DIS 5.

ENGINEERING PROCEDURES

SECTION 5 - PIPE SYSTEM CONSTRUCTION

MODULE 5.7 - UNDER PRESSURE WORKING

OCTOBER 1992

J175 ( Rev 12/97 )

.
 DIS 5.7

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE 1

2. REFERENCES 1

3. DEFINITIONS 2

4. SITE SUPERVISION AND COMPETENCE OF PERSONNEL 2

4.1 Competence 2

4.2 Site supervision 2

5. PROGRAMME OF WORK 2

6. PREPARATION AND PRECAUTIONS ON SITE 2

6.1 General 2

6.2 Cut-out sites 3

6.3 Under pressure connection sites 6

7. CUTTING OPERATIONS 6

8. TESTING 7

8.1 Testing with gas pressure 7

8.2 Low pressure tests 7

8.3 Medium pressure and intermediate pressure tests 7

9. DUCTILE AND CAST IRON MAINS 7

9.1 General 7

9.2 Position and size of tappings 7

9.3 Drilling and tapping procedures - metallic mains 8

9.4 Connection of polyethylene services up to 63 mm diameter by

drilling and tapping 8

9.5 Under pressure screwed connections 9

9.6 Under pressure tees 9

9.7 Use of bag tube equipment 10

9.8 Use of iris stop equipment 10

9.9 Use of flow stopping equipment 11

10. POLYETHYLENE MAINS 11

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Page

10.1 General 11

10.2 Jointing operations 11

10.3 Use of squeeze-off equipment 11

11. CONNECTIONS TO STEEL MAINS 12

11.1 Wall thickness 12

11.2 Connection of services up to and including 63 mm (2 in.) diameter 12

11.3 Use of bag tube equipment 12

11.4 Use of iris stop equipment 13

11.5 Use of under pressure tees, wrap-round tees, welding nipples

and welded bosses for branch connections 13

12. LIVE GAS OPERATIONS INVOLVING A RELEASE OF GAS

TO ATMOSPHERE 13

13. CHANGING METER CONTROL VALVES 15

14. ABANDONMENT OF MAINS 15

TABLES

1 Tapping sizes for mains below 200 mm nominal size 8

2 Pressure limitation of mains for bag tube equipment 11

FIGURES

1 Typical under pressure branch connection with sealed damper plate arrangement
and operating pressures up to 75 mbar; test pressure 350 mbar 17

2 Typical under pressure branch connection with valve suitable for operating
pressures up to 2 bar; test pressure 3 bar 18

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 DIS 5.7

FOREWORD

This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification GBE/DIS 5.7. It reflects the identity and organizational structure of Transco - a part of BG plc.

This Transco specification has been approved for use throughout Transco.

Comments and queries regarding the technical content of this Transco specification should be directed to:

Lead Role Engineer

Transco
West Area Office
Glevum House
Bristol Road
Gloucester
GL2 6YA

Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco specification (not the designation) and your
cost code.

Transco specifications are revised, when necessary, by the issue of amendments or new editions. Users should
ensure that they are in possession of the latest versions by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.

Contractors and other users external to Transco should direct their requests for further copies of Transco
specifications to the department or group responsible for the initial issue of their contract documentation.

Compliance with this specification does not confer immunity from prosecution for breach of statutory or other
legal obligations.

DISCLAIMER

This specification is provided for use by Transco and such of its contractors as are obliged by the terms of
their contracts to comply with this specification. Where this specification is used by any other party it is the
responsibility of that party to ensure that the specification is correctly applied.

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DIS 5.7

BRIEF HISTORY

First published as BGC/PS/DIS 5.7: Part B* August 1984

First update to BGC/PS/DIS 5.7: Part B published* June 1986
Second update to BGC/PS/DIS 5.7: Part B published* February 1987
Third update to BGC/PS/DIS 5.7: Part B published* April 1989
Reissued as GBE/DIS 5.7 (incorporating all updates) in bound
form and without reference to 'Part B' February 1992
First update to GBE/DIS 5.7 published October 1992
Amendment No.1 published** February 1995
Erratum No.1 published** May 1995
* Loose-leaf editions.
** Incorporated in this re-issue

© BG plc 1992

This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.

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 DIS 5.7

ENGINEERING PROCEDURES
SECTION 5 - PIPE SYSTEM CONSTRUCTION
MODULE 5.7 - UNDER PRESSURE WORKING

1. SCOPE
This Module 5.7 of the Transco Engineering Procedures (formerly Code of Practice for Distribution)* gives
guidance for under pressure working on distribution mains and services operating in a pressure range not
exceeding 7 bar.
* Hereinafter referred to as 'this Module 5.7'

2. REFERENCES
This Module 5.7 makes reference to the documents listed below. Unless otherwise specified the latest editions
of these documents, including all addenda and revisions, shall apply.

