Oisd STD 144 PDF

Sr.
Number:OISD/DOC/2017/04
OISD STANDARD 144
Second Edition, October 2005

Amended Edition, July 2008
Amended Edition, October 2017
FOR RESTRICTED
CIRCULATION ONLY
LIQUEFIED PETROLEUM GAS (LPG)
L
INSTALLATIONS
C
Prepared by
IO
FUNCTIONAL COMMITTEE ON
Oil Industry Safety Directorate

Government of India Ministry of Petroleum & Natural Gas
th
8 Floor, OIDB Bhavan, Plot No. 2, Sector 73, Noida 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr. Number:OISD/DOC/2017/04
Page No. I
PREAMBLE
Indian petroleum industry is the energy lifeline of the nation and its continuous
performance is essential for sovereignty and prosperity of the country. As the
industry essentially deals with inherently inflammable substances throughout its
value chain upstream, midstream and downstream Safety is of paramount
importance to this industry as only safe performance at all times can ensure
optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of
Indian petroleum industry, Oil Industry Safety Directorate (OISD) was set up in
1986 by Ministry of Petroleum and Natural Gas, Government of India as a
knowledge centre for formulation of constantly updated world-scale standards for
design, layout and operation of various equipment, facility and activities involved in
this industry. Moreover, OISD was also given responsibility of monitoring
implementation status of these standards through safety audits.
In more than three decades of its existence, OISD has developed a rigorous, multi-
layer, iterative and participative process of development of standards starting
and public at large L

with research by in-house experts and iterating through seeking & validating inputs
from all stake-holders operators, designers, national level knowledge authorities
with a feedback loop of constant updation based on
ground level experience obtained through audits, incident analysis and
environment scanning.
C
The participative process followed in standard formulation has resulted in
excellent level of compliance by the industry culminating in a safer environment in
the industry. OISD except in the Upstream Petroleum Sector is still a regulatory
(and not a statutory) body but that has not affected implementation of the OISD
IO
standards. It also goes to prove the old adage that self- regulation is the best
regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of

technology content requiring its operation to keep pace with the relevant world
scale standards & practices. This matches the OISD philosophy of continuous
improvement keeping pace with the global developments in its target
environment. To this end, OISD keeps track of changes through participation as
member in large number of International and national level Knowledge
Organizations both in the field of standard development and implementation &
monitoring in addition to updation of internal knowledge base through continuous
research and application surveillance, thereby ensuring that this OISD Standard,
along with all other extant ones, remains relevant, updated and effective on a real
time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain.
This, besides other issues, calls for total engagement from all levels of the stake
holder organizations, which we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director
Oil Industry Safety Directorate
Page No. II
FOREWORD
The Oil Industry in India is over 100 years old. As such, various practices have been
in vogue because of collaboration/ association with different foreign companies and
governments. Standardization in design philosophies, operating and maintenance
practices remained a grey area. This coupled with feedback from some serious
accidents that occurred in the past in India and abroad, emphasized the need for
the industry to review the existing state-of-the-art in designing, operating and
maintaining of oil and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a
Safety Council, assisted by Oil Industry Safety Directorate (OISD) staffed from
within the industry for formulating and implementing a series of self-regulatory
measures aimed at removing obsolescence, standardizing and upgrading existing
standards to ensure safer operations. Accordingly, OISD constituted a number of
functional committees comprising of experts nominated from industry to draw up
standards and guidelines on various subjects.
benefits. The document on "LPG

L
Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as well
as with industrial applications due to its unique properties and environmental
in 1994
and subsequently with the adoption of new process & technology, revised in
C
October 2005 and amended in July 2008.
The present document "

has been prepared by the functional committees based on the accumulated
knowledge and experience of industry members and updation of national and
international codes and practices related to LPG.
IO
We, at OISD, are confident that the provisions of this standard, when implemented
in totality, would go a long way in ensuring safe operation of the target group of
locations.
Needless to mention, this standard, as always would be reviewed periodically based

on field level experience, incident analysis and environment scanning. Suggestions
from all stake holders are fervently solicited.
Page No. III
NOTE
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil
and gas industry under Ministry of Petroleum & Natural Gas. These are the property
of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and
loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use.
The figures and annexures used in the document are representative in nature.
These documents are intended only to supplement and not to replace the prevailing
statutory requirements.
Where ever BIS standards are referred same relates to the latest version of the
standard.
L
C
IO
Page No. IV
(Amended Edition October 2017)
MEMBER COORDINATOR
Sh. Mahesh K. Goyal Oil Industry Safety Directorate, Noida
FUNCTIONAL COMMITTEE
(Second Edition - October, 2005)
NAME ORGANISATION
LEADER
Hindustan Petroleum Corporation Ltd.,
Sh. R. Krishnan Mumbai
MEMBERS
Deptt. of Explosives, Nagpur
Sh. A.N. Biswas
Sh. N. Rajkhowa,
LEngineers India Limited, New Delhi
C
Sh. B.S. Giridhar Indian Oil Corporation Ltd., - HQ, Mumbai
Sh. N. Dasgupta Bharat Petroleum Corporation Ltd., Mumbai

IO
Sh. T.Koteeswaran Chennai Petroleum Corporation Ltd., Chennai
Sh. B.J. Phukan Numaligarh Refinery Ltd., Assam
Sh. P. Jaidevan Indian Oil Corporation Ltd., Calicut
Sh. S. Ramesh Bharat Petroleum Corporation Ltd., Noida
MEMBER COORDINATOR
Oil Industry Safety Directorate, New Delhi
Sh. S. C. Gupta
Page No. V
FUNCTIONAL COMMITTEE MEMBERS

(First Edition April 1994)
NAME ORGANISATION
LEADER
Sh. S.C. Tandon Indian Oil Corporation Ltd., ( Ref.)
MEMBERS
Sh. H.G. Bhinde Indian Oil Corporation Ltd., ( Mkt.)
Sh. A.C. Kelkar Indian Oil Corporation Ltd., ( Mkt.)
Sh. V. Narayana Rao Bharat Petroleum Corporation Ltd., (Mkt.)
Sh. P. Kumaraswamy
LBharat Petroleum Corporation Ltd., ( Ref.)
C
Sh. P.P. Nadkarni Hindustan Petroleum Corporation Ltd., (Mkt.)
Sh. S. Mathur Engineers India Limited, New Delhi

IO
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
Page No. VI
CONTENTS
---------------------------------------------------------------------------------
S. No. DESCRIPTION PAGE No.
---------------------------------------------------------------------------------
1 Introduction 1
2 Scope 2
3 Definitions 2
4 Statutory Rules/ Regulations 3
5 Installation Layout 4
6 Design Considerations 10
7 Storage & Handling of Bulk LPG 20
8 Bottling Operations 39
9
10
Maintenance & Inspection
L
Statutory Testing of LPG Cylinders
42
64
C
11 Fire Protection Facilities 70
12 Gas Monitoring System 81
13 Emergency Management Plan 84
IO
14 Safety Audit 91
15 References 114
---------------------------------------------------------------------------------
OISD STD 144 Sr. Number:OISD/DOC/2017/04
Page no. 1
LIQUEFIED PETROLEUM GAS (LPG) INSTALLATIONS

INSTALLATIONS
1.0 INTRODUCTION
Liquefied Petroleum Gas (LPG) is a mixture of light hydrocarbons primarily C3 & C4
derived from petroleum, which is gaseous at ambient temperature and atmospheric
pressure, is liquefied at ambient temperature with application of moderate pressure. LPG
due to its inherent properties is susceptible to fire, explosion and other hazards. Such
hazards can have an impact on the property, equipment, plant personnel and public.
Liquefied Petroleum Gas (LPG) handling, bottling and distribution throw major challenges
due to its inherent properties. Major incidents i.e. fires/explosions in LPG facilities in
world have underlined the need for total in depth review of design, procedures,
maintenance, firefighting and safety aspects in LPG handling.
The oil and gas industry over the years have learnt lessons from fires and explosions
and have been updating and standardizing design, operations, bottling and distribution of
LPG.
L
Some of the important properties of LPG are as below:
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times
heavier than air. It is readily liquefied under moderate pressures. The density of the
liquid is approximately half that of water and ranges from 0.525 to 0.580 @ 15 oC.
C
The pressure inside a LPG storage vessel/ cylinder is equal to the vapour
pressure corresponding to the temperature of LPG in the storage vessel. The
restriction on vapour pressure is stipulated by IS
IS-4576.
LPG has an explosive range of 1.8% to 9.5% volume of gas in air. This is
IO
considerably narrower than other common gaseous fuels. This gives an indication of
hazard of LPG vapour accumulated in low lying area in the eventuality of the leakage
or spillage.
Water, being insoluble in LPG, if present in LPG can cause rust and corrosion and
freeze-up of valves, drain valves, excess-flow check valves, cylinder valves and
regulators thereby affecting their functioning and at times can lead to leakage of LPG.
LPG liquid has low viscosity of around 0.3 CS @ 45 oC and can leak when other
petroleum products normally cannot, thus demanding a very high integrity in the
pressurised system to avoid leakage.
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however,
suffocate when in large concentrations due to the fact that it displaces oxygen. In
view of this the vapour possesses mild anesthetic properties.
LPG is colorless both in liquid and vapour phase. During leakage the vapourisation
of liquid cools the atmosphere and condenses the water vapour contained in them
to form a whitish fog which may make it possible to see an escape of LPG.
The coefficient of expansion is around 0.00237 per oC. At liquid full condition any
further expansion of the liquid, the container pressure will rise by approx. 14 to 15
kg./sq.cm. for each degree centigrade.
LPG has only a very faint smell, therefore, ethyl mercaptan is normally used as
expressly disclaims any liability or responsibility for loss or damage resulting

from the use of OISD
Page no. 2
stenching agent for identifying the leakage as per IS: 4576.

o
The auto-ignition temperature of LPG ranges from 410 to 580 C.
2.0 SCOPE
This standard lays down the minimum safety requirements on design, layout, storage,
loading / unloading, operation, inspection & maintenance, fire protection, emergency
planning and safety audit systems of LPG Installations. This standard does not cover
process plants, the distribution of LPG to domestic & non-domestic consumers and
pipeline operations, road / rail transportation, A u t o L P G D i s p e n si n g s t a t i o n s ,
refrigerated and mounded storage facilities for LPG and LPG Plants covered under OISD-
GDN-169.
The green belt /buffer zone beyond the installation boundary is outside the scope of this
standard. Such provisions may be considered based on local environment / security
requirements.
The fire protection and firefighting requirement for the combined POL a n d LPG facilities
in the same premised shall be as given in OISD-STD-117 under item 4.2.15.
3.0 DEFINITIONS
Approved Type: Any equipment which has specific approval for use under specified
L
conditions by competent authority or authorised person as the case may be.
Area Classification: It is a method of classifying an area zone wise/ group wise based
on the presence of explosive gas/ vapour - air mixture vis-a-vis the requirement of
precautions for construction and use of electrical apparatus.
C
Bonding: Bonding is the process by which two electrical conducting bodies are
connected using a conductor to maintain electrical continuity to prevent sparking between
two conducting bodies.
Bulk Vessels: A pressure vessel used for more than 1000 litres water capacity for
IO
storage or transportation of L PG .
Bullet: A horizontal cylindrical pressure vessel used for storage or transportation of LPG
by rail/ road.
Compressed Gas: Any permanent gas, liquefiable gas or gas dissolved in liquid under
pressure or gas mixture which in a closed container exercises a pressure either
exceeding 2.5 kg/sq.cm. abs @ 15 oC or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50
oC or both.
Cylinders: A portable LPG container upto 1000 litres water capacity used for both
domestic and industrial purposes.
Explosive mixture: It is a mixture of combustion agent (oxidising product-gas, vapour,
liquid or solid) and a fuel (oxidisable product - gas, liquid or solid) in such proportions
that it could give rise to a very rapid and lively oxidisation reaction liberating more energy
than is dissipated through conduction and convection.
Earthing: Earthing is the provision of a safe path of electrical current to ground, in
order to protect structures, plant and equipment from the effects of st ray electric al
current, and electrostatics discharge.
Filling Ratio: It is the ratio of weight of LPG in a container to the weight of water the
o
same container can hold at 15 C.
Fire safe: As applied to valves, it is the concept of controlling the leakage to an acceptable

Page no. 3
level after damage encountered during and after the fire achieved by dual seating.
Fire proofing: It is an insulation that provides a degree of fire resistance to protect
substrates like vessels, piping and structures for a predetermined time period against fire.
Flammability: It is the percentage of volume of any flammable vapour in air-vapour
mixtures capable to form an explosive mixture.
Flammable (or inflammable): Any substance which when tested in a specified manner
will ignite when mixed with air on contact with a flame and will support combustion.
Gas-Free: it means the concentration of flammable or toxic gases or both in a pressure
vessel or pipeline is within the safe limits specified for persons to enter and carryout
hot work in such vessels/ pipelines.
Horton Sphere: A spherical pressure vessel used for storage of LPG.
Hot Work: It is an activity which may produce enough heat to ignite a flammable air-
hydrocarbon mixture or a flammable substance.
Installation: The facilities where LPG is stored or loading/ unloading operations or
bottling operations a r e carried out.
Kerb Wall: A wall of appropriate height and size constructed of suitable material and
designed to contain the LPG spillage and to direct it to a safe location around the storage
vessel.
L
Liquefied Petroleum Gas (LPG): The term applies to a mixture of certain light
hydrocarbon predominately C3 & C4, derived from petroleum & natural gas which are
C
gaseous at ambient temperature and pressure, may be condensed to a liquid state at
normal ambient temperature by the application of moderate pressure and conforming to
IS: 4576 or IS: 14861.
Purging: It is the act of replacing the atmosphere within a container by an inert
substance in such a manner as to prevent the formation of explosive mixture.
IO
Purging into Service: is the replacement of air in a closed system by an inert substance
and replacement of the later by combustible gas, vapour, or liquid.
Purging out of service: is the replacement of normal combustible content of a closed
system by an inert substance, and replacement of the later by air.
Tare Weight: The weight of the cylinder together with any fitting permanently attached to
it including the weight of valve.
Maximum Working Pressure: It is saturated vapour pressure of LPG at 65 oC for LPG

cylinders and 55 oC for bulk vessels.
Water Capacity: The maximum volume of water in litre that a container can hold at 15
oC.
Authorised Person: - An individual whose job description includes the concerned jobs.
Shall: - Indicates that provision is mandatory.
Should: - Indicates that the provision is recommended as a good engineering practice.
4.0 STATUTORY RULES / REGULATIONS
The LPG installation & various facilities are covered under many regulations and require
specific approval / license from concerned statutory authorities. The various regulations
applicable to LPG installation facilities, inter alia, are as follows:

Page no. 4
a. Gas Cylinder Rules 2016 (Under Indian Explosives Act, 1884)

b. Static & Mobile Pressure Vessels (unfired) Rules - 2016 under Indian Explosives Act 1884.
c. The Factories Act 1948 (with latest amendments)
d. Indian Electricity Rules
e. The Legal Metrology (General) Rules, 2011 under Legal Metrology Act, 2009. (With latest
revisions and amendments)
f. Legal Metrology (Packaged Commodities) Rules, 2011 (With latest revisions and
amendments)
g. Liquid Petroleum Gas (Regulation of Supply & Distribution) Amendment Order dated
25th Oct'2012 (With latest revisions and amendments)
h. The Motor Vehicles Act - 1988.
i. Environmental Regulations:
Water (Prevention & Control of Pollution) Act-1974 (With latest revisions &
amendments)
Air (Prevention & Control of Pollution) Act- 1981 (With latest revisions & amendments)
The Environment (Protection) Act
L 1986
Manufacture, storage & import of Hazardous Chemicals Rules - 1989.
C
"The Hazardous and Other Wastes (Management and Trans boundary Movement)
Rules, 2016"
j. Petroleum
leum and Natural Gas Regulatory Board (Codes of Practice for Emergency
Response and Disaster Management Plan (ERDMP)) Regulations, 2010
IO
Provisions of all the statutory Acts and rules& regulations framed thereon shall apply as per the
extant version notwithstanding the year mentioned against them anywhere in this standard.
5.0 INSTALLATION LAYOUT
5. 1 G ENERAL
The layout of the LPG facilities including the arrangement and location of plant roads,
walkways, doors and operating equipment shall be designed to permit personnel and
equipment to reach any area affected by fire rapidly and effectively. The layout shall
permit access from at least t wo directions.
The general principles of layout of LPG storage, bottling and bulk handling facilities have
been detailed. The various facilities within LPG installation shall be located based on
Table-I and Table-II.
5.2 LOCATION & SEPARATION DISTANCES:
5.2.1 LOCATION
While assessing the suitability of any site for location of LPG installation, the following
aspects shall be considered:
a) The location of residential quarters, other industries, railways, roads, waterways,
overhead power lines, places of public assemblies etc. This shall be covered in risk
analysis study of the proposed site. The study shall also be used to plan for
emergency measures.

Page no. 5
b) Adequate availability of water from a reliable source or alternate arrangements proposed.

c) The topogra phical nat ure of the site with specific reference to its effect on the
accidental release of LPG.
d) The availability of space for future extension of LPG facilities, if any, shall also c omply
with the safety norms.
e) The meteorological data of the location including predominant wind direction & velocity,
high flood level, temperatures etc.
5.2.2 SEPARATION DISTANCES
The separation distances as given in Table- I & II are the distances in plane between the
nearest point on a vessel other than the filling/ discharge line and a specified feature, e.g.
adjacent vessel, site boundary etc.
5.3 LAYOUT
The following aspects shall be considered while establishing layout of LPG storage
vessels. Bullets or spheres are used for above ground storage of LPG.
a. The access of mobile firef ighting equipment to the storage vessels shall be at least
from two sides.
L
b. Longitudinal axis of static storage vessels (above ground bullets) shall not be pointed
towards other vessels, vital equipment e.g. LPG cylinder sheds, tank lorry/tank
wagon gantries, LPG pump house, first ROV of mounded vessels and buildings
wherein control panels for fire and gas detection/ actuation panels are situated.
C
c. Storage vessels s h o u l d b e located i n pre-dominant downwind of potential ignition
sources at lower elevation.
d. No foreign material / combustible substances shall be stored i n storage area.
e. Storage vessels shall be laid out in single row in each group.
IO
f. Storage vessels shall not be located one above the other.

5.4 LPG STORAGE FACILITIES:
(a) CONFINEMENT/ GRADING -
Kerb wall shall be provided around all sides of the storage vessel with concrete flooring
of the ground under vessel and extending upto minimum distance of D/2 or 5M
whichever is higher and at least 5 M (min.) from the edge of the storage vessel
with a slope of 1:100 (min.).
Grading of the ground underneath should be levelled and directed to an area
connected with water seal away from the storage vessel.
Kerb wall height shall be minimum 30 cm but shall not exceed 60 cm otherwise
evaporation of spilled LPG may get affected.
Spillage diversion area shall be located at a distance where the flames from fire will
not impinge on the vessel. This distance shall be equal to the diameter of the
nearest vessel or 15 M whichever is more. No accumulation of LPG should be
possible underneath the storage vessel in any condition.
(b) PIPING - Only piping associated with the storage vessels shall be located within the
storage areas or between the storage area and the manifold system.
(c) SURFACE DRAINAGE - In order to prevent the escape of spillage into the main
drainage system, surface water from the storage area and from the manifold area

Page no. 6
shall be directed to the main drainage through a water seal to avoid the spread of
LPG. In case plant drain is discharging into storm drain going outside the plant, water
seal shall also be provided at interconnecting sump inside the plant.
Water seals shall have adequate capacity to drain firefighting sprinkler water without
overflowing. Water seals shall be provided with permanent water connection with
metallic float for auto replenishment of water.
Plant shall prepare the drawing of complete plant drainage with water seal locations.
(d) GROUPING - Vessels shall be arranged into groups, each having a maximum of six
vessels. There shall be minimum spacing as specified in Table-I between adjacent
vessels. Each group shall be separated by roads on all four sides for easy access
and emergency handling.
(e) Spheres, bullets and mounded vessels shall be treated as separate groups. Groups
shall be separated by minimum 30 M distance. This inter-distance shall be measured
between the vertical shadow of adjacent vessels of the concerned groups.
Separation distances in case of two groups of Mounded Vessels shall be as per OISD-
STD-150.
Top surfaces of all the vessels installed in a group shall be on the same elevation.
Separate manifolds with independent pumping facilities should be provided for groups
L
with dissimilar elevation. In case manifold from two groups with dissimilar elevation are
interconnected, they shall be connected through fail safe device like 3-way valves or
equivalent system e.g. logic controlled/ interlocked valves to prevent migration of LPG
from vessels with higher elevation to the vessels at lower elevation due to gravitation so
C
as to avoid any chances of inadvertent overfilling.
5.5 LPG B U L K LOADING / UNLOADING FACILITIES
5.5.1 LPG tank lorry loading/ unloading gantry shall be covered and located in a
separate block and shall not be grouped with other petroleum products.
IO
5.5.2 LPG loading/ unloading rail gantries shall have separate rail spur and be grouped
separately at least 50 M from other rail shunting facilities.
5.5.3 Space for turning with minimum radius of 20 M for tank lorries shall be provided
commensurate with the capacities of the tank trucks.
5.5.4 LPG tank wagon loading/ unloading shall be restricted to a maximum of half rake,
not exceeding 600 tonnes. If full rake loading/ unloading is envisaged this shall be
done on two separate rail gantries separated by a minimum distance of 50M.
5.5.5 Maximum number of LPG tank lorry bays shall be restricted to 8 in one group.
Separation distance between the two groups shall not be less than 30 M.
5.5.6 For adequate permanent protection for tank lorry discharge, pipeline island shall be
provided. The minimum width of such pipeline island shall be 1 M.
5.5.7 The layout of the unloading location shall be such that tank truck being unloaded
shall be in drive out position.
5.5.8 The weigh bridge of adequate capacity shall be provided with proper
maneuverability for vehicles.
5.5.9 Tank truck shall be loaded/ unloaded with suitable arrangement for cold flaring of
hose content, if used at the end of the operations.
5.5.10 LPG tank truck parking area (Bulk/ Packed) shall be located in a secured area with
entry/exit gates. Parking area shall be provided with adequate no. of hydrants /

Page no. 7
monitors to provide firefighting coverage for entire parking area from all sides.
-time visual
supervision (Security Guard/CCTV Cameras). Proper slotting/marking shall be done
for safe parking of bulk and packed Lorries in parking area.
5.5.11 Parking area shall be adequate for parking of bulk Lorries & packed Lorries so as to
avoid parking of the bulk/packed trucks on the plant approach road.
Parking area shall be adequate to accommodate (minimum) following requirements of
the plant: -
(a) Bulk Lorries required for 8 hours of maximum rated capacity of the plant bottling.
(b) In case of bulk loading location, bulk Lorries required for 8 hours of maximum rated
bulk loading capacity of the plant.
(c) Packed Lorries required for 4 hours of maximum rated capacity of the plant bottling.
5.6 LPG BOTTLING FACILITIES
5.6.1 LPG bottling facilities shall be located at a safe distance from other facilities with
minimum ingress of traffic and upwind direction with respect to bulk storage.
There shall not be any deep ditches in the surrounding areas at least within 15 M
5.6.2 L
from storage sheds to avoid settling of LPG vapour.
LPG Bottling section shall be of single storey. Antistatic mastic flooring
conforming to IS-8374 shall be provided in the LPG filling shed/ cylinder storage
including valve changing shed to avoid frictional sparks. The shed shall be
C
supported by RCC columns alternatively structure steel columns shall be covered
with concrete or fire-proofing material upto full height of columns. Anti- static
mastic coating upto 1.5 m (Min.) shall be done of the supporting columns of the
shed.
5.6.3 The bottling operation shall be carried out in the filling shed. Separate sheds for
IO
filled storage, valve changing and degassing shall be provided.

Degassing unit can also be provided in valve change shed, however closed loop
vent pipe arrangement shall be provided for venting out the gas released during
water filling at a height not less than 1.5 m above the eves of the shed. Vapour
extraction system and GMS sensor shall be provided near degassing unit. Valve
changing unit without evacuation can b e provided in filling shed itself.
Empty cylinders storage area shall be properly segregated from filling machines
by 5 M (Min.). Cylinders shall always be stacked vertically with maximum stack
height of 1.5 m. For details of cylinders stacking pattern refer Figure - I.
5.6.4 LPG cylinder filling machines and other related testing facilities shall be provided
in sequential order.
5.6.5 Cylinder storage shall be kept on or above grade and never below grade in cellar
or basement.
5.6.6 Filled cylinders shall not be stored in the vicinity of cylinders containing other
gases or hazardous substances.
5.6.7 Escape routes shall be specified and marked in LPG sheds for evacuation of
employees in emergency.
5.6.8 There shall be sufficient no. of crossovers to avoid trapping of personnel in LPG
sheds by conveyors, cylinders and other facilities. Further, sufficient no. of escape
routes shall be provided.

Page no. 8
5.6.9 All steps forming part of the escape routes shall be minimum 1.2 M with treads 30
cms (minimum) and maximum rise of 15 cms.
5.7 PROTECTION OF FACILITIES
5.7.1 Properly laid out roads around various facilities shall be provided within the
installation area for smooth access of fire tenders etc. in such way that all facilities
are accessed at least from two sides in case of emergency.
5.7.2 Proper industry type boundary wall at least 3 M high with 0.6 M barbed wire on
top shall be provided around the installation unless the bottling plant is protected
as a part of refinery complex.
5.7.3 Emergency exit with proper gate shall be provided in the earmarked zone.
5.7.4 In case provision for green belt is made, the same shall be segregated from
hazardous area by 1 M high wall / chain link fencing. Alternatively, it shall be
treated as a part of hazardous area.
L
C
IO

Page no. 9
5.8 UTILITIES
Utilities consisting of fire water pumps, admin. Building, canteen, motor control center,
DG room, air compressors, dryers etc. shall be separated from other LPG facilities and
located as per the separation as specified in Table-I.
TABLE - I
INTERDISTANCE FOR LPG FACILITIES
---------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8
---------------------------------------------------------------------------------------------------------------------------
1. LPG Storage vessels * T-II 30 30 50 30 15 60
2. Boundary/property line/ T-II ** 30 30 50 30 30 **

group of bldgs. not
associated with LPG
installation
3. Shed-LPG 30 30 15 30 50 30 15 60
4. Tank truck gantry
5. Tank wagon gantry

LPG 30
50
30
50 L 30
50
30
50
50
50
50
50
30
30
60
60
C
6. LPG/other rail spurs 30 30 30 50 50 50 30 60
7. Pump house/ Comp. 15 30 15 30 30 30 ** 60

house (LPG)
8. Fire Pump House/ storage 60 ** 60 60 60 60 60 **
tank
---------------------------------------------------------------------------------------------------------------------------
IO
Notes:
1. All distances are in meters. All distances shall be measured between the nearest
points on the perimeter of each facility except in case of tank vehicle
loading/unloading area where the distance shall be measured from the center of
each bay and for storage vessels where the distance shall be measured from the
nearest point on the vertical shadow of the vessel.
2. Explanation:
T-II - Refer Table II
* 1/4 of sum of diameters of adjacent vessels or half the diameter of the
larger of the two adjacent vessels, whichever is greater.
** Any distance for operational convenience.
3. Distance of stabling line shall be as per Railway guidelines.
4. Shed-LPG: - Minimum 20 M inter distance shall be maintained between the cylinders
loading/unloading fingers & boundary wall/property line/ group of buildings in a collinear
direction of the LPG Shed fingers.

