above 2”/63mm diameter up to and
including 10”/250 mm diameter, may be commissioned by the controlled opening of a valve,
using direct purging only (A slide valve is not permissible). Care must be taken not to damage
the seals of the valves.
Short stubs, whose length is less than eight diameters, are not classed as branches and will
automatically be purged by natural convection.
Any loops must be isolated by valves or stopping off equipment and then treated as branches.
For branched systems, when simultaneously purging, it is necessary to calculate mains diameters
equivalent to the sum of the cross-sectional areas of all the pipes being purged, and to check effective
sizes of riders and vents, to ensure that minimum velocities are maintained.
Indirect purging, using an inert gas, is employed where the minimum velocity for direct purging cannot
be met. It is a specialist activity, requiring operatives, specifically trained for the task.
A purging operation involving the use of nitrogen must be carried out as a non-routine procedure, in
accordance with a Safe Control of Operations procedure.
When indirect purging, the pipeline or main to be commissioned must be physically isolated from the
parent main. Alternatively, it may be isolated by an approved flow stop technique provided that the
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nitrogen injection pressure is limited to less than the pressure in the live main and the minimum
velocity can be achieved.
At all times during indirect purging, a velocity of not less than 0.6 m/s must be maintained with riders
and vents sized in accordance with Table 8 as follows:
(mm)
21 mb 30 mb 75 mb 350 mb 2 bar
0-150 32 32 32 32 32
150-200 63 63 63 32 32
200-250 63 63 63 63 32
250-300 90 90 63 63 32
300-450 90 90 90 63 63
The volume of inert gas and gas required to ensure complete displacement is shown in Table 9 as
follows. The minimum volumes stated in the table include a safety factor of approximately 50% above
the actual main volume.
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100 1.3
180 3.0
200 5.0
250 8.0
315 12.0
400 20.0
450 25.0
600 45.0
750 70.0
900 100
1050 135
1200 175
Inert gas for purging mains not greater than 315 mm diameter is normally supplied from one or more
cylinders or a bank of nitrogen cylinders. The capacity of a typical 1.5 m long cylinder is usually 7.7
m3. The maximum flow rate from a cylinder or bank is typically 1 m3/min. The nitrogen facility must be
able to deliver the minimum flow rate.
Example:
When purging a 300mm main, a flow rate of 2.6m3/min. is required, therefore three nitrogen cylinders,
each with their own high capacity regulators, will be required, discharging simultaneously.
(All cylinders must be carefully checked to confirm that the contents are nitrogen. For nitrogen, the
colour of the cylinder will be FRENCH GREY with a BLACK band at the top).
Where large quantities of inert gas are required for mains greater than 315 mm diameter, the use of
an inert gas generator, which produces a mixture of carbon dioxide, water vapour and nitrogen should
be used. Competent personnel must operate the generator. Alternatively, a tanker of liquid nitrogen
and vaporizers can be used.
For mains having lengths greater than 250 metres, slug purging may be used as a substitute for
complete displacement, for economic reasons. This is a specialist activity.
The slug volume of inert gas must be not less than 10% of the pipe volume.
Each branch must be isolated and purged individually simultaneous purging of branches by slug
purging is not permitted.
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4.2.24 Pressurisation
After purging to gas the mains must be slowly pressurised so that the pressure in the supply main
does not fall below the minimum allowable. The final connections that were not included in the test
and any exposed sections must be checked as pressure increases, to ensure that there is no
leakage.
For MP and IP mains this is done in incremental stages of pressure to identify leakages at an early
stage.
Prior to de-commissioning a medium or intermediate pressure system, every effort must be made to
reduce gas venting, by passing gas in a controlled manner into a system operating at a lower
pressure.
Before decommissioning low pressures mains for insertion or abandonment decay tests must be
carried out.
Purges may be undertaken using a compressor to expel gas out of a vent, or an ejector utilised (for
direct purging only) to draw the gas out of the main and draw air in through an open hole.
The main to be de-commissioned must be isolated from the parent main by physical isolation if a
compressor is used to undertake the gas purge. Alternatively, an approved stopping off method may
be used provided the purge pressure is limited to 1/3 of the pressure in the live main, and the
minimum purge velocity can be achieved.
A double block and bleed valve will be required if an ejector is used to draw the gas out of the main.
For low-pressure mains not greater than 180 mm diameter, isolation may be undertaken using a
single faced valve or a single squeeze off, ensuring the isolation is sound.
Prior to cutting off a main for abandonment or insertion, decay tests must be undertaken to ensure
that:
Tests must be undertaken at times when a significant quantity of gas could be expected to be
consumed.
Essentially decay testing involves the isolation of the main in question, and the monitoring of
pressures within that section. A significant pressure drop in the section to be abandoned could
indicate the presence of gas consumers still connected or that gas supplies to the downstream
system are insufficient. If pressures are found to be stable during the monitoring period, the isolated
system should be vented and then monitored to identify any pressure increase. Such an increase
indicates the presence of a back feed, which must be found and disconnected. In both cases further
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work must be carried out to determine the cause of the fall or rise. This may involve any of the
following:
• Insertion of a camera.
To prevent stratification vent sizes must be those given in the Table 7. In order to achieve the purge
velocity, minimum air inlet holes and vent diameters together with the minimum size of compressor
must be as shown. Multiple holes may be drilled to achieve the same inlet hole cross-sectional area,
e.g. 2 x 2 in. diameter holes = 1 x 3 in. diameter hole.
A compressor may be used to purge mains up to 10 in. diameter. Above this, an ejector must be
used; the 150 mm ejector will purge pipelines or mains not greater than 600 mm diameter. The 250
mm ejector is required for pipelines greater than 600 mm diameter.
When an ejector is used, the vent holes must all be the size of the vent hole in the largest diameter
pipe. The ejector must be fitted to the end of the largest pipe and the branches purged in descending
order of size.
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A single tool compressors deliver 1.9m3/min to 2.8m3/min (70ft3/min to 100ft3/min) Two tool
compressors deliver 3.9m3/min (140ft3/min).
4.2.25.3 Decommissioning By Indirect Purging
Where minimum purge velocities cannot be met, indirect purging should be carried out, Riders,
vents and inert gas facilities must be sized to achieve a minimum velocity of 0.6 metres per second.
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If a slug purge is used (for mains lengths in excess of 250 metres), a minimum slug volume of inert
gas of not less than 10% of pipe volume must be used.
Each branch must be isolated and purged individually; simultaneous purging of branches by slug
purging is not permitted.
4.2.26 Records
• Depth
• Diameter
• Material
• Pressure
• Lay method
• Crossing Pipes/Connections
Adequate information should be provided to allow the location of the position of the service
connection to the parent main. This point should be located using at least two dimensions.
In addition the depth of the connection must be indicated, together with a confirmation of the size
and material of the parent main.
• Records of pressure tests for mains designed to operate at pressures greater than 2 bar must
be retained for the life of the system, whilst those for mains operating at 2 bar or lower need
to be retained for a minimum of two years.
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A gas service is defined as pipework connected to the distribution main and conveying gas to the gas
consumers premises terminating at the customers emergency control valve (ECV). All subsequent
downstream pipework conveying gas to appliances is defined as installation pipework.
A service shall be installed at right angles to the main to assist future identification, and terminate at a
meter location as close to the connecting main as practical to minimise service length.
All above ground pipework should be in steel pipe to avoid degradation due to high ambient
temperatures.
• In an external meter box or purpose built compartment on the front or within 2m of the front
face building.
• In an internal position, sited on the internal face of an external wall terminating no more than
2m from the external face (maximum service operating pressure 75 mbar).
The maximum pressure drop for a service pipe is 2mbar providing a minimum pressure at the
downstream side of the ECV of 19mbar.
Service design must be carried out using the approved software tool.