Transco specifications

E4 - Specification for inflatable, self-centreing bag-stoppers for use on

operating mains up to and including 300 mm nominal size

F2 - Specification for main to service pipe fittings for use up to 2 bar

L2 - Specification for steel pipe 15 mm to 450 mm nominal size for service

at pressures up to 7 bar (Supplementary and amending specification to
BS 3601: 1974)

PL3 - Specification for mechanical fittings/joints for polyethylene (PE) pipe

for natural gas and suitable manufactured gas:
Part 1 - Self anchoring fittings for pipe sizes up to and including
63 mm
Part 2 - Self anchoring fittings for pipe sizes 75 mm to 180 mm
inclusive

SFP4 MD/102 - Transco procedures for dealing with reported gas escapes

Engineering Procedures:

Module 3.1 - Health and safety at work

Module 4.1 - Excavations for pipelaying

Module 4.2 - Permanent and temporary anchorage for mains and large services

Module 5.1 - Steel pipe systems

Module 5.2 - Ductile iron systems

Module 5.3 - Polyethylene systems

Module 5.5 - Pressure testing

Module 5.6 - Commissioning and de-commissioning of mains and services

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Module 8.3 - Electrical equipment used in site operations

Module 8.6.1 - Iris stop operations

Module 8.6.2 - Bag stop operations

Module 8.9 - Breathing equipment - operation and maintenance.

3. DEFINITIONS
For the purposes of this Module 5.7 the following definitions shall apply:

Engineer: The competent engineer appointed to be responsible for the application of all or part of the
Engineering Procedures.

Engineer's representative: A suitably competent and experienced person acting on behalf of the Engineer.

Supervisor: A person having the competence to supervise or carry out the work being undertaken in a safe
and proper manner.

low pressure: operating pressures not exceeding 75 mbar (30 in. wg).

medium pressure: operating pressures above 75 mbar (30 in. wg) but not exceeding 2 bar (30 lbf/in 2 ).

intermediate pressure: operating pressures above 2 bar (30 lbf/in 2 ) but not exceeding 7 bar (100 lbf/in 2 ).

4. SITE SUPERVISION AND COMPETENCE OF PERSONNEL

4.1 Competence
4.1.1 All persons engaged in the design, construction, commissioning, operation, 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.

4.1.2 All live gas operations shall be carried out by approved operatives.

4.1.3 In addition to the team leader, at least one other person who has received training in fire-fighting
and simple First Aid shall be present on site.

4.2 Site supervision

4.2.1 Connections of service up to and including 63 mm (2 in.) diameter to mains with operating
pressures not exceeding 2 bar, may be carried out by approved team leaders under normal supervision.

4.2.2 For other types of live gas working, the Engineer shall decide on the level of supervision required.

5. PROGRAMME OF WORK
It may be appropriate on some jobs, at the Engineer's discretion, for a programme of work to be produced in
accordance with District procedures. Consideration should be given to the timing of live gas operations such
that the integrity of the gas supply is maintained.

6. PREPARATION AND PRECAUTIONS ON SITE

6.1 General
6.1.1 Breathing apparatus
Where appropriate, operatives working on live gas shall wear breathing apparatus. Reference should be made
to Module 8.9. Resuscitation equipment shall be made available at the discretion of the Engineer.

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 DIS 5.7

Every precaution shall be taken to ensure safety, particularly in a confined situation. Maximum ventilation
shall be provided.

6.1.2 Fire extinguishers

At least two 9 kg dry powder extinguishers should be placed in a convenient position on site for use in an
emergency.

6.1.3 Protective clothing

Operatives involved in live or free gas working shall wear gloves and flame retardant overalls. Where two-
piece overalls are issued, both the top and the bottom parts of the suit shall be worn. Reference should be
made to Module 3.1.

6.1.4 Excavation
6.1.4.1 Adequate space shall be provided in the trench for access and escape routes, execution of the work
and fitting of operational equipment. Any necessary trench support system shall be arranged to permit
handling of pipes, valves, etc.

6.1.4.2 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.

6.1.4.3 Barriers and fencing shall be placed so as to ensure that the maximum practical distance is kept
between the work site and passing traffic and pedestrians.

6.1.4.4 Reference shall be made to Module 4.1.

6.1.5 Sources of ignition

All equipment which could be an ignition source shall be sited in a designated safe area. Reference shall be
made to Modules 3.1 and 8.3.

6.1.6 'No Smoking'/'No Naked Light' signs

'No Smoking'/'No Naked Light' signs shall be displayed at the site of any live gas operation.

6.2 Cut-out sites

6.2.1 Fitting of bypass to mains
6.2.1.1 Unless its omission is specifically authorized by the Engineer, a bypass shall be fitted over every
cut-out or operation which stops or reduces the flow of gas in a low pressure main. The size of bypass will be
at the discretion of the Engineer. In the case of a metallic main, a low resistance electrical continuity bond
shall be fitted across the cut-out.

6.2.1.2 Generally, bypasses should be constructed from rigid or approved flexible steel pipes. Where the
Engineer is able to satisfy himself that no undue fire hazard exists and that the bypass is safe from
interference and accidental damage, flexible bypasses constructed of polyethylene (PE) materials may be
used. The bypass should be pressurized slowly until it achieves full line pressure, ensuring safe
commissioning of the pipework and fittings.

6.2.1.3 Where appropriate, the bypass connections to the main may be in the same excavation as the other
site works. Exposed live PE bypasses shall not be left unattended without the authority of the Engineer.

6.2.1.4 Only transition fittings which comply with PL3: Parts 1 and 2 shall be used.

6.2.1.5 The bypass shall be reasonably protected from mechanical damage and may be buried or sleeved at
the discretion of the Engineer.

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DIS 5.7

6.2.1.6 Where a bypass operates at pressures above low pressure, the design and construction of the bypass
will be determined by the Engineer.

