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DESCRIPTION OF PARTS USED AND GENERAL LAYOUT (as the gas flows) OF PIPELINE
SYSTEM FROM GAS SOURCE TO INDIVIDUAL KITCHENS

1.1 Cylinder Bank (manifold, click-on adaptor, cylinder pigtail, and non-return valve):

A cylinder bank consists of two sets of manifold. On each manifold, the required number of
cylinders which can meet the total gas demand are connected. As stated earlier a bank consists of 2
batteries or sets of cylinders (or 2 manifolds), one in active mode and the other reserve. A manifold
is basically a seamless pipe of 1” diameter. Its length is determined by the number of cylinders
which are connected to it (about 10”/per cylinder). Threaded nipples are welded on the manifold.
Each point of connection of the cylinder to the manifold has got a click-on adaptor, a cylinder pigtail
and a non-return valve. An adaptor is like a pressure regulator which is fitted directly onto the
cylinder. However, unlike the regulator, the adapter does not reduce the pressure. When adaptor is
turned on, gas starts flowing out of the cylinder at unreduced pressure thus coming out of the
cylinder at full cylinder pressure. A cylinder pigtail is a flexible wire-braided rubber tube which has
a brass nut / capon both ends. Its one end is screwed on the adaptor and the other end on the non-
return valve. When a pigtail is damaged it can be easily replaced by unscrewing the old one &
screwing in the new one. A non-return valve, whose one end is screwed on the cylinder pigtail and
whose second end is screwed on the threaded manifold nipple, shuts off the gas supply coming out
of an individual cylinder to the manifold in case the cylinder pigtail of that cylinder bursts. The non-
return valve also shuts off supply if there is a fault in the adaptor or the connection is loose. Thus,
there is no interruption in the gas supply system & all other cylinders continue to supply the gas
except the cylinder which has a defective adaptor or pigtail. In the meantime, the defective
pigtail/adaptor is replaced. When we open the adaptor on each cylinder, gas starts flowing from each
cylinder to the common manifold & thus manifold gets a huge supply of gas which is sufficient to
meet the demand of entire Colony.

1.2 Pressure gauge, manifold isolation valve:

A pressure gauge is installed in each manifold which measures the pressure in the manifold before
the first stage regulator. This pressure is same as the full cylinder pressure. After the pressure gauge
isolation valve is installed on each manifold. If you shut off this valve, the entire supply of gas from
that manifold is stopped.

1.3 Fire Extinguishers:

Fire extinguishers and sand buckets are kept near the cylinder bank system to meet any fire hazards
near the manifold as per the statutory requirements.

1.4 Pipeline and its branches:

This is a long steel pipeline which runs throughout the colony right from the cylinder bank to each
individual flat of the colony. It has many branches whose diameters and lengths depend on the
number & location of flats. Although it is preferable to lay open pipeline, one has often to lay
concealed or underground pipeline due to architectural or structural design considerations. When a
pipeline is laid deep in the earth (3 feet deep) across a road, it is covered with a concrete Hume pipe
of larger diameter so that no big load of traveling vehicles comes on it directly. The pipes used in the
system are ERW welded pipes conforming to heavy-duty class of IS: 1239. In the case of
multistoreyed apartments, it is a common practice to lay a vertical branch pipeline to feed the flats
whose kitchens lie vertically one above the other. Such a pipeline is called Riser Pipeline. An
isolation valve is installed near the ground level of each riser pipeline. If you shut off this valve, the
gas supply to that set of vertical flats is stopped. Similar arrangement is done on a branch pipeline
which feeds a few flats together & these flats may not lie vertically one above the other. This is done
to take care of any emergency arising out of any leakage in that section of pipeline which is feeding
a cluster of flats. From the riser pipeline or the horizontal branch pipeline, a tapping is taken which
goes to each individual kitchen.

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2. TECHNICAL SPECIFICATION OF CRITICAL COMPONENTS

2.0 At present there are no technical specifications issued by Bureau of Indian Standards on components
like click-on adaptors, flexible wire-braided cylinder pigtails, non-return valve, cylinder manifold,
isolation valves, pressure regulators, gas meters, quarter turn valves - used in commercial and
industrial LPG installations. However, we are indicating below technical requirements of the
components used in consultation with Oil Industry and foreign specifications. The pipeline
contractor should furnish manufacturer’s test certificate of the components supplied.

2.1 Click on Adaptor:

2.1.1 Function of adaptor - An adaptor is like a pressure regulator which is fitted directly onto
the cylinder. However, unlike the regulator, the adapter does not reduce the pressure. Its
one end is connected to the cylinder & second end to the cylinder pigtail. When adaptor is
turned on, gas starts flowing out of the cylinder at unreduced pressure thus coming out of
the cylinder at full cylinder pressure. Thus normal gas pressure in an adaptor is from 3.5
kgf/cm2 to 5 kgf/cm2 (50 to 70 psig).