The following factors must be taken into account when planning to install a service:
• Pressure requirements?
• Is the service subject to an elevated pressure? A service operating above 75mbar must not
be installed internally to the premise.
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• Does the premises encroach upon the minimum proximity distances of the main and can the
pipe material be altered to meet the minimum requirements?
• Allow minimum distance from windows, vents, other openings and electrical apparatus for MP
service governor.
A service should be constructed from a single piece of pipe with the minimum number of joints
possible. However, it may be necessary to install composite services comprising pipes of different
diameters in order to minimise the installation costs. Manifold Connections must not be installed.
The bore of the connection should be the same as that of the pipe immediately downstream of it.
Any proposed connection must only be installed using a standard, equivalent size, connection fitting
specifically designed for the purpose.
For the design methodology for gas installations to supply flats and other multi dwelling buildings
reference shall be made to IGE/G/5.
Medium and High Rise buildings whose design renders them liable to progressive collapse shall not
be supplied with gas unless a written assurance is obtained from the owners that the building has
been satisfactorily strengthened.
The steps to be followed for the design of gas connections to flats and multi occupancy buildings are
as follows:
• Selection of suitable meter position (IGE/G/5 – section 5) in increasing risk level these are
• External Bank
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• Provision and location of Isolation Valves (IGE/G/5 – Section 9 also see Section 3.4 Figures 1
-6)
The design of gas services to flats building should be undertaken in full consultation between the
designer, the Gas Authority, the Architect and the Developer.
Provision shall be made for expansion joints to ensure that service risers are not stressed due to the
expansion and contraction of above ground pipework. The designer shall ensure that the specified
expansion joints will tolerate daily ambient pressure cycling of – 5 to + 50 0 C for the lifetime of the
service pipe.
Gas service connections should be carried out in accordance with IGE/TD3 and IGE/TD/4.
Connection designs should take account of pressure loss across the connection components.
All connections must be made under controlled gas conditions and be carried out in accordance with
approved written procedures supplemented as necessary by permits to work, risk assessments and
method statements.
Under pressure tees fitted to mains must incorporate a construction valve in the connection.
The bore of the pipe must not be restricted through use of reduced diameter fittings or branch drilling.
Any proposed connection must only be installed using a standard, equivalent size, connection fitting
specifically designed for the purpose.
Where a top tee connection is to be used account must be taken of the pressure losses across the
tee.
The diameter of the downstream pipe should be no greater than the nominal diameter of the
connection tee.
For connections to steel pipes the wall thickness should be established by ultrasonic testing, or similar
approved method and a minimum wall thickness of 4mm established before direct drilling may be
used. Where this is not possible the connection should be made using a full encirclement fitting.
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Prior to any excavation taking place, the route of the service should be walked and a visual record
(either photographic or video evidence) made of any damage to roads or structures and any other
potential sources of claims for compensation. Where existing damage is identified, the extent of the
damage should be agreed with owners in advance of work.
Utility plant information should be collated, located with a cable and pipe locator, identified and its
position marked on the road surface. Precautions should be taken to avoid damage to overhead plant
by vehicles or mechanical excavators.
When planning to excavate parallel to adjacent boundary walls, a stability check needs to be made in
order to ensure safe working in the vicinity of the wall.
Excavation work should not proceed if the wall is leaning, cracked or showing any signs of instability.
Factors which must be taken into account when deciding the route of the service include:
• Avoidance of unventilated voids. - Service pipes must not be installed within a cavity, a cavity
wall or in the space between the floor and the ceiling below, unless it is to pass through the
wall or floor from one side to the other and take the shortest practical route and be enclosed
in a gas tight sleeve.
• Avoidance of damage to foundations and other parts of premises. A service must not be
installed under the foundation of a building, the base of a load bearing wall or a floating raft
foundation. The service must not be installed in such a way such as to impair the structural
integrity of the building or the fire resistance of the structure of the building.
• Meter locations.
• Where the building construction involves a concrete raft, and there is not the recommended
depth of cover between the raft and the proposed finished ground level (375 mm), the
developer must provide a slot or vertical channel in the raft to allow safe installation of the gas
pipe.
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• A service installed above ground must be properly supported to ensure that no undue risk of
accidental damage to the pipework.
• Is there a known vandalism problem in the local area - use of a below ground entry fitting
(bend) and steel riser.
Reference should be made to IGE/UP/8 Gas Installations for caravans, holiday homes, residential
park homes and permanently moored boats for further information on installation requirements in
temporary buildings.
IGE/UP/7 Gas Installations in Timber Frame Buildings should be consulted for detailed information on
installations in timber frame buildings.
Table 11 details the minimum recommended depth of cover for services up to and including 63mm.
The minimum recommended depth of cover in private property is 375 mm. The laying of the pipe
should be laid with a slight gradient towards the main.
The normal minimum depth of cover in highways should be 450 mm. However, the depth of cover
should be increased to ensure that there is 75 mm of fine fill between the bottom of the road
foundation and the top of the service pipe.
The trench must be excavated to the correct depth and the service pipe fully supported throughout its
length on firm ground, free from stones or projecting rock. Wherever possible, the trench bed should
have a continuous downward gradient towards the main.
Because of their proximity to road junctions, mains may be laid at 750 mm minimum depth under
footpaths. Services at these locations should be laid at a minimum of 450 mm depth, sufficient to
provide 75 mm of fine fill between the top of the service and the bottom of the adjacent road structure.
Where it is necessary to lay at less than 375 mm cover, protective measures to prevent damage must
be installed such as the additional protection of sleeving, concrete marker tiles or a change in
material.
Where the recommended depths cannot be achieved on of the following shall be adopted:
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• Additional protection over the pipe for shallow depths, e.g. use of concrete slabs, steel plates
or reinforced marker tape.
The result of the risk assessment must be recorded within the project documentation and ‘as laid’
drawing marked up accordingly indicating the protective measures taken, e.g. depth.
The trench width should be kept to a minimum and should not exceed 300 mm.
• PE 80 polyethylene
• PE 100 polyethylene
The choice of material is dependent upon the desired Maximum Operating Pressure (MOP),
environmental factors, laying technique and safety factors, such as proximity to buildings and
susceptibility to damage, or above ground for special crossings such as bridges.
Service pipes are supplied in SDR 11, with the exception of 16mm diameter and 20mm diameter,
which are supplied in SDR 7 and 9 respectively.
There are two types of colour coded PE 100 pipe, orange and multi layer - (Profuse) yellow with
brown stripes. Multi layer pipe was introduced in 2003 as an alternative pipe for diameters from
250mm upwards and excludes close fit pipe diameters. The different SDRs and their pressure
limitations can be found in IGE/TD/3 – Section 5.6 – Table 4. It should be noted that due to ongoing
development in materials and SDR’s manufacturers recommendations must be consulted to ensure
the latest specification is applied.
This utilises PE100 SDR 21 pipe to provide a system, which maximises capacity via the thinner wall,
provides greater flexibility than SDR 11 PE 100 and permits a higher maximum operating pressure
than PE 80. The pipe diameters range from 250mm to 630mm operating at pressures up to 2 bar. The
peel off polypropylene skin provides a surface which requires no scraping prior to jointing, thus saving
considerable time and improving joint quality. The contrast between the pipe colour of the skin and
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the core pipe provides clear evidence of any surface damage, occurring during delivery, storage,
handling and during the pipe laying process. The brown strip on the skin of the pipe identifies the pipe
as a multi-layer.
This material has significant strength and crack resistance advantages over PE 80. It can be used for
both direct burial and insertion applications. Manufactured in SDR 11, it is used for systems operating
between 2 and 7bar, and is orange in colour.
Note: Further information on maximum operating pressures with respect to the ambient temperature
range, refer to manufacturers’ recommendations.