6.2.2 Pressure gauges

Pressure gauges shall be fitted on each side of every cut-out or operation which stops or reduces the flow of
gas in a main. Pressure recorders may also be fitted at the discretion of the Engineer. Unless the equipment is
specially designed, gauges and recorders shall be independently impulsed from the main on each side of the
cut-out.

6.2.3 Purging of cut-out section

Purging of the section to be cut out shall be in accordance with Modules 5.6, 8.6.1 and 8.6.2.

6.2.4 Size of fittings

The diameter of the pipe to be cut should be carefully measured to ensure that the fitting to be inserted can
readily be jointed to it.

All pipes, fittings, tools, jointing rings, stoppers and other equipment required should be laid out in convenient
positions and checked.

6.2.5 Tools - elimination of ignition sources

6.2.5.1 Impact between steel tools such as hammers and chisels can cause a spark which can ignite a gas-
air mixture. Sparks can also be easily produced when 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.

6.2.5.2 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 to the ground before a pick or any other tool is used.

When a pipe is being broken out with a hammer, the pipe shall first be thoroughly purged and the pipe and
hammer shall both be wet in areas where impact or friction is likely to take place. This can be achieved by
wrapping the pipe with a wet cloth.

6.2.6 Bag failure

In the event of bag failure, remedial action should be in accordance with Modules 8.6.1 and 8.6.2.

6.2.7 Joints
Joints should be made in accordance with the appropriate clauses in Modules 5.1, 5.2 and 5.3.

6.2.8 Valves
6.2.8.1 A single-faced valve should not be relied upon for gas tightness, and should not be the sole means
of retaining gas.

Unless a valve is fitted with an interface vent, it shall be treated as a single-faced valve.

6.2.8.2 The operation of all valves should be controlled by one person, in accordance with the programme,
and a record should be made of the opening and closing of all valves together with the direction and number of
turns taken. For all valve operations on the mains system, pressure gauges shall be installed at each side of the
valve and shall be continuously monitored as the valve is operated. This requirement applies not only to
permanent valves laid in the line of the main, but also to any temporary valve, blank or damper plate used for
the purpose of system alteration, such as that on the outlet of an under pressure tee. Wherever possible, the
pressure tapping shall be made in the same excavation to that in which the valve is positioned.

6.2.8.3 Whenever possible, a rehearsal of valve operations should be carried out to check their freedom of
movement and their degree of tightness.

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 DIS 5.7

6.2.8.4 If a valve on a main or service which:

a) operates at above 75 mbar, or

b) has an outside diameter greater than 300 mm and operates at 75 mbar or less,

is to be blanked temporarily or permanently, a drilled and tapped flange which includes a pressure relief
facility should be fitted. Any valve that is blanked off shall be left in the closed position.

6.2.8.5 Copies of valve record cards for all valves affected by the operation should be available on site, or
the relevant details included within the written procedure.

6.2.8.6 Before removing a blank flange from an operational valve, it shall be established that the valve is in
the closed position. This should be determined by reference to the valve record information and if necessary,
by fully operating the valve in both directions in accordance with a written procedure. The valve shall be left
in the closed position before removal of the flange.

6.2.8.7 If the blank flange to be removed from a valve has a pressure relief installed, a vent pipe complete
with flame trap and pressure point should be installed and the pressure released before the blank flange is
removed.

Additionally, if checks show that the valve is not sealing adequately, further precautions shall be taken to stop
the flow of gas before the removal of the blank flange is undertaken. The precautions outlined in 12.4 shall
also be taken.

6.2.8.8 If no pressure relief facility is available on the blank flange to be removed, the operation shall be
treated as a live gas operation and the precautions outlined in 12.4 shall be taken. Additionally, the bolts
securing the flange shall only be released sufficiently to allow the flange joint to be separated.

When the flange is separated from the valve, it shall be confirmed that the valve is fully closed before
continuing with the operation.

6.2.8.9 To eliminate the need for purging in back-fed systems, a positive pressure should be maintained
between closed valves and the cut-out site by means of a governed bypass and vent over the valves. A
competent person should be stationed at each valve location throughout the period of the job to monitor and
regulate the pressure. Facilities should be provided for recording all pressures during the job. Controlling the
pressure through the main line valve shall not be attempted.

6.2.9 Restraining mains

6.2.9.1 When a main is stopped off by Flo stops, Slyd stops, iris stop, bag stop, squeeze-off or valve
operation, a longitudinal thrust is imposed on that stopper and mains system. Pipe joints and fittings near to
the stopper will also be subjected to this longitudinal thrust, which has to be restrained.

6.2.9.2 When connections are to be made in medium or intermediate pressure systems, consideration should
be given to the possibility of reducing pressures. This will reduce the resultant thrust, and hence anchorage
requirements. If the operations can be carried out under low pressure conditions, anchorage may not be
necessary.

6.2.9.3 No external restraint is normally required when stopping off and cutting out mains which are part of
a low pressure system. However, if it is felt that joint slippage could occur due to weak ground or steep incline
conditions, anchorage should be considered.

6.2.9.4 It is necessary to restrain mains working at medium or intermediate pressure when the presence of
end load fittings cannot be assured, e.g. if the pipework is jointed by normal lead yarn, flexible type or
compression joints which rely on frictional resistance to prevent movement. Where restraint is considered

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DIS 5.7

necessary, the pipework should be anchored by means of concrete blocks or a load bearing frame clamped to
the main either side of the cut-out section (see 6.2.9.7).