Page no. 10
TABLE - II
DISTANCE BETWEEN LPG STORAGE VESSELS AND PLANT BOUNDARY/
GROUP OF BUILDINGS NOT ASSOCIATED WITH LPG INSTALLATION
---------------------------------------------------------------------------------------------------------------------------
Capacity of each Distance
vessel (Cu.Mt. of water) (in meter)
---------------------------------------------------------------------------------------------------------------------------
10-20 15
> 20-40 20
>40-350 30
>350-450 40
>450-750 60
>750-3800 90
> 3800 120
--------------------------------------------------------------------------------------------------------------------
6.0 DESIGN CONSIDERATIONS
6.1 GENERAL
This section describes the design and safety features required in a typical LPG bottling
installation.
6.2 LPG STORAGE VESSELS
L
The minimum requirements w.r.t. design considerations and various fitting to be provided
LPG storage vessels shall be as under
under::
C
6.2.1 MECHANICAL DESIGN
i. The storage vessel shall be designed in accordance with the codes i.e. ASME SEC.
VIII or IS-2825 or PD - 5500 or equivalent duly approved by CCE. Design shall take
into account the Static and Mobile Pressure Vessels (Unfired) Rules 1981 also.
IO
A single code shall be adopted for design, fabrication, inspection and testing of the
same storage vessel.
ii. Material shall be in line with design code. ASTM A516 Gr. 60 shall be used for
refinery service (BS-5500
(BS- shall not be used for the same) and for marketing
installation where H2S is not present ASTM A 516 Gr. 70 or A 537 CLASS 1 can be
used. Micro-alloyed steel containing Ni, Mo, Va shall not be considered. Maximum
specified tensile stress shall not be more than 80 ,00 0 psi.
o o
iii. Design temperature: (-) 27 C to (+) 55 C.
2
iv. Design Pressure: 14.5 Kg/cm g (1.42 Mpa) vapour pressure of LPG at top of the
vessel (as per IS: 4576 or IS: 14861) at 55 oC.
The recommended design pressure and temperature shall be treated as MINIMUM
requirement and other design consideration and statutory requirements shall also be
considered.
v . Other Design Considerations
Corrosion Allowance: minimum 1.5 mm
Radiography: Full
Stress Relieving: 100% irrespective of t h i c k n e s s.
Wind pressure: as per IS: 875
Earthquake pressure: as per IS: 1893

Page no. 11
Hydro test pressure: As per Design Code

Where ever extreme climatic conditions or security reasons warrants, suitable alterations
in design can be made with approval from statutory bodies.
6.2.2 FITTINGS
Spheres/ bullets other than underground shall have a single nozzle at the bottom for
liquid inlet as well as outlet. The nozzle shall be full welded pipe, stress relieved along
with the vessel and shall extend minimum 3 meters from the shadow of the sphere/ bullet.
A remote operated shutdown valve (ROV) shall be provided on this bottom nozzle at a
distance of at least 3 meters from the shadow of sphere/ bullet. The nozzle pipe shall
o
have a minimum slope of 1.5 to horizontal.
There shall not be any other flanges, manhole, and instrument tapping on this nozzle up to
the ROV or on sphere / bullet bottom. In order to avoid stress on the nozzle due to
relative settling of support and storage vessel, suitable supports for the bottom nozzle
shall be provided.
The top vapour zone of the vessel shall be provided with nozzles for vapour outlet,
recirculation wherever applicable. These lines shall be provided with fire safe ROV
(Valve). ROVs for vapour a n d / or recirculation lines should be provided at the
ground level with an isolation valve at top. In case, ROV is provided at top of the
L
vessel, there is no need to provide an isolation valve.
Fire safe ROVs (Valve) shall also be provided on liquid line and vapour line at TLD, Tank
wagon gantry and on the entry of liquid lines at LPG filling shed. ROVs shall be provided
with QB detector & sprinkler nozzles to cool the complete ROV uniformly in case ROV is
C
provided within 15 m from such facilities.
Provision for shut down operation in local mode shall be made for ROVs from operating
station located at a minimum distance of 15 M from the facility.
All ROV's shall have provision for electro-pneumatic actuation.
IO
Nozzles for two independent level indicators of different type, a high level switch, two safety
relief valves, pressure gauge and a manhole shall be provided on top.
Facility for water draining to be provided through a water draw off line between the liquid
ROV of vessel and the subsequent isolation valve. Two valves, with suitable distance piece
between them, shall be provided between ROV and the first isolation valve. The first drain
valve from the vessel should be of quick shut-off type valve while the second valve should be
throttle type (Globe Valve).
All the fittings shall be suitable for use at the design parameters of the storage vessels and
for the temperatures appropriate to the worst operating conditions. The remote operated
valves on the storage vessel connecting pipelines shall be fire-safe type conforming to
API 607 or equivalent.
The flange joints of these valves shall either have spiral wound metallic gaskets or ring
joints. Plain asbestos sheet / reinforced gaskets shall not be used. Gasket used shall
conform to ASME B16.20 or equivalent. The studs used shall conform to ASTM A 194
Gr 2 H/ ASTM A 193 Gr B7 or equivalent.
Flange connections shall be of minimum of 300 lb rating confirming to ANSI B16.5 class
300 or equivalent. All tapings or openings shall be of mi nimum 20 mm thickness.
6.2.3 INSTRUMENTS
i) E a c h storage vessel shall have a t least two level indicators, each working on
different principles. In addition, one independent high level switch shall also be

Page no. 12
provided. High level alarms shall be set at not more than 85% level of the volumetric
capacity of the vessel. Audio visual indication shall be at local panel & control room.
On actuation of high level alarm, the ROVs of the affected vessel shall close.
ii) Each storage vessel shall have at least two safety relief valves with isolation
arrangement set at different values and at not more than 110% of design pressure
of the vessel and each having 100 % relieving capacity adequate for limiting the
pressure build up in the vessel not more than 120% of design pressure.
The relieving load for the safety valves shall be based on fire condition and no credit
shall be taken for fire proofing on the vessel, if provided.
The discharge of safety valves shall be connected to flare system, wherever available. In
this case, safety valves shall have lock open (or car seal open) type isolation valves on
both sides of saf et y valves.
In case of non- availability of flare system, the discharge from safety valve shall be
vented vertically upwards to atmosphere at an elevation of 3 meter (minimum) for
effective dispersion of hydrocarbons. In this case, isolation valve on downs tream of
safety valve is not required. A weep hole with a nipple at low point shall be provided on
the vent pipe in order to drain the rain water which may get accumulated otherwise.
Weep hole nipples shall be so oriented that in case of safety valve lifting and consequent
fire, the flame resulting from LPG coming out from weep hole does not impinge on the
shall be provided on top of saf ety valve. L

Sphere or structure. A loose fitting rain cap with a chain (non sparking) fitted to vent pipe
Typical safety fittings on a LPG storage vessel are indicated in Figure-II.

C
6.3 LPG LOADING/ UNLOADING FACILITIES
Each loading station shall consist of the following:
i. Excess flow check valve & non return valve shall be provided in LPG loading lines.
IO
ii. A vapour return line with an isolation valve connected back to the storage vessel/
suction line with NRV.
iii. Properly designed loading arm or LPG hoses shall be provided at the end of filling and
vapour return lines for connecting to the tank truck vessel. The loading arm shall be
provided with breakaway couplings. An isolation valve shall be provided before the
breakaway coupling. Provision shall be made for cold flaring of this section before
disconnecting the arm from the tank truck. Alternatively, Hoses (hoses having
integrated valve in each end fittings, which, if the hose assembly experience a
catastrophic hose failure, shall instantaneously shutting down the flow in both directions)
shall be used. Loading arm shall be of approved type and be tested as per OEM
recommendations. In case, LPG hoses are used, it shall conform to OISD-STD-135 or
equivalent as approved by CCE.
iv. The hose - coupling / flange joint shall be of Class 300 lb rating with metallic
gasket. The hose coupling shall be provided with a cap or blind flange by which the
nozzle can be cl ose d when not in use.
v. Weigh bridges of suitable capacity for road / rail movements and mass flow meters
for pipeline transfers shall be provided. The mass flow meters shall be certified for its
use with LPG.
vi. A check valve shall be provided in the vapour return line.
Unloading of LPG from tank truck is carried out with vapour compressors using pressure
differential method of liquid transfer. The compressor used for unloading shall be

Page no. 13
provided with the following facilities:

i. Vapour line with isolation valves
ii. Excess flow check valve & non return valve shall be provided in LPG unloading lines
with isolation valves
iii. Weigh bridge of suitable capacity
Additionally, following shall be ensured.
i. Suitable provision shall be made for evacuation of LPG from bulk storage vessels to
tank truck or another vessel to empty the vessel in case of emergency or for statutory
testing.
ii. Tank truck shall be unloaded with suitable arrangement for flaring of hose content
at the end of the operations. In case unloading arms are used for unloading operation,
the section from tank truck valve to the first isolation valve in the arm shall be
depressurized by cold flaring before disconnection of the arms from the tank truck.
iii. Unloading arms shall be used for unloading the LPG TT at LPG installation. Th The
unloading arms shall be provided with breakaway couplings. Isolation valve should be
provided before the breakaway coupling. Alternatively, LPG Hoses (hoses having
integrated valve in each end fittings, which, if the hose assembly experience a
L
catastrophic hose failure, shall instantaneously shutting down the flow in both directions)
shall be used. Unloading arm shall be of approved type and be tested as per OEM
recommendations. In case, LPG hoses are used, it shall conform to OISD-STD-135 or
equivalent as approved by CCE.
C
iv. The hose - coupling / flange joint shall be of 300 lb rating with metallic gasket. The
hose coupling shall be provided with a cap or blind flange by which the nozzle
can be close d when not in use.
6.4 CYLINDER FILLING FACILITIES
IO
i. The cylinder filling area shall be completely open type and covered from top with roof
designed to ensure good natural ventilation. RCC roofing shall not be used.
ii. The filling area shall not be on upper floors of building or in cellars unless specifically
required on account of extreme weather conditions.
iii. As far as possible, the floor area shall not have any channels or pits. Where these
are necessary for conveyors or other equipment like weigh machine etc., suitable
gas detection system shall be provided. Additionally, proper ventilation system
through ducts fitted with blowers shall be provided to release LPG outside of the
shed at safe location. The whole of the LPG filling shed flooring shall be provided
with mastic flooring.
iv. All carousels including electronic ones & leak detectors sh a l l be of type approved by
Chief Controller of Explosives.
v. Adequate lighting shall be provided in the cylinder filling area. Emergency lighting
shall also be provided at critical places.
vi. Water drains from the cylinder filling area shall be provided with water seals wherever
they interconnect with an inside or outside drainage system.
vii. A drawing shall be kept readily available with complete plant drainage system and water
seal locations displayed therein.
viii. Proper access shall be made available for other firefighting equipment i.e. fire
tender, foam trolley etc.

Page no. 14
ix. Cylinder storage area requirement shall be worked out based on the stacking
pattern of filled and empty cylinders as described in Figure-I.
x. The filling machines shall be provided with auto cut-off system so that LPG supply is
cut off when the desired quantity of product has been filled in the cylinders. The filling
pressure shall not be more than the design pressure of the cylinders i.e. 16.9
kg/sq.cm.g.
xi. Filling machines in a carousel/ stationary filling machines shall not have a
weighment error of more than + 150 gm of the net quantity of the LPG filled in the
cylinder, with a capacity of 14.2 kg or as specified in Weights and Measures Rules.
xii. On-line check weighs scales with a minimum of 50 gms graduation be installed so
that all the cylinders are check weighed after filling.
xiii. Compact Valve Tester to check valve and 'O" ring shall be installed on line.
Alternatively, electronic leak detectors shall be provided.
xiv. Water test bath or electronic leak detectors shall be provided to detect body and
bung leak cylinders. Facility shall be provided for all capacities of cylinders being filled
in the plant. Electronic leak detectors if provided shall be of type approved by Chief
Controller of Explosives.
xv. Vapour extraction system at strategic locations near carousel, cylinder evacuation
L
unit, valve changing unit, degassing shed and at locations where leaking LPG is
expected to accumulate shall be provided. Further, it shall be interlocked with
filling machine so that filling does not start without vapour extraction unit being
functional.
C
6.5 UTILITIES
(A) Compressed air
The quality of instrument air shall conform to the requirements as recommended by the
manufacturers of instruments/ equipment:
IO
If one compressor is envisaged to run normally, another standby compressor of 100%

capacity shall be provided. When more than one compressor running is envisaged, 50%
standby capacity shall be provided.
(B) Service Water
Service water is required for the cylinder washing equipment and leak check bath,
compressor cooling and in hose stations for washing etc.
Water may be provided at a pressure of about 3 Kg/sq.cm.g. If one pump is envisaged to
run normally, another pump with 100% capacity shall be provided as a standby. Where
more than one pump running is envisaged, 50% capacity as standby shall be provided.
Water Quality
Water shall be of potable quality conforming to IS: 10500 - Specification for Drinking
Water.
(C) Emergency Power
The installation shall be provided with battery / diesel generating set for operating the
essential systems such as the instrumentation and safety systems (gas detectors,
automatic fire water sprinkler system) and minimum lighting during the grid power failure.
6.6 LPG PUMPS
i. LPG Pumps shall be designed for handling of LPG and safely withstands the maximum

Page no. 15
pressure which could be developed by the product and / or transfer equipment.

Pumps shall conform to API 610 or equivalent.
ii. Check valves shall be installed on the delivery side of all centrifugal pumps.
iii. LPG Pumps shall be provided with suction and discharge pressure gauges, a high
point vent to safe height or flare, and a suction strainer.
iv. Double Mechanical seal with seal failure alarms shall be provided.
v. Anti-cavitation protection through a pressure switch, taken from discharge end,
actuating a low pressure alarm both in control room as well as local annunciator shall be
provided. Actuation of low discharge pressure alarm shall trip the LPG Pump
automatically.
vi. Pumps shall be designed to build a discharge pressure such that the pressure at the
carousel filling machine is at least 5.0 kg/sq.cm.g. above the vapour pressure at
the operating temperature.
vii. Pumps shall have a by-pass valve and other suitable protection against high
discharge pressure on the delivery side.
viii. The electrical motor drive and switchgear shall conform to area classification as per
OISD Standard-113 / IS -5572. Belt drives shall be of the anti-static type.
panel provided in the LPG pump house. L

ix. Provision shall be made for Audio Visual indications of various safety trips in the local
Typical sketch of a bottling pump installation is enclosed as Figure-III.

C
6.7 LPG VAPOUR COMPRESSOR
i. Compressors shall be suitable for handling LPG and designed to safely withstand the
maximum outlet pressure to which these will be subjected. Compressors shall
conform to API 618 or API 619 or equivalent.
IO
ii. The belts used in shall be of anti static type & fire resistant.
iii. Compressor shall be provided with the following features as a minimum:
- Pressure gauges in suction and discharge.
- Temperature gauge in discharge
- Discharge safety valve and a vent valve, their outlets leading to flare/ safe height
outside the shed.
- Low Suction Pressure Trip
- Suction strainer
- High Discharge Pressure Trip
- High Temperature Trip
- Check valve in discharge
- A discharge to suction recycle valve for achieving capacity turndown during startup.
- Low cooling water pressure trip
- Audio Visual indications of various safety trips in the local panel provided in the LPG
compressor house
- Provision for unloading shall be provided and compressor shall start in unloading

Page no. 16
condition only.
iv. A suitable size scrubber or liquid knockout drum shall be installed upstream of the vapour
compressor. It shall be equipped with a gauge glass, safety relief valve, a drain and high
liquid level shut down device.
Typical sketch of compressor installation is enclosed as Figure-IV.
6.8 PIPING
Piping shall be designed for handling of LPG. Piping that can be isolated and need thermal
2
safety valves shall have minimum design pressure of 24 kg/cm or the maximum
pressure which could be developed by the transfer equipment or any other source
etc., whichever is higher and comply with the following:
i. Piping shall conform to the prov isio ns of ANSI B 31.3.
ii. The material shall conform to API 5L Gr. B / ASTM A106 Gr B or equivalent.
iii. Seamless pipes shall be used. Furnace butt welded or spiral welded pipes shall not be
used.
iv. Pipe joints should be welded as far as practicable with full penetration weld. Number of
flanged or threaded joints should be kept to a minimum.
L
v. Low point drains and high point vents shall be plugged or capped suitably.
vi. Buried piping shall be protected against physical damage and corrosion with suitable
sleeves, properly sealed at both the ends, at road crossings.
C
vii. Same MOC shall be used for LPG liquid, vapour and venting pipe line.
viii. Pressure relief & thermal relief valves shall be constructed of steel. For existing plants,
shall be implemented at the time of replacement of the concerned item/s.
6.9 THERMAL PRESSURE RELIEF SYSTEM
IO
Any equipment or section of pipeline in which liquid LPG may be trapped e.g. between shut
off valves, shall be protected against excessive pressure developed by thermal expansion of
the LPG by providing suitable thermal pressure relief valve(s). If pressure relieving devices
discharge to atmosphere, the discharge shall be cold flared vertically upwards at an
elevation of 2M (minimum) from the point of TSV discharge for effective dispersion.
Set pressure of Thermal Safety Valve shall be not more than 110% of design pressure of
the pipe lines on which they are installed.
6.10 VALVES
Steel valves conforming to relevant API standards shall be used. Cast iron valves should
not be used.
6.11 FITTINGS
i. Steel flanges and flanged fittings conforming to API 105 Class 300 (forged) or eq.
shall be used. Slip on or weld neck flanges should be used. Screwed flanges for
sizes 50 mm or smaller may be used. Steel flanges should conform to the
applicable provisions of ANSI B 16.5.
ii. Steel screwed fittings and couplings shall conform to ANSI B 16.11 or equivalent.
Steel unions shall have ground metal to metal seats. Gasket type unions shall not
be used.
iii. Plugs shall be of steel. Cast iron or brass plugs shall not be used.

Page no. 17
iv. All flanges shall be connected for bonding for electrical continuity.
6.12 EVACUATION FACILITY FOR DEFECTIVE CYLINDERS
a. The cylinder evacuation facility shall consist of:
- Cylinder emptying vessel (s)
- Compressor
- Four way valves or equivalent
- Cylinder rack, header to be provided with pressure gauge and a strainer with isolation
valves.
- The LPG line exit cylinder evacuation area to be provided with a non-return valve
before joining the main LPG return header.
- Independent earthing connections.
b. Each of cylinder emptying vessels mentioned above shall be equipped with the
following:
- Pressure gauge
-
-
-
Level gauge
L
High level alarm switch set at 85 % with trip / switchover arrangement.
Pressure relief valves with isolation arrangement and set at values not exceeding 110% of
C
design pressure of the vessel. In case one SRV is considered for vessel less than 1000 lt
capacity, such unit shall be kept idle till the time a calibrated SRV is replaced.
- Vent valves discharging to 1.5 m above the shed.
- Other trims like drain valve, utility connection.
IO
Typical sketch of cylinder evacuation facility is enclosed as Figure-V.

6.13 PURGING OF NEW CYLINDERS/ TANKERS
(a) The new LPG cylinders containing air shall be evacuated with a vacuum pump. The
evacuation facility shall consist of
of:
- Vacuum pump (water/ oil / air cooled type)
- Purging manifold
- Vacuum receiver fitted with vacuum gauge, vent and drain.
- LPG vapour header
- Purging adapters
- Vacuum pump with suction strainer
- Pressure regulator, relief valves
Typical sketch of new cylinder purging system is enclosed as Figure-VI.
(b) Purging of tankers/ vessels shall be done using either Nitrogen or by filling water and
displacing with LPG vapours.
6.14 EQUIPMENT FOR ETHYL MERCAPTAN SERVICE
6.14.1 Material of Construction of Ethyl Mercaptan containers

Page no. 18
Stainless steel and copper free steel alloys are the preferred materials of
construction of equipment for mercaptan service. Aluminum of desired pressure
rating can also be used. Use of Iron or carbon steel shall be avoided as there is
the hazard of formation of Iron-Sulphur complexes which are pyrophoric. Copper
or copper bearing alloys shall not be used for mercaptan service as mercaptan
readily attacks and contaminates them.
6.14.2 Pumps for Mercaptan service
Only hermetically sealed pumps shall be used.
6.14.3 Piping and Fi tt ings
i. Seamless stainless steel piping shall be used. Threaded fittings can be used
provided they meet the service requirement ratings. A fluoroplastic tape sealant is
recommended.
ii. Flexible connections shall be seamless stainless steel with pipe nipples welded
to each end.
iii. Relief valves shall be full nozzle, disc type, closed bonnet carbon steel body
with 304 stainless steel trim and stainless or aluminized steel spring.
iv. For transfer valves, stainless steel ball valves with fluoroplastic seats and
v.
vi.
Fluoroplastics shall be used for gasketing.L
stainless steel (SS316) trim or their equivalent are recommended.
For pressure gauges, stainless steel diaphragm type is recommended w i t h

C
stainless steel socket and tip.
vii. Provision for analysis in line with IS:4576 or IS14861 as applicable shall be
made.
6.15 SELECTION OF ELECTRICAL EQUIPMENT
IO
i. Electrical equipment shall be selected, sized and installed so as to ensure

adequacy of performance, safety and reliability. The equipment in general shall
conform to relevant Indian Standards and shall be suitable for installation and
satisfactory operation in the service conditions envisaged.
ii. All electrical equipment shall be selected considering the system neutral earthing.
iii. Electrical equipment including for lighting system shall conform to hazardous area
classification and be selected in accordance with IS:5571. These shall be tested
by agencies such as CMRI, ERTL, CPRI or independent test laboratory of country
of origin for such equipment. Indigenous Flameproof equipment shall comply
with relevant BIS standard a s per requirements of statutory authorities. All
equipment used in hazardous area shall be approved by Chief Controller of
Explosives.
iv. For details on hazardous area classification, enclosure protection etc., OISD-
STD 113, OISD-RP-149, NEC 1985, IS/IEC 60079-1 (2001), IS:5571, 5572,
Petroleum Rules, 2002 shall be referred.
6.16 Installation Lighting
i. Sufficient lighting shall be provided so as to enable plant operators to move safely
within the accessible areas of installation and to perform routine operations. In the
event of normal power failure, emergency lighting shall be provided.
ii. Normal lighting system shall be on 415/ 240V AC supply, whereas emergency

Page no. 19
lighting will be either on 220V or 110V DC.

iii. Lighting requirements provided during the failure of power supply for Normal lighting
are intended broadly,
a. to facilitate carrying out of specified operations, for safe shutdown of the
installation.
b. to gain access and permit ready identification of firef ighting facilities such as
fire water pumps, fire alarm stations etc.
c. Escape route for safe evacuation of operating personnel.
iv. Under normal operation, both emergency and normal lighting shall be fed by normal
power source. On failure of normal supply, emergency lighting shall be transferred to
emergency source until the start of D.G. set within 15 seconds. Critical lighting (D.C.
supply based) shall be normally kept During power failure, battery bank shall
be used to provide power.
v. Low pressure sodium vapour lamps shall not be installed in hazardous areas.
vi. The illumination levels in different areas shall be as per good engineering practice.
Depending on the nature of job activities to be carried out the suggested minimum
illumination levels for various areas are covered in OISD-STD-
OISD-STD-149.
149.
L
vii. The lighting fixtures on various circuits shall be suitably interlaced so that failures of
any one circuit do not result in complete darkness.
viii. Switches controlling the lighting fixtures and exhaust fan shall be installed outside
C
the battery room.
ix. Switches of lighting panels installed in hazardous area, shall have a pole to break
the neutral in addition to the poles for phases.
When the means of isolation is located in a non-hazardous area, the switch shall
break all poles including neutral or alternatively may break only live poles, the neutral
IO
being isolated by a removable link.

For details on inspection practices OI SD standard 147 to be referred.
6.17 Installation Earthing
i. All electrical equipment shall be suitably earthed. Earthing system shall cover
the following:
Equipment earthing for personnel safety.
System neutral earthing, and
Protection against Static and Lightning discharges.
The earthing system shall have an earthing network with required number of earth
electrodes connected to it. The following shall be earthed:
System neutral
Metallic non-current carrying parts of all electrical apparatus such as
transformers, switchgears, motors, lighting / power panels, terminal boxes,
control stations, lighting fixtures, receptacles etc.
Steel structures, loading platform etc.
Cable trays and racks, lighting mast and poles.
Spheres, Bullets etc.

Page no. 20
Electrical equipment fencing (e.g. transformer, yard etc.)

Cable shields and armor.
Flexible earth provision for wagon, truck.
ii. Installation earthing design shall be carried out in accordance with the requirements
of Indian Electricity Rules and IS: 3043. All earth connections should be visible for
inspection to the extent possible.
iii. Where installed, lightning protection shall be provided as per the requirements of
IS/IEC 62305-1: 2010, IS/IEC 62305-2: 2010 & IS/IEC 62305-3: 2010.
iv. The resistance values of an earthing system to the general mass of earth should be
as below:
For the electrical system and equipment, a value that ensures the operation
of the protective device in the electrical circuit but not in excess of 4 Ohms.
10 Ohms in the case of all non-current
-current carrying metallic parts of major
electric apparatus or any metallic object.
v. The earth conductor shall be adequately sized to carry the applicable maximum earth
fault current without undue temperature rise. All joints shall be protected against
corrosion.
L
vi. All the electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grid.
C
vii. The main earthing network shall be used for earthing of equipment to protect it
against static electricity.
viii. An independent earthing network shall be provided for lightning protection and this
shall be bonded with the main earthing network below ground, minimum at two
points.
IO
ix. Every Sphere/ bullet shall be electrically connected with the earth in an efficient
manner by not less than two separate and distinct connections. The connections and
the contacts required shall have as few joints as possible. All joints shall be riveted,
welded or bolted and also soldered to ensure both mechanical and electrical
soundness. The resistance to earth shall not exceed 7 Ohms and the resistance to
any part of the fitting to the earth plate or to any other part of fitting shall not exceed 2
Ohms.
x. All joints in pipelines, valves in installations, and associated facilities and equipment
for LPG shall be made electrically continuous by bonding or otherwise; the resistance
value between each joint shall not exceed 1 Ohm.
7.0 STORAGE AND HANDLING OF BULK LPG
7.1 GENERAL
This section deals with the safe practices and provisions applying to l o a d i n g
a n d unloading of bulk LPG and storage of bulk LPG at installations. There should
be strict compliancew.r.t selection, deployment of proper skilled manpower for
effective operation and maintenance.
7.2 BULK HANDLING FOR MOVEMENT BY ROAD
The tank truck for road movement shall be designed, constructed and tested in
accordance with the Static and Mobile Pressure Vessels (Unfired) Rules, 1981 and
OISD-STD-159.

Page no. 21
7.2.1 SAFETY PRECAUTIONS

Following precaution should be taken due to associated hazards during transfer of
LPG to or from a tank truck.
1. No source of ignition must be allowed in the area where product transfer
operations are carried out.
2. Fire extinguishers shall be placed near the tank trucks during transfer operations.
3. The first operation after positioning the truck should be to provide proper
earthing. Earthing shall be disconnected just before the release of the truck.
4. Before removing plugs or caps, always crack open to allow for release of
trapped LPG and further to ensure that the valves are effectively sealing.
5. Hoses shall be handled with care and inspected periodically as per OISD-STD-
135.
6. While disconnecting hoses/arm, connections shall be loosened only slightly at
first to allow release of trapped pressure, if any.
7. Do not expose hands, face or clothing to liquid LPG. Always use personal
protective equipment while making or breaking the connections to avoid cold
burns.
L
8. The master switch shall be put off immediately after parking the truck in position.
No electrical switch on the truck shall be turned " on" or " off" during the transfer
operation.
C
9. No repairs shall be made on the truck while it is in the loading area.
10. Availability of wheel chokes.
11. New tank trucks vessels or vessels received after repair shall be purged as
per laid down procedure.
IO
12. In case, the receiving vessel is having a pressure of less than 1 Kg/sq.cm.g, it
shall not be filled. Such vessel shall be taken for filling only after detailed
safety checks.
13. Venting and purging of LPG during transfer operation shall not be carried out
in open atmosphere. It shall be piped to a suitable flare system. Where such
facility does not exist, vent pipes shall be provided to carry the vented product
to a safe distance and released at a height not less than 1.5 m above the eves
of the structure.
14. Filling/transfer operations should be stopped immediately in the event of -
i. Uncontrolled leakage occurring
ii. A fire occurring in the vicinity
iii. Lightning and thunder storm
7.2.2 PROCEDURES F O R O P E R A T I O N
(a) LOADING OPERATIONS
1. Check for following in a tank truck as per statutory regulations before
accepting it for filling:
Provision of two safety valves, level gauge, Excess flow check and
control valve on liquid and vapour lines, pressure gauge, temperature

Page no. 22
gauge on the vessel / bullet.

Fire screen between cabin and vessel is provided. For this purpose,
cabins with metallic back cover without any opening will be considered as
fire screen.
Provision of 2 nos. of 10 Kgs. DCP Fire Extinguishers.
Spark arrester welded to the exhaust pipe of the prime mover/horse and
spark arrester shall be of a type approved by the CCE.
Any alternate spark elimination system duly approved by CCE shall also
be acceptable e.g. in case exhaust of diesel engine is based on design
having electronic fuel management with unit injectors and electronic
control unit coupled with turbo charger and intercooler arrangement, no
separate spark arrester be provided.
No leakage in exhaust silencer pipe exists.
Manufacturer's name plate with date of testing is fitted on the vessel.
Valid Explosive License and RTO certificate is available.
Approved drawings of vessel are available.
Availability of Earthing cable. L

Blind flanges/caps are provided on vessel.
Bonding between vessel and chassis and between flanges is satisfactory.

C
Earthing / bonding point is available.
Third party inspection/test certificates for vessel/fittings are available.
Liquid / vapour line valv es are in good condition.
Provision of internal EFCV on the vessel of the Tank Truck
IO
Air brakes are not bypassed.

Master switch (300
((300-amp
300-amp
-amp rating) with double pole wiring
Valid authorization either on the driving license or on the certificate issued by
RTO for carrying hazardous goods as per MV Act
Dedicated second crew in tank truck
2. Move truck to the loading bay/weigh bridge and record the weight of the empty tank
truck.
3. Place the truck on loading bay and place choke blocks at front and rear wheels.
Keep the truck in neutral mode with hand brakes "ON".
4. Stop the engine and switch off all electrical equipment. The master switch shall be put
off immediately after parking the truck in position. No electrical switch on the truck shall
on.
5. All persons should leave the driver's cabin.
6. Make earthing connections of the vehicle at specified point to the fixed grounding
system.
7. Connect liquid and vapour lines suitably with the loading point. Crack open valves
on loading & vapour return lines and inspect Arms/ hoses & connections for
leakage. Loading should start only when the system is leak free.

