NATURAL GAS SYSTEM

TRAINING MANUAL
 CONTENTS

1 INTRODUCTION

2 SYSTEM DESCRIPTION

3 EQUIPMENT & MATERIAL DESCRIPTION

4 OPERATION

5 MAINTENANCE SCHEDULE

6 EMERGENCY MEASURES

7 DO’S & DONT’S

8 REFERENCE SCHEMATIC DRAWINGS

1. INTRODUCTION
 INTRODUCTION

Project :

Location :

Client :

Local Consultant :

Main Contractor :

Natural Gas Cont. :

2. SYSTEM DESCRIPTION
 SYSTEM DESCRIPTION

Natural Gas is the main source of cooking fuel for the residential apartments and villas. The Natural
Gas shall be carried out to all residential & villas through gas networks which clearly defined on the
approved shop drawings. The gas supplied to each residential apartment and villas will be metered to
read the gas consumption of each individual kitchen. The gas meter will be interfaced to the BMS
using the interfacing unit. The towers will be having a Main Gas Metering Station located the nearest
periphery of the building to monitor the total gas consumption of the five towers.

The Natural Gas System will be having a centralized gas monitoring system which will monitor of
any gas leakage in the main gas risers. The Gas Control Panels of each tower will be connected to the
Fire Alarm Panel and to the BMS respectively. If in any case that leakage is found in the main gas
risers, the same will be detected thru the Gas Control Panel and the supply of gas will be shut-off for
the whole building. All domestic kitchens will be also be having a local loop gas detectors which is
controlled by a solenoid valve and an emergency switch which will shut off gas supplies in that
specific area only.
3. EQUIPMENT & MATERIAL
DESCRIPTION
 EQUIPMENT & MATERIAL DESCRIPTION &
OPERATION

3.1. CARBON STEEL PIPES & FITTINGS

Seamless Sch. 40 Carbon Steel Pipes & Fittings has been installed for the main risers,
droppers and gas branches. The method of jointing the pipes was by Electric Arc Welding.
These pipes were coated with 2 coats of Zinc Oxide primer and 2 coats of yellow paint 345 as
per GASCO Specifications.

3.2 COPPER PIPES & FITTINGS

Copper Pipes & Fittings has been installed for Internal Kitchen Area. The method of jointing
the pipes was by Brazing with the use of Acetylene / Oxygen Cylinder. These pipes were
coated with 2 coats of yellow paint as per GASCO Specifications.

3.3 GAS DETECTION PANEL

The Gas Control Panel was installed in the Fire Control Room at Level 3. The Gas Control
Panel monitors and ensures of the smooth supply of gas. In case of any leakage in a specific
area of the building, the gas will shut- off gas supplies automatically when it receives signal
from the gas detectors installed at lower level for each individual shafts. The Gas Detection
Panel also controls the function of the solenoid valve & gas detectors.

3.4 KITCHEN GAS DETECTORS

Kitchen Gas Detectors has been installed in each kitchen of the flat. The Kitchen Gas Detector
is used to monitor any gas leakage inside the kitchen. In case of gas leakage, the gas detector
will send signal to the solenoid valve located inside the Gas Meter Cabinet and shut-off the
gas supply. The Gas Detector also alarms continuously to give attention to personnel that
there is a gas leakage in that particular kitchen. The same can be reset once the leak has been
rectified.

3.5 ISOLATING VALVES

Isolating Valves are used to isolate the gas supply. This is normally installed inside the
kitchen cabinets of each flat at the inlet and outlet point.

3.6 SOLENOID VALVES

A 220 V AC solenoid valve has been installed inside the kitchen cabinet of each flat located at
the upstream of the regulator. The solenoid valve is controlled by a switch which is normally
 called an Emergency Gas Switch. The Switch is often installed near the kitchen door. If in any
case that gas leakage is detected by the Kitchen Gas Detector, a signal will be sent to the
Solenoid valve and the same will shut-offs gas supply to the kitchen.

3.7 THIRD STAGE REGULATOR

The third stage regulators are used to reduce the inlet pressure from 75 mbar to outlet pressure
of 21 mbar. The third stage regulator is located on the Upstream of the Gas Meter.

3.8 GAS METER

The gas meter is used to measure and monitor the gas consumption of each kitchen. The gas
meter provides a remote reading facility in order to monitor the consumption of gas at the fire
command center or to the BMS.

3.9 AUTO SHUTT- OFF VALVE / EXCESS FLOW VALVE

The auto shut- off or excess flow valve is used to control or maintain the constant supply of
gas. In case of any excess flow or less flow of gas, the gas supply will be shut-off
automatically.

3.10 BALL VALVE

Ball valves are used to cut- off supply of gas during maintenance periods. Ball valves are
usually installed in the PRV Stations and Gas Droppers.
4. OPERATION
4.1 GENERAL

The Natural Gas System shall be operated through the Main Gas Detection Leak Detection
System and Solenoid Valve assemblies located in different areas of the building. While
operating the System, it should be confirmed that all Solenoid Valves, Gas Leak Sensors are
in good working condition and operational. Electrical connections of all electronic equipments
shall also be considered and maintained to avoid electrical faults.

The pressures of each gas pipes and equipments shall be noted and checked. It shall be also
confirmed that there will be no hazardous materials which will cause damage to the system.