6.2.9.5 Mains systems that are all welded steel, fused PE or circlip jointed ductile iron need not be
restrained during stopping off or cut-out operations. Anchorage shall be provided on these mains systems
whilst at medium or intermediate pressure when non-end load fittings are incorporated or circlip continuity is
not assured.

6.2.9.6 When external anchoring is required, the stopping off should wherever possible be carried out in
separate excavations to the cut-out. This three trench system will:

a) provide the main with vertical support during cut-out;

b) give the main additional axial restraint due to the frictional resistance of the soil;
c) limit the effects of any accident by isolating the three work sites from each other whilst
allowing access to the stopping off equipment.

6.2.9.7 Where temporary or permanent thrust restraint is required, it shall be constructed in accordance
with Module 4.2, as directed by the Engineer or his representative.

6.3 Under pressure connection sites

6.3.1 Excavation
The excavation must be large enough to enable the drilling machine to be fitted, tested where appropriate, and
for the operation to be carried out without undue difficulty. Full provision shall be made for safe entry and
exit from the trench.

6.3.2 Branch connections

The pressure in the parent main shall be monitored throughout the main drilling operation to ensure that the
correct main is being drilled and that the district pressure does not fall below the minimum local requirements.
Wherever possible, the pressure tapping shall be made in the same excavation as the under pressure tee is
positioned.

7. CUTTING OPERATIONS
7.1 The points at which the main has to be cut should be determined and the pipe marked accordingly.
The position selected should be free from large corrosion defects and hard encrustations and the main should
be thoroughly cleaned by scraping and wire brushing before the tool is assembled.

7.2 Before the main is cut, it is necessary to pack it up with timber so that the cut ends and the cut piece
are well supported. The packing shall be so placed that it is clear of the pipe or fitting to be inserted and does
not impede the jointing.

7.3 The method of cutting will be determined by the Engineer and will depend on the diameter and
material of the main involved.

7.4 Additional cuts should be made to ensure that the cut out piece of pipe is removed with the
minimum of effort.

7.5 As soon as the cut piece of pipe has been removed, the open ends of the pipes shall be plugged with
expanding stoppers.

7.6 Before the pipe or fitting to be inserted is placed in position, a check shall be made to ensure that no
tools, stoppers, or other materials have been left in the open ends of the main.

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8. TESTING
8.1 Testing with gas pressure
Whenever possible, all new pipework shall be tested in accordance with Module 5.5. If it proves necessary to
test a number of joints and plugs, using gas pressure, on completion of a live gas operation, this testing shall
be carried out as detailed in 8.2 and 8.3.

8.2 Low pressure tests

All plugs and joints shall be tested for soundness at district pressure with an approved leak detection solution.
Any solution applied to PE pipes shall be washed off with clean water.

8.3 Medium pressure and intermediate pressure tests

All medium pressure and intermediate pressure pipework shall be securely anchored before any attempt is
made to test joints and plugs under operating pressure.

In the case of cut-outs involving Iris or Flowstopping equipment, consideration should be given to the
restraining of the adjacent pipe joints.

Whenever possible, mains and services operating at medium pressure and intermediate pressure shall be
tested at low pressure and, if no leakage is evident, re-tested when normal operating pressure has been
reached.

9. DUCTILE AND CAST IRON MAINS

9.1 General
It is intended that full use is made of equipment designed to reduce to a minimum the amount of gas
discharged during drilling and tapping and other operations.

Although this equipment shall be checked before use, it is necessary to be prepared for mechanical or other
failure and in consequence the requirements of clauses 6 and 7 shall be observed.

9.2 Position and size of tappings

9.2.1 Service connections shall be made at least 200 mm from the face or rear of any socket of the main
or split collar fitted to the main.

9.2.2 Where connections to mains are close to existing tappings, an axial distance of 200 mm should be
allowed between the centres of the two tappings.

9.2.3 The maximum nominal size of tapped holes which may be used is a quarter of the nominal size of
the main where the main is 200 mm nominal size or over. Below this size, the tapping sizes specified in
Table 1 shall normally apply.

9.2.4 When it is necessary to use a tapping in excess of the maximum sizes given in Table 1, a split
fitting should be fitted to the main.

9.2.5 Where holes to be drilled in mains are larger than 2 in. diameter, a non-tap plug shall be used.
Non-tap plugs shall not be fitted to tapped holes.

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DIS 5.7

TABLE 1 - Tapping sizes for mains below 200 mm nominal size

9.3 Drilling and tapping procedures - metallic mains

9.3.1 The procedure for drilling and tapping is specified in 9.3.2 to 9.3.6 inclusive.

9.3.2 A position on the main shall be selected where there are no large corrosion defects or hard
encrustations and the main cleaned by scraping and wire brushing.

9.3.3 A machine saddle should be selected according to the main size or fitting, its condition checked, and
fitted to the machine or main as appropriate. The fixing chain nuts shall be tightened evenly to a moderate
hand torque with the spanner provided and the level of the machine checked to see that it is appropriate for the
work.