Page no. 23
8. Start the loading pump.

9. The quantity loaded into the truck can be determined by -
i. Liquid level
ii. Weighment
iii. Positive displacement meter
iv. Mass flow meter
The quantity of LPG filled shall not exceed the RLW of the tank truck.
10. Liquid level may be determined by roto-gauge or fixed liquid level gauge. Percentage
O
volume to be filled shall not exceed 85 % at 55 C i.e. the allowable filling limit as per
CMV Rules.
11. Where weigh bridge is used, it is necessary to determine the density of the product
being loaded to avoid excess filling in terms of volume. The weigh bridge shall be
periodically calibrated and stamped by Weights & Measures Authorities.
12. When the filling operation is in progress, the pressure within the tank truck vessel
shall be observed to ensure that it does not approach the start-to
start-to-discharge
start-to-discharge
-discharge pressure
L
of the relief valve. Filling rate may be regulated as required.
13. The couplings may then be removed and plugs/caps replaced on the tank truck
valves. Re-check
-check tightness with soap solution.
C
(b) Unloading Operations
1. Operations described under Item 1 through 6 in para 7.2.2(a) should be
carried out.
2. Liquid line and vapour line of the tank truck shall be connected to the respective
u n l o a d i n g a r m s o r hoses fixed to the designated unloading point.
IO
3. Test the connections for leaks by slightly opening the valves for pressurising. When
satisfied, valves on the tank truck and the receiving vessel shall be opened.
4. Start the LPG compressor. Vapours will be sucked from the receiving vessel and
will be discharged into the vapour space of the tank truck vessel creating pressure
differential thereby pushing the liquid from the tank truck vessel to the receiving
vessel.
5. Care should be exercised to see that the pressure created within the
delivering vessel does not reach or exceed the set pressure of the relief valve.
6. An authorised person of the company shall supervise the transfer operation and
respond immediately in the event of an emergency.
7. After the liquid has been expelled, the vapour recovery operation may be started.
Care should be taken not to bring down the pressure of the delivering vessel below
2
1.5 Kg/cm g.
Checklist for bulk LPG tank Trucks at unloading locations is given at Annexure 7 I.
7.3 BULK HANDLING FOR MOVEMENT BY RAIL
LPG is moved in Tank Wagons by the Railways. These wagons are designed
by RDSO and are fitted with various devices as shown in Figure-VII.
The loading facilities are similar as for tank truck loading while unloading of LPG

Page no. 24
from tank wagons shall be done with the help of compressor. The compressor is used
to create a differential pressure between the receiving and discharging vessels
by withdrawing vapors from the receiving vessel and forcing it at high pressure into
the discharging vessel thereby establishing a smooth flow. The content of tank
wagons can be ascertained by weighment on weigh bridge before and after
emptying or, alternatively, mass flow meters can be used.
Checklist for bulk LPG tank wagons at unloading locations is given at Annexure 7
II.
7.3.1 SAFETY P R E C A U T I O N S
1. Do not allow the locomotive to come on the weigh bridge unless its capacity is
designed to take the locomotive load.
2. Sufficient number of dummy wagons shall be used to avoid coming
within 15 m from first fill point during placement or withdrawal of rake.
3. The first operation after positioning the wagon shall be to provide for proper
earthing. Earthing shall be disconnected just before the release of the wagon.
4. For connecting and disconnecting arms or hoses, only non
non-sparking tools shall be
used.
L
5. After the wagons are placed on weigh bridge and before the loco is detached,
the hand brakes on each and every wagon shall be applied.
6. Like-wise, before the wagons are moved from the weigh bridge, release brakes on
C
all the wagons.
7. Safety shoes shall be worn by all the operating crew members.
8. Ensure that the lower portion of Flapper Bridge at wagon side is fitted with rubber
or wooden padding.
IO
9. Ensure that electrical continuity of the sy stem is intact.
10. Ensure that all fittings on the wagons are checked physically.
11. Hoses shall be tested as per OISD-STD-
OISD-STD-135 and records maintained.
12. The loading/unloading operation shall be carried out under close supervision of
authorised person.
13. During unloading operation, after the liquid transfer is over, the wagon pressure
shall not be reduced below 1.5 Kg/sq.cm.(g).
7.3.2 OPERATING PROCEDURES
(a) LOADING OPERATION
1. Place the wagon on Weigh Bridge taking care to see that all the four wheels
are properly accommodated on the platform. Engage hand brakes.
2. Ask loco to move away and exhibit caution sign at suitable distance away
from the wagons on both ends.
3. Switch off loco engine, if parked nearby.
4. Apply brakes on all wagons
5. Ensure fire system, safety interlocks, communication system are OK
6. Take loading advice.

Page no. 25
7. Connect earthing lugs to the wagons.

8. Lower the flapper bridge slowly on the wagon.
9. Open the lid of the wagon.
10. Take the tare weight reading and set the pointer of the scale to zero.
Compare this with the marked tare weight on the wagon. Alternatively, use
mass flow meter to fill the wagons.
11. Connect the filling hose or loading arm and vapour return line hose or arm to
the wagon. Ensure that the flare connection valves are closed.
12. Ensure that the header is charged with LPG and the bulk loading pump is
running.
13. Open the tanker filling line valve and vapour return line valve.
14. Check t he system for leaks.
15. Open the valve on the vapour return line. Now slowly open the valve on the
filling line. Increase the valve opening and gradually open the valve fully.
Ensure filling is upto safe filling level keeping in view temperature factors.
Take mass flow meter readings if used.
L
16. Once the filling is over, close the wagon filling and vapour return lines valves
and also valves on filling and vapour return lines at the loading point.
17. Open the valve on flare line connection to both feed line and vapour return
C
line slowly while depressurizing to avoid ice formation. Then, close the flare
line connection valves.
18. Disconnect the filling and vapour return line a rm o r hose connections from
the wagon. Replace and tighten the plugs on filling and vapour return lines.
IO
19. Close the top cover of the wagon and seal it properly. Remove earthing
connections.
20. Release the hand brake of the wagon.
21. Release all the wagons on the loading points in the lot.
22. Check the gross and net weight at the weigh bridge.
Use loading arms for loading / unloading operations.
(b) Unloading Operations
1. Ascertain that the liquid discharge valve and the vapour valve within the tank
wagon cover are in the closed position.
2. Open the port covers in the side of the dome shell, if exist. Unscrew the plugs
in the outlets of the vapour valve and the liquid valves using a box wrench.
This must be done slowly.
3. If there is any sound of escaping vapour or if there seems to be pressure
behind the plugs, the pressure must be allowed to relieve itself past the
threads before the plugs are entirely disengaged.
4. If the vapour discharge continues or if there is evidence of a liquid discharge,
the valves should be re-tightened.
5. First having applied a modest quantity of sealant to the male threads,
keeping the sealant away from the end of the thread. Tighten nipples with a

Page no. 26
pipe wrench.
6. Connect the two liquid transfer unloading swing arms or hoses to the nipples
attached to the liquid discharge valves. Connect the vapour or equalizing swing
arm or hose to the nipple attached to the vapour valve. In most of the
cases, these connections will be made by means of either a ground joint union
or a hose coupling.
7. In the event, a ground joint union is used, no gasket will be required. If a hose
coupling is employed, ensure that the appropriate gasket is in place. Make sure
that they are secured tightly by appropriate means.
8. After the vapour and liquid hoses have been connected and before any valve
is opened, the valves on the tank wagon are crack opened in order to apply
pressure to the hoses / loading arms as a test for leaks.
9. If any leak appears, the valve should be immediately closed and corrective
measures applied.
10. Recheck the lines and connections to make sure that they are connected
correctly.
11. After the liquid and vapour lines have been secured and tested, both liquid
L
education valves should be opened slowly and completely. Then, open all other
valves in the liquid line working from the tank wagon to the storage tank.
12. If the tank wagon pressure is higher than that in the storage tank, do not
open the valves in vapour line or operate the compressor. When the rate of
C
liquid flow drops to an unsatisfactory level with the storage tank filling valve
wide open, open the vapour valves between the tank wagon and the storage
tank.
13. At this point, make sure that the control valves at the compressor are in a
position which allow the compressor to draw vapours from the storage tank
IO
and force it into the tank wagon, then start the compressor.
14. When the tank wagon is held at a pressure of 2.0 to 2.5 Kg/sq.cm. above the
storage tank pressure, the tank wagon should be emptied into the storage
vessel.
15. A flow of gas instead of liquid through the sight-flow glass in the unloading
line indicates that the wagon is empty of liquid. Recheck this by opening the
sample valve in the tank wagon dome.
16. When the tank wagon is emptied of all liquid, stop the compressor and close
the liquid valves beginning at the storage tank and progressing to the tank
wagon.
17. If the facilities are so arranged that vapours may be removed from the tank
wagon, the pipeline at the compressor should be arranged so that the
compressor will draw vapour from the tank wagon and force it into the storage
tank.
18. In this operation, the vapour should be discharged below the surface of the
liquid in the storage tank to hasten the liquefaction and, in turn, help prevent
excessive pressure in the storage tank.
19. Restart the compressor and when the tank wagon pressure is reduced to about
1.5 - 2.0 Kg/ sq.cm. stop the compressor and close all the valves in the vapour
line.

Page no. 27
20. After bleeding off the pressure in the a r m s o r hoses, disconnect both
the liquid and vapour lines. Replace all the plugs in the tank wagon valves
and the unloading fittings.
21. Recheck sample valve, gauging device and thermometer well to determine that
they have been returned to their original condition and are closed tight. Lower
the dome cover carefully and lock it in place with the locking pin or secure by
appropriate means.
22. Remove bonding connections.
23. Reverse or remove and replace the "Flammable" placard with "Dangerous -
Empty" placard.
24. Remove the "Stop - Tank Wagon Connected" sign and wheel blocks.
25. Any defect observed in the tank wagon should be noted on the appropriate
forms and routed in accordance with acceptable procedure.
26. Notify the railways in writing about release of wagon and ensure that it is
removed from the siding promptly.
27. Gauge the storage tanks, within the installation, which have received the LPG
to determine that the liquid level is appropriate.
L
28. In the event of LPG received on weight basis, the tank wagon may require
weighing following the completion of the unloading operation.
7.3.3 DEGASSING O F S I C K / LEAKY T AN K W AG O N S
C
(a) Recommended Procedure
In the degassing system recommended for LPG wagons, vacuum cycle purging
technique should be followed as outlined below:
Vessel shoul d be evacuated repeatedly by a vacuum pump.
IO
Vapour should be discharged through high rise vent, keeping the steam on.
Maximum possible vapours should be sucked out in first step depending on
the capacity of vacuum pump/compressor. As per RDSO, vessel can sustain
the full vacuum also.
Between the two vacuum cycles, nitrogen/inert gas should be used for
breaking the vacuum.
Cycle should be repeated till the LPG concentration is found below the end
point of LPG (for butane, it is 4% by volume when purging is done by
nitrogen). Periodically, samples should be drawn from suitable location and
analysed for LPG concentration.
Finally, the vessel should be flushed with air to displace the nitrogen.
Barrel should be tested finally with explosive meter to ensure that
hydrocarbon concentration is below 10% of LEL.
(b) Alternate Procedure
Alternately, wagons may be degassed by steaming or filling with water.
However, it should be ensured that wagon is made water free after degassing.
7.4 BULK HANDLING FOR MOVEMENT BY PIPELINE TRANSFER-
For interface between pipeline operator & consumer terminal compliance of all the
relevant provisions of OISD-STD-214 shall be ensured.

Page no. 28
7.5 BULK HANDLIN G FO R MOVEMENT BY SEA

Transportation of LPG in bulk by tankers may be carried out under fully-
pressurized, semi-pressurised (semi-refrigerated) or fully refrigerated at atmospheric
pressure conditions.
7.5.1 CARGO C A R R I E R D E S I G N & C O N S T R U C T I O N
The design and construction of cargo carrier is in line with International Maritime
Organisation (IMO) Gas code.
7.5.2 TANKER FACILITIES
The cargo handling equipment in a tanker usually comprise of Cargo pumps
(submersible and booster), Compressors, Condensers, Heat Exchangers,
Vapourisers, Cargo heaters etc.
The deep well pump supplies liquid to the booster pump to send the product ashore.
In pressurised ship, liquid is withdrawn by pressurising the tank through vapour
compression from other tanks. All semi and fully-refrigerated tankers are provided
with cargo heaters to enable the vessels to discharge into pressure storage
ashore and a booster pump if the discharge pressure is significantly above 9
bars. Each cargo tank is provided with the following equipment:
L
a) Two cargo pumps, one each on either side of the longitudinal bulk head.
b) Liquid discharge line from the tank dome, connected to the main liquid line.
c) All emergency pump trunk way.
C
d) A liquid loading line connected to the main liquid line.
e) Two liquid level indicating devices one on each side. These usually consist of a
float attached to a self-winding tape which moves up and down, either on guide
wires or inside a guide tube. The liquid level is read off the tape through a gas-
IO
tight window at the top of and outside the tank.
f) Two sets of purge lines at the top and bottom of the tank. These are used
to distribute inert gas or vapour for gas-freeing or gassing-up of the cargo tanks.
g) A vapour line for withdrawal of vapour to the compressor.
h) Sample tubes.
Safety Devices
(a) At least two safety valves in each cargo tank
(b) High and Low level alarms
(c) Overfill alarm. When actuated, this will shuttle main loading valve and sound
an alarm.
However, the design of the tankers with regard to provision of facilities, equipment,
accessories and safety features must be in accordance with the IMO requirements.
7.5.3 TRANSFER PIPING
The following facilities on transfer piping between Terminal and Shore tanks should
be provided:
(a) ROVs at both the ends of transfer line. (Additional ROV at critical locations in
the pipe line route.)

Page no. 29
(b) Relief valves on liquid line to surge vessel with an audible alarm system
connected to high safe venting system
(c) Physical protection against impact to vent/drain pipes
(d) Protection of pipeline against corrosion, particularly when the pipeline passes
under public road way, which is likely to be water-logged
(e) Pipe work passing public road way be designed to acceptable public highway
authority standard in terms of roadway axle weights
7.5.4 TERMINAL FACILITIES
Transfer of LPG from ship to terminal and vice versa is accomplished using loading
arms of approved type as per OCIMF guidelines. Provision of vapour return facility
shall be made.
In case of pressurised gas transfer, it is observed that the pumping rate falls off
gradually due to back pressure of the shore tank. A suitable vapour recovery system
or re-liquefaction of the gas from the receiving tank shall be provided.
7.5.5 UNLOADING OPERATIONS
It is essential that the ship and terminal operators are familiar with the basic
L
characteristics of each other's facilities, are aware of the precise division of
responsibilities and are able to communicate effectively during the time they are
together involved in the joint operation of cargo handling.
7.5.6 COMMUNICATION
C
Reliable and effective communications, irrespective of whether these are directly
between the tanker and the terminal or indirectly via third party, are pre- requisites
of safe and efficient cargo operations before the tanker comes alongside and during
the period of cargo operations and until the tanker departs. Terminal communication
shall be compatible with tanker's system.
IO
7.5.7 PRE-CARGO TRANSFER DISCUSSIONS

Before any cargo transfer operation, it is imperative that the intended procedures are
thoroughly discussed between the responsible personnel from the tanker and the
terminal with a view to make both sides fully conversant with the characteristics of
the tanker and shore cargo handling systems, the envisaged operational and
safety procedures and requirements and the parameters to be adhered to during
the transfer.
The broad outlines for the discussions are as under:
(a) The names and roles of terminal and ship personnel who will be responsible for
cargo transfer operations may be noted.
(b) The terminal representatives shall check that pre-arrival instructions to the ship
on cargo, cargo disposition and cargo conditioning have been carried out. They
also shall check that all necessary tanker equipment inspection and tests
have been performed.
(c) Similarly, the tanker's officers shall satisfy themselves that the relevant
terminal equipment and inspection checks have been carried out satisfactorily.
(d) Terminal representatives and customs and/or independent surveyors, where
necessary, will be informed of the cargo tank data e.g. temperature, pressure,
whether free of cargo, liquid heel or arrival dip, composition of tank vapour
and quantity of cargo on board.

Page no. 30
7.5.8 SHIP / SHORE SAFETY CHECKLIST

Checklist for Ship/Shore safety is given in Annexure 7-III.
7.5.9 DISCONNECTION O F H O S E / UNLOADING ARM
On completion of unloading operation, the tanker discharge pipeline need to be
purged to push liquid LPG to the receiving tank. Purging may be done by LPG
vapour, inert gas or water as per the design of the system. However, before
disconnecting hoses or unloading arm, it is to be ensured that there is no liquid LPG
left between the tanker main valve and shore isolation valve. Product from this
length of pipeline is to be safely vented.
7.6 STORAGE OF BULK LPG
Precautions for storage of LPG in bulk:
a) Liquid level in the vessel shall not exceed the permissible limits. Filling shall not
exceed safe permissible filling ratio.
b) Vessel shall be inspected daily for any LPG leakage and corrective action taken.
c) All gauges, viz. High level alarm, measuring gauges, pressure gauges,
temperature gauges should be kept in operating condition at all times and be checked
daily.
L
d) High level alarm of storage vessels shall be physically checked by raising the bulk level
up to 85% capacity of bullets once in a year under supervision of authorised person of
the company.
C
7.7 SAMPLING A N D D R A I N I N G
7.7.1 SAMPLING
Sampling is primarily required at supply locations i.e
i.e. Refineries, Gas Processing Plants,
Import Terminals, etc. Sampling of LPG for different analytical tests shall be carried out in
IO
accordance with IS:1448. During handling of LPG samples, t he following safety

precautions shall be followed:
(i) Special sampling bombs shall be used for LPG sampling. Arrangement of rupture disc
or any other suitable safety relief device shall be incorporated in the sampling bomb.
(ii) Sampling bombs shall be inspected periodically and tested hydrostatically at regular
intervals. Record of such inspection/test shall be maintained.
(iii) Sample bombs shall be earthed effectively before and during discharge of sample.
(iv) LPG samples shall be collected only in open/ventilated areas and the person
taking the sample shall stand on the windward side.
(v) The sampler shall wear protective goggles, hand gloves, shoes etc. while taking
samples.
(vi) Samples, after collection, shall be properly labeled and kept at designated place.
(vii) Sampling of LPG should preferably be done in bombs with provision of pre-charge at
one end. This will not only eliminate the possibility of undesirable presence of air in
the bomb, which may become a safety hazard, but also minimizes flashing of sample
during collection, thereby providing a truly representative sample.
7.7.2 DRAINING
Storage vessel should be drained regularly for its water content, sediments, caustic

Page no. 31
contents etc. Draining operation should be carried out under the supervision of an
authorised person.
For draining of water from LPG vessels, following procedure shall be followed:
(i) The valve nearer to the vessel shall be opened first and closed. Then, draining shall be
carried out by gradually opening the valve farther from the vessel. The operation shall
be repeated till LPG release starts.
(ii) The point at which LPG is exposed in the open for first time during draining shall be at
least 3 M away from the shadow of the LPG storage vessels. They shall also be outside
the shadow of the associated pipeline manifold. The individual discharge end of the
water draw off piping shall be visible & shall not directly discharge into a closed drainage
system.
It is important not to attempt removal of the entire quantity of water as considerable
liquid LPG may escape in the process. At the first sign of appearance of LPG, the
operation shall be stopped. Escape of LPG may lead to formation of ice block at the valve
seat, preventing closure of valve. This will result in escape of uncontrolled vapour to the
atmosphere causing a very serious hazard.
The valve shall be operated slowly to avoid ice formation.
L
C
IO

Page no. 32
ANNEXURE - 7 - I
CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION

1. CHECKS REQUIRED TO BE CARRIED OUT BEFORE ALLOWING ENTRY OF TT
INSIDE LICENCED AREA
ON THE TANK TRUCK:
- Properly fitted spark arrestor of make and design approved by CCE, Nagpur.
- Proper Fittings i.e. SRV, Internal EFCV, temperature & pressure gauges etc. as per
the extant SMPV (U) Rules & OISD-STD-159.
- 2 nos. of 9kg or 10 kg. DCP extinguishers in easily accessible and removable position
with Truck No. date of checking and charging painted on it.
- Provision of quick closing manifold valve with lever indicating close and open status.
- No visible dent on the bullet.
- Airbrakes are not bypassed
- Dedicated second crew is available in the tank truck
-
-
ELECTRICALS:
All junction boxes are properly sealed
Any loose electrical wiring/ terminal
L
C
- Electrical wiring is insulated and provided with suitable over current protection.
- Truck is self-starting
- Readily accessible double pole master switch of minimum 300 Amp rating for switching off
the engine is provided inside the cabin.
IO
- The battery shall be mounted inside the cabin in an easily accessible position within a
metallic cover with openings in line with OISD STD-
STD-159.
Dipole wiring.
TANK FITTINGS:
- Leakage from any fittings or joints.
2. CHECKS REQUIRED TO BE CARRIED OUT BEFORE ISSUING LOADING MEMO
(DURING THE COURSE OF UNLOADING OPERATIONS)
TANK TRUCK
- Height barrier provided as per specifications
- Fuel tank is protected by means of stout guard and fuel tank cap is locked.
- Paint of bullet is not peeling off.
GENERAL
- First aid kit is available.
3. CHECKS REQUIRED TO BE CARRIED OUT ON RANDOM BASIS TO COVER
MINIMUM ONE TANK TRUCK PER DAY AND EACH TANK TRUCK AT LEAST
ONCE IN A QUARTER:
TANK TRUCK:

Page no. 33
- Internals of fire extinguishers in good condition

- Carries TREM CARD, instructions booklet detailing instructions on handling emergencies en
route.
- Carries route map
- Has valid CCE license and authenticated copy of drawing
- Carries RTO permits
- RLW-ULW> Licensed capacity
- HAZCHEM sign, name of contractor with address and telephone No. displayed prominently.
- Bullet has no sign of external corrosion.
- Valid authorization either on the driving license or the certificate issued by RTO for
carrying hazardous goods as per MV Act
TANK FITTINGS:
- Valid test certificates for excess flow check valves are available
- Liquid / vapour lines are adequately anchored and are well protected by means of stout
steel guard.
-
L
Liquid/ vapour pipe lines are in single piece from excess flow check valve to discharge
valves - Safety fittings viz., safety valve, roto-gauge, pressure gauge and temperature
gauge are adequately protected.
C
- Operative fittings like roto gauge, pressure gauge and temperature gauge are operational.
GENERAL:
- Flanges and bend pipe on liquid /
vapour lines should be of rating of 300.
IO
Following are available in Tank Truck:
- Tools for all fittings
- 4 Nos. caution sign board with luminous paint for stopping traffic in case of any emergency.
Based on the nature of defects either all the deficiencies should be got corrected at the
unloading location itself or the tanker should be allowed to get the repairs done en route
and submit the details at loading location.

Page no. 34
ANNEXURE - 7- II
CHECKLIST AT UNLOADING LOCATION FOR BULK LPG TANKWAGONS

VISUAL EXAMINATION OF WAGON FOR
- POH/ ROH OVERDUE: FOR BARREL Y/N
- FOR UNDERFRAME Y/N
- Damage to Tank Barrel Y/N
- Damage/ missing tank fittings Y/N
- Leakage from dome fittings Y/N
- Seal intact Y/N
- All valves, fittings are in working order Y/N
- The surface is free from rust. Y/N
- The paint on the barrel is in good condition Y/N
and has not lost its reflecting characteristics.
L
The matter regarding tank wagon not complying with any of above checks shall be taken up
with loading location for corrective action.
C
IO

Page no. 35
ANNEXURE 7 - IIII
LIQUEFIED GAS-CARGO TRANSFER CHECK LIST

(Items to be checked before cargo transfer begins)
SHIP: _ DATE:
PORT &BERTH: _ TIME: _
S.NO CHECK POINT FOR SHIP FOR SHORE
1. Has information on cargo and ship-

shore connection been supplied?
2. Is the agreed ship-shore communic -
ation system operative?
3. Are fire and other emergency
procedures agreed?
4. Are local regulations being
5.
6.
observed?
Has safe access been provided and
warning notices posted?
Are moorings secure and agreement
L
C
reached on the use of tension
winches?
7. Are emergency
ergency towing-off wires
correctly positioned?
IO
8. Is the ship ready to move under its
own power?
9. Are smoking restrictions in force
and notices posted?
10. Are naked light restrictions being
observed?
11. Are portable electrical equipment
cables disconnected?
12. Are all hand torches and portable
R/T sets of approved type?
13. Are ship's main transmitting
aerials and radar switched off
and earthed?

Page no. 36
14. Some doors and ports have to be

closed: are they actually shut?
15. Are all air conditioning intakes
correctly trimmed and window type
units closed?
16. Is the water main ready for
immediate use?
17. Is the water spray system ready
for immediate use?
18. Are dry powder and all other
firefighting appliances correctly
positioned and ready for immediate
use?
19. Is necessary protective clothing
available or being worn?
20.
21.
Are void spaces properly inerted?
Is the required ventilation
equipment in operation?
L
C
22. Is the cargo system set for the
operation?
23. Are all remote control valves in
working order?
24. Are cargo tank relief valves
IO
correctly set and in good order?

25. Are the required cargo pumps and
compressors in good order?
26. Is reliquefaction or boil-off
control equipment in good order?
27. Is gas detection equipment set for
the cargo, calibrated and in good
order?
28. Are cargo system gauges and alarms
correctly set and in good order?
29. Are scuppers plugged and suitable
drip trays in position?
Contd...