The whole system shall also be tested all in accordance to the specifications and relevant
standards. The system shall also be checked and certified by authorized approving bodies
prior to operation.

In handling such system, all operatives must have full knowledge and trained accordingly.

4.2 OPEARTING DETAILS

Before operating the system, attention is required to the following areas for the successful and
safety of the users.

4.2.1 MAIN GAS DETECTION PANEL

Users of the system shall be aware that the Gas System has a Gas Control Panel which
detects and monitors all possible leakage in the gas risers and other areas which has
gas leak sensors. Gas panels shall be tested & commissioned and shall be in good
operating condition prior to permanent use.

A. OPERATING CHECKLISTS:

A.1. Check the main circuit of the Main Gas Detection Panel.
A.2. Check the power supply to the panel.
A.3. DC Batteries shall be in charging mode.
A.4. Check the Zone display on the screen.
A.5. Check all the gas detectors and connections on the panel.
A.6. Solenoid Valves shall be in proper working condition and in operation.
A.7. Check for any alarm on the panel.
4.2.2 GAS DISTRIBUTION BOX
The gas distribution box and its components inside shall be inspected thoroughly for
the proper functioning of regulators, solenoid valves, auto shut-off valves etc. Any
malfunction of each of the items shall be replaced or rectified immediately.

B. OPERATING PARAMETERS:
B.1. Open the main isolating valve of the distribution box.
B.2. Check the emergency switch for opening the solenoid valve.
B.3. Check the pressure of the supplied gas through the pressure gauge. Make sure
that the minimum pressure will be 0.50 bars.
B.4. Regulate the pressure to 37 millibar by the use of the Third Stage Regulator.
B.5. Check if gas flow is present in the gas meter.
B.6. Open the isolating valve to allow gas to flow inside the gas cooker.

4.2.3 BRANCH VALVES

Branch Valves are located at different areas to isolate gas flow to a specific area only.
Make sure that pressure is maintained in those specific locations to be 0.5 bars only.
Open branch valves which only require gas to prevent unnecessary usage or spillage of
gas in case there are open gas outlets from the cooker.
5. MAINTENANCE
5.1. MAINTENANCE SCHEDULE

During maintenance observe the main gas detection panel and check the status of all zones. Observe
all the panels to check the status of the kitchen appliances. Solenoid valves are to be disconnected and
tested. All the isolation valves, kitchen gas detectors & gas switches should be checked and
confirmed that all are operational. In this case, a basic maintenance schedule shall be followed to
ensure that the system is in proper operation all the time. (See figure 5.1.A.)

Figure 5.1.A

S. N. DESCRIPTION DUARTION

1 Gas Pipes Protective Coatings Whenever Required

2 Visual inspection for Pipelines Monthly

3 Calibration of Gas Detectors Every Six Months

4 Solenoid Valves Every 3 months of

Continuous operation

5 Gas Meter Calibration Every Six Months

6 Pressure Gauge Calibration Every Year

7 Pressure Testing of Gas Lines Every Year

5.2. MAINTENANCE PROCEDURES/ GUIDELINES

No persons deemed to be less than competent and suitably experience should carry out any
maintenance activities on the items/equipments covered by this manual. All works are to be
carried out in accordance with the current Local Authority or authorities’ regulations. The
method of installation and support should be carefully noted when dismantling units/
equipment that are to be replaced so that replacing/reinstalling may be expedited efficiently
and effectively, thereby maintaining the integrity of the initial installation. The following
guidelines should be taken into considerations during maintenance.
 5.2.1. ADJUSTMENTS, TESTING & CALIBRATION
Adjust the regulator inside the distribution box to get the required pressure of 30 to 37
mbar and set the same. Calibration is to be done for the main gas detection panel.
Pressure gauges are to be calibrated.

5.2.2. REPLACEMENT/ REPAIRS OF GAS COMPONENTS

It is very much recommended and advisable to replace any damage components such
as ball valves, gaskets, gas detectors & solenoid valve during maintenance. This may
also prevent from any undesirable circumstances like fire.

5.2.3. GAS PIPELINES INSPECTION & TESTING

It is also advisable to conduct pressure testing on pipelines once in every year to check
any minimal gas leakage in the system. The development of cracks and formation of
rust on the surface of MS pipes which can be caused by damage in painting, hitting of
pipes with materials and equipments and other climatic conditions should be avoided
in order to eliminate any chance of gas leak formation and its further development.

5.2.4. PREVENTIVE MAINTENANCE

Frequent observation and maintenance is required on gas manifolds, distribution
boxes, PRDP, gas detection panel and sampling panel in order to confirm the safe and
systematic working of the above items and to avoid gas leakage and fire hazards in
future. During maintenance gas installation should be operated and maintained by only
trained and authorized staff. Avoid inflammable objects near the enclosure. Honour
the warning signs Avoid the formation of electric spark at any circumstances. Make
sure proper functioning of ventilation inside the kitchens

5.3. TOOLS & EQUIPMENTS DURING MAINTENCE

5.3.1. Standard Tool Box Kit (Mechanical & Electrical Tools)

5.3.2. Portable Gas Detector
5.3.3. Pliers
5.3.4. Spanners
5.3.5. Welding & Brazing Kit
5.3.6. Grinding Machines
5.3.7. Drilling Machine
5.3.8. Cutting Tools