9.3.4 A parallel threaded drill tap should be fitted to the chuck and inserted in the machine. In the case of
double spindle machines the fitting spindle and fitting should also be assembled to the machine. An air test at
a pressure equal to 1.5 times the maximum working pressure in the main or 350 mbar whichever is the
greater, should be applied and the machine seal checked with an approved leak detection solution. No leakage
should be apparent. If leakage is observed the machine should be removed and the main cleaned further, or
mastic applied beneath the seal. The fixing chain nuts shall not be overtightened in an attempt to achieve a
good seal.

9.3.5 The pressure gauge used for this test (i.e. that gauge incorporated on the drilling equipment) shall
be left connected, and monitored whilst the main is being drilled to determine the mains pressure (see 6.3.2).
This pressure shall be recorded in an appropriate manner.

9.3.6 The main shall be drilled and tapped, the end of the feed screw and drill tap being lubricated with
oil or grease. If excessive force is needed this should be investigated. The drill tap shall be withdrawn and, for
single spindle machines, the valve closed.

9.3.7 The service fittings should conform to F2.

9.3.8 Where it is intended to utilize an existing drilled and tapped hole, the existing service shall be
disconnected in accordance with 12.5 and the appropriate service tee screwed into the existing hole.

9.4 Connection of polyethylene services up to 63 mm diameter by drilling and tapping

9.4.1 Only service tees with end-loading conforming to PL3 shall be used.

9.4.2 Drilling and tapping of the required hole and connection of appropriate tee shall be as detailed
in 9.2.1 to 9.3.6 inclusive.

9.4.3 Connections for service renewals shall be as detailed in 9.3.8, and 12.5.

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9.5 Under pressure screwed connections

When connections greater than 63 mm are to be made to larger diameter cast iron mains, screwed plugged
nipples may be used where appropriate.

9.6 Under pressure tees

9.6.1 Pressure gauges shall be installed at each side of the damper plate/valve and the gauges shall be
continously monitored as the damper plate/valve is operated. Wherever possible, the pressure tappings shall
be made in the same excavation to that in which the damper plate/valve is positioned.

9.6.2 Glanded ductile iron type under pressure tees may be used on cast, spun and ductile iron mains.

9.6.3 For low pressure mains, where the tee outlet does not exceed 300 mm (12 in.) diameter, a damper
plate of the self sealing type may be used. Low pressure tees above 300 mm (12 in.) branch outlet diameter
and all medium and intermediate pressure tees shall be fitted with an approved valve.

9.6.4 The tee and damper plate/valve shall be tested in accordance with Module 5.5 and the following:

a) The tee and damper plate/valve should be set up as shown in Figures 1 and 2 depending on the
type of tee and operating pressure. The valve should be opened and, in the case of damper
plate valves, the plate removed and the slot sealed before carrying out any testing.
b) The standpipe shall be equipped with a relief valve set to blow at 10% above the appropriate
test pressure.
c) The standpipe and pressure gauge shall be so fitted that it can be observed and controlled
without a person entering the trench or standing in line with the offtake.
d) In the case of medium pressure tests, the nitrogen supply shall be physically isolated from the
tee before a person enters the trench to test the joints.
e) No person shall be in the trench when the pressure is being raised.
f) No person shall stand in front of the offtake throughout the period of the test.
g) The test pressure should be supplied from a bag pump for low pressure tests. A governed
nitrogen bottle or bag pump shall be used for medium pressure tests. Compressors shall not be
used as a source of pressure for testing under pressure tees. The test pressure shall be 1.5 times
the maximum working pressure in the main or 350 mbar whichever is the greater.
h) Air/nitrogen should be admitted into the assembly until the gauge indicates the appropriate
pressure. The stand pipe should then be valved off and physically isolated from the pressure
source before a person enters the trench to test the joint.
i) The test pressure shall be maintained for 15 min and the gauge observed to ensure no loss of
pressure has occurred.
j) An approved leak detection solution shall be applied to all joints to check if they are sound.

9.6.5 The pressure in the parent main shall be monitored throughout the main drilling operation to ensure
that the correct main is being drilled. This will allow the district pressure to be monitored to ensure that it
does not fall below the minimum local requirements. Wherever possible, the pressure tapping shall be made in
the same excavation as the under pressure tee is positioned.

9.6.6 When fixing and drilling under pressure tees the following checks shall be made:

a) The main is clean before fitting the tee.

b) The under pressure tee and rubbers are of the correct size.
c) The tee (and valve) are to the correct pressure rating.

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d) The drilling machine is to the correct pressure rating, and the flange matches the under
pressure valve.
e) The damper plate or valve is free and able to seat correctly.
f) The valve is in the fully open position, or the damper plate has been removed from its housing
and the cover replaced.
g) The spring clip on the end of the pilot drill is satisfactory and in good condition.
h) The travel of the drill is measured and marked to ensure that it is of adequate length to drill the
front wall of the main without cutting into the rear wall.
i) The branch can be sealed by the damper plate or valve when the drill is in the retracted
position. The pilot drill must be in position when this check is made.
j) Before drilling, the drilling machine is concentrically fitted, supported and rigidly attached to
the outlet fitting, and a satisfactory pressure test carried out on the assembled drill.
k) The test pressure is maintained for 15 min and the gauge observed to ensure no loss of
pressure has occurred.
l) The pressure gauge used for this test (i.e. that gauge incorporated on the drilling equipment)
shall be left connected, and monitored whilst the main is being drilled to determine the mains
pressure (see 6.3.2). This pressure shall be recorded in an appropriate manner.
m) After drilling and withdrawing the drill, the damper plate is closed, or in the case of a valve,
the body vent closed, the valve closed, and the body vent re-opened.
n) Before unbolting the drilling machine, the gas is effectively sealed off. Breathing apparatus
shall be worn during this operation if the machine is not equipped with a test cock.
o) After the drilling operation, leak testing the tee again with an approved leak detection solution.
p) The piece of main cut out has been retained for inspection.
q) The tee outlet has been blanked-off or capped-off if the new connection is not to be
commissioned immediately.