Page no. 37
30. Are cargo and bunker hoses in good

condition and properly rigged, have
certificates being checked?
31. Are unused bunker connections
blanked and bunker tank lids
closed?
32. Are unused cargo connections
(including inert gas line) securely
blanked?
33. Are automatic shutdown systems
working properly?
34. Does shore know the closing rate
of ship's automatic valve at
operating temperature; does ship
have a similar details of shore
35.
system?
Are all personnel (including
supernumeraries and new arrivals)
aware that cargo transfer is to
L
C
begin?
36. Have all personnel been allocated
emergency stations?
37. Are non-essential personnel clear
of the cargo area?
IO
38. Are those directly involved aware

of the agreed cargo transfer
sequence?
========================================================================
REMARKS:
We have checked with each other the items on the above check list and have satisfied ourselves
that the entries we have made are correct to the best of our knowledge.
CHECKED BY
(For Ship) (For Terminal)

Page no. 38
ANNEXURE - 7 - IV
CHECK LIST FOR PACKED CYLINDER TRUCKS
CHECKS REQUIRED TO BE CARRIED OUT ON RANDOM BASIS: -
- Properly fitted spark arrestor of make and design approved by CCE or any spark
elimination system duly approved by CCE.
- 2 nos. 9 Kg or 10 kg. DCP extinguishers in easily accessible and removable position
with Truck No., the last date of checking and charging painted on it.
- Air brakes are not bypassed
- Valid authorization either on the driving license or on the certificate issued by RTO
for carrying hazardous goods as per MV Act
- Dedicated second crew available in the packed trucks
- All junction boxes are properly sealed
- Any loose electrical wiring/ terminal
- Electrical wiring is insulated and provided with suitable over current protection.
- Truck is able to self-start
-
-
L
Double pole master cut-off switch of minimum 300 amp rating for switching off the
engine is provided inside the cabin in a readily accessible position.
Battery is mounted inside the cabin within a metallic cover with openings in an easily
C
accessible position.
- Fuel tank is protected by means of stout guard and fuel tank cap is locked.
- Exhaust shall be fitted in the front side of the vehicle in line with OISD STD-
STD-159
IO

Page no. 39
8.0 BOTTLING OPERATIONS

8.1 GENERAL
This section covers the operations in the LPG bottling plants,
Safe work practices shall be established to ensure safe operation, maintenance, and
modification activities while carrying out various jobs. These practices shall be
documented and approved. The manuals shall be updated on need basis upon yearly
review for changes.
Activity on bottling line including valve change, shall be carried out by trained personnel.
8.2 BOTTLING OPERATIONS
The Bottling Operations can be classified under following heads:
i. Receipt of LPG cylinders
ii. Filling & dispatch of LPG Cylinders
iii. Handling & storage of LPG cylinders
iv. Auxiliary Operations
8.2.1 Receipt of LPG cylinders
L
Cylinders shall be received in capped condition. Cylinder shall conform to IS:3196.
8.2.2 Filling of LPG cylinders
C
(a) Pre-filling
-filling operation: Cylinder before filling shall be checked for following:
- Visually inspected as per IS:
IS:15966
15966
- Ò' Ring (joint packing) is present and there is no apparent damage to valve.
- Tare weight is legible.
IO
(b) Filling operation - All cylinders shall be filled on gross weight basis on filling
machine. Negative & positive tare weight setting shall be maintained in electronic
carousels to avoid filling of cylinders having variation in actual tare weight beyond set
limit.
Maximum permissible errors on net quantity declared by weight shall be in accordance
with the Legal Metrology (Packaged Commodities) Rules 2011. The filling pressure
should not exceed maximum working pressure of cylinder i.e. 16.9 kg/cm2 at Carousel/
Unit Filling Machine (UFM) pipeline manifold.
(c) Post Filling Operation - Cylinders of all capacities shall be counter weighed with check
scale. Variation of net weight shall not exceed statutory limits. All under-filled/ over-filled
cylinders should be corrected before dispatch.
Cylinder shall be checked for Ò" ring condition and for valve leak by means of
Compact Valve Tester (CVT) or electronic leak detector.
CVT or electronic leak detector shall be calibrated to detect leakage beyond 0.5
gm/hr. For cylinders found with Ò' ring defect, the Ò' ring shall be replaced with a
new one. Further all "O" ring or valve change cylinders shall be rechecked for leakage
with CVT or electronic leak detectors.
The on line valve replacement machines shall be checked for containment integrity with
regard to proper sealing. The machine shall be further checked every day w.r.t. torque
settings before being put in use. The maintenance shall be carried out as OEM

Page no. 40
recommendation.
Cylinder shall be checked for body leak and bung leak by dipping in water test bath or
by an established electronic leak detection system. Cylinder shall be capped prior to
dipping in test bath water.
Only those cylinders found passing all above checks shall be processed further for
sealing.
Cylinders shall be sealed with PVC seal or Aluminum seal. Seal shall have
identification mark of oil company, preferably name of plant and period of filling.
Evacuation Facility shall be provided to handle all types and capacity of cylinders being
filled at the location.
No bypassing of safety interlocks, fire water system, gas detection system, vapour
extraction system and heat detection system shall be permitted unless authorised by
plant manager in writing.
8.2.3 Handling & Storage of LPG
Handling and storage of LPG cylinders shall be governed by Gas Cylinders Rules, 2016.
Following safe practices shall be observed:
a) Handling of LPG Cylinders - LPG cylinders shall not be dropped, rolled on body
L
and shall not be subjected to any violent contact with any other cylinder or object.
Cylinder shall be moved by rolling on its foot ring or on conveyors or hand trolleys.
Telescopic conveyors should be provided for unloading/loading of cylinders from/to the
trucks at unloading/loading fingers of the shed.
C
b) Defective filled cylinders - Any cylinder having body leak, bung leak, bulge, fire
ravaged or spurious shall be evacuated immediately.
Any cylinder with valve leak shall be immediately capped and thereafter evacuated
immediately.
IO
Cylinders requiring repairs other than valve leak shall be degassed for repairs.
All above cylinders shall be clearly identified, with markers, to their nature of defects
and shall be kept capped during storage.
c) LPG cylinder storage - All cylinders shall be stacked vertically (with valve in
upright position) in not more than 1.5 m.
Cylinders of different capacity and type shall be stacked separately.
All cylinders shall be capped during storage.
The cylinders shall be stacked in small lots of 4 rows and 25 cylinders length. A
minimum access path of 1 mtrs. must be maintained on both sides of 4 rows and 2
meters after every 5 such lots. After each length of 25 cylinders, there must be a
passage of 2 meters. The cylinder storage space shall be properly marked/ painted on
the flooring.
Typical stacking arrangement for 14.2 kg cylinder is given in F ig u r e -I.
Empty and filled cylinders shall be demarcated clearly.
Minimum distance of 15 meters from cylinder loading area and minimum distance of
10 meters from filling point shall be observed for all filled cylinders stack.
8.2.4 Auxiliary O p e r a t i o n s
a) Cylinder requiring valve removal and valve fixing

Page no. 41
Cylinder having defective valve and with bung leak shall have to undergo valve removal
and valve refixing operation.
Following safe procedures shall be observed for the operation:
- Cylinder shall be evacuated of its product upto pressure, 1.5 kg/cm2 or less, thereafter
depressurised to near atmospheric pressure through cold flare before opening the
defective valve.
- The valve of cylinders with bung / valve leak shall be replaced.
- Cylinder bung shall be cleaned with 3/4" NGT tap and cylinder bung threads checked
with L1 and L9 gauge.
- Only cylinders passing above tests shall be taken up for valve change operation.
- Good valve shall be fixed using a torque wrench. The torque shall not exceed 20 +/-
2kg.m. Before fixing the valve suitable jointing compound shall be used. Jointing
compound shall be compatible with LPG, water and metallurgy of cylinders and ValvesValves.
Teflon tape/ paste of suitable valve joining material are recommended as jointing material.
b) Purging of cylinders
- New cylinders and cylinders degassed for repairs shall be purged of air prior to be
-
L
taken up for refilling with LPG. Following safe procedure shall be observed for
purging of LPG cylinders:
Connect the cylinder valve to vacuum pump and evacuate air so that the pressure
in cylinder is brought down to maximum 0.35 kg/cm2 absolute. Inject LPG vapour
C
in the cylinder so that pressure is minimum 1 kg/cm2 and not above working pressure
of cylinder i.e. 16.9 kgf/cm2 at 65
65-degree
-degree C.
- Purging Facility shall be provided to handle all types and capacity of cylinders being
filled at the location
IO
c) Degassing of Cylinders:
Cylinders shall be evacuated and depressurised to near atmospheric pressure. The residual
LPG in the cylinder should be cold flared in the atmosphere at a vent outside the shed at 1.5
m height above the eves of the shed.
Valve shall be removed with suitable torque wrench or by using online valve changing
machines. Cylinders shall be filled with water fully and water should be allowed to over
flow. Thereafter, cylinders shall be emptied out of water and checked with explosimeter
for degassing. Not more than 6 cylinders shall be degassed at a time.
8.3 DISPOSAL OF ETHYL MERCAPTAN CONTAINERS
It shall be ensured that the drums are emptied of mercaptan to the extent possible.
The empty drums then can be washed with water and detergent, followed by wash
with a 5% bleach solution. After again washing with copious amount of water, the
drums will be ready for disposal.
(ii) Treatment of Leaks and Spills
Leaks and spills of mercaptan can be treated with commercially available masking
agents (e.g. Aldor and Neutroleum Alpha etc.) to make them odorless. Large
mercaptan spills shall be covered with sand or activated carbon or any other
absorbing material, which are then buried or incinerated. The area over the spill should
then be washed with ordinary household bleach solution and then thoroughly with
water. Dry bleaching powder should never be used in treating mercaptan spills. A
violent reaction could occur.

Page no. 42
9.0 MAINTENANCE & INSPECTION OF EQUIPMENT

9.1 GENERAL:
This section covers the maintenance and inspection practices to be followed to
ensure safe and trouble free operation of various equipment.
9.2 MAINTENANCE SCHEDULES:
To facilitate the maintenance service to be rendered in a planned manner, a
preventive maintenance schedule covering the necessary work to be done, mentioning
the periodicity
i.e. daily, weekly, monthly, half yearly and yearly schedules, must be worked out. While
basic recommendations given by the manufacturers should be considered and modified
bearing in mind the local conditions (refer Annexure 9- I-IV).
9.3 PERSONAL PROTECTIVE EQUIPMENT:
Necessary personal protection equipment such as Hand gloves, Safety shoes, Helmets,
Safety belts, Safety goggles etc. shall be used (for details refer OISD- STD-155).
9.4 WORK PERMIT SYSTEM:
Any maintenance, inspection, disassembly or removal of fittings while any part of the
approved procedure. L
system is under pressure shall not be carried out without a proper work permit and
1. All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard;
C
OISD-STD-105 on "Work Permit System".
2. Electrical maintenance/ inspection, provisions of OISD-STD-
OISD-STD-137 shall be adhered to.
9.5 INSPECTION & MAINTENANCE OF VARIOUS FACILITIES IN LPG INSTALLATIONS:
9.5.1 STATIC EQUIPMENT:
IO
a) PRESSURE VESSELS & STORAGE FACILITIES:

OISD Standard OISD-STD-128 on "Inspection of Pressure Vessels shall be followed.
Weld cracking has been experienced in the lower half portions of LPG vessels.
Small amounts of wet H2S present in LPG is supposed to be responsible for this
in service stress corrosion cracking of welds. LPG vessels made from micro-
alloyed high tensile steels have shown greater susceptibility to such cracking.
Wet Fluorescent Magnetic Particle Testing (WFMPT) is considered the most
reliable test method for detecting these micro-cracks. WFMPT should be carried
out prior to hydraulic test wherever cracks are found, their depths should be
assessed by ultrasonic testing. All cracks having depths less than corrosion
allowance may be removed by grinding, edges smoothened and areas left as
such after final WFMPT check. Weld buildup of grooves so formed is essential
wherever depths of groove is more than corrosion allowance.
b) SHUT-OFF VALVES, CONTROL VALVES, NON-RETURN VALVES, EXCESS
CHECK VALVES, PIPELINES, VALVES AND FITTINGS:
All new valves shall be inspected and tested to ensure conformation to required
specifications and for leak tightness. All new valves shall be inspected and tested
as per requirements of API-598. The closure torque during testing for hand wheel
and gear operated valves shall not be greater than that obtainable by hand
tightening. Further fire safe valves shall comply with following:

Page no. 43
Low pressure seat test shall be conducted with the ball and seat dry and free
of oil, grease or any lubricant.
The high pressure seat test is not required except for threaded and valves.
No leakage shall be permitted.
Fire-safe test shall be carried out as per API: 607.
Valves shall be dismantled at the time of specified comprehensive inspection or during
the shutdown of the line to permit examination of all internal parts. Body thickness
measurements shall be made at locations inaccessible before, dismantling, particularly at
locations showing evidence of erosion. Bodies of valves operating in severe cyclic
temperature service shall be checked internally for cracks.
Gate valves, which have been used for throttling, shall be measured for thickness at the
bottom between the seats, as serious deterioration may have occurred because of
turbulence. This is particularly weak point because of the wedging action of the disc
when the valve is closed. The seating surface shall be inspected visually for defects
which might cause leakage. The wedging guides shall be inspected for corrosion and
erosion. The stem and threads on the stem and in the bonnet of valves shall be
examined for corrosion which might cause failure., The connection between stem and disc
shall be inspected to assure that the disc will not detach from the stem during operating.
L
Swing check valves shall be inspected by removing the cover or cap. The clapper or disc
shall be checked for freedom of rotation and the nut holding it to the arm shall be checked
for security and presence of a locking pin, lock washer, or tack weld. The arm should be free
to swing and the anchor pin shall be inspected for wear. Also the seating surface on both
C
the disc and valve body shall be checked for deterioration by feeling them with the fingers.
After the valve has been reassembled, it shall be hydrostatically and/or pneumatically tested
for tightness. If tested pneumatically, a soap solution shall be applied to the edges of the
seating surface and observed for any evidence of leakage.
9.5.2 Flanges, Gaskets and Bolts
IO
The gasket faces of flanged joints, which have been opened, shall be inspected
visually for corrosion and for defects such as scratches, cuts and gouges which might
cause leakage. The gasket faces shall be checked for true flatness or warping by
placing a straight edge across the diameter of the face of the flange and rotating it
about an axis through the center line of the flange. Grooves and rings of ring joints
shall be checked for defects.
Flanges bolts should be inspected for stretching. Where excessive bolt loading is indicated
or where flanges are deformed, nuts may be rotated along the entire length of the stud. If
studs are stretched, thread pitch will be changed and nuts will not turn freely. Inspections
involve checking to determine whether bolts of the proper specification have been used and
may involves chemical analyse or physical tests to determine the yield point and the
ultimate strength of the material. If flanges are bolted too tightly, they may bend until the
outer edges of the flanges are in contact. When this occurs, there may be insufficient
pressure on the gasket to assure a tight joint. Visual inspection of the gasket will reveal this
condition. Permanently deformed flanges must be replaced.
9.5.3 PIPELINES
(i) Inspection data as well as thickness data of newly constructed pipelines shall be
collected at the earliest and withi n two years of their commissioning to function
as base for establishment of corrosion rates.
(ii) External inspection of LPG pipelines within the installation shall be carried out once
in three years which shall include both visual inspection and ultrasonic thickness

Page no. 44
readings taken externally.

The details of thickness survey shall be maintained on an isometric sketch.
(iii) Comprehensive inspection of LPG pipelines shall be carried out once in 5 years
which shall cover the following:
i) Visual inspection
ii) Hammer test
iii) Ultrasonic thickness measurement
iv) Dye penetration test or Magnetic particle test
v) Hydro test
(iv) Piping in coastal installations and in corrosive environment shall be visually inspected
once a year. Years of inspection experience have revealed that failures of most of
the Offsite pipelines are due to external corrosion and that internal corrosion failures
are minimum.
(v) The underground lines having wrapping and coating as well as cathodic protection
shall be inspected whenever current leaks are observed and/or any damage to
the coating is suspected. Parameters of cathodic protection like pipe-
pipe-to-soil
(vi)
voltage or pipe-to-water
L
-water voltage shall be monitored once a month.
All underground lines having only wrapping and coating shall be inspected once
in three years using Pearson Survey for locating coating damage, if any.
C
Additionally, all these lines shall be visually inspected at random once in ten years
by digging at a few locations. Pipelines crossing the roads and dykes shall be
inspected once in ten years by digging and exposing the line completely.
Provisions of OISD Standard; OISD-STD-130
OISD-STD- on "Inspection of Pipes and Valves and
Fittings" shall be followed.
IO
9.5.4 HOSE AND FLEXIBLE CONNECTION:

LPG hoses shall be inspected & tested at maximum interval of 4 months as detailed in
OISD Standard; OISD-STD-135
OISD-STD-135 on "Inspection of Loading and Unloading Hoses for
petroleum products" and records maintained thereof.
LPG hoses shall be discarded after 3 years of service or earlier in case the
permanent elongation exceeds 5%.
9.5.5 STRAINERS AND FILTERS:
Strainers & filters shall be inspected and cleaned as per following frequency, unless
sluggish operation warrants earlier inspection:
TYPE / LOCATION FREQUENCY
Air filters Weekly
Strainers on evacuation Weekly line
Pump Suction Quarterly
Up stream of filling Quarterly carousel
up stream of PD-Meter Quarterly
9.5.6 SAFETY RELIEF VALVES
Safety Relief valves shall be tested once in a year. Further an on stream visual

Page no. 45
inspection should be carried out at least once in every 6 months to check the following:
a) Gags, blinds do not exist.
b) Upstream and downstream isolation valves, if any, are opened and sealed.
c) Seals protecting the spring setting have not been broken.
d) Relief device is not leaking. This may be checked visually and by thermography,
contact thermometers or by hand touch at outlet nozzle wherever practicable.
e) The continuous operation of heat tracing provision, if any, provided for low temperature
application on valve and discharge piping.
f) Condition of insulation and cladding on the heat traced piping and valves.
a) Inspection and test of the valve shall be done in as received condition. This is important
and helps in establishing the frequency of inspection.
Provisions of O I S D Standard; OISD-STD-132 on "Inspection of Pressure Relieving
Devices" shall be followed.
9.5.7 ROTARY EQUIPMENT:
a) COMPRESSORS: OISD Standard No. OISD-120
120 on "Inspection of Compressors"
Annexure-I to be followed.
b) PUMPS: OISD Standard No. OISD-
OISD-110 on Inspection of Pumps
In addition, periodic checks as detailed in Annexure-
Annexure-II
L
shall be followed. In addition, periodic maintenance checks, as detailed in
II to be followed.
be followed.
C
c) DIESEL ENGINES: OISD Standard No. OISD-123
OISD-123 on "Inspection and Maintenance of
Rotating Equipment components shall be followed.
9.5.8 FILLING EQUIPMENT
It shall be ensured that the equipment is in good working condition to ensure quality
IO
output and also safe operation. Inspection checks are given at Annexure 9- III for
the following equipment:
a) CAROUSEL
i. Drive units
ii. Centre column
iii. Running Rail
iv. Introduction and Ejection devices
v. Filling machines
b) Check Weigh Scales
c) Chain/ Roller conveyor
d) Drive Units for Conveyors
e) CVT-leak detector
f) Cylinder Test Bath
g) General
9.5.9 INSTRUMENTATION

Page no. 46
a) TEMPERATURE INDICATING D EVICES

Temperature indicating devices shall be checked daily for its proper functioning and
shall be calibrated once in 6 months.
b) LEVEL GAUGING DEVICES
The gauging devices shall be checked daily for proper functioning. Zero level check
and calibration shall be carried out monthly and annually as applicable.
c) PRESSURE GAUGES
Pressure gauges shall be checked daily for its proper functioning and shall be
calibrated once in 6 months.
d) FLOW MEASURING DEVICES
All flow measuring devices shall be checked daily for proper functioning and calibration
shall be carried out monthly and quarterly as applicable.
9.5.10 FIRE FIGHTING EQUIPMENT
Firefighting equipment shall be inspected and tested as per. OISD-STD-
OISD-STD-142 -
"Inspection of Fire Fighting Equipment".
9.5.11 ELECTRICAL EQUIPMENT
L
Proper functioning of electrical equipment can only be ensured by means of
periodic preventive and predictive maintenance of the equipment. This enhances
equipment life and also ensures safety of the equipment, installation and operating
C
personnel.
Maintenance shall be daily, weekly, quarterly or annual depending upon the type of
equipment. Adequate logs shall be maintained to ensure that maintenance is
carried out as per approved checklists. Preventive maintenance should be
carried out as per schedules laid down in OI S D-STD-
D-STD-137.
IO
Special emphasis shall be laid on the maintenance of equipment installed in

hazardous areas.
All electric apparatus and wiring in a hazardous area shall at all times be so
maintained as to retain
Precautions to be taken for repairs and testing of flameproof equipment shall be
as below:
i. No Flame proof or intrinsically safe apparatus shall be opened an d no work likely
to impair the safety characteristics of such apparatus or electric wiring connected
thereto shall be carried out until all voltage has been cut off from said apparatus
or wiring. The voltage shall not be restored thereto until the work has been
completed and the safety characteristics provided in connection with the apparatus
and wiring have been fully restored.
ii. Use of soldering apparatus or other means involving flame, fire or heat or use of
industrial type of apparatus in a zone area shall be permitted for the purposes
of effecting repairs and testing and alterations, provided that the area in which
such apparatus or wiring has been installed, has first been made safe and
certified by a competent person after testing with an approved gas testing
apparatus to be safe and free from inflammable vapours, gases or liquids and is
maintained in such conditions, so long as the work is in progress.
iii. No alteration that might invalidate the certificate or other document relating to the
safety of the apparatus shall be made to any apparatus.

Page no. 47
Replacement fasteners, nuts, studs and bolts shall be of the type specified by
the manufacturer for the particular apparatus. No attempt shall be made to
replace or repair a glass in a flameproof enclosure e.g. in a luminaire or other
enclosures, except by replacement with the complete assembly or part
obtainable from the manufacturer, complying with the approval certificate.
If replacement components such as cable glands, conduit or conduit
accessories, are available only with thread forms which differ from those provided
on the apparatus, suitable adaptors having necessary certification and approval
shall be employed.
iv. Equipment enclosures and fittings shall be examined to see that all stopping plugs
and bolts are in position and properly tightened. Locking and sealing devices shall be
checked to ensure that they are secured in prescribed manner.
v. If at any time, there is a change in the area classification or in the characteristics of
the flammable material handled in the area or if the equipment is relocated in the
area, the area classification drawing should be correspondingly revised and a check
shall be made to ensure that the equipment selection corresponds to the revised area
classification.
vi. A system shall be established to record the results of all inspections and the action
taken to correct defects.
L
C
IO

Page no. 48
ANNEXURE 9-I
MAINTENANCE SCHEDULE
COMPRESSORS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Artily
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
1. Check Lube Oil Level of plunger *
pump unit & top up if necessary.
2. Check the oil level in the crank *

case & top up if necessary.
3. Before start check flow of *

cylinder jacket cooling water.
4. Check oil flow from plunger pump

to gland packing assembly.&
compressor cylinder.
*
L
C
5. Check for flow rate from plunger *
pump
6. Drain water from receiver/ liquid trap. *
7. Check belt tension and *

IO
adjust if necessary.
8. Ensure tightness of foundation bolts. *
9. Flush out lube oil system

system: *
a) Crank case
b) Pump chamber and fill fresh oil.
10. Flush jacket water cooling system. *
11. Check alignment of c o m p r e s s o r & motor *

pullies.
12. Change lube oil filter and clean LPG Suction *
filter.
13. Clean oil strainer *
14. Clean Breather *
15. Open and inspect suction and discharge *

valves.
16. Check instrumentation calibrate if necessary. *
--------------------------------------------------------------------------------------------------------------------------------

Page no. 49
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
17. Check safety release valve. *
18. Suction & discharge valves of compressor cylinder *
19. Interlock with High level alarm *
20. All Safety Trips . *
21. Pressure & Temperature Gauges *
22. Control Panel *
23. Complete over-haul. *
L
C
IO

Page no. 50
ANNEXURE 9-II
CENTRIFUGAL PUMP
Sr. E quipment Checks PERIODICITY
Daily Weekly Monthly Qrtly
Annually
(1) (2) (3) (4) (5) (6) (7)
1. Check lube oil & top up level

* if necessary.
2. Check cooling water flow *

(where provided).
3. Check mechanical seal/ gland *

leakage.
4. Check the AMPS are within limits. *
5.
6.
Change lube oil every 800 running
hours.
Check coupling and coupling

bolts and replace worn out
L *
*
C
parts.
7. Check tightness of foundation bolts. *
8. Clean suction strainer of: *

a) Product pumps
IO
b) Other pumps
9. Check alignment of pump and motor. *
10. Overhaul. *
11. Greasing of Bearings. *
12. High Level Alarm *
13. Relief Valve *
14. All Safety Trips *
--------------------------------------------------------------------------------------------------------------------------------

Page no. 51
ANNEXURE 9-III
FILLING EQUIPMENTS
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half
Annually Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
I. CAROUSEL:
(A) DRIVE UNIT:
1. Check oil level & top up if required. *
2. Check oil pressure. *
3. Put oil drop in orifice of cut-off valve. *
4.
5.
Grease guide rollers.
Check & adjust drive belt.

L *
*
C
6. Unscrew magnetic plug and clean. *
7. Change hydraulic oil & clean filter. *
8. Clean hydraulic oil tank. *

IO
9. Inspect gears for wear and tear. *
10. Check electric motor & grease motor bearing. *
11. Complete overhaul of the drive unit. *
(B) CENTRAL COLUMN
1. Check air & gas joints for *

leakage.
2 Grease bearing. *
(C) RUNNING RAIL :
1. Clean & apply graphite. *
2. Lubricate rail wheels. *
3. Check rail levels. *

Page no. 52
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Annually Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
(D) INTRODUCTION AND EJECTION DEVICES:
1. Blow the air filter free of water & dirt. *
2. Check & top up oil in air lubricator. *
3. Oil the introduction arms. *
4. Check functioning & adjust if required. *
5. Greasing all grease points. *
6. Tighten guide rollers. *
7. Check & repair leaks. *
8. Inspect for wear and tear. *
9. Overhaul the unit. *
(E) FILLING MACHINES:
1. Thoroughly cleaning by using *

dry air.
2. Checking & adjustment of auto *
cut off device.
3. Check operation of filling head *

by supplying air.
4. Check leakage of LPG and repair. *
5. Check condition of LPG filling hoses. *
6. Check oil level in air lubricators. *
7. Lubricate pullies holding filling guns. *
8. Carry out calibration and adjustment. *
9. Suspension system bearings & *

knife edges to be thoroughly
cleaned.
10. Inspect knife edges for wear & *

tear and repair where required.
11. Complete overhauling. *

Page no. 53
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Annually Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
(F) CHECK SCALE:
1. Thorough cleaning by using dry air. *
2. Air Filter:
a) Blow-out dirt & condensate. *
b) Clean. *
3. Check oil level in lubricator *

and its functioning.
4. Calibrate with standard weights. *
5. Greasing of cylinder stop unit. *
6.
7.
Clean suspension system bearings
knife edges etc.
Check for wear & tear of knife edges

& replace if necessary.
L *
*
C
8. Complete overhauling. *
II. CHAIN CONVEYOR:

1. Top up soap solution trays. *
IO
2. Check position of tension roller *

of chain and adjust if required.
3. Lubricate tension rollers & wheels. *
4. Clean soap solution tray. *
5. Grease the bearing *
6. Check foundation bolts of conveyor *

frame for tightness.
III. DRIVE UNIT OF CONVEYORS:
1. Check & top up oil level. *
2. Check coupling bolts & *

rubber bushings. Replace
the cracked or worn out
bushings.
3. Check alignment of gear box *

& correct if necessary.

Page no. 54
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Annually Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
4. Clean & lubricate chain. *
5. Tighten foundation bolts. *
6. Drain & change oil. *
7. Inspect for wear & tear. *
IV. O-Ring/Valve LEAK DETECTORS

(Manual or Electronic) :
1. Check for proper functioning. *
2. Top up Every shift

kerosene
3. Verification: - Verification of
Twice in a
O-ring & Valve leak detectors shift
(Manual or Electronic) shall
be done minimum twice in
each shift with test cylinder.
L
C
Before each verification test
cylinder shall be checked with
approved manometer as per
OEM procedure.
Calibration: - Calibration of O-
O
IO
4. ring & Valve leak detector *
(Manual or Electronic) shall
be done minimum once in a
week or whenever detectors
fail during above verification.
5. Dismantle/ clean the interiors & *
apply silicon grease to "O" ring.
V. CYLINDER TEST BATH:
1. Fill with clean water. *
2. Lubricate moving parts. *
3. Clean tank walls from inside. *

4. Check & lubricate *
pneumatic circuitry of all
.
5. Check all fasteners and *
tighten.
6. Paint tank walls from inside. *
-------------------------------------------------------------------------------------------------------------------------------

Page no. 55
ANNEXURE 9-IV
DIESEL ENGINES
MAINTENANCE STEPS
1. KEEP THE DIRT OUT OF THE ENGINE.
2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.
3. REGULATE THE ENGINE'S FUEL.
4. CONTROL OPERATING TEMPERATURES.
5. GUARD AGAINST CORROSION.
6. LET THE ENGINE BREATHE.
7. PREVENT OVERSPEEDING.
8.
9.
KNOW YOUR ENGINE'S CONDITION.
CORRECT TROUBLES WHILE THEY ARE SIMPLE.

L
C
10. SCHEDULE AND CONTROL YOUR MAINTENANCE.
IO

Page no. 56
DIESEL ENGINES
"A" CHECK EVERY DAY
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
1. CHECK PREVIOUS DAY'S ENGINE 1A CORRECT AS REQUIRED

LOG BOOK.
2. DRAIN WATER AND SEDIMENT 2A BEFORE STARTING ENGINE.

FROM FUEL TANK AND FUEL
FILTER THROUGH DRAIN COCK.
3. CHECK ENGINE OIL LEVEL AND 3A MUST BE SLIGHTLY LESS THAN OR

TOP UP IF NECESSARY EQUAL TO "H" MARK ON DIP STICK
WHEN ENGINE IS STOPPED AND HAS
STOOD FOR 20 MINUTES OR MORE
(MUST BE MEASURED AFTER ALL OIL IS
DRAINED BACK INTO OIL PAN).
4. CHECK FOR FUEL,OIL,WATER 4A CORRECT IF LEAKING.
5. FILL RADIATOR/SURGE TANK WITH 5A RADIATOR CAP MUST BE FIRMLY

TREATED WATER (CHROMATE TIGHTENED BACK INTO THE
CONCENTRATION 3500 PPM). RADIATOR/SURGE TANK NECK, ENGINE
MUST NOT BE OPERATED WITHOUT
THE RADIATOR CAP SINCE THIS WILL
CAUSE AERATION AND OVERHEATING
OF THE COOLANT.
6. CHECK AIR CLEANER OIL LEVEL 6A USE CLEAN ENGINE OIL.

AND CHANGE OIL, IF REQUIRED (IF
OIL BATH TYPE) CLEAN DUST PAN
AND PRECLEANER OF DAY TYPE
AIR CLEANER.
7. CHECK AIR LINE CONNECTIONS 7A CORRECT AS REQUIRED

FOR LEAKS.
8. REMOVE AND CLEAN AIR COM- 8A FILL WITH CLEAN OIL, UPTO MARK.
PRESSOR BREATHER, IF
EQUIPPED.
9. DRAIN AIR RECEIVER TANK AT THE

BEGINNING OF EACH SHIFT AND
THEN CLOSE THE DRAIN COCK.

Page no. 57
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
10. CLEAN CRANKCASE BREATHER 10A DISCARD PAPER TYPE ELEMENT,
11. CHECK OIL LEVEL IN HYDRAULIC 11A CHECK FOR LEAKS, USE
GOVERNOR, IF PROVIDED. SPECIFIED ENGINE OIL FOR
TOPPING UP.
12. START THE ENGINE AND NOTE 12A IF THERE IS A CHANGE IN OIL THE
PRESSURE BOTH AT IDLING AND OIL PRESSURE FROM THAT
MAXIMUM SPEED. RECORDED IN THE LOG BOOK ON
EARLIER OCCASION THEN STOP
ENGINE AND CHECK THROUGH
TROUBLE SHOOTING TECHNIQUE
THE CAUSE FOR OIL PRESSURE
CHANGE AND CORRECT IF
NECESSARY (FOR ASSISTANCE IN
DIAGNOSING THE CHANGE IN OIL
L
PRESSURE CALL YOUR SERVICE
REPRESENTATIVE IF NECESSARY.
C
13. RECORD OIL PRESSURE 13A REFER O&M MANUAL FOR LUB. OIL
PRESSURE LIMITS.
USE CLEAN FUEL AND A STRAI

14. FILL FUEL TANK AT THE END OF 14A
NER.ALSO CLEAN THE CAP AND
THE SHIFT.
SURROUNDING AREA BEFORE
IO
OPENING THE FILLER CAP.