Fusion fittings with integral heating elements are fused to polyethylene (PE) pipes using electrical
energy supplied to a heating element integral with the fitting. The energy is supplied via a control box,
which operates for a selected time depending upon the fitting type and size.
Fittings are classified as class B (suitable for use at operating pressures not exceeding 5.5 bar) or
class C (suitable for use at operating pressures not exceeding 7 bar). It is essential that the pipe be
supported to prevent it being moved during the heating, fusion and cooling phases. Long pipes should
be supported to avoid misalignment due to sagging.
• Fusion time(s)
• Cooling time
Precautions should be taken when carrying out pipe jointing when the air temperature is below -5°C
or above 40°C. These include the use of temporary tenting to prevent the electrofusion process from
being affected.
Pipes must be supported using proprietary clamps, which allow fitting to remain aligned and still when
electrofusion, during the heating, fusion and cooling phases. The fittings should always be stored in
their plastics bags until ready for use on site. All pipes and fittings should be inspected for cuts, deep
scratches or other damage before use. Where damage is found to be greater than 10% of the SDR,
the fittings or pipe must not be used.
Care should be taken not to handle or contaminate the surface of the fitting containing the heating
coil. Prior to carrying out any Electrofusion the gas in the atmosphere around the electrofusion
process must be confirmed to be less than 20% LEL. Should the reading be greater than 20% LEL,
the process must not start until readings are brought down to a safe level.
Joints must be made only with dry pipe and fittings. Pipe ends should be cut square using suitable
tooling and any burrs removed. A fusion surface which has been cleaned by scraping should not be
touched. Electrofusion joints need not be protected by an anti-shear sleeve. Pressure testing must not
be carried out until the complete system has cooled down to ambient temperature.
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Multi layer pipe comprises a core of PE 100 material, which is clad with an external peelable skin. The
reason for producing a multi-layered pipe in this format is to improve the quality of jointing by
achieving a consistent surface quality for the top tee installation procedure for electrofusion purposes.
Instead of scraping the pipe, a skin is peeled off the outside of the pipe to reveal a pipe surface, which
can be welded onto without any further preparation.
• That the fusion indicators have risen and that no melted material or wire has extruded from
the ends of the fitting.
• That the area around the joint is clean and there is evidence of scraping.
• When using multi layer pipe the outer skin must have been removed to allow the electrofusion
joint to take place.
If the pressure test shows a failure of the tapping tee or coupler on the spigot, cut off the stack to
prevent it from any future use.
Should the power fail during the fusion process, DO NOT attempt to re-heat the fitting. The tapping
tee must be cut off at the stack.
Select a new position for the new tapping tee, minimum of 100 mm from the failed tee.
Where a joint has failed the reason for the joint failure must be investigated to determine the mode of
failure. Common failures include:
• Equipment Failure
• Fitting Failure
• Human Failure
For steel mains up to 3 ‘’ in diameter a full encirclement fitting must be used for the service
connection.
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On completion of pipe construction work, all sections of steel pipe and fittings that do not have a
factory applied protective coating must be protected with an approved anti-corrosion tape or other
coating, after satisfactory completion of the appropriate pressure test.
Anti corrosive tapes should be applied to all bare sections of pipe to give a 55% overlap in all cases.
Particular attention should be given to fittings, such as valves, flanged joints, service tees and other
items where tapes require moulding to the profile of the fitting during application.
For sizes up to and including 63 mm, anti-shear sleeves must be installed whenever a PE/steel
transition is made.
Electrofusion joints need not be protected by an anti-shear sleeve, but the outlet pipework should be
adequately supported so as to resist loading of the joint.
All service pipes must be laid so as to ensure that they are not left in tension.
Pressure testing must not be carried out until the complete system has cooled down to ambient
temperature.
For threaded joints, taper-to-taper, or taper (male) to parallel (female) threads may be used. Pipe
threads must comply with BS 21. All such threaded joints must be assembled using an approved
jointing material.
Threaded joints should not be used on main and service laying working where operating pressures
exceed 2bar.
The welding of pipes in nominal sizes up to 50 mm must be carried out using fillet welding in
conjunction with fittings to BS 3799, Class 300. Pipes and fittings in nominal sizes above 50 mm must
be butt welded, using full penetration welding.
4.3.7 Valves
Valves should be installed on new connections to the existing network or to maintain or safeguard
supplies during maintenance or for management of a supply emergency.
Plastic bodied valves may be installed on pipe diameters up to and including 180mm at a pressure up
to and including 2bar. Plastic bodied valves must not be used as a construction valve.
Valves on services are installed for the purpose of emergency control valves, service isolation valves,
tamper proof valves, additional emergency control valves and excess flow valves.
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• Medium pressure (MP): operating pressures greater than 75 mbar where no SEFV is fitted.
• Where a service excess flow valve cannot be fitted a service valve must be installed.
• Wherever the property being supplied has the service entering below ground terminating in a
cellar or other locations deemed as a confined space.
Means of external isolation of service pipes should be incorporated in all services entering premises
above ground.
PE valves shall be used in preference to metallic valves for below ground installation.
Service valves must be installed in an accessible position as near as possible to the property
boundary and clearly indicated with a surface cover marked G or GAS.
Service isolation valves 63 mm and below do not require pressure or rider points fitted either side.
The service valve should be installed in the service as close as possible to the boundary of the
premises and must be installed with an approved surface box fitted flush with the ground surface.
Service valve covers should have a concrete surround or purpose made plastic chamber and installed
over the centre line of the valve.
When a service valve has been closed for any reason then, if the service is not to be immediately re-
commissioned, the service should be disconnected at the meter and securely capped off at
Emergency control valve. The ECV must be left in the closed position. Open ends on the meter
installation pipe work should be securely capped.
An Emergency Control Valve is for shutting off the supply of gas in an emergency to be operated by
the gas consumer.
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If the emergency control valve is lever operated, the lever should be so attached that the downward
movement turns the valve to the OFF position.
Where a meter is not to be immediately connected or re-connected at the time a service is laid, then,
immediately following the testing and purging of the service, the emergency control valve must be
securely capped and sealed with the valve left in the closed position.
The specification of the Emergency Control Valve should be compatible with the maximum operating
pressure and maximum incidental pressure of the associated network.
The outlet of the Emergency Control Valve defines the interface between the gas network and the gas
supply meter installation.
The outlet of the Emergency Control Valve should be either of flanged or threaded connection.
MP ECVs must not be installed internally as they do not meet fire resistance standards for use inside
a building.
All new and replacement medium pressure services must have a SEFV fitted into the service pipe,
normally at its junction with the main. The SEFV is designed to reduce the volume of gas released
should damage occur where the service is cut or severed. It will automatically restore the gas supply
when the damaged section of pipe has been repaired.
The maximum pressure drop across an SEFV is 8 mbar and this should be taken into account in the
design of mains and service systems. When considering integrated MP systems all services should
be designed using the pressure drop associated with the highest MOP.
• Marker Plate - marker plate must have the diameter, valve number, pressure and distance,
which are attached to a marker post or wall.
• Valve covers/marker disc - the valve cover should be marked “gas”. Alternatively a marker
disc should be fitted over the valve spindle.
A record card/sketch must be made out on which the following information is included:
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• Date fitted
• Function of valve
• Maintenance history
Single Stage regulator installation for: – Inlet pressures between 75 mbar and 2bar. Connected to a
gas service having a MOP pressure not exceeding 2bar and a Lower Operating Pressure (LOP) not
less than 75 mbar.
Two Stage regulator installation for: – Inlet pressures between 350 mbar and 2bar. Connected to a
gas service having a MOP pressure not exceeding 2bar and a LOP not less than 75 mbar.
All boundary MP service regulators must be sited a minimum distance of 3 metres from inhabited
property.