9.7 Use of bag tube equipment

Whenever sections of mains are to be removed for connection or repair, under pressure flow stopping
equipment shall be used, except by special arrangement with the Engineer. Bag tube equipment may be used
on mains up to and including 300 mm (12 in.) diameter subject to the maximum mains operating pressures
detailed in Table 2.

All equipment and fittings used during a stopping off operation should comply with the relevant Transco
specifications, and work carried out in accordance with Module 8.6.2. All bags used should be in accordance
with E4.

Where pressure reduction is not practicable, iris stop or flow stopping equipment should be used to stop off:

a) a main larger than 300 mm nominal size, or

b) any main at operating pressures in excess of those in Table 2.

9.8 Use of iris stop equipment

Iris stop equipment may be used on mains in the size range 100 mm (4 in.) to 1200 mm (48 in.) diameter
inclusive, subject to the maximum mains operating pressure detailed in Module 8.6.1.

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9.9 Use of flow stopping equipment

It is important to note that to stop off a main at operating pressures in excess of those in Modules 8.6.1 and
8.6.2, and where pressure reduction is not practicable, it will be necessary to use a proprietary stopping off
system in accordance with Modules 8.6.1 and 8.6.2 and the appropriate manufacturer's recommendations.

TABLE 2 - Pressure limitation of mains for bag tube equipment

10. POLYETHYLENE MAINS

10.1 General
Full use shall be made of equipment designed to minimize the amount of gas discharged during drilling and
other operations. Although this equipment shall be checked before use, it is always necessary to be prepared
for mechanical or other failure and in consequence the precautions detailed in clause 6 shall be observed.

10.2 Jointing operations

All jointing operations involving electrofusion or fusion techniques shall be carried out in accordance with
Module 5.3.

10.3 Use of squeeze-off equipment

10.3.1 General
The most practical method of stopping off the flow of gas in PE pipes up to and including 180 mm diameter is
squeeze-off. Squeeze-off tools for 25 mm and 32 mm sizes are hand operated. Above 32 mm preference
should be given to hydraulically operated tools with safety stops to guard against hydraulic failure. The
operation of the squeeze-off equipment shall be in accordance with the manufacturer's instructions.

10.3.2 Cutting out or replacing a section of pipe under pressure

10.3.2.1 An electrical continuity bond is not required at PE cut-out sites although full provision shall be
made to prevent a spark from static electricity by placing damp cloths around the pipe on each side of the cut.

10.3.2.2 A single squeeze-off on the live side of each cut may be adequate under normal circumstances, but
a second squeeze-off and vent should be fitted at the discretion of the Engineer or his representative. For
mains above 180 mm (6 in.) diameter operating at low pressure (0 to 75 mbar) or mains above 63 mm
diameter operating at medium pressure (75 mbar to 2 bar) double squeeze-offs with an intermediate vent
should be applied. Reference should be made to Module 5.3 for squeeze-off positions.

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DIS 5.7

10.3.2.3 Purging and gassing of the repaired section of a pipe above 63 mm diameter may be carried out,
with extreme caution, by releasing the squeeze-off pressure.

10.3.2.4 On completion of a squeeze-off operation, the pipe shall be re-rounded and an approved tape
marked 'Squeeze-off applied' affixed to the pipe.

The same squeeze-off position shall not be used again and at least six pipe diameters distance shall be
allowed between squeeze-off positions on the same pipe.

10.3.2.5 PE pipe which has been in any way distorted by a squeeze-off operation is not suitable for jointing
operations either by fusion or mechanical techniques.

10.3.2.6 A squeeze-off unit shall not be used as a closed end for test purposes.

11. CONNECTIONS TO STEEL MAINS

11.1 Wall thickness
Existing steel systems may be of thin wall construction and/or have significant wall thickness reduction due to
corrosion and should be ultrasonically tested to determine wall thickness prior to welding. Welding shall not
be attempted if the wall thickness is less than 4 mm in which case connections to the steel pipe shall be made
using mechanical fittings.

Steel pipes with a wall thickness of 4 mm or greater and operating at pressures not exceeding 75 mbar may be
drilled and tapped as for ductile and spun cast iron mains. The procedures detailed in 9.2 and 9.3 shall be
observed.

11.2 Connection of services up to and Including 63 mm (2 in.) diameter

11.2.1 Wall thickness less than 4 mm
Where it is known or suspected that the wall thickness of the main may be less than 4 mm, a pipe saddle or
split collar shall first be fitted to the main. A nipple and full-bore valve (in the open position) shall then be
fitted into the tapping of the saddle or collar and tested in accordance with Module 5.5. The main can then be
drilled using a drilling machine with a long reach drill.

The drill shall be retracted, the valve closed, the drilling machine removed and the service connected to the
valve.

11.2.2 Welded service connections

11.2.2.1 The preferred method of service connection is to use a weld-on service tee incorporating a threaded
plug/perforator. Such tees are available with a variety of outlet connections to suit both steel and PE services
up to and including 32 mm (1 in.) diameter. See Modules 5.1 and 5.3.