.
--------------------------------------------------------------------------------------------------------------------------

Page no. 58
DIESEL ENGINES
"B" CHECK EVERY 250 HOURS
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
1. REPEAT ALL MAINTENANCE STEPS 1B
OF CHECK "A" 1 TO 14.
2. CHANGE ENGINE OIL 2B WHEN LUB. OIL IS EXAMINED THROUGH
LUB. OIL ANALYSIS IN LABORATORY. OIL
CHANGE PERIOD MAY BE EXTENDED IN
SUCH CASES. (REFER TO YOUR
SERVICE REP).
3. FIT NEW LUBRICATING OIL FULL 3B INSPECT THE CHANGED FILTER

FLOW FILTER ELEMENT ELEMENTS AND CHECK FOR PARTICLES
AND OIL SLUGING/ OXIDATION.
4. REMOVE CLEAN AND INSPECT DRY

TYPE AIR CLEANER ELEMENT,
REMOVE AND CLEAN DUST PAN.
INSPECT FOR HOLES AND TEARS,
L 4B BLOW OUT DUST WITH COMPRESSED
AIR IN THE OPPOSITE DIRECTION OF
THE NORMAL AIR FLOW, IF VERY DIRTY
WITH OIL AND CARBON WASH IN
C
CHECK GASKETS AND "O" RINGS SOLUTION OF WARM WATER (120-140
FOR DAMAGE. DEG F) AND NON-SLUDGING
DETERGENT ALLOW IT TO DRY FIRST,
THEN USE COMPRESSED AIR. REPLACE
IF WASHED TWO TIMES. CAUTION
EXCESS AIR PRESSURE WILL DAMAGE
IO
PAPER. AIR NOZZLE MUST BE KEPT AT

LEAST 20 cm FROM THE ELEMENT.
MUST NOT BE USED IF EVEN ONE PIN
HOLE EXISTS. DISCARD ELEMENT IF
PUNCTURED AND ALSO CHANGE
GASKET ALONG WITH ELEMENT.
5. CLEAN OIL BATH AIR CLEANER 5B

TRAY SCREEN.
6. CHANGE LUBRICATING OIL BY- 6B RECORD OIL PRESSURE.
PASS FILTER ELEMENT AND
GASKET, IF PROVIDED.
7. CLEAN FLOAT TANK AND/OR MAIN 7B
FUEL TANK BREATHER.

Page no. 59
8. CHECK COOLANT PH VALUE- 8B CHANGE CORROSION PRESISTER

CONCENTRATION OF DCA/ ELEMENT IF PH VALUE IS BELOW
CHROMATE CONCENTRATION NORMAL RANGE 8.5-10.5. CHECK
(3500 PPM). CHROMATE CONCENTRATION AT 3500
PPM. FOR DCA REFER O&M MANUAL.
9. CHECK MAGNESIUM PLATE IN 9B CHECK MAGNESIUM PLATE FOR PITTING

ASSEMBLY CORROSION OR BEING EATEN AWAY CHANGE IF
REGISTER CHANGE WATER FILTER MORE THAN 50% OF AREA IS LOST. USE
ELEMENT. DCA SERVICE ELEMENT OR CHROMATE
ELEMENT OR CHROMATE ELEMENT
BAGS (AR95679) IF CONCEN- TRATION IS
LOW.
10. CHANGE FUEL FILTER ELEMENT 10B.CLEAN

CLEAN SHELL FUEL FILTER CHANGE
WASHER AND "O" RING ELEMENT WHEN RESTRICTION EXCEEDS
VACUUM 200MM OR MERCURY
11. CHECK OIL IN ANEROID CONTROL, 11B.

11B.USE
USE SAME OIL AS USED IN OIL PAN.
IF REQUIRED.
12. CHECK & ADJUST BELTS.NEW 12B.TIGHTEN
BELTS WILL STRETCH WITHIN ONE
HOUR OR USE THEY MUST BE
LBELT TENSION
MAINTENANCE MANUAL.
REFER
C
READJUSTED.
13. TIGHTEN FOUNCTION BOLTS AND 13B.
FLEXIBLE COUPLING BOLTS OF
ENGINE AND ALTERNATOR
14. CHECK ALL AIR CLEANER 14B.CORRECT AS REQUIRED.
IO
CONNECTIONS FOR CRACKS

CHAFING ETC. TIGHTEN ALL AIR
INTAKE CONNECTIONS.
15. CHECK FAN HUB AND DRIVE 15B.USE SPECIAL TOOL FOR TIGHTENING
THE FAN HUB NUT.
16. CLEAN/CHANGE AIR COMPRE
COMPRESSOR 16B.CHANGE ELEMENT FOR NATURALLY
BREATHER ELEMENT ASPIRATED ENGINE CLEAN SCREEN FOR
TURBO ENGINE.
17. CHECK THROTTLE LINKAGE 17B.

Page no. 60
DIESEL ENGINES
"C" CHECKS EVERY 1500 HOURS

----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
1. REPEAT ALL MAINTENANCE STEPS 1C

OF CHECKS "A" & "B".
2. CHECK THERMOSTATE OPERATION 2C IT SHOULD START OPENING AND
OPEN FULLY WITHIN RANGE 165 DEG.
F. OR 170 DEG. F. DISCARD AND FIT
NEW THERMOSTATE IF OPERATION IS
NOT SATISFACTORY.
3. CHECK FAN HUB AND DRIVE 3C CHECK MOUNTING BOLTS AND END
BEARING PLAY.
4. CHECK IMPLELLER WATER PUMP 4C CORRECT IF NECESSARY.
FOR PLAY.
5.
6.
CHECK FOR TURBOCHARGER OIL
LEAKS.
TIGHTEN
MOUNTING NUTS.
TURBOCHARGER
L 5C CORRECT AS REQUIRED.
6C TIGHTEN TO THE SPECIFIED TORQUE

DO NOT TIGHTEN WHEN ENGINE IS
C
HOT.
7. CHECK INLET AIR RESTRICTION 7C CHECK AFTER CLEANING DRY TYPE
AIR CLEANER ELEMENT. IF
RESTRICTION IN EXCESS OF 1000 MM
WATER A NEW ELEMENT MUST BE
IO
FITTED.
8. CLEAN OIL BATH AIR CLEANER 8C REMOVE COMPLETE ASSEMBLY AND
SCREENS. CLEAN INCLUSIVE OF FIXED.
9. CLEAN AND TIGHTEN ALL ELEC
ELEC- 9C
TRICAL CONNECTIONS.
10. CHECK GENERATOR BRUSHES AND 10C REPLACE AND CLEAN AS REQUIRED.
COMMUTATOR.
11. CLEAN ENTIRE ENGINE 11C HIGH PRESSURE AND SOAP WATER
MIXTURE PREFERRED AFTER
SPRAYING ENGINE WITH CLEANSER
TAKING CARE OF PROTECTING
ELECTRICAL SYSTEM.

Page no. 61
DIESEL ENGINES
"C" CHECK EVERY 1500 HOURS
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
12. TIGHTEN ALL MOUNTING BOLTS 12C TIGHTEN AS REQUIRED. OVER
AND NUTS TIGHTENNING MAY RESULT IN
DISTORTION OR DAMAGE.
13. CLEAN ANEROID AIR BREATHER 13C REPLACE BREATHER IF NECESSARY
14. CHECK SEA WATER PUMP (MARINE 14C CHECK FOR LEAKS/ OPERATION/
APPLICATION ONLY) PERFORMANCE.
15. CHECK HEAT EXCHANGER 15C CLEAN ELEMENT TUBES/CHANGE
ELEMENT ZINC PLUG (MARINE PLUGS.
APPLICATION).
16. CHECK EXHAUST AND INLET 16C

MANIFOLD NUTS AND CAPSCREWS.
17. CHECK ENGINE BLOWER.
L 17C READINGS IN EXCESS OF
RECOMMENDED LIMITS. CORRECTIVE
ACTION MUST BE TAKEN. THOROUGH
ANALYSIS WITH THE HELP OF
C
TROUBLE
ROUBLE SHOOTING CHART.
18. CLEAN RADIATOR 18C BLOW AIR THROUGH THE RADIATOR

CORE IN OPPOSITE DIRECTION TO
THE NORMAL FLOW OF AIR, IF
IO
WORKING UNDER DUSTRY/ DIRTY

CONDITIONS. (REVERSE FLUSHING
CHECK SHAFT END CLEARANCE
19. CHECK AIR COMPRESSOR 19C

20. ADJUST INJECTORS AND VALVES 20C FINAL ADJUSTMENTS MUST BE
CARRIED OUT WITH ENGINE HOT AND
WITH CORRECT TORQUE AS
SPECIFIED (REFR O&M MANUAL).
21. CLEAN FUEL INLET CONNECTIONS 21C
22. CHANGE HYDRAULIC GOVERNOR 22C USE ENGINE LUBRICATING OIL.

OIL/ ANEROID OIL
CHECK WOBBLE AND ECCENTRICITY
23. CHECK VIBRATION DAMPER. 23C
ALIGNMENT MARKS ON RUBBER TYPE.
DISCARD DAMPER IF MISALIGNMENT
IF MORE THAN 1/16 IN.
ALIGNMENT MARKS ON RUBBER TYPE.
DISCARD DAMPER IF MISALIGNMENT
IF MORE THAN 1/16 IN.

Page no. 62
DIESEL ENGINES
"D" CHECK EVERY 4500 HOURS
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
1. REPEAT ALL MAINTENANCE STEPS 1D
OF CHECKS "A", "B" & "C".
2. CHECK EXHAUST AND INLET 2D
MANIFOLD NUTS AND CAPSCREWS.
3. TIGHTEN ALL MOUNTING BOLTS 3D
AND NUTS.
4. CLEAN TURBOCHARGER DIFFUSER 4D
AND IMPELLER AND CHECK END
FLOAT.
5. CHECK TURBOCHARGER REARING 5D ONLY END FLOT ON SEMI FLOATING
CLEARANCES. BEARINGS IF IN EXCESS OF LIMITS,
REPLACE.
IF IN EXCESS OF RECOMMENDED
6. CHECK CRANKSHAFT END FLOAT 6D
LIMITS. CORRECTIVE ACTION IS
INDICATED.
CLEAN INJECTOR INLET SCREENS.

7. 7D
8. CLEAN AND CALIBRATE ALL 8D MUST BE DONE ONLY IF A

PERFORMANCE DETERIORATION IS
INJECTORS.
EVIDENT. SOME OF THE INDICATIONS
FOR PERFORMANCE DETERIORATION
ARE
1. BLACK SMOKE
2. CHANGE OF FUEL MANIFOLD
PRESSURE.
3. LOSS ODF POWER.
4. MALFUNTION OF ANERIOD
9. CHECK FUEL PUMP CALIBRATION 9D
10. REPLACE ANEROID BELLOWS AND 10D

CALIBRATE ANEROID.
11. REPLACE FUEL PUMP FILTER 11D
SCREEN AND MAGNET.
12. STEAM CLEAN ENGINE 12D IF STEAM IS NOT AVAILABLE, THEN
USE CLEAN SOAP WATER SOLUTION
IIC.

Page no. 63
DIESEL ENGINES
È' CHECK EVERY 8000 HOURS
1. Repeat all maintenance steps of check À', `B', `B' & `D'.
2. The È' maintenance check is necessary only when the engine operating conditions
signify deterioration in performance as can be ascertained by the symptoms:
(1) Heavy smoke

(2) Loss of power
(3) High oil temperature high water temperature
(4) Loss of lube Oil pressure
(5) Unusual noise & vibrations.
The È' maintenance check is a methodology for inspection of wear or assembly

deterioration of parts and assemblies, and should be resorted to only when trouble
shooting in addition to performing A, B, C & D maintenance checks, which may
L
eliminate the engine performance problem and bring the engine back to normal
operating conditions. It is anticipated that good operating and maintenance practices
as prescribed through A, B, C & D checks will ensure that the engine will perform
beyond 25,000 hours before that the engine must be dismantled for inspection
prelude to a major overhaul. The time internal of 8,000 hours is a period at which
C
the engine may develop symptoms ascribed above at 1-5 and are indicative of
performance deterioration due to inadequate A, B, C & D checks and failure to
identity performance deterioration. This figure has been arrived at on the basis of
current maintenance practices and should not be treated as an absolute for making
an È' check. However, it is essential that the above routine analysing engine
IO
performance be strictly followed in order to prevent dismantling of engine whose
performance can be simply corrected by trouble shooting and routine maintenance
checks.
3. The È' maintenance check is often referred to as "in frame inspection" where some
key parts, such as bearings, are checked for wear to determine if the engine may
be operated for another service period. Likewise, oil consumption, oil pressure and
other signs of wear should be analysed during the check wear limits and other
information is available from distributor and dealers. (it must be clearly understood
that the decision to inspect key parts must be arrived through routine outlined in point
two above).

Page no. 64
10.0 STATUTORY TESTING OF L P G CYLINDERS

All cylinders used for filling LPG are required to be tested periodically in line with
the applicable statutory requirements to ensure fitness of the cylinders for further
service. Such tests shall be conducted at the PESO recognized cylinder testing
facilities only.
10.1 TESTING PROCEDURE
10.1.1 DEGASSING O F L P G CYLINDERS
All the LPG cylinders are depressurised in the approved premises by opening valves
by means of suitable adapters to ensure that the internal cylinder pressure is
reduced to atmospheric pressure. Only after depressurising the cylinder, cylinder
valve is removed and LPG cylinder is taken up for water filling and water is
overflown and retained in the cylinder for not less than one hour to remove any
traces of LPG. Degassing can also be achieved by stripping, Nitrogen purging, etc.
10.1.2 SURFACE CLEANING
a) After depressurising the cylinder and emptying out the water, the same is kept in
inverted position and stroked gently with a nonnon-sparking
-sparking hammer such as wooden
mallet to remove any dust, rust or any loose remnants in the cylinders.
L
b) The depressurized cylinder bung is plugged and is taken up for surface cleaning by
immersing the cylinder in the caustic soda bath and soap water and the same is then
rinsed with water.
C
10.1.3 CHECKING TARE WEIGHT:
All the LPG cylinders shall be weighed and if the loss in tare weight is more than 5%
of original weight such cylinders shall be segregated and scrapped. At the time of
weighing the weight of valve is also accounted.
IO
10.1.4 VISUAL INSPECTION:
a) The detailed visual inspection of the cylinder body shall be carried out as per IS:
16054:2013
b) Depending upon the visual inspection, cylinders are segregated for scrapping, for cold
repairs and for hot repairs in case required.
c) The interior of the cylinder shall be visually examined with low voltage FLP lamp.
The internal examination shall be carried out as per IS: 16054:2013
d) LPG cylinders selected at random may be cut into two holes for assessing internal
corrosion.
e) In case of dented/ buckled cylinders, visual inspection of welds needs to be done more
carefully since the welds are more susceptible to cracking. Denting or buckling by
more than nominal plate thickness may be attended by repairs/ replacement.
10.1.5 HYDROSTATIC TESTING:
a) All the n e w LPG cylinders shall be taken up for hydrostatic test w i t h i n an interval
of 1 0 years f r o m t h e d a t e o f m a n u f a c t u r i n g for first testing and subsequent
testing after every 5 years in accordance with IS:16054. Only water should be used
as a medium for hydrostatic testing and the pressure to be applied should be the test
pressure marked on the cylinder body (25.35 kg/sq.cm) and the same should be
retained for a minimum period of 30 seconds. Any reduction in pressure noticed
during the test, any leakage, visible bulge or deformation should be treated as a

Page no. 65
case of failure. Such cylinders should be properly marked, observation recorded and
segregated for scrapping and disposal.
b) Pressure Gauges shall be calibrated at least once a week and the Pressure Gauges
used for verification should be tested once in every three months.
10.1.6 VALVE FIXING:
a) Before commencing the fitting of valve operation, all the water inside the cylinder
should be drained and the cylinder should be made dry with the use of hot air jet.
Before refitting the valve, internal threads of the cylinder bung should be cleaned with
3/4" NGT thread tap and checked against thread damage. In case old valves are
being refitted the same should be tested by compressed air at 7 kg/sq.cm for
leakage from seat.
b) Teflon paste/ suitable sealing compound should be used as a sealing material for
tightening the valve and the torque of 20+/-2 kg. m. should be applied. In no case
spanners and ordinary wrenches be used for tightening the valves.
10.1.7 PNEUMATIC TEST:
a) The Pneumatic test should be applied to the cylinder at a pressure of 12 kg/sq.cm for
a minimum of 60 seconds as per IS:16054.
16054.. This is basically to check the tightness of
the valve cylinder joints.
L
b) With the cylinder under pressure, a soap solution should be applied to the cylinder
valve bung joint to ensure that there is no leak. The same can be checked by dipping
the cylinders in water bath. Depressurise the cylinders. All the Pressure Gauges used
C
for Pneumatic test shall be calibrated at least once in 3 weeks and the Pressure
Gauge used for verification should be tested once in every three months.
10.1.8 PAINTING OPERATIONS:
a) To enhance the life of the cylinder and to project a better image to the customers,
IO
maintaining a well painted surface of cylinder is most desirable.
b) All LPG cylinders are painted with one coat of zinc chromate primer and a coat of
super synthetic enamel paint of signal red colour {IS:2932 (Part 1):2013 shade 5
537}.
Special care should be taken to paint the cylinders in vulnerable areas like
underneath the foot ring.
c) The valve should be protected while painting the cylinder.
10.1.9 CHECKING MARKING THE TARE WEIGHTS
a) Tare Weight of the cylinder should be ascertained and if in variance with the original
tare weight (this could be as a result of change of cylinder valves) the observed tare -
weight should be punched as close to the original tare weight marking as recorded in
the register maintained.
b) The observe tare weight should be stenciled with paint on the shoulder and as well as
on inside of one of the vertical stay.
c) Gross weight punched/ stenciled on the cylinder should be changed in case of change
of tare weight.
d) Weighing machines used for checking the tare weight should be duly certified by
Weights & Measures Authority. The machine should be tested daily with the
standard weights to verify accuracy. The test used for checking should be tested
against standard weights and the same must be stamped periodically by Weights
and Measures Authority. The minimum graduations of 50 gms. must be available.

Page no. 66
e) Weighing scale error should not be greater than 1.0%.

f) The tare weight should be recorded with an accuracy of +/-50 gms. and rounded off as
per IS:2.
10.1.10 PUNCHING O F MAR KS:
In addition to punching of revised tare weight/ gross weight wherever applicable,
following details should also be punched on the cylinder body as close to the
previous markings as practicable:
a) Date of retest
b) Code marking for the Test Plant/ Repairer.
c) Tare weight of the cylinder should be stenciled with black paint within the V.P.
Ring circle diameter at 3 places for easy identification by filling operators. The
recommended lettering size is 25 mm and the thickness of the numerals is 6-7
mm.
d) It is also recommended that the net weight of LPG to be filled should be stenciled
on the body of the cylinders outside the V.P. Ring diameter. The size of the
lettering recommended is 18 mm and the thickness of the numerals is 4-5 mm.
L
Route card process and batch formation for statuary pressure testing activities shall
be followed as per IS 16054: 2013. Sequence of operations for statutory pressure
testing of L P G Cylinders is given at Annexure 10
10.1.11 COLOUR CODING OF CYLINDER
10- I.
C
This is done primarily to facilitate easy segregation of cylinders for repairs at installations
without going through the test date of manufacturing dates punched on each and every
cylinder. Currently, the following colour codes are used for determination of hydro-testing
cycle of cylinders and the same color coding shall be repeated after every ten years cycle.
Revised colour coding schemes as per latest guidelines is attached as Annexure 10-II
IO
10.1.12 CERTIFICATION:
A detailed record of each cylinder tested at the installation or at the repairer's premises
should be maintained. The record should include the minimum following details:
a) Running serial number
b) Date of testing
c) Serial number of cylinder & name of manufacturer
d) Month and year of test
e) Weight of cylinder
f) Punched on cylinder
g) Observed weight
h) Whether satisfactory/ rejected
i) Visual defects
j) Internal
k) External
l) Whether passed/ rejected

Page no. 67
10.1.13 HYDROSTATIC TEST/ HYDROSTATIC STRETCH TEST:

a) Whether passed/ rejected
b) Condition of bung threads (internal)
c) Whether satisfactory/ rejected Pneumatic Test
d) Whether passed/ rejected
e) Quarter/ year of retest punched on t h e cylinder
f) Stenciling/ colour coding for age profile
g) Relevant test certificate number
REMARKS:
(The Remarks columns should indicate whether the cylinder has been finally passed or
rejected besides any other relevant details not covered above).
The test certificate issued by the Plant or by the Repairers should include:
- Running Serial Number of cylinder
- Cylinder Serial Number
- Date of testing
L
C
IO

Page no. 68
ANNEXURE - 10- I
SEQUENCE OF OPERATIONS FOR STATUTORY
PRESSURE TESTING OF LPG CYLINDERS
1. Receipt of Cylinders
2. Depressurising
3. Recording details (like S. No., Test Dates, Tare weight, Manufacturer's name)
4. Valve Removal
5. Degassing
6. External surface cleaning
7. Internal cleaning and internal inspections
8. Visual Inspections of external surface and bung threads by L-1 and L-9 plug gauges
9. Tare weight checking
10. Hydrostatic testing
11.
12.
Internal cleaning and checking
Primer coating
L
C
13. Signal red painting
14. Punching of new test date and repairer's identification mark
15. Tare weighing
16. Colour code painting to indicate ownership of c
cylinders, stenciling new tare weight, new
IO
weight and next test date
17. Tapping the bung thread, cleaning the same by brass wire brush and checking the bung
threads by L-1 & L-9 plug gauges.
18. Valve fixing
19. Pneumatic test
20. Certification and dispatches.

Page no. 69
Annexure -10-II
COLOUR CODING SCHEME
Due date of Testing Back Ground Colour of

Letters
Quarter Year COLOUR Shade as per IS:5
A/B/C/D 2017 Indian Brown 415 White

A/B/C/D 2018 Satin Blue 177 Black
A/B/C/D 2019 Bus Green 299 White
A/B/C/D 2020 Black 521 White
A/B/C/D 2021 Yellow 355 Black
A/B/C/D 2022 White 127 Black
A/B/C/D 2023 Sea Green 217 Black
A/B/C/D 2024 Dove Grey 694 Black
A/B/C/D 2025 Aircraft Blue 108 White
A/B/C/D 2026 Salmon Pink 443 Black
L
The above scheme is for cycle of 10 years and shall therefore repeat at an interval of every 10
years e.g. the scheme for 2027 shall be same as for 2017.
C
IO

Page no. 70
CHAPTER 11
FIRE PROTECTION FACILITIES
11.1 GENERAL
LPG Installations shall have well defined in-built fire prevention and protection system to
mitigate any exigency. The requirements of fire prevention and protection system shall be
as under:
11.2 DESIGN CRITERIA
i) The single largest fire risk shall be considered.
ii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump /
compressor Houses, remote operating valves /motor operated valves on LPG lines Bulk
Lorry and Tank Wagon Gantries shall be fully covered by medium velocity water spray
system.
iii) Fire Protection Facilities shall have firef ighting access, means of escape in case of
fire and also segregation of facilities so that the adjacent facilities are not endangered
during the fire.
iv) Heat Detectors for detection of fire for automatic actuation of medium velocity water
L
sprinkler system shall be provided. The QB/EP detectors shall be placed directly
overhead or inside the hazard. In areas without specific hazard, detectors shall
be placed evenly across the ceiling or with maximum spacing of 3 meter inside the
shed. Any other detectors if provided shall comply with the design requirements.
C
11.3 FIRE WATER SYSTEM
The main components of the fire water system are:
Fire Water Storage
IO
Fire Water Pumps
Fire Hydrant/ Monitor distribution piping network.
Water Sprinkler/ Deluge system.
11.4 FLOW RATE DESIGN
The Fire Water pumping requirement for medium velocity spray system shall be
calculated based on minimum spray density as 10.2 LPM/Sq.M of the exposed surface or
area to be cooled, in case of LPG Pump/ compressor it shall be 20.4 LPM/Sq.M.
a) Storage Vessels
MV sprinkler system with automatic heat detection having remote/ local operated Deluge
valve with spray density of Minimum 10.2 LPM/ Sq.M shall be provided on all above
ground storage vessels.
For water flow calculations aggregate surface area of all vessels within distance of 30
Mts. from the periphery of the affected LPG vessel shall also be considered as single
risk.
b) Sheds
valve with spray density of minimum 10.2 LPM/Sq.M shall be provided in the entire shed
including the loading / unloading fingers.
For spray water calculations, the shed can be divided into suitable number of zones, each

Page no. 71
served by independent deluge system. The adjacent zones shall be operative around
the zone under fire and the same shall be considered as a single risk. The width of a
zone shall not be less than 10 meter except of the zone on either end of the shed. As
there is no storage of cylinders in the loading / unloading fingers, spray system can be
taken as separate zone with independent deluge valve to optimize the f ir e water
requirement.
c) LPG Pump / Compressor House
valve with spray density of Minimum 20.4 LPM/Sq.M shall be provided.
The entire LPG pump /compressor house shall be considered as single risk area:
alternatively, it can be divided into suitable number of zones, each of which shall have
width not less than 10 meter. Each zone shall be served by an independent deluge system.
d) Tank Lorry Gantry
In case of Tank Lorry Gantry, automatic detection of heat for automatic actuation of MV
sprinkler system having remote and local operated deluge valve with spray density 10.2
LPM/Sq.M of surface area shall be provided. A maximum of 8 bays shall be considered
as single risk area. In addition to the tank lorry surface, MV spray system shall
effectively cover the tyres, manifold and dish ends of various size of tank Lorries. There
L
shall be at least 3 t i e r s of M V sprinkler system to uniformly cool the top, middle and t he
bottom of the tank lorry. Each zone shall be served by an independent deluge system.
e) Tank Wagon Gantry
C
MV sprinkler system with automatic heat detection having remote and local operated
deluge valve with effective spray density of 10.2 LPM/Sq.M shall be provided. The
gantry can be divided into suitable number of zones with minimum zone length of 30
meters and adjacent zones shall operate around zone under fire and same shall be
considered as single risk. Each zone shall be served by an independent deluge system
There shall be at least 3 tiers of MV sprinkler system to uniformly cool the top, middle and
IO
the bottom of the tank wagons. The spray system shall also cover the associated LPG
pipelines in the gantry.
The fire water system in the plant shall be designed to meet the highest fire water flow
requirement of a single largest risk of any of the above cases at a time plus 288 Cu.M/Hr.
for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
MV Sprinkler Zone drawing shall be prepared detailing all the zones and identifying their
independent deluge valve systems. The drawing shall be kept readily available in the plant
and displayed prominently in the field.
11.5 FIRE W A T E R SYSTEM DESIGN
i) The Fire Water pressure system shall be designed for a minimum residual pressure of
7.0 kg/ cm2 g at the remotest place of application in the plant.
ii) A fire water ring main shall be provided all around perimeter of the LPG Plant
facilities with hydrants/ monitors spaced at intervals not exceeding 30 M when
measured aerially. Fire hydrants and monitors shall not be installed within 15 Meters
from the facilities/ equipment to be protected.
iii) Fire hydrant network shall be in closed loops to ensure multidirectional flow in the
system. Isolation valves shall be provided to enable isolation of any section of the
network without affecting the flow in the rest. The isolation valves shall be located
normally near the loop junction. Additional isolation valves shall be provided in the
segments where, the length of the segment exceeds 300 Mts. Isolation valves shall

Page no. 72
have visible indication for open & close condition.

iv) Suitable over pressure relief mechanism shall be provided in the hydrant line against
thermal expansion or sudden closure of valves so as to ensure the pressure in the line
never exceeds its design pressure, even in transient condition.
11.6 FIRE WATER STORAGE
i) Water for the hydrant service shall be stored in any easily accessible surface or
underground lined reservoir or above ground tanks of steel, concrete or masonry.
The effective capacity of the reservoir above the level of suction point shall be
minimum 4 hours aggregate working capacity of pumps. Where make up water
supply system is 50% or more this storage capacity may be reduced to 3 hours
aggregate rated capacity of pumps.
Large natural reservoirs having water capacity exceeding 10 times the aggregate
water requirement of fire pumps may be left unlined.
ii) Storage tank/ reservoir shall be in two inter connected compartments to facilitate
cleaning and repairs. In case of steel tanks there shall be a minimum of two tanks.
11.7 FIRE WATER PUMPS
i) Centrifugal pumps having flooded suction shall be installed to meet the design fire water
L
flow rate and head. If fire water is stored in underground tanks, an overhead water tank
of sufficient capacity shall be provided for flooded suction after accounting for leakage in
the network, if any. Pumps shall be provided with suitably sized strainers and NRVs on
suction and discharge lines respectively.
C
ii) The system pressure has to be maintained at 7 kg/cm2g at the farthest end of the
hydrant system with the help of Jockey Pump operating automatically. The Jockey
Pump shall start-stop automatically actuated by pressure switches. A standby jockey
pump shall be provided if the number of hydrant points is more than 100. One monitor
shall be considered as equivalent to 4 hydrant points.
IO
iii) The fire water pump(s) including the stand by pump(s) shall be diesel engine driven.
The pumps shall be capable of discharging 150% of its rated discharge at a minimum
of 65% of the rated head. The shut-off head shall not exceed 120% of rated head for
horizontal centrifugal pumps. Each engine shall have an independent fuel tank of
suitable size for 6 Hrs. continuous running at the desired head and discharge of the fire
pump concerned. Fuel tanks should be installed outside the fire pumps house and shall
have provision for venting. If tanks are located inside the fire pump house, the vent shall
have provision for venting outside the pump house.
Where power supply is through adjoining captive power generation facility, electrically
driven centrifugal pumps can be used up to a maximum of 50 % of total number of
pumps installed. Power supply to such pump motors shall be from two separate
feeders.
iv) At least one standby fire water pump shall be provided when the no. of main pumps
does not exceed 2 nos. When the said requirement exceeds 2 pumps, at least 2
standby pumps of the same capacity, head & characteristics shall be provided. All the
fire water pumps shall be of same rated capacity, head & similar characteristics.
v) Fire water pumps shall be used exclusively for Fire protection and prevention
purpose only.
vi) Suction and discharge valves of fire water pump shall be kept open all the time.
vii) Fire engines shall have provision for high coolant temp & low lube oil pressure alarms.