Ducting used for the gas services must be perforated. Prior to installing the new service, a check of
the proposed, finished ground level must be carried out to ensure that the service meets with the
recommended minimum depths of cover required. Warning tape must be placed a minimum of 75mm
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over the crown of the duct. .A pre-laid service duct may be used for PE service pipe laid external to
buildings.
The service ducting specification is BS 4962 ‘Specification for plastic pipes and fittings for use as sub
soil field drains’; The ducting must be overlaid with gas caution tape for identification. The duct must
be of the perforated type to allow for any potential gas ingress to disperse and not track to a nearby
property.
Installation Requirements
• Service pipe ducting must be yellow in colour and Gas marker tape applied a minimum of
75mm above the duct over its entire length to avoid interference damage to gas pipes.
• The ducting should wherever possible be laid perpendicular in a straight line any bends
should not exceed the permitted radii.
• For ease of insertion, the internal diameter of the duct must be sufficient to allow insertion of
the PE pipe with out damage.
• The external ducting must terminate adjacent to the service entry point, allowing a minimum 1
metre of pre-excavated ground to assemble entry fittings.
• The mains connection excavation must be left open with sufficient ducting to receive the
service pipe.
• A check must be made to ensure that the proposed finish levels to allow the ducting and PE
service are correct at the correct depths.
• The ducting must be laid on a prepared bed or soft ground and the first 75mm backfilled with
imported fine fill.
Ensure that the PE pipe does not exceed the minimum bend radius for PE pipe. The minimum bend
radius equals 15x diameter of the PE pipe.
The technique can be used to lay a full service from main to property or for part of the route as
circumstances dictate. Long distance sections of open cut should normally be avoided in favour of
alternative techniques.
On completion of installation of the service the emergency control valve must be fitted, capped and
sealed with the label completed and be secured to the emergency control valve or as near as
practical upstream of it using a cable tie of sufficient length to allow a person to be able to read the
information on the label.
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For information on service entries and typical meter locations reference should be made to IGE/TD/4
– Section 5 and IGE/G/5 and also later in this specification.
Polyethylene (PE) services must not enter occupied premises if the operating pressure exceeds 75
mbar.
PE services must not enter any premises, including integral and attached garages, unless enclosed in
a metallic pipe that is either gas tight or where the annular space is filled with an approved material.
A service must not be installed under the footing of the building, under the base of a load-bearing wall
or under a floating raft.
Where the building construction involves a concrete raft, and there is not the recommended depth of
cover between the concrete raft and proposed finished ground level (375 mm), a slot or vertical
channel in the raft should be provided to allow safe installation of the gas pipe.
All buried parts of service pipes should be of PE material. The only exceptions being:
• Where, due to existing ducts or the exceptional circumstances of a particular case, another
material is more appropriate.
In all cases, corrosion protection must be applied to all metallic pipes in accordance with Chapter B of
the Work Procedures.
Where a service pipe is installed through any wall or through any floor of solid construction the service
pipe must be enclosed in a sleeve. Mechanical pipe joints must not be installed within the sleeve.
Equipotential electrical bonding should comply with BS 7671. For domestic premises, rated at 100A or
less the main equipotential bond conductor must be copper with a minimum cross-sectional area of
10mm2 and green/yellow PVC insulation, construction reference 6491X. The requirements for
industrial and commercial premises with electrical supplies greater than 100A single phase are given
in BS 7671.
Electrical insulation joints serve to prevent the flow of stray electrical current from installation pipe
work through metallic pipe work which may result in corrosion of metal pipe work.
Metallic gas services must be electrically insulated from the meter installation pipe work in premises.
For all services, the optimum position of the electrical insulation joint is above ground level as close as
possible to the entry point to the premises. Electrical insulation joints for services larger than 32 mm
nominal size should be installed in this position.
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Electrical insulation joints may alternatively be fitted directly upstream of the ECV. However, where
exposed metallic pipe work exists between the entry point to the premises and the insulation joint, the
pipe work and fittings should be wrapped to provide adequate insulation of this section of pipe work.
Where the service is of all PE construction, and the PE is above ground, an electrical insulation joint is
not required.
Where services are constructed from PE, terminating with a steel tail into the premises, and where
part of the steel tail is buried, electrical insulation is required.
New metallic services off metallic mains should also be insulated at the main to service connections
unless the service is to be protected by the corrosion protection system applied to the main.
The preference should be given to the installation of external meter boxes either on or within 2 metres
within the face of the building. Where an internal meter position is to be used the service should
terminate on an internal face of the external wall within 2m of entry into the building.
The locations listed below must not be used for the siting of the meter position.
• In bathrooms.
• Meters must not be installed into any lockable meter housing unless the consumer has been
provided with a suitably labelled key for the lock.
• A meter and its ancillary controls must not be installed on or under a stairway, in a common
hallway, passageway or any other part of the building which provides the sole means of
escape in the event of fire.
An above ground entry using a service house entry can be used where fitting a meter box is not
practical.
The annulus between the inserted house entry tee and the wall must be sealed, externally and
internally.
The position of the entry fitting and riser must be selected to avoid ventilation bricks, flue outlets and
other external building features.
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Any above ground service pipe entry must be retained by the use of pipe clips at a maximum of 1
metre intervals.
Where a service is to terminate in the basement/cellar then a service isolation valve (SIV) must be
fitted external to the property.
Meter boxes must not be located directly above drains, air bricks, manholes, under appliance flues or
where access / egress may be restricted in the event of an emergency e.g. narrow foot walks.
Surface mounted or semi concealed meter boxes must never be installed on public footpaths or
highways where damage from pedestrians or vehicles can occur.
The meter box must be fitted onto an external wall and must not bridge the damp proof course
(DPC).
In timber-framed properties, the sleeve must end flush with the inner plaster finish, and all pipes must
be sealed with mastic or plaster to prevent air movement into the inner leaf framework.
All sides of the box must be fully bedded into mortar to hold it into the wall with the outer frame flush
with the outer brickwork.
The spigot supplied will pass completely through wall up to 278 mm thickness and can easily be
trimmed to length during installation of the internal pipe work.
Under no circumstances must any other holes be made in the box for gas pipe work or electrical cross
bonding cables.
For secure installation, the box or boxes must be built into the outer leaf as the building progresses.
Nails or spikes must not under any circumstances be used to locate the box.
Medium pressure (MP) services to premises must be installed in surface mounted or semi concealed
type meter boxes.
The installation of gas services to this type of structure offer varying constraints when the special
features of their construction are considered. Further guidance on the design and construction can be
found in IGE/UP/7.
For mobile dwellings, the meter position must be installed externally to the dwelling, in either a
standard meter box or purpose built meter housing with adequate ventilation. Where purpose built
housing must be provided, the total amount of ventilation should be equal to 3% of the floor area of
the housing.
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The same, calibrated, test equipment must be used for the initial, intermediate (if any) and the final
pressure readings. The test instrument used on pressure tests between 2 and 10.5 bar must have an
accuracy of 3 mbar (for an instrument with a range 0-10.5 bar must the accuracy required will be
0.0285%) or greater resolution of 0.1 mbar.
Precautions should be taken to ensure mobile telephones; radios etc are not used near the
instrument, as pressure indications may become erratic.
Creep and barometric pressure need not be considered on LP and MP service tests, as these factors
are negligible over a short duration test and small volumes of pipe work. Temperature however, could
have a small factor in the accuracy of the test, all testing equipment and pipe should be protected
from direct sunlight.
Where the pipe work system under test contains flanged or threaded joints, pressure testing must be
undertaken prior to wrapping the joints.
Water
manometer or
Service 75 100 0 5
electronic
device
After completion of a successful pressure test the service will be directly purged by complete
displacement of air by natural gas.
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• There must be no smoking or naked lights or other sources of ignition present, and NO
SMOKING signs should be displayed.
• Precautions against static electricity in plastics pipes and hoses must be observed.