11.2.2.2 The plug/perforator type of fitting is not suitable for tees with an inlet size above 32 mm (1 in.)
diameter and weld-on service tees which incorporate a threaded plug only should be used for 1.25 in., 1.5 in.
and 2 in. diameter tees.

11.2.2.3 The outlet connections of tees for PE services must conform to PL3.

11.2.3 Connection using welded bosses

Plain or threaded welded bosses may be welded to the main and an approved clear-bore valve connected to
the outlet of the fitting. The main can then be drilled using a drilling machine with a long reach drill as
in 11.2.1.

11.3 Use of bag tube equipment

11.3.1 With the exception of the method of connection to the main, bag-tube equipment shall be used as
detailed in Module 8.6.2.

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 DIS 5.7

11.3.2 The method of connection to the main will be determined by the Engineer and will depend on wall
thickness and the operating pressure of the main. The following alternatives should be considered:

a) Direct drilling and tapping of low pressure mains with a wall thickness exceeding 4 mm.
b) Welding of threaded bosses to the main which are designed to accept the appropriate adaptors
to enable drilling and insertion of bag tube equipment. See Module 5.1.

11.3.3 It should be noted that steel pipe to L2 has the internal weld root bead removed to facilitate the use
of all types of flow stopping equipment. With all other electric resistance welded (ERW) pipe, the leakage of
gas past the bags may be increased as will the risk of bag failure.

11.4 Use of iris stop equipment

11.4.1 Iris stop equipment shall be used as detailed in Module 8.6.1. Connections of equipment to the main
shall be carried out in conjunction with non-tapped plug equipment.

11.4.2 The requirements of 11.3.3 are also applicable to iris stop equipment.

11.5 Use of under pressure tees, wrap-round tees, welding nipples and welded bosses for
branch connections
11.5.1 The method of connection of the branch to the main will be determined by the Engineer and will
depend on wall thickness and the operating pressure of the main. The following alternatives should be
considered:

a) Glanded ductile iron under pressure tees may be used on steel mains operating at pressures not
exceeding 2 bar.
b) Full encirclement branch connection.
c) Flanged welding nipple.
d) Welded boss plus weld-neck flange.

11.5.2 The under pressure branch connection shall be tested and drilled in accordance with 9.6.3 to 9.6.6
inclusive.

12. LIVE GAS OPERATIONS INVOLVING A RELEASE OF GAS TO ATMOSPHERE

12.1 Circumstances may arise where it is necessary to carry out work on a gas main or service which
will involve a release of gas.

12.2 District requirements regarding work programmes, 'Permits to Work' and level of supervision
employed shall be observed.

12.3 Where the work involves a release of gas the Engineer will specify the minimum mains pressure
during venting.

Official pressure recorders within a 500 m radius of the job shall be monitored throughout the operation.

12.4 Where appropriate, the recommendations detailed in clauses 4, 5 and 6 shall be observed. In
addition the following precautions a) to f) inclusive shall be taken:

a) Where breathing apparatus is to be used, there shall be at all times a minimum of two persons
experienced and trained in such work; one acting as guard for the other wearing the apparatus.
b) At least two sets of apparatus shall be available and ready for emergency use.

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DIS 5.7

c) In certain cases the Engineer or his representative may decide to augment the standard
breathing apparatus supplied to teams.
d) To reduce the possibility of gas pockets being formed, tunnelling or undercutting shall not be
carried out when live gas working is taking place. Working under road or footpath plates shall
not be attempted.
e) Consideration should be given to using safety harnesses and life-lines, e.g. when working in
deep excavations or locations where the exit route from the excavation is difficult due to the
presence of other apparatus.
f) Consideration should be given to closing the adjacent highway and footpaths during the release
of gas to the atmosphere.

12.5 A large number of services were constructed prior to the utilization of service tees which provide a
means of isolating the service from the gas supply. In many cases the connection to the main was provided by
a long radius bend or long screw. The procedure set out in 12.5.1 to 12.5.13 inclusive shall be observed when
disconnecting this type of service from the main. All work associated with disconnection of services should
also comply with SFP4 MD/102.

12.5.1 Excavation shall be made at the service connection to the main and the wrapping removed from the
service pipe in two places approximately 300 mm apart and 300 mm from the bend. Where practicable, the
pipe shall be cleaned with a wire brush or emery cloth.

12.5.2 An electrical continuity bond shall be fitted to bridge across the section of pipe to be removed.

12.5.3 Prior to cutting, the pipe shall be wrapped with a suitable service bandage. Mastic paste or tape
should also be available to seal the saw cut.

12.5.4 The service shall be cut by hacksaw in such a manner as to enable the cut piece to be easily
removed. The cut shall be sealed with mastic as cutting proceeds to minimize the discharge of gas.

12.5.5 On completion of the cuts, the cut piece shall be removed and immediately an expanding stopper
shall be inserted into the live side. The dead side shall be sealed temporarily.

12.5.6 The bend and the short length of pipe from the main shall be unscrewed carefully and the service tee
or plug fixed immediately. The threads shall be coated with an approved jointing material.

To avoid the build up of static charge and the possibility of a spark, the tee or plug should be earthed by
resting the tee or plug on the main about 350 mm from the hole and sliding it along the surface of the pipe to
the hole.