Page no. 73
viii)All the Fire Engines shall be set at the rated RPM of the fire pump. As all the fire
engines are to start in auto mode, throttling of the fire engines governors for setting the
engine speed below the rated RPM shall not be permitted.
ix) The OEM drawing of the cooling system of the fire engines clearly marking the minimum
and maximum inlet and outlet cooling water pressures permitted in the line, location of
the pressure regulator and its settings etc. shall be available. Manual opening of the
valves of cooling line after engine starts in auto mode shall not be permitted.
x) The fire water pumps shall be provided with auto starting facility. The auto starting logic
shall ensure that, if the pump - designated to start first - fails to build up the required
pressure in the fire water ring main system within 20 seconds (max.) or fails to start at
all, the next designated pump shall start and continue the same cycle.
11.8 FIRE HYDRANT NETWORK
i) Fire hydrant ring main shall be lai d above ground ensuring that:
a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground
level.
b) The mains shall be supported at regular intervals not exceeding 6 meters or as
per design approved.
c) The system for above ground portion shall be analyzed for flexibility against
thermal expansion and necessary expansion loops where called for shall be
provided.
ii) However, the ring main may be laid underground at the following places:
a) Road crossings.
b) Places where above ground piping is likely to cause obstruction to operation and
v eh icl e movement.
c) Places where above ground piping is likely to get damaged mechanically, particularly
i n the LPG storage area where water supply lines are laid for feeding sprinkler
deluge system.
d) Where Frost conditions warrant and ambient temperature is likely to fall below zero
deg. centigrade underground piping at least 1 meter below the ground level should
be provided. Alternatively, for above ground pipelines, water circulation to be
carried out.
iii) For Fire water ring main laid underground the following shall be ensured:
a) The Ring main shall have at least one-meter earth cushion in open ground, 1.2
cushion under the road crossings and in case of rail crossing, provisions
stipulated by Indian Railways shall be complied.
b) The Ring main shall be suitably protected against soil corrosion.
c) In case of poor soil conditions, it may be necessary to provide concrete/
masonry supports under the pipe line.
iv) Fire water ring main shall be sized for 120% of the design water flow rate. The
velocity of water shall not exceed 5 meter per second in fire water ring main. Design
flow rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.
In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally or other suitable coating material shall be used.

Page no. 74
v) Hydrants/ monitors shall be located considering various fire scenario at different

sections of the premises to be protected and to give most effective service. At least
one hydrant post shall be provided at every 30 mtrs of external wall measurement or
perimeter of battery limit in case of high hazard areas. For non-hazardous area,
they shall be spaced at 45 mtrs intervals. The horizontal range & coverage of hydrants
with hose connections shall not be considered beyond 45 mtrs.
vi) Hydrants shall be located at a minimum distance of 15 mtrs from the periphery of
storage tank or equipment under protection. In case of buildings this distance shall not
be less than 2 mtrs and not more than 15 mtrs from the face of building. Provision of
hydrants within the building shall be provided in accordance with IS: 3844.
Hydrant/Monitors shall be located along road side berms for easy accessibility.
vii) Double headed hydrants with two separate landing valves on 3"/ 4" stand post shall
be used. All hydrant outlets shall be 1.2 mtrs above ground level.
viii) Monitors shall be located to direct water on the object as well as to provide water
shield to firemen approaching a fire. The requirement of monitors shall be
established based on hazards involved and layout considerations. The location of
the monitors shall not exceed 45 mtrs from the hazard to be protected.
ix) Hydrants and monitors shall not be installed inside the dyked areas.
x) LPG tank wagon loading/ unloading facility and Tank Truck gantry area should be
provided hydrants having multipurpose combination nozzles for jet spray & fog
arrangement and fire hydrants located at a spacing of 30 mtrs on both sides of the
gantry. The hydrants & monitors shall be located at a minimum distance of 15 mtrs
from the Tank Wagon/Tank Trucks measured from edge of the facilities.
xi) Fire water monitors shall be provided with independent isolation valves.
xii) Hose box with 2 nos. hoses and a nozzle shall be provided at each hydrant points.
xiii) The fire water deluge valves shall be kept outside the kerb wall at a safe distance in
case of sphere/ bullet, and located 15 M away from limits of other sheds or shadows of
spheres. A fire wall shall be provided for the protection of the deluge valve and for
personal protection of the operator.
xiv) Pipes made of composite material shall be laid underground.
11.9 MATERIAL SPECIFICATIONS
All the materials used in fire water system using fresh water shall be of type as indicated
below.
i) Pipes : Carbon Steel as per IS: 3589/IS: 1239/IS: 1978 or Composite Material
or its equivalent for fresh water service. In case saline, brackish or
treated effluent water is used, the fire water ring main of steel pipes,
internally cement mortar lines or glass reinforced epoxy coated or pipes
made of material suitable for the quality of water able to withstand the
temperature and pressure shall be used. Alternately, pipes made of
composite materials shall be used. The composite material to be used
may be as per API 15LR/API 15HR / IS: 12709.
ii) Isolation Valves: Gate valve or quick shut off type isolation valves made of Carbon Steel
having open/close indication shall be used. Other materials such as
cupro-nickel for saline / brackish water can be used. The material of
the valve shall be suitable for the service.
iii) Deluge valve : Carbon Steel

Page no. 75
iv) Hydrant
Stand post : CS
Outlet valves : Gunmetal/ Aluminum
v) Monitors : CS
Equivalent or superior materials meeting the design requirements can also be used.
vi) In case of underground mains, the isolation valves shall be located in RCC/ brick
masonry chamber.
vii) The above ground fire water main and the fire hydrant stand post shall be painted with
corrosion resistant Fire Red" paint as per IS: 5.
viii) Water monitor, hydrant point and hose box shall be painted "Luminous Yellow' IS: 5.
11.10 MEDIUM VELOCITY SPRINKLER SYSTEM
i. The medium velocity spray system shall be provided in all critical areas like LPG
Storage Area, LPG Sheds having cylinder filling, cylinder storage, cylinder
loading/unloading fingers (including packed trucks covering at least the cylinder
thereon), LPG Pump/Compressor House, Bulk Tank truck/ wagon loading /
unloading gantries, piping manifold, cold repair sheds etc.
L
ii. Spray nozzles shall be directed radially to the vessel at a distance not exceeding 0.6
m from the equipment surface. Only one type and size of spray nozzle shall be
used in a particular facility. The horizontal extremities of water flow from spray
C
nozzles shall at least meet.
iii. Where projections (manhole flanges, pipe flanges, staircase, and supports brackets)
obstruct the water spray coverage, including rundown or slippages on vertical surface,
additional nozzles shall be installed around the projections to maintain the wetting
pattern. First valve of the vessel shall be adequately covered with sprinklers.
IO
iv. Horizontal dry piping downstream of the block valve and after deluge valve shall
have adequate drain facilities at selected locations.
11.11 AUTOMATIC FIRE PROTECTION SYSTEM
i. Automatic fire protection (Fixed) system based on heat detection through thermal fuses/
quartz bulbs/ EP detectors shall be employed. Sensors shall be installed at all
critical places wherever medium velocity spray system has been installed as described
below;
a. For LPG storage vessels, such detectors shall be provided in multiple rings (at least
two rings for bullets and three rings for spheres) encircling each vessel, detectors
equi-spaced with a maximum horizontal spacing of 1 meter, the lowest ring starting
at an elevation of within 1.5 meter from the bottom of vessel. Also minimum 2 nos.
detectors shall be provided at the top of the vessel at each flange or flange cluster
as the case may be and at least one near the liquid line ROV to take care of failure
of flanges. In case of an automatic thermal fuse based fire protection system the
instrument air supply pressure to thermal fuses shall be maintained through a
pressure control valve and a restriction orifice and/or solenoid valves.
b. Heat Detectors shall be placed at critical locations in LPG sheds (cylinder filling,
cylinder storage, testing, evacuation, cylinder loading/unloading fingers including
packed trucks covering at least the cylinders thereon, etc.), bulk Tank truck & Tank
wagon loading/ unloading gantries, LPG Pump & Compressor house, piping
manifold, cold repair sheds etc. At bulk Tank truck & Tank wagon loading &
unloading gantries heat detectors shall be provided at least in 2 tiers. Upon

Page no. 76
actuation there shall be alarm in control panel, LPG pumps and compressors
shall trip, ROVs (wherever provided) on LPG supply and return lines shall close and
the deluge valves on fire water sprinkler system will get actuated.
ii. In case, Quartzoid Bulbs are used for detection, the same shall be designed to blow
at 79 deg. centigrade (max.) and Quartzoid Bulb network shall be maintained with
plant air at a pressure not more than 3.5 kgs/sq.cm.g and shall be such that the
discharge of a i r through one Quartzoid Bulb will depressurize the system to
actuate the deluge valves.
iii. In case of Electro pneumatic (E.P) heat detectors, it shall actuate the deluge valve in
a n y of the following conditions:
o
a) Rate of rise : 10 C/min of temp.
b) At 79 deg. C (max.)
The EP detectors shall be divided in groups and alternate detectors shall be
connected in one circuit. Two detectors from two different groups shall function/
operate for actuation of sprinkler system.
iv. Water spray nozzles and heat detection system shall be of approved type and duly
certified for the performance.
v.
L
The actuation of detectors shall initiate the following:
a. Opening of deluge valve of the affected zone as well as adjacent zones.
C
b. Audio-visual alarm indicating the affected zone at the fire pump house and
manned control panel. The control panel shall also have status indications for
deluge valves with facility for actuation.
c. Electrically operated Fire Siren, audible up to 1 K.M. from the periphery of the plant.
d. Closure of all Remote Operated Valves in affected facility.
IO
e. Tripping of main power supply barring the emergency power.

f. The water spray from all nozzles within 30 seconds.
g. The fire water pump(s) shall start based on their set pressure to supplement/ to
maintain the fire water pressure in the ring main.
Additionally, for each deluge valve suitable systems like push buttons etc. for initiating all
the above actions shall be provided on remote operating panel. Further similar system like
push buttons and/or air release valves etc. shall also be provided for each deluge valve in
the field at easily accessible locations placed at a minimum distance of 15 M from the
protected facility for enabling manual actuation by an operator. In case, the zoning concept
is used for MV sprinkler system, the concerned Zone shall be clearly marked on each of
the push buttons. In the field, manual bypass valves of fire water deluge valves shall also be
provided.
The performance test certificates after installation in respect of spray density, flow rate,
response time for each facility to be protected provided by manufacturer shall be maintained
at the LPG Installations and verified once in 6 months and records maintained thereof.
Further, all spray nozzles shall be inspected for proper positioning, corrosion and cleaned if
necessary at intervals of not more than 12 months or earlier based on actual experience.
Care shall be taken in positioning nozzles so that water spray does not miss the targeted
surface and reduce the efficiency or calculated discharge rate.
Design details of fire hydrant system, deluge valve and MV Sprinkler system including

Page no. 77
design pressure, operating pressure, test pressure & hydraulic calculations shall be kept
readily available at the plant.
11.12 FIRST AID FIRE FIGHTING EQUIPMENT
11.12.1 PORTABLE FIRE EXTINGUISHERS
i) Portable fire extinguishers shall be located at convenient locations and shall at all
times be readily accessible and clearly visible.
ii) The maximum running distance to locate an extinguisher in working areas shall not
exceed 15 meters.
iii) The top surface of the extinguisher shall not be more than 1.5 meter high.
iv) The fire extinguishers shall be provided at various locations as under:
Area Portable Fire Extinguisher
LPG Storage: - 2 Nos. 9kg or 10 kg DCP extinguisher for each Vessel
LPG cylinder: - 2 Nos. 9kg or 10 kg DCP extinguisher per 200 Sq.m.Area. Sheds
LPG Pump: - 2 Nos. 9kg or 10 kg. DCP extinguisher pe r 50 Sq.m. Area. Houses
Tank Truck loading/unloading Gantries: - 1 No. 9kg or 10kg DCP Extinguisher in each
bay.
bay
L
Tank Wagon loading/unloading gantries: - 1 No. 9kg or 10kg DCP Extinguisher for
every 15/20 meters of g a nt r y .
C
Other Pump Houses: - 2 Nos. 9kg or 10 kg DCP extinguisher
Office/Canteen/ Stores: - 2 9kg or 10 kg DCP extinguishers in each building
MCC / DG Room / HT Room: - 2 x. 4.5 kg CO2 extinguisher in each room or for floor
Area of about 100 Sq.m. & 4 sand buckets & a
IO
stand shall be provided in MCC/ DG Room.
v) 100% spare CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher
Capacities) shall be stored in the LPG plant.
11.12.2 WHEELED/ MOBILE FIRE FIGHTING EQUIPMENT
i) One No. Mobile 75 Kg DCP fire extinguisher shall be provided in filling shed, LPG
storage vessels/ LPG Pump House area, Tank truck loading/ unloading gantry area &
tank wagon loading/ unloading gantry area.
ii) The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based or
Sodium Bicarbonate as per OISD-GDN-115. Nitrogen/ Carbon Dioxide shall be used
as expelling gas.
iii) A trolley containing first aid fire protective accessories shall be readily available in
the LPG plant.
11.12.3 HOSES, NOZZLES AND ACCESSORIES
i) Reinforced rubber lined hoses (63mm) conforming to IS: 636 (type A or B) shall be
provided.
ii) The hoses shall be of 15 Meters standard length and shall be provided with Gun
metal/ Aluminum alloy male & female couplings of instantaneous pattern.
iii) Minimum of two or 25% sp are Hoses shall be stored in the LPG plant.

Page no. 78
iv) In addition to the nozzles provided in the hose boxes there shall be at least 2 Nos.
spare nozzles in each category viz. Jet Nozzles with branch pipes, Fog Nozzles,
universal Nozzles, water curtain Nozzles, Spray Nozzles and Triple purpose nozzles
in the plant.
v) The following accessories/ first aid items shall be provided in the plant:
1. Fire hoses :- Two nos. for each Hose Box
2. Safety helmets : - 1 no. for each person (min. 10 nos.)
3. Hose Box : - At each hydrant point.
4. Stretcher with Min. 2 Nos. blankets.
5. First aid Box :- Min. 2 nos.
6. Rubber hand gloves for electrical (BIS approved) purpose: - Min. 2 pairs
7. Low temperature rubber hand gloves for LPG emergency as per OISD-GDN-115:-
4 pairs
8. Low temp. Protective clothing for LPG emergency: Min. 2 sets
9. Fire proximity suit :- Min. 1 No.
10. Resuscitator
11. Red/Green Flags
:- Min. 2 No.
:- As reqd
L
C
12. Self- contained breathing apparatus with one spare cyl (Cap. 30 minutes): Min. 1 No.
13. Water jel blankets :- Min. 2 nos.
14. Portable Gas detectors / Explosimeter :- Mi n . 2.
The above are guidelines and minimum requirements of each item and can be
IO
increased depending upon the scale of operations, statutory/ mandatory requirement

of local bodies/ State Governments or any other expert body.
11.13 EMERGENCY CONTROL / ALARM SYSTEM
11.13.1 FIRE ALARM SYSTEM
i) Manual call points near to filling shed, storage area, tank truck and/or tank wagon
gantry, pump house, etc. shall be provided in the installation with marking of the
concerned facility on the said call points . Operation of these points shall raise
audio visual alarm in control room.
ii) Electricity operated Fire Siren shall be audible up to 1K.M. from the periphery of the
plant.
iii) Manually operated fire sirens shall be provided at strategic places.
iv) The following fire siren codes shall be followed for different emergency situations.
FIRE : - wailing sound for 2 minutes.
DISASTER : - wailing sound for 2 minutes repeated thrice with a gap of 60
seconds.) total duration of Disaster siren shall be eight minutes.
ALL CLEAR: - straight run sound for 2 minutes.
TEST SIREN: - straight run sound for 2 minutes.
v) Fire siren shall be tested at least once in a week

Page no. 79
11.13.2 COMMUNICATION SYSTEM

i) Communication system like telephone/ PA or paging or walkie-talkie shall be provided.
ii) In the hazardous areas, flame-proof / intrinsically safe telephones shall be provided.
iii) Wherever possible Hot line connection between City Fire Brigade / nearb y major
Industries shall be provided.
iv) Plant shall have a Mutual Aid' arrangement with nearby industries.
11.14 SPECIAL FIRE PROTECTION
The most hazardous situation in LPG vessel is the possibility of BLEEVE. This usually
takes place when the vessel is subjected to external fire.
The unwetted (vapour space) portion of the shell gets overheated and fails even at
the operating pressure. As such, it is important that metal temperature in the vapour
space is protected from overheating by some measures. A passive measure like fire
proofing/ insulation or fire retardant coating will provide protection in the initial period
of fire which is very crucial. This will give some breathing time for activating other
firefighting measures like starting of pumps, organizing people, opening of valves etc.
This will also take care of automation failure wherever it is provided.
L
The fireproofing of LPG storage vessel should be decided based on the risk analysis
keeping in view local considerations, availability of water and societal risk.
The fireproofing of LPG storage vessel shall be decided based on the fire safety analysis
keeping in view local considerations, population density, availability of water, societal
C
risk and fire protection measures provided.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect the
shell material from overheating and consequent failure. The minimum rating for fire
proofing shall be as under:
LPG storage vessel & connected lines up to the fire safe ROVs: - 1 hr.
IO
Supporting legs of all above: - 2 hrs.

Fire proofing is not required for diagonal bracing
bracing, including tie rods, or redundant members
that are not necessary for supporting the static loads.
Before fire-proofing application, protected metal surfaces shall be prepared through such
means as sand-blasting and corrosion-protective primers. Particular attention shall be
given to the top junction of the fire-proofing with the protected metal to prevent water
ingress. OISD-STD-164 on "Fire proofing" shall be referred for details on fire proofing. Fire
water line to each sphere should be so routed that it is not exposed to direct fire.
This is to protect it from failure in the initial period when water flow has not commenced. It
is recommended that riser should be located away from bottom ROV. The horizontal
run of the Fire Water line may be buried if fire engulfment cannot be avoided otherwise.
Fire proofing shall include connected LPG lines and pipe supports within 15 M of a
storage vessel or in the drainage paths.
11.15 INSPECTION AND TESTING
The fire protection equipment shall be kept in good operating condition all the time.
The firef ighting system shall be periodically tested for proper functioning and logged for
record and corrective actions. In addition to routine daily checks/ maintenance the
following periodic inspection/ testing shall be ensured.
11.15.1 FIRE WATER PUMPS

Page no. 80
i) Every Pump shall be in test run at least twice a week for half an hour at the rated
conditions as per OEM guidelines. Suitable provision should be made in fire water pump
house to ensure that during test run of any individual fire pump, firefighting system of the
entire plant continues to be on auto mode.
ii) Once in a month each pump shall be checked and tested and the shut-off
pressure observed and logged.
iii) Each pump shall be run continuously for 4 hours at its rated head & flow using
circulation line of fire water storage tanks at least once a year and observations logged.
iv) The cooling line of the fire engines shall not require manual intervention. The line
pressure inlet-outlet shall be as per OEM to avoid bursting of water jacket.
v) Fire engine and Fire Pump RPM should match to get rated performance. Fire pumps
should be operated as rated RPM
vi) Each pump shall be checked & tested for its performance once in six months by opening
required nos. of hydrants/monitors depending on the capacity of the pump to verify that
the discharge pressure, flow & motor load are in conformity with the design parameters.
vii) The Jockey pump operation shall be checked periodically. Frequent start/ stop condition
of Jockey pump indicates that there are water leaks in the system, which should be
attended to promptly.
11.15.2 FIRE WATER RING MAIN L
i) The ring main shall be kept pressurized at 7 kg/sq.cm.g with the help of one or more
C
jockey pumps.
ii) The ring main shall be inspected for any visual leaks, defects, damage and corrosion
at least once in week and relev ant records shall be maintained.
iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/ operation
and lubricated once in a month.
IO
11.15.3 FIRE WATER SPRINKLER SYSTEM

i) All deluge valves and sprinkler system shall be operated and checked once in a
quarter for correct remote operation performance of each nozzle and effectiveness of
system in total.
ii) Testing of sprinkler system in the sheds shall be carried out by closing the outlet of
the deluge valve for correct remote operation once in a quarter.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.
11.15.4 FIRE WATER RESERVOIR
In case of a Reservoir the same shall be cleaned once in 6 months or earlier as and
when needed so that there shall not be any foreign particles/ fungus/ vegetation in the
reservoir.
11.16 MAKE UP WATER
Facilities to make up water during firefighting shall be provided.
If bore wells are available within the plant, yield there from should be recorded on quarterly
basis for each bore well.

Page no. 81
CHAPTER 12
GAS MONITORING SYSTEM

12.0 GENERAL
The best method of prevention of explosion is to avoid basic buildup of gas concentration
immediately on occurrence of leakage. This would require basically a reliable and
continuous detection system with warning annunciation to alert the plant personnel to
take corrective action.
The Gas Monitoring system shall provide early warning on buildu p of dispersed gas
concentration below the LFL limits.
The system shall be designed considering small leaks (leaks which have secondary
closures) such as mechanical seals failure, sampling point left open, gasket leaks, hose
pinholes, valves gland leakage, drain point left partially open, relief discharge in
manifold area, filling/ evacuation hoses leakage.
12.1 APPLICATION
i) The detectors for the gas monitoring system shall be strategically located in LPG
ii) L
Bottling Plant at all facilities close to the potential source of leakage.
The detection control equipment should be provided in the control room for
continuous monitoring even during power failure.
C
12.2 DETECTORS
Amongst the various methods of detection available, the following proven systems for LPG
can be considered.
i) Catalytic detectors
IO
ii) Infra-red detectors

12.3 CONTROL SYSTEMS
i) This is critical equipment for safety. Hence, the system should have
independent control equipment, power supply, UPS to ensure that the system
remains in operation even if the plant DCS or other common process controls are
not functioning. In case of bottling plant in Refineries, dropping of the signals on
the DCS is acceptable wherever hot standby DCS control system is available.
ii) In case of failure or during maintenance when the system is not in operation, the
plant safety officer should keep the plant personnel on alert to be more vigilant
during operations and night security patrolling.
iii) The control equipment should have data logging facilities to provide print outs of the
history of the events with date and time of leakages. Suitable graphical representation
for activation of each sensor shall be generated for analysis of leakages on daily basis.
iv) The control equipment should be able to generate at least two alarms at
different levels of LEL concentration of gas.
v) The control equipment is not required to have automatic corrective action capabilities
on sensing leakages as this is basically a warning device. However, in case of any
specific recommendations made in the risk analysis / HAZOP studies, the same
should be implemented.

Page no. 82
12.4 ANNUNCIATION SYSTEMS

Appropriate f i e l d & r e m o t e annunciation system shall be available to ensure
that all the alarms generated, both audio and visual are available to the plant
personnel, who are authorized to take corrective action. Depending on the deployment
pattern of the plant, the alarms both audio and visual can be repeated at additional
location to ensure fast corrective action.
12.5 LOCATION OF DETECTORS
i) The behavior of the gas leakage governs the positioning of the gas detector. As
LPG is heavier than air, the height of the detector should not be more than 0.3 M
from the mounting level.
ii) The pre-dominant wind direction should be considered with respect to the
potential source of leakage to ensure positioning of the detector on the downstream
side of the wind direction.
iii) The detectors especially the catalytic type should not be positioned very close to
the potential source of leakage to avoid poisoning of the detectors (temporary
malfunctioning). The detectors should be located at least 0.3 mtrs away from
the potential source of leakage.
v)
L
iv) In case of infra-red detectors, the same shall be installed on the downw ind side
ensuring the path is free from obstructions. In case any additional expansion/
construction if undertaken, the detectors will have to be pre-positioned.
The minimum detectors facilities-wise are as given below:
C
a. Storage vessels (above ground):
ground): - 1 No. on top near SRVs
- 1 No. near bottom ROV.
- One each near water draining/sampling points.
IO
b. LPG pump house: - 1 No. in pump house & 1 No. in manifold.
c. Filled cylinder shed:
shed: - 2 Nos.
d. Valve change shed:
shed: - 1 No.
e. Empty-cum-filling shed:
shed - 2 Nos. near carousel, 1 No. near evacuation unit tank, 1
No. weight correction unit.
f. TLD: - one at each manifold and at ends.
g. Tank wagon gantry: - 1 no. for every two bays or 30 m whichever is less at bottom.
Additionally, some detectors at selected locations shall be provided at the top of
platform.
The number and location of the detectors required over and above the minimum
requirements specified above shall be as per the specific requirements identified in the risk
analysis / HAZOP study report.
The location can be decided by assessing the behavior of gas drift and consequential
safety risk.
vi) Inspection and testing
The gas monitoring system shall be kept in good operating condition all the time. The
inspection of the system shall be done at an interval of 1 month in which the gas shall be
released at all the detectors and the performance of the systems shall be established.
The calibration of the equipment shall coincide with the monthly inspection schedule every

Page no. 83
three months for calibration of the gas detectors the calibrated gas with known and certified
level of concentration shall be used.
The drift in the sensitivity of the individual detectors shall be recorded in maintenance
history log book during calibration and the detectors with abnormal or wide drift in
sensitivity.
The plants should have at least 2 Nos. spare detectors for each system maintained at all
times to facilitate immediate replacement of defective detectors.
L
C
IO

Page no. 84
CHAPTER 13
EMERGENCY MANAGEMENT PLAN
13.0 GENERAL
The best way to manage any emergency is to prevent it. Following guidelines for
emergency prevention shall be followed:
a) Sound engineering practice in the design, fabrication, installation and maintenance of
facilities.
b) Careful selection and correct use of equipment.
c) Observance of safety and security regulations.
d) Proper and constant training and guidance to all personnel working in the Plant, with
particular reference to product knowledge and maintenance practices.
e) Good House-keeping.
f) Constant supervision and alertness.
13.1 EMERGENCY PLANS:
L
Plant Manager shall ensure that suitable instructions are issued to both Corporation's and
contractor's personnel identifying the action to be taken by each one in an emergency. This
should be achieved by display of organization chart/ posters not only for firefighting but
also for other likely emergencies. Likewise, for emergencies of large magnitude Emergency
Response Plan (or Disaster Management Plan) to be drawn out in coordination with related
C
outside agencies, such as local administration, Police authorities, Fire Brigade, hospital
authorities, home guards, neighboring industries etc. Periodic mock drills for all such plans
to be conducted, and plans to be updated/ modified based on experience gained during
such drills.
Provision of Petroleum and Natural Gas Regulatory Board (Codes of Practices for
IO
Emergency Response and Disaster Management Plan (ERDMP)) Regulations, 2010 shall
be ensured.
13.1.1 CHECK FOR LPG LEAKAGE AT FOLLOWING LOCATIONS
a) Through water drain valve while draining.
b) Leaking sample valve.
c) Breakage of glass on Sight Flow Indicator on the pipeline.
d) Opening of pop-off valve, gland/ packing etc.
e) Leakage through LPG compressor/ pump.
f) Leakage due to bursting/ rupture of hose or through swivel joints of body arms.
g) Leakage from the filling guns.
h) Escape of liquid/ vapour LPG during maintenance/ repairs.
13.1.2 SOME OF THE COMMON CAUSES OF FIRE:
i) ELECTRICAL:
ii) Short circuiting due to loose wiring including that of automobile moving in the area.
iii) Use of non-flame proof fittings such as lights, torch, motors, fan, telephone,
temporary lighting etc. (Note: Flameproof fittings become non-flame proof due to