• All operational personnel should wear full personal protective equipment including ear
protection devices.
• Care must be exercised when venting/purging large volumes of gas in built-up areas.
• Once a purge has commenced it should continue without interruption until complete.
• For all purging operations, a system of communication should be organised and tested for
personnel involved in the control of the purge. This system must be intrinsically safe or
positioned outside the 5m exclusion zone.
• Two successive tests confirm 90% gas in air (GIA) at the outlet of the purge hose using a
Gascoseeker or:
• When the service has been purged with natural gas for one second for each metre length of
service pipe not greater than 32 mm diameter, and four seconds for each metre length for a
63 mm diameter service.
• A pre-fabricated flexible purge hose, 32mm fitted with a flame trap is used for all service
purging operations.
When diverting or altering a gas service pipe the following should be considered:
• When a service is to be cut off for any alteration work, it must be cut at least 2m from the
building line ensuring that adjacent vents and any other openings have been temporary
isolated or closed. Any other potential sources of ignition should be identified and isolated
where possible i.e. extinguish pilot lights on balanced flue appliances, extractor fans, etc...
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• If a service alteration is downstream of an above ground entry tee, with an integral stopper,
the integral stopper should be used as a means of isolation. This can be determined by a ‘let
by’ test using a pressure gauge connected to the outlet of the Emergency Control Valve
(ECV) to confirm that the entry tee is not passing gas.
• The correct squeeze off distances must be maintained between fittings or joints.
• Wherever possible services should be laid perpendicular between the service entry point of
the building and connection to existing pipe work.
• Compression fittings must not be used for reconnection of services within 2m of a property.
• Prior to leaving the site, adjacent buildings must be checked to ensure that supplies have not
been affected by the work undertaken.
• If the new section of service pipe to be laid increases the length of the existing service pipe
then the total service length pressure drop should be calculated to ensure that the correct
pressure is maintained at the ECV. Table D3 Pressure Loss over given length and diameter.
All disconnections must be made under controlled gas conditions wherever possible and be carried
out in accordance with any necessary approved written procedures supplemented by associated
permits to work, risk assessments and method statements. Breathing apparatus and fire extinguishers
must be placed adjacent to the working area of the activity being undertaken and available for
immediate use.
Where service pipes are to be disconnected under uncontrolled conditions, breathing apparatus must
be worn and fire extinguishers placed adjacent to the working area for immediate use. The use of
additional protective equipment must be used including fire suits, lifting equipment, guard lines etc…
Medium pressure service connections that do not contain a means of controlled isolation should be
reduced in operating pressure to a safe level before the service cut off is undertaken.
Before and after cutting off the service, check adjacent properties for a dual service i.e. a visual
inspection on the service entry positions, pipe location equipment, asking the consumer/s.
Service pipes should be disconnected at the mains connection, to avoid future leakage and potential
interference damage.
Only approved mains sealing plugs must be used (taper plugs and reducers are not permitted).
There must be a physical break on the line of the service pipe from the main to the premises to break
any potential gas path. All exposed pipe ends must be capped with an appropriate fitting.
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The service must be cut off at a minimum distance of 2m from the property to avoid any gas ingress
into the property.
The purpose of a temporary continuity bond is to protect the operative and ensure that an ignition
source will not be created by an electrical discharge across a temporary gap in pipework.
A TCB must be fitted before any part of a metallic main, service meter or other plant is connected,
disconnected or cut and when installing an insulation joint. Continuity bonds should not be fitted such
that it bridges an insulation joint.
TCBs must be fitted so that they will not be disturbed during the progress of the work and must not be
removed until the work has been completed. Bonds must not be removed until the connection or
disconnection work has been completed, and must be fitted or removed in a gas-free area only.
TCBs should be constructed from fully insulated wire having at least 10 mm2 cross-sectional area.
Clamps should be to BS 951 or approved equal. Ensure that the TCB is the correct type for the task
to be undertaken.
Before de-commissioning a service pipe, any meters connected to that service should be
disconnected, removed and open installation pipework capped using an appropriate fitting prior to
starting the decommissioning. The meter should be placed in a well ventilated area until it can be re-
fitted. If the meter is not to be re-fitted it should be capped and returned to the depot.
Prior to starting work the meter installation must be checked with a voltstick and a temporary
continuity bond fitted.
After disconnecting the service from the gas main, the service riser should be removed and both ends
of the service sealed and capped. Any existing entry points in the floor or wall must be sealed as
appropriate.
Where the existing standpipe cannot be removed without damaging the fabric of the building, the
standpipe should be left capped and the service information label must be attached to the redundant
service pipe with the ‘Disconnected Service’ details completed.
The following section describes typical distribution system configurations and provides information to
aid the selection of the most appropriate configuration for a given location.
A selection Table is included at the end to factors for and against any option.
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An off-take will be taken from the Transmission system which will be regulated to a maximum of 16
Bar and a Minimum of 7 Bar. One or more primary feeder pipelines will be run to operate at a
maximum Pressure between 7 Bar & 16 Bar.
Pressure reduction stations will be installed at selected points off this primary supply pipeline to
reduce the pressure to a maximum of 4 Bar. From this Pressure Reduction Station supply mains will
be run to operate at a maximum pressure of 4 Bar.
Individual Large Loads (Industrial or Commercial Users) will be supplied directly at 4 Bar with a
suitable pressure regulator installed locally.
Individual residences in suitable locations will also be supplied directly at 4 Bar with Meter / Regulator
sets close to but outside the residence.
Further Pressure Reduction Stations may be installed if need to supply at 75 mbar directly to
premises with a Governed Meter outside the residence or in a suitable internal location where
proximity distances dictate.
This option will be best suited to more heavily Industrialised areas with small areas of residences.
An off-take will be taken from the Transmission system which will be regulated to a maximum of 16
Bar and a minimum of 7 Bar. One or more primary supply pipelines will be run to operate at a
maximum Pressure of between 7 Bar & 16 Bar.
Pressure reduction stations will be installed at selected points off this primary supply pipeline to
reduce the pressure to a maximum of 2 Bar. From this Pressure Reduction Station, supply mains will
be run to operate at a maximum pressure of 2 Bar.
Individual Large Loads (Industrial or Commercial Users) will be supplied directly at 2 Bar with a
suitable pressure regulator installed locally.
Individual residences in suitable locations will also be supplied directly at 2 Bar with Meter / Regulator
sets close to but outside the residence.
Further Pressure Reduction Stations may be installed if need to supply at 75 mbar directly to
premises with a governed meter outside the residence or in a suitable internal location.
This option will be best suited to areas of Commercial / Light Industrial activity with more densely
populated areas of residences.
An off-take will be taken from the Transmission system which will be regulated to a maximum of 16
Bar and a Minimum of 7 Bar. One or more primary feeder Pipelines will be run to operate at a
maximum Pressure between 7 Bar & 16 Bar.
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Pressure reduction stations will be installed at selected points off this primary supply main to reduce
the pressure to a maximum of 4 Bar. From this Pressure Reduction Station supply mains will be run
to operate at a maximum pressure of 4 Bar. These will be interconnected to form a ring system.
Individual Large Loads (Commercial Users) will be supplied directly at 4 Bar with a suitable pressure
regulator installed locally.
Individual residences in suitable locations will also be supplied directly at 4 Bar with Meter / Regulator
sets close to but outside the residence.
Further Pressure Reduction Stations may be installed if need to supply at 75 mbar directly to
premises with a governed meter outside the residence or in a suitable internal location.
This option will be best suited to areas with many residences and flats and some commercial
developments.
An off-take will be taken from the Transmission system which will be regulated to a maximum of 16
Bar and a minimum of 7 Bar. One or more primary feeder pipelines will be run to operate at a
maximum Pressure between 7 Bar & 16 Bar.