12.5.7 The electrical continuity bond shall be removed.

12.5.8 Where, in an emergency, it is not expedient to make the initial cut-off at the main, the service shall
be cut and the live section sealed in an approved manner, as far as possible from the property. The mains
connection shall be removed and the main plugged as soon as possible. Reference should be made to
SFP4 MD/102.

12.5.9 For each service cut off an excavation shall be made at the service entry point to ensure that the
correct service has been isolated, and to facilitate the removal of the old service. The service shall be cut after
fitting an electrical continuity bond.

The old service should be removed from the property, the service entry sealed and the wall made good. The
ends of any abandoned pipework left in the ground should be sealed with mastic and approved tape.

12.5.10 If the service inside the property is encased in concrete or its removal would create severe
disturbance, the service entry should be examined, made good as appropriate and the end of the service

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 DIS 5.7

plugged and sealed. The stand pipe inside the property should be removed to a point below floor level, sealed
and the floor made good.

12.5.11 When a supply to a domestic premise is isolated by the use of a riser tee plug, or a service
incorporating a riser tee is cut off, it will not normally be necessary to access to the premise, unless there is
evidence that other supplies to the premise exist.

When isolating or cutting off services to all other premises, and there is reason to believe more than one meter
is installed or the age of the premise or service is such that other supplies may exist in the premise, access
shall be gained to the premise to ensure that all supplies have been isolated.

12.5.12 Whenever mains are abandoned from which services are laid to properties not using gas, access
must be gained to those properties, the standpipe removed and the service plugged below floor level. If
removal would create significant disturbance to the occupier, the meter control cock should be removed, the
standpipe capped and a notice 'service cut off at main' fitted. The service should on all occasions be cut off
and sealed outside the property and the service entry point made good.

12.5.13 When live services are to be cut off in conjunction with mains renewal work, the service may be cut
and capped at the intersection with the new main until the existing main has been abandoned. Where this
procedure is adopted the capping of the service shall be carried out with approved mechanical fittings and
checks made with a Gascoseeker to ensure that no leaks exist on the live service tail.

13. CHANGING METER CONTROL VALVES

13.1 There are a number of approved methods of changing meter control valves which may be used in
accordance with District Procedure by the Service or Distribution functions which do not necessitate
disconnection of the service outside the property. Whenever these methods of changing controls are employed,
the precautions listed in 13.1.1, 13.1.2 and 13.1.3 shall be observed to ensure that an escape of gas has not
resulted from disturbance of the pipe.

13.1.1 All exposed joints shall be tested with an approved leak detection solution.

13.1.2 Any underfloor spaces through which the service passes shall be tested with a Gascoseeker set on
the 10% LEL scale.

13.1.3 The new meter control valve shall be capped off and then tested with an approved leak detection
solution in both the open and closed positions.

13.2 On those occasions when the service outside a property is disconnected to change the meter control
valve, the disconnected section of service and the new control valve shall be tested in accordance with
Module 5.5 before reconnection to the live supply.

14. ABANDONMENT OF MAINS

14.1 All mains to be abandoned shall be purged in accordance with Module 5.6 after cut-outs and
proving tests are complete

All cut-outs shall be carried out in accordance with clauses 6 and 9. Reference shall also be made to
Modules 8.6.1 and 8.6.2.

The main should be isolated with the bypass fully commissioned and the decay tests carried out and, subject to
a satisfactory test, the section removed with the bypass still fully commissioned. These tests are intended to
prove:

a) that there are no consumers still connected to the section being abandoned; and
b) that there is an adequate supply to the main beyond the section to be abandoned.

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DIS 5.7

14.2 Where there is a known backfeed:

a) The bypass shall be closed slowly whilst pressures on water gauges are observed.
b) If the pressure on either side of the cut-out falls to below 20 mbar, the bypass shall be opened
and the cause of the pressure loss investigated, e.g. no backfeed, or consumers are still
connected.
c) If the pressure holds, a vent shall be fitted to the main to be abandoned and gas shall be vented
slowly whilst pressures on water gauges are observed. If pressures fall below 20 mbar, the
vent shall be closed and the pressure allowed to recover.
d) When the tests and purging are completed satisfactorily, the main shall be capped in the
normal manner and the equipment removed.

14.3 Where no backfeed is suspected:

a) The bypass shall be closed slowly whilst pressures on water gauges are observed.
b) If the pressure on either side of the cut out falls to below 20 mbar, the bypass shall be opened
and the cause of the pressure loss investigated, e.g. consumers are still connected.
c) If the pressure holds, a vent shall be fitted to the main to be abandoned and the gas vented
slowly until the pressure falls to 20 mbar. The vent shall be closed and the pressure gauge
observed for any build up of pressure which would indicate an unknown backfeed.
d) When the tests and purging are completed satisfactorily, the main shall be capped in the
normal manner and the equipment removed.

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 DIS 5.7

NOTE - Pressure gauges to be fitted both sides of the damper plate valve.

FIGURE 1 - Typical under pressure branch connection with sealed damper plate arrangement
and operating pressures up to 75 mbar; test pressure 350 mbar

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DIS 5.7

NOTE - Pressure gauges to be fitted both sides of the valve.

FIGURE 2 - Typical under pressure branch connection with valve suitable for operating
pressures up to 2 bar; test pressure 3 bar

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