Page no. 85
poor maintenance e.g. increase in gap in junction boxes, due to missing nuts and
bolts or improper glands used for connection to junction box, or sealing
compound not used in junction boxes etc.)
iv) Static electricity as result of improper bonding/ grounding to tanks, conveyor
system, tank truck, tank wagon etc.
(b) VEHICLE:
i) Exhaust of vehicle, if effective spark arrestors are not provided.
ii) Operation of non-FLP electrical switches such as vehicle ignition.
iii) Spark from the loose contact on vehicle batteries.
iv) Spark from exhaust of railway engine.
v) Cinders from the steam locomotives.
(c) OTHERS
i) Landing of crackers (flying type) in hazardous areas.
ii) Chiseling/ hammering.
iii)
iv)
v)
Lighted agarbatti in a truck. L
Spark from studded shoes, with steel button by friction against ground/ metal.
Excessive release of vapour beyond safe limit and fire due to outside source of ignition.
C
vi) Lighting
vii) Smoking.
13.2 ACTION DURING EMERGENCY
13.2.1 Immediate action is the most important factor in emergency control because the first
IO
few seconds count, as LPG fires develop and spread very quickly unless prompt
and efficient action is taken. In the event of fire/ gas leak within LPG Plant the
following action shall be taken as quickly as possible:
a) Take immediate steps to stop LPG leakage/ fire and raise alarm simultaneously.
b) Initiate action as per Fire Organization Plan or Disaster Management Plan, based on
gravity of the emergency.
c) Stop all operations and ensure closure of all ROVs and isolation valves.
d) All-out effort should be made to contain the spread of leakage/ fire.
e) Saving of human life shall get priority in comparison to stocks/ assets.
f) Plant personnel without specific duties should assemble at the nominated place.
g) All vehicles except those required for emergency use should be moved away from the
operating area, in an orderly manner at pre-nominated route.
h) Electrical system except for control supplies, utilities, lighting and firefighting system,
should be isolated.
i) If the feed to the fire cannot be cut off, the fire must be controlled and not extinguished.
j) Start water spray system at areas involved in or exposed to fire risks.
k) In case of leakage of LPG without fire and inability to stop the flow, take all precautions

Page no. 86
to avoid source of ignition.

l) Block all roads in the adjacent area and enlist Police support for the purpose if
warranted.
13.2.2 Fire Fighting Operations:
a) Enlist support of local fire brigade and neighboring industries.
b) If escaping vapour cannot be stopped, jets of water should be directed at the point of
leakage to assist controlled release of vapour and in between water fog should be used
for dilution and rapid dispersion of vapour cloud.
c) Firefighting personnel working in or close to un-ignited vapour clouds or close to fire
must wear protective clothing and equipment including safety harness and manned life
line. They must be protected continuously by water sprays. Water protection for fire
fighters should never be shut off even though the flames appear to have been
extinguished until all personnel are safely out of the danger area.
d) Exercise care to ensure that static charge is not generated in LPG vapour cloud. For
this purpose, solid jets of water must be avoided, instead fog nozzles should be used.
e) Fire fighters should advance towards a fire down wind if possible.
f)
g)
hit from flying cylinders.
L
Cylinder fire should be approached using proper barricades/ protection to avoid direct
If the only valve that can be used to stop the leakage is surrounded by fire, it may be
possible to close it manually. The attempt should be directed by trained persons only.
C
The person attempting the closure should be continuously protected by means of water
spraying (through fog nozzles), fire entry suit, water jell blanket or any other approved
equipment. The person must be equipped with a safety harness and manned life line.
h) Any rapid increase in pressure or noise level of product discharged through safety
relief valve of the vessel/ pipeline should be treated as a warning of over
IO
pressurization. In such cases all personnel should be evacuated immediately.

i) As in case of any emergency situation, it is of paramount importance to avoid
endangering human life in the event of fire involving or seriously exposing LPG
equipment or serious leakage of LPG without the fire.
13.2.3 Action in the event of LPG leakage without fire:
a) Take basic action as detailed in 13.2.1 above.
b) If escaping LPG is not on fire, close any valve which will stop the flow.
c) In some cases, like the leakage from a pressure vessel without a fire (such as leak
from tank truck bullet or overturning) it may be desirable to move the vessel to some
remote area such as block of isolated roadway or open field where it can be allowed to
leak safely without a source of ignition nearby. However, if this is to be done, the
vessel must be moved in an upright position. Never drag the vessel in a manner which
might damage valve or pipeline. Any attempt to turn a vessel back upright to move it to
some remote location should be done carefully to avoid damage to valve and pipelines.
d) Take necessary actions as detailed in 13.2.2.
13.2.4 Action in the event of LPG fire
a) Take basic action as detailed in 13.2.1 above.
b) Extinguishing Fires - A small fire at the point of leakage should be extinguished by

Page no. 87
enveloping with a water spray or a suitable smoothening agent such as carbon dioxide
or dry chemical powder. However, it is again stressed that LPG fire should not; except
in special circumstances explained earlier; be extinguished until the escape of product
has been stopped.
c) Firefighting procedure - Firefighting procedures would vary depending upon various
factors such as nature, sources, size, location, etc. of fire. Basic firefighting techniques
have been explained earlier in section 13.2.2. However, for the purpose of guidelines,
firefighting techniques for few common cases are as follows:
(i) Cylinder Fire: If a filled cylinder is involved in fire, internal pressure may start
2
rising and if not relieved the built up pressure could rise above 70 kgf/cm g
and ultimately rupture the container. Ignition of the escaping gas would aggravate
the fire but the release of pressure would reduce the possibility of rupture of the
Container. No attempt should be made to extinguish the burning gas. But the
container and other containers in the vicinity should be kept cool by water sprays
until the contents of the container have burnt away. If the gas leakage does not
ignite, the container should be approached from upwind (if in the open air) and be
removed to a place of safety remote from sources of ignition. Cylinders not directly
involved in the fire should be moved away from heat exposure, while applying
cooling water sprays on cylinders directly involved.
(ii)
L
Fire on storage vessel: If a pressure vessel is exposed to radiant heat from
external fire, it should be kept cool by water sprays to prevent excessive
pressure rise in the vessel. Cooling water sprays must be applied without delay
to the heat affected area using fixed water sprinkler system or equivalent spray
C
water coverage, through fixed monitors or other equipment. Cooling the vessel
with water sprays reduces the heat input to the vessel and thereby reduces the
pressure, thus, reducing the rate of discharge from the relief valves.
(iii) Leakage of LPG burning at the outlet of a cylinder valve:
Extinguish the fire by means of a portable fire extinguisher, or smoothening
IO
with a thick non

non-synthetic
-synthetic cloth (preferably wet) or sand/ earth etc.
Fix safety cap on the valve to prevent further leakage.
After the fire is extinguished, if the leakage cannot be stopped the cylinder should
be moved carefully to a safe location to vent out the contents under controlled
conditions.
(iv) Fire of LPG vapour escaping from a damaged vessel fitting (flame not playing
on vessel):
Allow fire to continue till exhaustion.
Spray vessel with water to cool it, if vessel is being heated by radiation from the
flame or if flame is endangering other plant equipment.
Cool adjacent vessels and structures.
(v) Fire at Safety Relief Valves of vessels exposed to adjacent fire.
(vi) Fire in Oil storage area adjacent to LPG storage:
Start water sprays only on those LPG vessels exposed to fire/ heat.
Isolate affected vessels and run out fire water hoses in case hose stream cooling
becomes necessary.
Monitor pressure in LPG vessels.

Page no. 88
If LPG vessel's SRVs have started blowing vapour, take no further action (apart
from cooling) unless vessel pressure continues to rise.
If fire enters LPG storage area, concentrate available cooling water on LPG
vessels, most affected.
Do not try to empty LPG vessels exposed to fire. They become more vulnerable
to overheating as their liquid content decreases.
13.2.5 Fire Fighting Organization Plan
(a) A plan of action for use in the event of a major LPG product leakage with a fire or
risk of fire is essential. Such a plan must be carefully prepared for each plant. It
should be fully understood by all LPG plant supervisory personnel and other
personnel responsible for action as per plan. It shall be based on the following:
(i) Plant personnel shall be fully trained for the specialized techniques necessary
for combating LPG leakages and LPG fires.
(ii) If leakage and/ or fire occur, all personnel should use the equipment provided and
to carry out their allotted tasks as detailed in the firefighting organization plan.
(iii) All personnel should be conversant with fire control equipment and also its
location.
(iv)
(v)
Remove Operation valves (ROVs) in the plant.L
LPG plant personnel should know the position and method of operation of all
Plant personnel should be familiar with the standard recognition markings of fire
C
control, first aid and all safety equipment, must know the location of emergency
exits, and they should know the location of water hydrant points/ monitors and must
be familiar with the sound of the emergency (fire) alarm.
(b) The Fire Fighting Organization Plan together
togeth with layout of firefighting and safety
devices shall be displayed at prominent places and explained to all personnel. It
IO
shall include the following functions, expanded to suit the location facilities/
requirement: -
(i) Sounding the emergency (fire) alarm.
(ii) Shutting off the LPG supply to any leakage point/ fire.
(iii) Summoning the fire brigade/ police.
(iv) Fire control, with first aid, firefighting equipment.
(v) LPG vapour dispersal.
(vi) Operation of LPG vessel's fixed water sprinkler system, starting of fire pump (s) and
application of water hose jets/ sprays for containing/ extinguishing fires.
(vii) Cooling of vessels/ cylinders and other equipment/ facilities.
(viii) Closing down all operations in the plant including closure of valves and stopping of
pumps.
(ix) Preventing all sources of ignition in case of LPG leakage.
(x) Evacuation of vehicles.
(xi) Evacuation and mustering of personnel.
(xii) Establishing an emergency fire-control center.

Page no. 89
(xiii) Traffic control.

(xiv) Stations and duties of all personnel.
(xv) Policing of affected areas.
(xvi) Any other specialized duties.
(xvii) Display of fire brigade, ambulance, Police telephone numbers etc.
(xviii) All clear signal by competent person.
(c) Liaison with local fire brigade:
Close co-operation with the local fire authorities is essential and shall take the following
form:
(i) The fire brigade should be made familiar with the layout of the plant and the
location of important equipment/ facilities provided, and their method of use. Mock
fire drills/ exercise jointly by plant personnel and local fire brigades shall be
planned.
(ii) Firefighting equipment at the plant shall be compatible with the fire brigade
equipment, otherwise adapters shall be kept ready for hoses, hydrants etc.
(iii)
(iv)
L
The fire brigade shall be aware of the plant's firefighting organization plan and the
views held at the plan regarding the most effective LPG fire control methods.
In the event of an emergency/ fire, the plant manager and/ or his representative shall
advise the Fire Officer about particular or potential hazards that may be present e.g.
C
stocks of filled cylinders at that particular point of time.
(d) Fire Drills & Training:
i) Drills for all Plant personnel, making use of the "Firefighting Organization Plan" and
practicing the specialized techniques required for fighting LPG fires or dispensing/
IO
diluting LPG vapour clouds shall be held minimum once in a month.

ii) The drills should cover various types of incidents, e.g. major spillage, LPG bulk lorry
fire, cylinder fire etc.
iii) Extinguishers due for recharging/ due for hydro testing shall be discharged during drills
and replenished subsequently 50% (Min.) stock of refills as replenishment for FEs
should be maintained.
iv) The fire pump should be run, sprinkler system activated, emergency systems tested,
water hoses run out and spray/ set techniques practiced during drills.
v) Fire alarms shall be sounded/ tested (neighboring plants/ factories and the fire brigade
shall be warned in advance of this test).
vi) Protective clothing, breathing apparatus and any other specialized safety equipment
available shall be tried out during drills to train all concerned in their application.
vii) The local fire brigade should be encouraged to participate in fire drills periodically.
viii) Any shortcoming, noticed during the drill shall be rectified.
13.2.6 Disaster Management Plan : ON-SITE
a) It is basically a pre-plan to handle any emergency situation of a higher
magnitude arising out of factors listed below:
i) Major fire/ explosions

Page no. 90
ii) Uncontrollable leakage of LPG

iii) Lightning
iv) Heavy floods
v) Earthquakes/ land slides
vi) Sabotage/ terrorist outrage
vii) War situation
The objective of the plan shall be to reduce the probability of serious loss/ damage
to general stock, plant and machinery, documents etc. utilizing combined resources of
the location itself and the outside agencies. In order to have an effective organization,
preliminary meeting shall be conducted with the representatives from local fire services,
police authorities, voluntary organizations like ambulance service/ Govt. medical service/
contractors and even Home Guards and defense personnel. In the course of the
meeting, there should be exchange of knowledge, training and plans for development of
expertise and skills to gain knowledge about the plant layout/ facilities, potential of likely
hazards/ risks, likely emergencies that may arise. This group should draw out
modalities of the exercises in the given situation and arrive at an agreed action plan which
should be updated from time to time and put to test in the form of periodical mock drills.
b)
L
Due to varying risk potentials and also varying hazards at/ around each location
`Disaster Management Plan' for each location shall be drawn up individually based
on the outline given below:
C
(i) Identify Disaster scenario i.e. The situation under which the plan would become
operational. Plan for the worst possible scenario.
(ii) Identify resources required from each of the outside agencies.
(iii) Establish outside agencies, role of each agency and obtain their commitment
for rendering the assistance in crisis situation as per the agreed plan.
IO
(iv) Establish organogram for Disaster Management based on available manpower in

various groups and identify the leader and alternative leader for each for the groups
and the role to be played by each team in various likely crisis situations.
(v) Identify Disaster control room/ group.
(vi) Furnish detailed data and drawings relevant for the crisis management.
(vii) Establish channel of communication at the local level to Statutory Authorities and
higher authorities within the organization.
(viii) Mock drills to be conducted minimum once a year.
(ix) Modify the plan based on the experience gained through mock drills and try out the
modified plan through subsequent mock drills.
(x) The plan shall be updated as and when the changes recorded in the plan occur and
communication sent to all concerned.
(c) Communication organogram:
As a part of Disaster Management Plan, communication organogram shall be drawn
up giving flow of communication from the originating location to various local agencies
and also to Statutory Authorities and upwards within the organization to mobilize support
and to consider alternatives for maintaining essential supplies.

Page no. 91
CHAPTER 14: SAFETY AUDIT

14.1 GENERAL:
Safety audit is a well- recognized tool to improve the effectiveness of safety program
and loss prevention measures by carrying out systematic and critical appraisal of potential
safety hazards involving personnel, plants and equipment.
For a structured and systematic safety audit of any plant/ facility, check lists are the most
important prerequisite. Check lists should cover all the operational areas, major equipment,
operating/ maintenance procedures, safety practices, fire prevention/ protection systems
etc. Observations/ recommendations of safety audit team should be presented in the
form of a formal report and action plan for corrective measures should be prepared and
subsequently monitored for implementation.
General guidelines on safety audit methodologies and techniques are also given in OISD-
GDN- 145.
14.2 TYPE OF SAFETY AUDIT AND PERIODICITY:
In view of the high hazard potential of LPG, safety audits at frequent intervals by the
teams/ personnel of various levels are advocated, Broad check lists for different
recommended safety audits are given in the Annexure 10 10-I, II, III, IV. These check lists
L
can be further supplemented and modified suitably to meet the specific requirements of
individual plant. Recommended minimum safety audits at different levels, their
frequencies and broad check lists to be used are indicated below: -
Daily audit essentially shall cover the compliance of recommended operating procedures/
C
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken on priority wherever required.
-----------------------------------------------------------------------------------------------------------------------------
Checklist
S.
Type of Safety Audit By Frequency (Annexure)
IO
No
------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5
------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------
Inspection Safety audit LPG Plant Safety Officer Daily 14-I
1.
of LPG Installation
Electrical audit of LPG Authorized Electrical Annual 14-II
2.
Installation Engineer
Detailed safety audit Multi-disciplinary Annual Checklist as
3.
of LPG Installation team of Region/ HQ per OISD-
GDN-145
Inspection and Personnel from Annual 14-IV

4.
maintenance audit of Inspection/ Maintenance
LPG Installation
5. External safety audit of OISD
LPG Installation
6. Self-audit Plant In-charge Quarterly 14 III
-------------------------------------------------------------------------------------------------------------------------------

Page no. 92
Daily audit essentially shall cover the compliance of recommended operating procedures/
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken along with the target dates shall be done
immediately. The compliance to other audit recommendations along with target schedules
shall be monitored on monthly basis. Alternate, safety measures shall be taken till the
recommendations are compiled in totality.
In case of external safety audit, following areas besides the points given in check list of
OISD- GDN-145 shall be covered.
1. Safety Organization
2. Security System
3. Fire prevention/ protection system
4. Preparedness to handle any emergency --Disaster control plan and mock drills.
5. Skill level and training needs for HRD.
6. Operating manual/ instructions, display of Do's/ Don'ts etc.
L
C
IO

Page no. 93
ANNEXURE 14- I
DAILY SAFETY AUDIT - CHECKLIST

FOR LPG BOTTLING PLANTS
LOCATION
Audit/ Inspection by
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation*Action Plan Target Date Review date
(status)
1 2 3 4 5 6
--------------------------------------------------------------------------------------------------------------------------------
A. SAFETY/ FIRE PROTECTION SYSTEM
A-01 Water level in static Yes/No

water tank is satisfactory.
A-02
A-03
Hydrant pressure
Maintained with jockey pump.
Record Pressure.
Fire water pumps/engines

L Yes/No
Yes/No
C
a) Are the batteries in good condition?
b) Are the diesel tanks full
c) Start one pump, record pressure developed.

IO
d) Whether auto start system working.
A-04 Fire alarm/ Yes/No

Communication system in working order.
A-05 Automatic Gas Detection Yes/No

system operating.
A-06 Vapour Extraction Unit operating Yes/No
A-07 Any unsafe condition of Yes/No

S&FP system observed
(Specify in brief under remarks column).
A-09 Regular surprise checks/ testing Yes/No

being done at gate/ at the plant.
A-10 Direction of wind Yes/No

(specify in remarks column by
Observing wind sock).

Page no. 94
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation*Action Plan Target Date Review date
(Status)
1 2 3 4 5 6
--------------------------------------------------------------------------------------------------------------------------------
A-11 Caution signs displayed Yes/No

at appropriate places.
A-12 Last fire drill in this area done on ----------
B. BULK STORAGE AREA
B-01 Whether water draining Yes/No

sampling done under constant
supervision.
B-02 Earthing connection Yes/No

apparently sound.
B-04
a) Whether level instruments are working.
Portable fire extinguishers

L
b) High level alarm in working condition (test check).
Yes/No
C
in position.
B-05 Water spray/ sprinkler Yes/No

system apparently O.K.
B-06 Housekeeping is in order Yes/No

IO
B-07 Gas detection system working Yes/No
B-08 Any sign of LPG leakage Yes/No
B-09 Any settlement of vessel observed Yes/No
B-10 Condition of Water seal Yes/No
B-11 ROVs in Auto shut off mode Yes/No
B-12 Pressure and temperature gauge Yes/No

Functional
B- 13 Bonding across flanges visible Yes/No
B-14 Last fire drill in this area done on -----------

Page no. 95
C. TANK WAGON UNLOADING
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(Status)
--------------------------------------------------------------------------------------------------------------------------------
C-01 Any visible sign of LPG leakage Yes/No
C-02 Earthing connection apparently Yes/No

sound
C-03 a) Whether hose condition/ Yes/No
connections are proper
b) Are these properly Yes/No

plugged if not in use.
C-04 Housekeeping in order. Yes/No
C-05
C-06
Portable fire
Extinguishers in position.
Water spray/ sprinkler

system apparently O.K.
L Yes/No
Yes/No
C
C-07 Housekeeping is in order Yes/No
Yes/No
C-08 Condition of Water seal
Yes/No
C-09 Gas detectors functional
IO
Yes/No
C-10 ROVs on remote mode
Yes/No
C-11 Pressure and temperature gauge
Functional
Yes/No
C-12 Bonding across flanges visible
C-13 Last fire drill in this area done on -----------

Page no. 96
D. BULK TRUCK UNLOADING

--------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6
(Status)
--------------------------------------------------------------------------------------------------------------------------------
D-01 Are all vehicles allowed in licensed Yes/No
a r e permanently fitted with PESO
a p p r o v e d spark arrestors on
exhaust Pipe (Random check)
D-02 Is the vehicle engine and master Yes/No

switch being shut off during
Unloading bulk LPG (site check)
D-03 Are the earthing connection Yes/No
properly made before connecting
Hoses to tank trucks.
D-04 Rotogauge, Fixed level instrument Yes/No

in working order (Random check.
Record TT No)
D-05 Any visible sign of LPG leakage Yes/No
D-06 Random safety check of Yes/No

Tank truck No.
a) CCE license available/ valid Yes/No
b) Fittings as per CCE Yes/No
c) 2 Nos. of fire extinguishers Yes/No

available in good condition/
easily accessible. (Physical check)
d) Safety instruction booklet Yes/No

TREMCARD available. Record
any abnormality/ discrepancies
observed.
e) Wheel choke used Yes/No
D-07 a) Portable extinguisher Yes/No

available in nominated places.
b) Sprinkler system in Yes/No

working condition.
D-08 Housekeeping in order Yes/No

D-09 Bonding of flange connection given Yes/No
D-10 Hose test date Yes /No
D-11 Last fire drill in this area done on -----------

Page no. 97
E. PUMP HOUSE/ COMPRESSOR ROOM
--------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6
(Status)
--------------------------------------------------------------------------------------------------------------------------------
E-01 Electrical connections apparently sound Yes/No
E-02 Earthing apparently proper Yes/No
E-03 Gauges on pumps/compressor Yes/No

in working condition, record pressure.
E-04 Drain/ vent connection cap in position. Yes/No
E-05 Safety guards in position Yes/No
E-06 Abnormal vibration/ excessive noise. Yes/No
E-07 Portable fire extinguisher in position
E-08 Any visible sign of LPG leak or any

Unsafe conditions observed (record
under remarks column).
L Yes/No
Yes/No
C
E-09 Housekeeping in order. Yes/No
E-10 Gas detection system working. Yes/No

IO
E-11 Last fire drill in this area done on -----------

Page no. 98
F. FILLING SHED
--------------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6
(Status)
--------------------------------------------------------------------------------------------------------------------------------
F-1 No ignition sources visible in operating Yes/No

areas or area in vicinity.
F-2 Are the LPG cylinders empty or empty Yes/No

or filled, properly loaded/ unloaded and
handled to avoid impact, falling, horizontal
rolling etc.
F-3 Are earthing connection on filling Yes/No

carousel properly made.
F-4 Are the cylinder chain conveyors Yes/No

adequately lubricated to avoid metallic
rubbing and friction?
F-5 Water in test bath is clean

and maintained up to the required level.
L Yes/No
C
F-6 Any sign of leakage of unsafe condition Yes/No
None of the filling guns or adapters used
for cylinder filling/emptying are leaking.
F-7 Are all the fire extinguishers available Yes/No

IO
in accessible location?
F-8 All electrical connection apparently Yes/No

intact & safe.
F-9 Is the concentration level of gas Yes/No

checked
hecked with explosimeter twice a
day in the filling area in filled and
empty cylinder area, pump/
compressor room. Record
reading for sample check.
F-10 Sprinkler system in working condition Yes/No
F-11 Housekeeping is in order. Yes/No
F-12 Rotary equipment/ coupling etc Yes/No
F-13 Gas detection system working. Yes/No
F-14 CVT is functional Yes/No
F-15 Last fire drill in the area -----------

Page no. 99
F-16 Vapour extraction system functional Yes /No
F-17 Emergency trip at Carousel functional Yes/No

G. CYLINDER STORAGE/ HANDLING
G-01 Are cylinders stacked properly Yes/No

in demarcated areas?
G-02 Any leaky overfilled cylinder kept at Yes/No
the end of the day. Record No. if
any, of the leaky un-evacuated
cylinder.
G-03 Safety cap fixed on cylinders in stock. Yes/No
G-04 Sprinklers functional
G-05 Cylinders loaded in to trucks Yes/No

through conveyors.
G-06 Rubber mats are used for Yes/No
G-07
unloading empty cylinders from
tank trucks and are in good
condition.
Last fire drill in the area
L -----------
C
* Put specific observation wherever the conditions are not in line with specified
requirement levels.
IO

Page no. 100
ANNEXURE 14 - II.
ELECTRICAL AUDIT OF LPG BOTTLING PLANTS

Dated
LOCATION
AUDIT/ INSPECTION BY
-------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS
REMARKS
1 2 3
-------------------------------------------------------------------------------------------------------------------------------
A. ELECTRICAL SUBSTATION/ SWITCH ROOM
A-1 Is painted line diagram of power/ lighting distribution provided?
A-2 Is the equipment easily accessible for operation, inspection &
maintenance?
A-3 MCC Panel condition:
a) Doors okay and closed
b) Dust/soot/ cobwebs not existed
L
c) Lugs existing at each cable, termination not loose.
C
d) Visual condition of switch contact fuse etc. O.K.
e) Control wiring condition satisfactory.
f) Jumper condition between bus and distribution okay.
IO
g) Grounding OK
h) Alarm/ trip circuit working.
A-4 Live parts of equipment made inaccessible by barriers/ shrouds.
A-5 No temporary electrical connection existing.
A-6 Condition of cable duct
a) Cables are on rack
b) Cable deck clear
c) Sealing of duct
d) Cable identification tags.

Page no. 101
-------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS
REMARKS
1 2 3
-------------------------------------------------------------------------------------------------------------------------------
A-7 Rubber mats (with ISI mark) existing are enough in number.
A-8 Protective relays set at recommended values.
A-9 All fuses are of proper type and rating as specified in single line
diagram.
A-10 Fire extinguishers are of proper type and are in working
condition.
A-11 Lighting condition OK (fixtures/ tubes/ switches etc.)
A-12 Emergency lighting system in order.
A-13 All energized equipment provided with caution boards.
A-14 Condition of transformer:
a) Grounding OK
b) No oil leak
c) Silica gel OK
L
C
d) Oil level OK
e) Terminal box earthing OK
f) Oil/winding temp. OK
g) Periodic oil quality test conducted.
IO
A-15 Whether location/type of transformer in conformity with area

classification drawings.
A-16 Housekeeping is good.
B. MOTORS IN PUMP HOUSE/ COMPRESSOR ROOM/ FILLING & STORAGE SHED ETC.
B-1 Is double independent earthing connection for all motors provided.

B-2 Is grounding wire OK (not loose).
B-3 a) Is terminal box and gland OK
Flame-proofness maintained and not tampered.
b) Existing cable termination are proper
B-4 a) Is push button earthed properly and flame proof condition not tampered.
b) General condition of push button good.
B-5 Ground resistance at motor/ push button measured and found okay.
B-6 No motor abnormality
- Vibration/ bearing condition, faulty guard, fan

Page no. 102
condition, excessive noise, high body temperature.

B-7 Existing preventive maintenance schedule OK.
B-8 a) Earthing resistance test schedules/ records satisfactory.
b) Earthing pit condition OK
B-9 a) Carousel machine frame to filling gun earthing continuity maintained.
b) Carousel machine frame to central column earthing continuity OK.
B-10 Conveyor system bonding and earthing maintained.
B-11 First-aid chart for treating electrical shocks displayed prominently in MCC room.
C. UNIT LIGHTING
C-1 All lighting fixture flame proof as per area classification. C-02 Whether flame proof
condition of fixtures ensured?
C-2 Whether proper earthing of fixture provided?
C-3 Condition of wiring good.
C-4
C-5
DB, switches, MCB well maintained?
any other unsafe point observed.
L
Does water enter and accumulate in fixture distribution boxes etc. C-06 Whether lighting
C
D. MAST LIGHTS (AREA LIGHTING)
D-1 Whether grounding of mast Okay?
D-2 Condition of junction boxes, switch board, fuses etc. OK
IO
D-3 Approach to electrical installation and ladder good and safe.

D-4 Condition of flood lights:
a) Is gasket present?
b) Is glass cover in good condition?
c) Is control gear condition OK
D-5 Is earthing electrode of mast OK and its connection with mast proper?