Pressure reduction stations will be installed at selected points off this primary supply pipeline to
reduce the pressure to a maximum of 2 Bar. From this Pressure Reduction Station Area supply
mains will be run to operate at a maximum pressure of 2 Bar. These will be interconnected to form a
ring system.
Individual Larger Loads (Commercial Users) will be supplied directly at 2 Bar with a suitable pressure
regulator installed locally.
Individual residences in suitable locations will also be supplied directly at 2 Bar with Meter / Regulator
sets close to but outside the residence.
Further Pressure Reduction Stations may be installed if need to supply at 75 mbar directly to
premises with a Governed Meter outside the residence or in a suitable internal location.
This option will be best suited to areas with densely populated residences and flats and some
Commercial development.
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Higher Pressures
There may be possible
Heavily Industrialised Area with enable smaller
Example 1 problems with proximity
small areas of Residences diameter pipes to be
of buildings
used
Higher Pressures
There may be possible
Many residences and flats with enable smaller
Example 3 problems with proximity
areas of Commercial Activity diameter pipes to be
of buildings
used
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Configuration 1
Design Configuration 1
City Gate
Pressure
Regulator
Single
Residences
fed direct 4 bar supply to Medium /Large
from 4Bar single Load
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Configuration 2
Design Configuration 2
City Gate
Pressure
Regulator
Single
Residences
fed direct 2bar supply to Medium /Large
from 2 Bar single Load
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Configuration 3
Design Configuration 3
City Gate
Pressure
Regulator
4 bar
commercial
Local 75 MBar supply
Network
4 bar
commercial
supply
4 bar to
75 mbar
Regulator
Local 75 mbar
Network
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Configuration 4
Design Configuration 4
City Gate
Pressure
Regulator
2 bar
commercial
Local LP Network supply
2 Bar
commercial
supply
2 bar to
75 mbar
Regulator
Local 75 mbar
Network
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Example 1
Single service run at 2 or 4 bar with meter governor unit external to property
2 / 4 bar
service
Property
2 / 4 bar
main
Meter & Regulator set
in external housing
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Example 2
75 MBar
service
Property
75 MBar
main
Meter in external
housing
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Example 3
Dual Low pressure service split in public with meter external or internal to property
75 MBar
75 Mbar Service
Main
Property
1
Meter in external or
internal housing
Property
75 Mbar
2
Service
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Example 1
Single service run at 2 or 4 bar, feeding bank of meter governor sets external to property. With
meter outlets run to individual properties
Floor 4
Floor 1
2 / 4 bar
service
Property
2 / 4 bar
main Bank of Meter /
Governors
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Example 2
Single service run at 75 MBar feeding meter external to property with outlet run to individual
property.
Floor 4
Floor 1
75 MBar
service
Property
75 MBar
main
Bank of Meters
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DETAILED DESIGN SPECIFICATION
Example 3
Single service run at 75 mbar pressure feeding riser to several meter positions internal to
property
Floor 4
Floor 3
Floor 2
Floor 1
LP service
Property
LP main
Riser with Laterals
supplying meters
internal to property
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SECTION 5
CONSTRUCTION MANAGEMENT
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5 CONSTRUCTION MANAGEMENT
The work elements associated with the construction process are listed as follows:
• Quality management system, including audit plans, and environmental management plan.
• Vendor certification.
Operatives undertaking work on gas systems shall be appropriately qualified to undertake the
activities on which they are employed. Examples of competency modules in the UK are listed as
follows:
GNO102 Working under supervision excavate holes and trenches in ground and pavement
structures
GNO104 Working under supervision, contribute to an efficient and effective work environment
GNO105 Working under supervision, contribute to Health, Safety and Environment in the
workplace
GNO106 Working under supervision, operate powered tools and equipment for routine and
predictable requirements during gas network operations
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GNO107 Working under supervision, join materials by manually controlled thermal processes
GNO109 Assist in preparing resources and segregating the area for highways works
GNO110 Assist in preparing resources and segregating the area for site works
GNO201S Locate and avoid supply apparatus and sub-structures during gas network operations
(service laying)
GNO202S Excavate holes and trenches in ground and pavement structures to access the gas
network (service laying)
GNO203S Re-instate excavation and pavement surfaces after gas network operations (service
laying)
GNO204S Contribute to an efficient and effective work environment during gas network
operations (service laying)
GNO205S Contribute to Health, Safety and Environment in the workplace during gas network
(service laying)
GNO206S Operate powered tools and equipment during gas network operations (service laying)
GNO209S Prepare resources and segregate the area for highways works during gas network
operations (service laying)
GNO210S Prepare resources and segregate the area for site works during gas network
operations (service laying)
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GNO215S Prepare work areas and materials for engineering activities (service laying)
GNO201M Locate and avoid supply apparatus and sub-structures during gas network operations
(Main laying)
GNO202M Excavate holes and trenches in ground and pavement structures to access the gas
network (Main laying)
GNO203M Re-instate excavation and pavement surfaces after gas network operations (Main
laying)
GNO204M Contribute to an efficient and effective work environment during gas network
operations (Main laying)
GNO205M Contribute to Health, Safety and Environment in the workplace during gas network
operations (Main laying)
GNO206M Operate powered tools and equipment during gas network operations (Main laying)
GNO209M Prepare resources and segregate the area for highways works during gas network
operations (Main laying)
GNO210M Prepare resources and segregate the area for site works during gas network
operations (Main laying)
GNO215M Prepare work areas and materials for engineering activities (Main laying)
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GNO301 Locate and avoid supply apparatus and sub-structures in diverse situations
GNO302 Excavate holes and trenches in ground and pavement structures in diverse situations
GNO305 Contribute to Health, Safety and Environment in the workplace in diverse situations
GNO306 Operate powered tools and equipment for routine and predictable requirements in
diverse situations
GNO315 Prepare work areas and materials for engineering activities in diverse situations
GNO319 Analyse and interpret the results of engineering tests in diverse situations
GNO309 Prepare resources and segregate the area for highways works in diverse situations
GNO310 Prepare resources and segregate the area for site works in diverse situations
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5.1.3 Deliverables
Reports, as laid drawings, and manuals shall be provided by the construction contractor.
The Authority Project Manager shall manage construction activities through an approved quality
management system which should ensure that construction is completed in accordance with the
design.
Prior to the commencement of construction, the Authority Project Manager shall be required to make
a submission in the form of a project specific quality management system, to address the following, as
a minimum. It is anticipated that any quality system would mirror the relevant parts of BS EN ISO
9001 or other appropriate standards and provide assurance that project requirements are met.
The Project Manager shall provide details of how monitoring, audit and appraisal shall be carried of
the following:
• Construction
• Installation
An effective and comprehensive safety management system is essential for good health and safety
performance during construction. Refer to Health and Safety Executive (HSE) guidebook ‘Successful
Health and Safety Management’ for the requirements of the safety management system. Construction
method statements are an essential part of the safety management system.
The Project Manager shall review method statements for all construction activities.
Construction Method Statements shall include, but not be limited to, the following:
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• Pipe bending.
• Welding.
• Pipe jointing.
• Narrow trenching.
• Pipe laying.
• Sleeves.
• Valve installations.
• Pipe corrosion protection coating (internal and external), including coating surveys (Close
Interval Potential Survey).
• Wrapping.
• Pigging.
The Project Manager shall create an Environmental Management Plan identifying all potential
environmental impacts (direct and indirect) and mitigation measures identified for the construction
works, reference the method statements to be utilised for each area and define the responsibilities.
The plan shall meet the requirements of ISO 14001 and shall enable the Project Manager to prepare
a schedule of environmental audits carried out to the EMP, work activities and environment record
keeping.
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• To ensure that standards of good construction practice are adopted throughout the
construction of the pipeline or installation.