2.1.2 Specification of adaptor - Body of adaptor is pressure die-cast from zinc alloy. Brass parts
used shall be made from free cutting brass bar. The rubber components such as O-rings
(minimum 2 O-rings) shall be made from nitrile rubber and should satisfy the technical
requirements of rubber specified in IS: 9798. The inlet of the adaptor shall have parallel
left-hand male threads conforming to Systems International threads with a thread angle of
60 degrees & a pitch of 1.814 mm. (see Fig 5 of IS: 8737). The outlet of the adaptor shall
have left hand male taper threads conforming to MECV (Male European Cylinder Valve)
so that it matches with the internal threads of the cylinder pigtail.
The adaptor shall be marked with the manufacturer’s brand name & the words “unreduced
pressure”.

2.1.3 Testing of adaptor - The body of adaptor shall be tested for a hydraulic pressure of 25.4
kgf/cm2 (360 psig). After machining, the adaptor shall be tested at a pneumatic pressure of
0.5 kgf/cm2 as well as at 17 kgf/ cm2 to check leakage at both low & high pressure. The
minimum gas flow rate should be 7 kg/hr at 7 kgf/cm2. The adaptor should work
satisfactorily in the temperature range of -20 deg + 65 deg centigrade when tested in
accordance with Annexure F of IS:9798.

2.1.4 Brand of adaptor used - Sakha

2.2 Flexible Wire-Braided Cylinder Pigtail:

2.2.1 Function - A cylinder pigtail is a flexible wire-braided rubber tube which has a brass nut
on both ends. Its one end is screwed on the adaptor and the other end on the non-return
valve. The gas passes through the cylinder at full cylinder pressure. The normal pressure is
between 50 to 70 psig. When a pigtail is damaged it can be easily replaced by unscrewing
the old one & screwing in the new one.

2.2.2 Specification - The rubber used in the tube shall synthetic & acrilo nitrile butadiele rubber
and resistant to LPG. The brass nuts used shall be preferably forged from wrought or
extruded sections. Alternatively it could be made from free cutting brass. The nuts shall
have left hand female threads conforming to FECV (Female European Cylinder Valve) and
shall match the outlet threads of click on adaptor. The nut shall be machined as per Fig 6 of
IS: 8737:1995

2.2.3 Testing - The raw tube shall be tested hydraulically at a pressure of 42 kgf/ cm 2 (600 psig).
The finished pigtail shall be pneumatically tested at a pressure of 17 kgf/cm 2 (240 psig).

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The burst pressure shall not be less than 33.8 kgf/ cm 2 (480 psig). The tubing shall be so
flexible that it will make contact with a cylindrical former of radius at least 40 mm for at
least 1100 of its circumference when tubing is placed over a former and a mass of 2 kg is
attached at both ends. The tube shall be subjected to a crushing force of 102 kgf/cm 2 (1450
psig) on the middle of the tube over a length of 25 mm for 5 minutes. After the removal of
force and lapse of 30 minutes, the tube shall not show any deformation or collapse, nor
shall leak when subjected to an internal pressure of 17 kgf/cm2 (240 psig).

2.2.4 Type tests - In addition the following type tests shall be conducted:
The rubber material shall not show a weight change of greater than 5% and a volume
change of greater than 10% after immersion in pentane for 72 hours. The hardness on the
flat surface of the slit/cut tubing shall be 60 IRHD with a tolerance of 5. The accelerated
ageing test on rubber shall be conducted in accordance with clause 4.3 of IS: 3400 (Part 4).
The rubber material shall not show a deterioration of its hardness by more than 10 IRHD.
The change in elongation shall be within + 25% and – 25%. The change in tensile strength
shall be within + 10% and – 30%. The material shall withstand a clamping pressure of 5
kgf/cm2 whereby it shall not press away, flow away or be bruised or damaged.

2.2.5 Brand used - Sakha

2.3 Non-return valve, NRV:

2.3.1 Function - A non-return valve, whose one end is screwed on the cylinder pigtail and whose
second end is screwed on the threaded manifold nipple, shuts off the gas supply coming out
of an individual cylinder to the manifold in case the cylinder pigtail of that cylinder bursts.
The non-return valve also shuts off supply if there is a fault in the adaptor or the connection
is loose. It does not allow the LPG to flow back from the manifold to the burst pigtail.
Thus, there is no interruption in the gas supply system & all other cylinders continue to
supply the gas except the cylinder which has a defective adaptor or pigtail. In the meantime,
the defective pigtail/adaptor is replaced. The normal pressure in NRV is between 50 to 70
psig.

2.3.2 Specification - The non-return valve size is designated as FECV x MECV. The FECV end
is fitted on the steel nipple of cylinder manifold & the MECV end is fitted on the cylinder
pigtail.