• To provide a framework for mitigating impacts that may be unforeseen or unidentified until
construction is underway.
• To provide a framework for compliance auditing and inspection to enable the Authority to be
assured that its aims for environmental performance is being met.
A pre-tender EMP consists of a set of generic environmental requirements with which prospective
Contractors will have to demonstrate how they will comply as part of the Invitation To Tender (ITT).
The EMP is further developed to reflect any consents and conditions, and again once the Contractor
has been appointed. At this stage, the Contractor's Method Statements are incorporated into the
EMP, after having been approved. As more information becomes available through further
environmental surveys, it will be passed on to the prospective Contractors through the tendering
process.
Each source of emission (e.g. liquid effluent, solid waste, etc…) should be discussed in detail,
possible impacts considered (e.g. water and ground pollution) and mitigation measures proposed to
include:
• Method statements.
• Management of:
• Pollution control.
• Waste management.
• Hydrostatic testing.
• Reinstatement.
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A project risk register should identify risks associated with the construction process, particularly with
the safety, integrity and quality of the assets, with impact on the environment and with respect to
operation and maintenance. The risk register should identify and categorise the risks, assess the
impact and identify the mitigation actions and plans to be used.
The Project Manager shall arrange access to site in accordance with the Authority safe control of
operations procedures.
5.1.11 Audit
Prior to construction commencement, an audit of the project quality management system shall be
carried out to ensure that the minimum technical standards in relation to asset integrity, operation and
maintenance are maintained.
The Project Manager shall carry out audits of the following construction activities:
• Materials traceability
• Construction works
• Testing
• Commissioning
• Corrosion Protection
• Reinstatement
The Contractor shall submit to the Authority for approval the following documentation at each stage of
the construction process.
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• Excavating procedures
• Laying of PE mains
• Laying PE Services
• Moling
• Electrofusion of PE pipe
• Environmental assessments
• IGE/GL/ 5 Process
• Waste Management
• Right of Way preparation, access and working areas set out, signed and fenced proposals
• Pre entry arrangements including material storage, site offices and working strip definition
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• Fine fill backfill, warning tape, impact protection installation and inspection report
• Top soiling and marker post (CP aerial and line marker) installation report
• Fitting material certification and data sheets – bends, tees, valves, flanges, reducers, “O”Lets,
gaskets, bolts
• Field testing (CIPPS, current drain tests etc) specification and requirements
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• Welding specification
• Welding procedures
• Gauge pig run proposals, report – gauge plate thickness and diameter and certification
• Testing procedure
• Testing equipment calibration certification including pumps, gauges, hoses, test ends etc.
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• Pressure volume plot including hold points and entrained air by volume calculation
5.1.12.9 Drying
• Drying procedure
• Dryness report
• Test reports
• Commissioning reports
The Project Manager shall manage the collation of documentation including information, forms and
certificates for handover documentation.
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APPENDICES
SECTION 6
APPENDICES
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APPENDICES
6 APPENDICES
6.1 References
IGE/SR/26a Horizontal Directional Drilling and Impact Moling, Site Operator’s Safety Guide
IGE/TD/1 Edition 4
Supplement 1 Handling, transport and storage of steel pipe, bends and fittings
IGE/TD/3 Edition 4
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APPENDICES
GIS/E17 Part 2 Technical specification for insulation joints Part 2 - Joints operating at
pressures not greater than 7 bar
GIS/E13 pt 1 Technical specification for gas filters (80mm nominal size and above) suitable
for use in the pressure range above 75 mbar and not exceeding 7 bar
GIS/F7 Technical specification for steel welding pipe fittings 15mm to 450mm
inclusive nominal size for operating pressures not greater than 7 bar
GIS/F9: Part 1 Specification for Metric and Imperial Carbon and Stainless Steel Single
Ferrule Compression Fittings for Tubes. Part 1 - General Requirements
GIS/F9: Part 2 Specification for Metric and Imperial Carbon and Stainless Steel
Compression Fittings for Tubes. Part 2 - Evaluation Procedure
GIS/L2 Technical specification for steel pipe 15mm to 450mm inclusive nominal size
for service at pressures up to 7 bar (Supplementary and amending
specification to BS 3601) + Amendment no.1 (September 1994)
GIS/PL 2-1 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 1 - General & PE compounds for use in PE
pipes and fittings.
GIS/PL2 Part 2 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 2 - Pipes for use at pressures up to 5.5 bar
GIS/PL2 Part 4 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas. Part 4 - Fusion fittings with integral heating
element(s)
GIS/PL2 Part 8 Technical specification for polyethylene pipes and fittings for natural gas and
suitable manufactured gas Part 8 - Pipes for use at pressures up to 7 bar
GIS/V7 Part 2 Specification for Distribution Valves - Part 2 plastic bodied valves of sizes up
to 180mm suitable for operation at pressures not exceeding 5.5 Bar
GIS/V7 Part 1 Technical specification for distribution valves Part 1 - Metal-bodied line valves
for use at pressures up to 16 bar and construction valves for use at pressures
up to 7 bar
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APPENDICES
Specification for line pipe BS 21 Specification for pipe threads for tubes and
API 5L
fittings where pressure-tight joints are made on the threads (metric dimensions)
Specification for gas meter unions and adaptors BS 951 Electrical earthing.
Clamps for earthing and bonding. Specification BS 1387:1985 Specification for
BS 746
screwed and socketed steel tubes and tubulars and for plain end steel tubes
suitable for welding or for screwing to BS 21 pipe threads
BS 1965 Specification for butt-welding pipe fittings for pressure purposes. Carbon steel
Specification for carbon steel pipes and tubes with specified room temperature
BS 3601
properties for pressure purposes.
Specification for steel pipe fittings, screwed and socket-welding for the
BS 3799 Class 3000
petroleum industry
Circular flanges for pipes, valves and fittings (PN designated). Specification for
BS 4504:PN 16
copper alloy and composite flanges
Specification for installation of domestic-sized gas meters maximum rated
BS 6400-1:2002 capacity not exceeding 6 m3/h (2nd and 3rd family gases). Low pressure (2nd
family gases)
Specification for optical performance of high-visibility garments and accessories
BS 6629
for use on the highway
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APPENDICES
Term Definition
additional emergency An AECV is a valve, not being the ECV, for shutting off the supply of gas
control valve (AECV) in an emergency, intended for use by a consumer of gas. An AECV may
be located within either the meter installation or installation pipework and,
as such, may not isolate all of the consumer’s pipework or meter
installation.
Note: An AECV performs the same function as the ECV with respect to
emergency isolation, usually of an individual premises or dwelling and is
required by GS(I&U)R in many situations. It does not, however, denote
the end of a network and is always fitted downstream of the ECV. The
existence of an AECV does not affect the required existence of an ECV
(which is always fitted).
air knife Tool that uses a blast of high pressure air to break up the ground when
excavating
alignment clamps Clamps used to hold pipes in the correct position prior to welding or heat
fusion.
ambient temperature The environmental temperature.
anchorage Fixing of pipe ends, bends, valves and tees in order to prevent
movement.
anchor block A concrete block (with or without reinforcement), used for anchorage.
bagging off The technique of stopping off the flow through a main, by inserting and
inflating bags in the main.
barometric pressure The downward pressure, at any given point in the atmosphere, of the
gases directly above that point.
butt fusion A method of jointing PE pipes and fittings, where the two pipe ends are
heated and brought together to be fused without the use of a separate
fitting.
butt welding A method of jointing metallic pipes and fittings where pipes and fittings of
the same diameter are welded, by bridging the gap between them with
successive deposits of weld metal.