2.3.3 Testing - The non-return valve is tested at a pneumatic pressure of 17 kgf/cm 2 for its
functional operation.

2.3.4 Brand used - Sakha

2.4 Cylinder Manifold:

2.4.1 Function of manifold - The manifold is a running storage place where the gas withdrawn
from a number of cylinders is fed into and it continuously gets a huge supply of running gas
which is continuously withdrawn by a whole set of consumers via an elaborate piping
system. It has two arms one in the “Active” mode and the other “Reserve”. The manifolds
are designated by the number of cylinders connected at a time. For example, a manifold
size of 2x26 indicates that it consists of two sets of cylinders, both sets being suitable for
connecting 50 cylinders at a time. The normal pressure in the manifold is between 50 to 70
psig.

2.4.2 Specification - A manifold consists of a seamless pipe of nominal bore of 1’’ conforming to
ASTM A-106. It is fabricated from a single length of a tube & has no joints in the running
length. MS nipples equaling the number of cylinders used are welded on the seamless tube
at regular intervals. The interval is 14” for cylinders upto 19 kg for standard manifold and

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8” for staggered manifold. The respective values are 17” and 9” for 50 kg cylinders. The
nipple end fits into the non return valve end of FECV & hence its size is MECV. The
manifold is painted red. One end of the manifold is blanked by welding forged or extruded
mild steel blanking plate. The distance between the blanked end of the arm and the centre
line of the nearest drilled hole(for fitting the steel nipple) shall be 3”( 76 mm) & the
corresponding distance at the non-blanked end shall be 6”( 150 mm)including the manifold
isolation valve.
The manifold should be factory-made & duly tested there. Fabrication of manifolds at site
is strictly prohibited.

2.4.3 Testing - The manifold will be pressure tested hydraulically at a pressure of 25.4 kgf/cm 2
(360 psig) for 30 minutes. All nipples and holes shall be suitably plugged before
commencement of the test. Any reduction in pressure during the test period or leakage or
sweating during the test period shall be treated as failure of the test. Also a similar
pneumatic test at 10 kgf/cm2 (142 psig) shall be done for 5 minutes.

2.4.4 Brand used - Sakha

2.5 Pressure Gauge in manifold:

2.5.1 Function – To indicate the gas pressure in the manifold. The normal pressure is between 50
to 70 psig.

2.5.2 Specification - The pressure gauge used at the manifold shall have a 4” dial, & shall be
suitable for pressure range 0 to 10 kgf/cm2.

2.5.3 Testing – The pressure gauge shall be tested against a calibrated gauge in the pressure
range specified.

2.5.4 Brand used – Sakha or Guru

2.6 Isolation Valve fitted on Pressure Gauge:

2.6.1 Function – It can stop or open the gas flow to the pressure gauge. Normally, the isolation
valve is open. If a pressure gauge becomes defective, the isolation valve is closed & the
defective pressure gauge removed & replaced by the new one. The normal pressure is
between 50 to 70 psig.

2.6.2 Specification – The brass valve body is either forged or made from free cutting brass. The
minimum tensile strength of the material of valve body shall be 40 kgf/mm2 & minimum
elongation 18%. The minimum izod impact strength as per IS: 1598 shall be 2.2 kgf.m. The
valve shall work satisfactorily in the temperature range of –200C and +650C.

2.6.3 Testing – The valve is tested pneumatically at a pressure of 17 kgf/cm2 (240 psig) as well
as at a low pressure of 0.5 kgf/cm2 ( 7 psig)

2.6.4 Brand used – Sakha

3. CODE OF PRACTICE FOR LAYING AND PRESSURE TESTING OF PIPELINE:

3.1 Laying of Pipeline:

The pipeline shall be laid as per IS: 6044 (Part 1): 2004 – Code of Practice for liquefied petroleum
gas storage installations (Part 1) Commercial and Industrial Cylinder Installations:

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3.1.1 When a pipeline is laid deep in the earth (3 feet deep) across a road, it is covered with a
concrete Hume pipe of larger diameter so that no big load of traveling vehicles comes on it
directly.

3.1.2 Two coats of red oxide will be applied on piping above ground.

3.1.3 Suitable insulation tape or coating will be applied on the surface of that portion of pipeline
which is laid underground so as to prevent its corrosion due to soil conditions.

3.1.4 Suitable electric welding machine will be used such as single phase or 3 phase transformer
type. The welding will be done by an experienced welder. The electrodes used will be
Advani Oerlikon brand.

3.2 Pressure testing of pipeline:

(i) Manifold - 25 kg/ cm2 hydraulically for 1 hour. The normal gas pressure in this section is
about 7 kgf/cm2. The maximum attainable pressure in this section at 65 deg centigrade is
16.87 kgf/cm2.

(ii) Piping after 1st stage regulator & before 2nd stage regulator - Pneumatically for 30
minutes at 2 kgf/cm2. The normal gas pressure in this section is about 0.7 kgf/cm2 (10 psig).

Note: The test duration will be 30 minutes for each 500 cubic feet (or 14.159 cubic metre
i.e. 14,159 litres of pipe volume (based on inner dia of pipe) or fraction thereof.

4. CIVIL CONSTRUCTION WORK

Digging of trenches – The width of the trench shall be commensurate with the pipe diameter. The depth will
be 3 ft where there is a road crossing and 2 ft otherwise.