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by-pass A pipe valve and gauge system, used to provide and control the
continuity of gas supplies, normally used when alterations to pipelines are
carried out.
carrier pipe The existing pipe into which another pipe is inserted.
cathodic protection A method of inhibiting corrosion of buried metallic pipe, fittings etc., by
ensuring that they are permanently cathodic, i.e. electrically negative, to
the electrolyte in the soil surrounding them.
close circuit television Method used to internally survey pipes
close-fit insertion An insertion technique where the new pipe is in close contact with carrier
pipe. See folded pipe, swagelining, rolldown etc.
collar A fitting used to join together the plain ends of two pipes
continuity bond An electrical connection made between two sections of a metallic pipe
prior to and during their temporary severance, to prevent sparking from
stray currents or static electricity.
controlled gas operation Work undertaken on gas mains where the release of gas is controlled
and minimised.
cross bonding Means of ensuring electrical continuity between gas pipe-work and the
customer’s electricity supply earth terminal
dip pipe A pipe inserted in a pipeline for removal of condensate and other liquids
double block and bleed Two flow stopping devices (both of which may be incorporated in an
individual block valve of appropriate design) with a vent between them.
Also known as a block and bleed.
double block and bleed A valve with two seats and a space between to which is connected a
valve bleed point
duct (also see “sleeve”) An encasement installed to protect a pipe or to facilitate its passage
through or under a structure
easement (Property Law) is the right enjoyed by a landowner of making limited use
of his/her neighbour’s land as by crossing it to reach his own property
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emergency control valve An Emergency Control (Valve) means a valve for shutting off the supply
(ecv) of gas in an emergency, being a valve intended for use by a consumer of
gas
encirclement fitting Two part fittings installed around a pipe jointed together longitudinally and
jointed to the pipe circumferentially at each end.
flanged adaptor A fitting with a flange on one side and a suitable fixing for the appropriate
pipe on the other.
foaming off The use of expanding foam injected into the main, which sets to stop the
flow of gas
folded pipe Technique where the pipe is folded to reduce its size prior to insertion
and is reverted to its original shape by pressure
fusion gauge pressure Pressure shown on a gauge, with no allowance for barometric pressure.
gauging Method of checking for size and suitability of the pipe into which
insertion is to take place
high density PE pipe of higher density and laid to either higher pressure than medium
polyethylene (PE100) density polyethylene or a thinner wall thickness.
intermediate pressure Operating pressures greater than 2bar but not exceeding 7bar
iris stop Technique for stopping off the flow through a main, by inserting and
inflating bags in the main that are supported by a metallic plate
landfill gas The mixture of gas produced as a result of microbial activity, when
biodegradable material is deposited in landfill sites.
live insertion Installation of a replacement pipe into an existing pipe, whilst the host
pipe remains live and in use.
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lower explosive limit The concentration of flammable gas in air, above which ignition can
(LEL) occur.
lower flammable limit The concentration of flammable gas, vapour or mist in air, above which
(lfl) combustion can be sustained.
marker post Post installed close to buried gas plant, to which a marker plate is affixed.
maximum incidental The maximum pressure to which the system may be subjected under
pressure (mip) abnormal conditions.
maximum operating The maximum pressure at which a system can be operated continuously
pressure (mop) under normal conditions.
maximum working The maximum pressure to which a main will be normally subjected whilst
pressure in operation.
medium pressure Operating pressures greater than 75 mbar but not exceeding 2 bar.
meter inlet valve (miv) A valve fitted upstream of, and adjacent to, a gas meter to shut off the
supply of gas.
mismatch Dimensional irregularity of two pipes to be jointed.
mole ploughing Technique for installing a continuous length of pipe by pulling a pipe
through the ground and feeding the pipe into the trench via the top of the
plough
multi layer pipe SDR 21 white pipe encased in a protective yellow sleeve with brown longitudinal
HDPE stripes.
National Geospatial A computerised map based records system for distribution and
System (NGS) transmission mains operating pressure (op) The pressure which occurs
within a system under normal conditions.
peak instant demand The highest instantaneous gas demand, normally measured at a rate per
hour, which occurs over a 60 second period.
pig A cylindrical device that is inserted into a main to clean/dry the pipeline,
gauge its diameter.
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pipe bursting A technique in which the existing pipe is fractured using an internal
mechanical force (burster), that forces the fracture pieces into the
surrounding ground whilst a new pipe of a similar or larger diameter is
drawn in behind the bursting tool. Usually used on cast or spun iron.
polyethylene sleeving Polyethylene sheet, which was snugly wrapped around the outside of
ductile iron pipes, to provide corrosion protection.
pressure Bar or mbar above atmospheric pressure, i.e. gauge pressure (1 bar =
100,000 Nm m-2)
primary meter A meter connected to a main or service, the index reading of which
constitutes the basis of charge for all gas supplied through that main or
service.
pup A short make-up piece of pipe.
purge gas The gas that is used for displacement when purging.
riser The vertical part of a service leading to one or more primary meter control
valves or ECV.
rolldown A Close-fit Insertion technique, where the diameter of the new pipe is
reduced by pulling it through concentric rollers. The pipe can be inserted
by Slip Lining techniques and is reverted to its original diameter by
pressurizing with warm water.
route maps Maps to a scale suitable for showing general details, for example
agricultural land, built-up areas, contours and all special crossings.
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saddle fusion Jointing of a shaped fitting onto the outside wall of a PE pipe.
service A pipe for supplying gas to premises from a distribution main, being any
pipe between a distribution main and the outlet of an ECV.
service excess flow A device, installed in an M.P. service, designed to reduce the flow of gas
valve released from a damaged pipe
service head adaptor A fitting used to provide a gas-tight seal between a PE service, its steel
service isolation valve A valve inserted in a service, outside a building, for shutting off the supply
of gas
service regulator service Apparatus for automatic regulator of pressure or of volume flow at a
tee selected point within a service
sliplining Insertion of a new pipe by pulling or pushing it into the existing
decommissioned pipe
single stage regulator A regulator which breaks down inlet pressure to outlet pressure in a
single stage
sleeve (also see “duct”) An encasement inserted into a prepared hole in a structure for the
reception of a service
split collar A fitting in two halves, installed around a live main, for making
connections or repairing a broken or leaking main
squeeze off Squeezing a pipe to close the bore and stop the flow of gas.
standard dimension The ratio of the outside diameter of a PE pipe to the minimum specified
ratio (sdr) wall thickness
strength test A specific procedure to verify that pipework meets requirements for
mechanical strength
strip maps Maps, to a large scale, showing the route of the pipeline and which may
contain marginal notes etc., giving information on land usage, ownership
etc. and profiles
syphon A vessel installed at a low point in the pipeline network, to collect
condensate and other liquids
swagelining A Close-fit Insertion technique, where the diameter of the new pipe is
reduced by pulling it through a circular die. The pipe can then be inserted
by slip lining techniques, and subsequently reverts to its original diameter
when pressurized.
tightness test A specific procedure to verify that pipework meets requirements for gas
tightness
trenchless technology Techniques for installing pipe with minimal excavation
two-stage regulator A regulator which breaks down inlet pressure to outlet pressure in two
stages in order to give a compact design with good control of outlet
pressure
underpressure tee Split fitting used to take a branch connection from a pressurised pipe
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vent pipe (main) Small diameter pipe, utilised for ventilating gases from a main that is
connected vertically the a main and terminated 2.5m above ground level
and constructed from steel
vent pipe (service) Small diameter pipe connected vertically to a pipeline and terminated with
a flame trap 2.5m above the ground level.
weldolet A forged fitting, of the saddle type, enabling the fabrication of a fully
welded branch connection.
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APPENDICES
Abbreviations
AE Authorising Engineer
BS British Standard
CV Calorific value.
DP Design pressure.
HP High Pressure
IP Intermediate Pressure
LP Low Pressure
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APPENDICES
MP Medium Pressure
NA Network Analysis
OP Operating pressure.
PE Polyethylene
QC Quality control.
RO Routine Operation
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