Page no. 103
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
E. TANKAGE AREA, PIPELINES, LOADING/ UNLOADING GANTRY

E-1 Are LPG pipelines provided with flange earth jumper connection for electrical continuity?
E-2 Are earthing provision on LPG storage vessel well maintained?
E-3 Condition of grounding electrode OK
E-4 Continuity of location, hoses maintained.
E-5 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.)
E-6 Connection of earth-bonding of railway track OK.
F. GENERAL
F-1 a) Area classification drawings duly approved by CCE, Nagpur?
b) Conditions if any, specified by CCE for electrical substation, switch room etc. and
their compliance.
L
F-2 Certificate in respect of FLP for each electrical equipment- records maintained.
F-3 Earthing network diagram available and site checks done from time to time.
C
F-4 Records for electrical testing/ checks maintained upto date.
F-5 Work permit system is effective and records are maintained.
Note: For developing a detailed check list refer OISD-GDN-
OISD-GDN-145-09 document on safety audit
check list for electrical system.
IO

Page no. 104
ANNEXURE 14- III

SELF SAFETY AUDIT OF LPG BOTTLING PLANTS
LOCATION Dated
-------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A. BULK STORAGE AREA
A-1 Area under the sphere is having concrete pavement with proper slope leading to shallow
sumps.
A-2 a) Water drain chamber provided away from shadow of sphere.
b) Double valves with suitable distance piece between them on water drain line provided:
the first drain valve from the vessel side of quick shut off type valve and the second
valve is throttle type (Globe valve).
A-3
is done under supervision.
a) Relief valves provided with isolation valves.
L
c) Safety instructions for draining operations displayed prominently and water draining
C
b) Isolation valves in locked open condition.
A-4 Last safety valve test done as per statutory requirement and record maintained.
A-5 Remote operated valves provided on liquid inlet/outlet lines with push buttons/ indication
control and located at safe distance.
IO
A-6 Two independent level instruments and high level alarm provided in storage vessels and
are in working condition.
A-7 All leg supports of Horton spheres/ vessels encased in concrete with fire proof coating/
motor.
A-8 a) Sprinkler system provided on all vessels and are in working condition.
b) Deluge valve is remote operated and is located at safe distance from storage vessels.
A-9 Gas detection system provided and in good working condition (To be checked).
A-10 a) All flame-proof electrical fittings provided.
b) Earthing connections properly maintained.
A-11 Statutory inspection/ hydro test records maintained.

Page no. 105
-------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
B. PUMPS/ COMPRESSORS AREA
B-1 a) All electrical motors/ push buttons properly earthed and flame proof condition
maintained.
b) Flame proof light fittings provided.
c) Earthing resistance test conducted periodically and record maintained.
B-2 Venting through high rise vents or flare systems only.
B-3 a) No leakage from mechanical seals.
b) Double seal provided to minimize chances of leakage.
c) No abnormal sound and vibration from motor and bearings condition OK.
d) Coupling guards in position.
B-4 Drain points/ vent points/ sample points capped when not in use.
B-5
B-6
Operating instructions Do's and Don'ts displayed.
L
Long range monitors/ fixed water spray with proper throw/ sprinkler system installed
and in good condition.
C
C. CYLINDER FILLING/ STORAGE AREA
C-1 LPG bottling facilities located at safe distance from other facilities with minimum ingress
to trucking traffic.
IO
C-2 Facilities provided for positioning of trucks 15 m away from storage shed for receipt/
loading of cylinders.
C-3 Transfer of cylinders from truck to conveyor.
- Telescopic conveyor
- Trolley use
C-4 Proper purging facilities provided for new/ retested/ reconditioned cylinders
C-5 a) Inspection/ visual checks followed for spurious/ defective cylinders and record
maintained.
b) Segregated storage marked for
Spurious
Hot repairs
5/7 years testing due cylinders
Other defects
C-6 Gross weight filling:
- Auto cut off after completion of filling
C-7 Hoses are of approved quality and periodically tested.

Page no. 106
C-8 Vapour extraction system provided for carousel and system is working satisfactorily.
C-9 100% weight checking facilities provided and in use.
C-10 Accuracy of check scales being checked daily and records maintained.
C-11 CVT checks done for Ò' ring defects.
C-12 Check facilities provided for valve seat leakage and working satisfactorily.
- CVT with verifier
- Electronic
C-13 Proper facilities/ correction conveyor loops are provided for defective cylinders (Ò' ring &
weight correction).
C-14 Bung leak/ body leak check are done through in-line water bath with caps in position.
C-15 Capping/ Pilfer proof sealing facilities provided.
- Aluminum foil
- PVC sealing
C-16 Neck label being put
- Plastic
- Paper L
C-17 Quality control checks (SQC) carried out/ records maintained.
C
C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily.
C-19 Cold repairs facilities evacuation for evacuated depressurized cylinders.
C-20 Valve removal/ replacement by use of torque wrench with proper settings.
- PTFE tape/ paste or other suitable sealing compound used.
IO
C-21 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys.
C-22 Mastic flooring provided on the floor storage area to avoid accidental sparks.
C-22 a) Cylinders stacked in vertical position
b) Stacking discipline with small lots of 4 rows and 25 cylinder lengths followed, a
minimum access path of 1M maintenance on both sides of 4 rows.
C-23 Cylinders are inspected for leakage with explosimeter or portable leak detector.
C-24 Sprinkler system provided in the storage shed and in working condition.
-------------------------------------------------------------------------------------------------------------------------------

Page no. 107

1 2 3
--------------------------------------------------------------------------------------------------------------------------------
D. BULK LPG UNLOADING FACILITIES
D-1 Whether the location and layout of the facilities meet statutory
distances/ design guidelines.
D-2 Effective earthing system provided and working satisfactorily.
D-3 a) Hoses used are of approved quality standard.
b) They are periodically tested and replaced after prolonged use.
D-4 Hose contents after unloading are released to high vent located at
safe distance.
D-5 Blocked hoses/ pipelines provided with TSVs.
D-6 a) Sprinkler system provided on the railway siding/ tank truck
loading/ unloading area are and working satisfactorily.
b) Fire hydrant/ long range monitors provided.
D-7
D-8 a) Weigh bridge provided on liquid loading headers.
b)
L
Remote operated valves provided on liquid loading headers.
Calibration certificate obtained from Weights & Measures

Authorities available.
C
D-9 a) Vehicles are properly checked for any sign of leak, proper fittings
and other valid documents.
b) 2 Nos. of fire extinguishers (DCP type).
c) Explosive license, safety certificate, fitness certificate.
IO
d) Proper earthing cable with clamps.

D-10 Loading/ unloading procedures along with safety precautions
prominently displayed.

Page no. 108
-------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
E. SAFETY/ FIRE PROTECTION SYSTEM
E-1 Fire organization chart prepared, updated and displayed.

E-2 Contingency plan updated for tackling major emergencies.
E-3 Important telephone Nos. of State Fire Services, Police, District
Admn./ other offices etc. displayed.
E-4 Are fire emergency mock drills conducted periodically and records
maintained?
E-5 Work permit system for repairs/ hot jobs etc. followed and records
maintained.
E-6 a) Fire water network (layout displayed)
- above ground/ under ground
- corrosion protection
- material of construction
b) Pressure at farthest end and flow
L
C
c) Condition of hydrants, long range monitors. Maintenance and
inspection schedules followed and records maintained.
d) Provision of sprinkler system and testing schedules for checking:
- Adequate water distribution: spray nozzle are clean.
IO
- Defective nozzles to be identified for replacement.

- Deluge valve operation satisfactory.
e) Strainers provided at inlet of deluge/ sprinkler water supply main piping.
f) Strainers are cleaned periodically and records maintained.
E-7 Fire Water Pumps:
- Adequacy of capacity, nos. discharge pressure etc.
- Auto starting (system security logic) provided.
- Working jockey pump operating parameters maintained.
E-8 Static water storage tank -
- capacity and adequacy
- Source of water supply and rate of replenishment.
E-9 a) Fire vehicles well maintained.
c) Mutual aid scheme with neighboring industries/ district
authorities existing.

Page no. 109
-------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
E-10 a) Fire extinguishers - type, make, capacity, location,

provision of tamper seals on retainer clips.
b) Maintenance procedures/ records of fire extinguishers.
E-11 a) Fire alarm and communication system working satisfactorily.
b) Testing schedule/ maintenance.
E-12 Protective clothing:
- Availability of special firefighting suits (Aluminized suits)
- Breathing apparatus & its upkeep
- Water jell blankets.
- Use of nylon clothes prohibited.
E-13 Automatic Gas Detection System:
- Working satisfactorily
- Regularly tested.
L
C
E-14 No smoking cautions/ signs in Hindi/ English local languages displayed at
prominent places.
E-15 First aid facilities maintained.
E-16 a) Emergency lighting system provided in strategic locations and system
working satisfactorily.
IO
b) Flame-proof torches available
F. MANPOWER AND TRAINING
F-1 Supervisory/ managerial cadre staff fully trained in all aspects of

LPG plant operations, Disaster control/ emergency handling.
F-2 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.
F-3 Training programmes are organized periodically in LPG
operations; firefighting/ emergency handling etc. for
a) Regular staff
b) Contractor workmen
c) Security staff
d) Tank truck operators/ drivers
F-4 All activities are effectively supervised with available manpower.
F-5 a) Operating manuals and standing instructions provided to working personnel.
b) Small handy safety booklets distributed to all including contractor
employees in English/ Hindi/ Local language.

Page no. 110
--------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
F-6 Important Do's and Don'ts displayed prominently in operation areas.
G. GENERAL
G-1 a) Plant approach/ access roads well maintained and at least two
emergency exits are there.
b) Fencing/ wall around the plant is in proper condition.
c) Segregated parking area for LPG trucks outside the plant.
d) Adequate escape route available for operational facilities.
G-2 a) Strict security checks employed for compliance to safety regulations.
b) Spot checks being done.
G-3 a) Valid CCE licenses available for:
- Storage of LPG
- Storage of LPG cylinders
L
C
- Filling of LPG cylinders
- Storage of HSD in tanks for running DG sets/ fire water engines.
- Layout plan approved by CCE (layout plan updated and approved by CCE).
G-4 Accident records maintained and updated.
IO
G-5 Hot work permit/clearance issued-proper procedures followed & documents maintained.
G-6 Following manual/ documents available:
a) LPG operating manual.
b) Safety and Fire Prevention manual
c) Emergency/ disaster control plan
d) Operation/ Inspection manual of equipment supplied by vendors.
e) Gas Cylinders Rules, 2016, SMPV Rules 1981 and other relevant BIS Standards with
latest amendments.
G-6 a) Records of periodic testing of hoses/ replacement.
b) Testing records of Safety relief valves/ pop action valves.
c) Inspection records of underground pipelines etc.
d) Weights & Measures certificates.
G-7 Updated P&I Diagrams, drawing of layout and other facilities available.
G-8 Records of "Daily Safety Audits" reviewed. Corrective action taken.
G-9 General housekeeping standards: area/ facility wise.
G-10 Pipeline color code system maintained.

Page no. 111
ANNEXURE 14- IV
INSPECTION & MAINTENANCE SYSTEM AUDIT
LOCAL DATED:
--------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A. GENERAL
A-1 Whether standard system of inspection/ maintenance
schedule developed and followed and records
maintained.
A-2 Whether equipment documents supplied by vendors
are readily available and recommended maintenance
procedures are strictly adhered to.
A-3
A-4
L
Whether spare parts for different equipment/ machinery are maintained.
Whether data card/ history records of static and rotary
equipment are maintained (as per OISD Std.127/28).
C
A-5 Whether proper work permit system is followed for
maintenance jobs and records maintained.
A-6 Whether personnel protective equipment such as hand gloves,
safety shoes, safety helmet etc. provided to the concerned
IO
workmen and their use is ensured (OISD Std.-155).
A-7 Firefighting equipment and portable fire extinguishers periodically
checked / tested as per maintenance schedules & records
maintained (OISD Std.-142).
A-8 Fire alarm/ communication system scheduled testing &
maintenance ensured.
A-9 Whether Explosimeters are periodically checked and calibrated.
A-10 Whether continuous monitoring devices are periodically checked
and calibrated.
A-10 Whether exhaust fans and other ventilation devices are properly
maintained and regularly used.
A-11 Whether inspection/ testing of pressure vessels carried out periodically as
per statutory requirements and records maintained.

Page no. 112
--------------------------------------------------------------------------------------------------------------------------------
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
B. BULK STORAGE HANDLING FACILITIES
B-1 Whether design of pressure storage vessels conform to relevant
BIS/BS/ASME code with standard engineering practices. All
required fittings/ instruments/ safety valves have been provided.
B-2 Whether inspection/ test certificate at the time of original
fabrication available and subsequent inspection/ hydraulic test
carried out as per SMPV Rules 1981 of CCE and records
maintained. Guidelines of OISD Standard-128 followed for
detailed inspection of pressure vessels.
B-3 Annual inspection and testing of safety valves carried out at
proper set pressure and records maintained.
B-4 All instruments, level indicators, pressure and temperature
gauges, ROVs are maintained in working condition following daily
scheduled checks, periodic calibration and preventing
B-5
maintenance schedule.
L
Regular operation checks are carried out on pumps/ compressors
(condition of bearings/ mechanical seal/ abnormal sound etc. as
per OISD STD-119, 120).
C
B-6 Preventive maintenance and servicing schedules for pumps and
compressors for daily/ weekly/ monthly/ yearly are checked and
records maintained.
B-7 Gas detection system is checked and calibrated periodically.
IO
Audio visual alarm/ security logic system maintained in working
condition.
B-8 Fire water system & sprinkler spray system checked/ tested
periodically and maintenance jobs carried out and records
maintained.
B-9 LPG bullets/ spheres having fire proofing are periodically checked
for cracks, spilling/ bulging and suspected area are further
inspected for presence of corrosion etc. and corrective steps
taken.
B-10 Earthing connections are periodically checked and good electrical
contact is maintained.
B-11 Records of resistance testing as outlined in OISD Std-137
maintained.
B-12 Foundation/ Anchor bolts, ladders, stairways, platforms/ structural
checked periodically for any corrosion/damage etc.
B-13 Annual testing of chain pulley blocks and other tool tackles is
carried out by certified agency.
B-14 Weigh bridges calibration and certification done once in a year.

Page no. 113
C. CYLINDER FILLING
C-1 LPG filling carousel - Drive unit, central column, running rails,
etc. are daily checked, scheduled maintenance (weekly,
monthly, quarterly, annual) are carried out and records
maintained.
C-2 Introduction/ Ejection devices and filling machines are checked
daily and scheduled maintenance/ overhaul work carried out.
C-3 Checking of pin travel done regularly and records maintained.
C-4 Check scales are well maintained and calibrations carried out on
daily basis with standard weights.
C-5 Calibration of CVT/DCVT detectors being done regularly and
maintenance schedule followed.
L
C
IO

Page no. 114
15.0 REFERENCES
(i) BIS CODES PERTAINING TO LPG OPERATIONS.
--------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
-------------------------------------------------------------------------------------------------------------------------------
IS: 2-1960 - RULES FOR ROUNDING OFF NUMERICAL VALUES
IS: 5-1978 - COLOURS FOR READY MIXED PAINTS & ENAMELS
IS: 1196-1978 - CODE OF PRACTICE FOR LAYING BITUMEN
MASTIC FLOORING
IS: 1435-1991 - PLATFORM WEIGHING MACHINE
IS: 1436-1991 - WEIGHBRIDGES
IS: 1437-1967 - AUTOMATIC WEIGHING MACHINES
IS: 1448(P: 70-1968) - RESIDUE IN LPG
IS: 1448(P: 71-1979) - VAPOUR PRESSURE OF LPG
IS: 1448(P: 72-1968) - VOLATILITY OF LPG
IS:1448(P:73-1968) - HYDROGEN SULPHIDE IN LPG
IS:1448(P:74-1968) - DRYNESS OF LPG
IS: 1448(P: 75-1968) - ODOUR OF LPG
IS: 1448(P: 76-1968) - DENSITY OF LPG
IS: 1448(P: 111-1983) - ANALYSIS OF LPG AND PROPYLENE
CONCENTRATES BY GAS CHROMATOGRAPHY
IS/IEC
/IEC 60079-1:200 - EXPLOSIVE ATMOSPHERES PART 1 EQUIPMENT
IS: 2808-1964 - METHOD FOR COMPUTATION OF CAPACITY

TABLES FOR PRESSURIZED STORAGE TANKS
IS: 2825-1969 - CODE FOR UNFIRED PRESSURE VESSELS
IS: 2827-1976 - METHODS FOR CALIBRATION OF
PRESSURIZED STORAGE TANKS
IS: 3196 (PART 1)-1992 - WELDED LOW CARBON STEEL GAS CYLINDER
EXCEEDING 5 LITRE WATER CAPACITY FOR
LOW PRESSURE LIQUEFIABLE GASES
CYLINDERS FOR LPG.

Page no. 115
--------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
-------------------------------------------------------------------------------------------------------------------------------
IS: 3710-1978 - FILLING RATIOS FOR LOW PRESSURE

LIQUEFIABLE GAS.
IS: 4246-1984 - SPECIFICATION FOR DOMESTIC GAS STOVES
FOR USE WITH LIQUEFIED PETROLEUM
GASES
IS: 4379-1981 - IDENTIFICATION OF CONTENTS OF INDUSTRIAL
GAS CYLINDERS
IS: 4576-1978 - SPECIFICATION FOR LIQUEFIED PETROLEUM
GASES
IS: 4786-1968 - VARIABLE HIGH PRESSURE REGULATORS FOR
USE WITH LPG
IS: 4991-1968 - CRITERIA FOR BLAST RESISTANT DESIGN
OF STRUCTURES FOR EXPLOSIONS
IS: 5116-1985 -
ABOVE
GROUND L
GENERAL REQUIREMENT FOR DOMESTIC
C
AND COMMERCIAL EQUIPMENT FOR USE
WITH LPG
IS: 5571-1979 - GUIDE FOR SELECTION OF ELECTRICAL
EQUIPMENT FOR HAZARDOUS AREAS
IO
IS: 5572 - CLASSIFICATION OF HAZARDOUS AREAS
(OTHER THAN MINES) FOR ELECTRICAL
INSTALLATIONS
IS: 5572(PART 1)-1978
1978 - AREAS HAVING FLAMMABLE GASES AND
VAPOURS
IS: 5844-1970 - RECOMMENDATIONS FOR HYDROSTATIC
STRETCH TESTING OF COMPRESSED GAS
CYLINDERS
IS:5845-1984 - CODE OF PRACTICE FOR VISUAL INSPECTION
OF LOW PRESSURE WELDED STEEL GAS
CYLINDERS IN USE
IS: 5903-1970 - RECOMMENDATIONS FOR SAFETY DEVICES
FOR GAS CYLINDERS
IS: 6044 - CODE OF PRACTICE FOR LPG STORAGE
INSTALLATIONS
IS: 6044(PART 1)-1971 - COMMERCIAL AND INDUSTRIAL CYLINDER
INSTALLATIONS
IS: 6044(PART 2)-1972 - INDUSTRIAL, COMMERCIAL AND DOMESTIC
BULK STORAGE INSTALLATIONS
IS: 6665-1972 - CODE OF PRACTICE FOR INDUSTRIAL LIGHTING

Page no. 116
--------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
-------------------------------------------------------------------------------------------------------------------------------
IS: 7142-1974 - WELDED LOW CARBON STEEL GAS CYLINDER
FOR LOW PRESSURE LIQUEFIABLE GASES,
NOT EXCEEDING 5 LT WATER CAPACITY
IS/ISO 6789:2003 - ASSEMBLY TOOLS FOR SCREWS AND
NUTS - HAND TORQUE TOOLS -
REQUIREMENTS AND TEST METHODS
FOR DESIGN CONFORMANCE TESTING,
QUALITY CONFORMANCE TESTING AND
RECALIBRATION PROCEDURE
IS: 7241-1981 - GLOSSARY OF TERMS USED IN GAS
CYLINDER TECHNOLOGY
IS: 8198(PART 5)-1984 - CODE OF PRACTICE FOR STEEL CYLINDERS FOR
COMPRESSED GASES ; LIQUEFIED PETROLEUM
IS: 8374-1977 - L
GAS (LPG)
SPECIFICATION FOR BITUMEN MASTIC, ANTI
STATIC ELECTRICALLY CONDUCTING GRADE
C
IS: 8451-1984 - CODE OF PRACTICE FOR VISUAL
INSPECTION OF HIGH PRESSURE GAS
CYLINDERS
IS: 8737 - VALUE FITTINGS FOR USE WITH LPG
CYLINDERS OF MORE THAN 5 LIT. WATER
CAPACITY
IO
IS: 8737(PART 1)-1979

1)-1979 - VALVE FITTINGS FOR REPLACEMENT PURPOSES
IS:8737(PART 2)-1978
1978 - VALVE FITTINGS FOR NEWLY MANUFACTURED
LPG CYLINDERS
IS: 8776-1988 - VALVE FITTINGS FOR USE WITH LIQUEFIED
PETROLEUM GAS (LPG) CYL. UPTO AND
INCLUDING 5 LIT WATER CAPACITIES
IS: 8790 - GENERAL REQUIREMENTS OF POWERED
INDUSTRIAL TRUCKS WORKING IN
HAZARDOUS AREAS
IS: 8790(PART 1)-1978 - INTERNAL COMBUSTION ENGINES
POWERED TRUCKS
IS: 8790(PART 2)-1979 - ELECTRIC BATTERY POWERED INDL.
TRUCKS
IS: 8867-1987 - SATURATED VAPOUR PRESSURE AND
TEST PRESSURE FOR LOW PRESSURE
LIQUEFIABLE GASES CONTAINED IN GAS
CYLINDERS
IS: 8868-1988 - PERIODICAL INSPECTION INTERVAL OF
GAS CYLINDERS IN USE

Page no. 117
-------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS: 9122-1979 - INSPECTION GAUGES FOR CHECKING TYPE 2
TAPER THREADS OF GAS CYLINDER VALVES,
TAPER 3 IN 25
IS: 9200-1979 - METHOD OF DISPOSALS OF
UNSERVICEABLE COMPRESSED GAS
CYLINDERS
IS: 9281 - ELECTRONIC WEIGHING SYSTEMS
IS: 9281(PART 1)-1979 - TERMS AND DEFINITIONS
IS:9281(PART 2)-1979 - METHODS OF MEASUREMENTS
IS: 9281(PART 3)-1981 - REQUIREMENTS
IS: 9281(PART 4)-1983 - CODE OF PRACTICE FOR USE
& INSTALLATION
IS: 9583-1981 - EMERGENCY LIGHTING UNITS
IS: 9639-1980
IS: 9777-1981
-
-
L CODE OF PRACTICE FOR VISUAL
INSPECTION OF LOW PRESSURE WELDED
STEEL GAS CYLINDERS IN USE
DATA SHEET FOR SELECTION OF
C
WEIGHBRIDGES FOR BULK
HANDLING EQUIPMENT
IS: 9798-1981 - LOW PRESSURE REGULATORS FOR USE
WITH LPG
IS: 9902-1982 - RECOMMENDED PRACTICE FOR
IO
LEAK TESTING
IS: 9975 - Ò' RINGS
IS: 9975(PART 1)-1981
1981 - DIMENSIONS
IS: 9975(PART 2)-1984 - MATERIAL SELECTION & QUALITY
ACCEPTANCE CRITERIA
IS: 9975(PART 3)-1984 - SEAL HOUSING DIMENSIONS AND
TOLERANCES
IS: 9975(PART 4)-1984 - TERMINOLOGY AND DEFINITIONS
OF TERMS
IS: 10733-1983 - ELECTRICALLY BONDED ROAD AND RAIL
TANKER HOSE OF RUBBER, RESISTANT TO
PETROLEUM PRODUCTS

Page no. 118
-------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS: 10908-1991 - FLEXIBLE RUBBER TUBING FOR LPG

IS: 11498-1985 - LEVER TYPE DIA GAUGES
IS: 12936-1990 - CODE FOR BASIC REQUIREMENTS FOR
DELIVERY PERSONS ENGAGED IN THE
DELIVERY OF LPG CYLINDERS
IS: 13258-2014 - WELDED LOW CARBON STEEL CYLINDERS
EXCEEDING 5 LT WATER CAPACITY FOR LOW
PRESSURE LIQUEFIED PETROLEUM GAS
CODE OF PRACTICE FOR INSPECTION AND
RECONDITIONING OF USED LPG CYLINDERS
IS: 13432 (PART 1)-1992 - GAS LEAK DETECTOR FOR USE WITH LOW
PRESSURE LIQUEFIED PETROLEUM GAS
BURNING APPLIANCES SPECIFICATION
IS: 16054:2013 -
L PART I MECHANICAL TYPE
PERIODIC INSPECTIONS AND TESTING:
WELDED LOW CARBON STEEL CYLINDERS
EXCEEDING 5 LITRES WATER CAPACITY FOR
C
LIQUEFIED PETROLEUM GAS (LPG) CODE
OF PRACTICE
--------------------------------------------------------------------------------------------------------------------------------
IO
ii. The Static and Mobile Pressure Vessels (Unfired) Rules-1981

iii. LPG (Regulation of use in Motor Vehicles) Order 2001
iv. Gas Cylinder Rules 2016 (Under Indian Explosives Act, 1884)
v. API Standard 2510 Design and Construction of LP Gas Installations
vi. API PUB 2510 A - Fire-Protection Considerations for the Design and Operation of
Liquefied Petroleum Gas (LPG) Storage Facilities
vii. API PUBLICATION 2510A - Fire-Protection Considerations for the Design and Operation of
Liquefied Petroleum Gas (LPG) Storage Facilities
viii. ASME Boiler and Pressure Vessel Code Sect. VIII Division 1 American Society
of Mech. Engrs., New York
ix. NFPA 58 : Storage and Handling of Liquefied Petroleum Gases
x. NEPA 59 : LP Gases at Utility Gas Plants
xi. OISD-STD-105 : Work Permit System.
xii. OISD-STD-113 : Classification of Areas for Electrical Installations at Hydrocarbon
processing and handling facilities

Page no. 119
xiii. OISD-STD-135 : Inspection of Loading/Unloading hoses for

Petroleum Products.
xiv. OISD-STD-150 : Design a n d L a y o u t o f L i q u e f i e d P e t r o l e u m G a s
Mounded Storage Vessels
xv. OISD-STD-158 : Recommended Practices on Storage and Handling

of Bulk Liquefied Petroleum Gas (LPG)
xvi. OISD-STD-159 : LPG Tank Trucks Requirements of Safety on

Design/ Fabrication & Fittings
xvii. OISD-STD-179 : Requirement of Safety for Compression, Storage,
Handling & Refueling of Natural Gas for Use in
Automotive Sector.
xviii. ASME B - 31.3 : Chemical Plant and Petroleum Refinery Piping
xix. ASME B - 31.4 : Liquid Transportation Systems for Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia and Alcohols
xx. PD-5500 :
L
Specification for unfired fusion welded pressure
vessels
C
IO

Page no. 120
Figure I

Page no. 121
Figur
e
IO
Figure II

Page no. 122
IO
Figure III

Page no. 123
IO
Figure IV

Page no. 124
IO
Figure V

Page no. 125
C
IO
Figure VI

Page no. 126


Oisd STD 144 PDF

Uploaded by

Copyright:

Available Formats

Oisd STD 144 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Oisd STD 144 PDF

Uploaded by

Copyright:

Available Formats

Sr.

OISD STANDARD 144

Second Edition, October 2005

LIQUEFIED PETROLEUM GAS (LPG)

Oil Industry Safety Directorate

and public at large L

Petroleum industry in India is significantly globalized at present in terms of

benefits. The document on "LPG

The present document "

Needless to mention, this standard, as always would be reviewed periodically based

Page No. III

(Amended Edition October 2017)

Sh. N. Dasgupta Bharat Petroleum Corporation Ltd., Mumbai

Sh. T.Koteeswaran Chennai Petroleum Corporation Ltd., Chennai

Sh. B.J. Phukan Numaligarh Refinery Ltd., Assam

Sh. P. Jaidevan Indian Oil Corporation Ltd., Calicut

Sh. S. Ramesh Bharat Petroleum Corporation Ltd., Noida

FUNCTIONAL COMMITTEE MEMBERS

Sh. A.C. Kelkar Indian Oil Corporation Ltd., ( Mkt.)

Sh. V. Narayana Rao Bharat Petroleum Corporation Ltd., (Mkt.)

Sh. S. Mathur Engineers India Limited, New Delhi

LIQUEFIED PETROLEUM GAS (LPG)

expressly disclaims any liability or responsibility for loss or damage resulting

stenching agent for identifying the leakage as per IS: 4576.

expressly disclaims any liability or responsibility for loss or damage resulting

Maximum Working Pressure: It is saturated vapour pressure of LPG at 65 oC for LPG

expressly disclaims any liability or responsibility for loss or damage resulting

a. Gas Cylinder Rules 2016 (Under Indian Explosives Act, 1884)

expressly disclaims any liability or responsibility for loss or damage resulting

b) Adequate availability of water from a reliable source or alternate arrangements proposed.

f. Storage vessels shall not be located one above the other.

expressly disclaims any liability or responsibility for loss or damage resulting

expressly disclaims any liability or responsibility for loss or damage resulting

filled storage, valve changing and degassing shall be provided.

expressly disclaims any liability or responsibility for loss or damage resulting

expressly disclaims any liability or responsibility for loss or damage resulting

1. LPG Storage vessels * T-II 30 30 50 30 15 60

2. Boundary/property line/ T-II ** 30 30 50 30 30 **

4. Tank truck gantry

5. Tank wagon gantry

7. Pump house/ Comp. 15 30 15 30 30 30 ** 60

expressly disclaims any liability or responsibility for loss or damage resulting

expressly disclaims any liability or responsibility for loss or damage resulting

Hydro test pressure: As per Design Code

expressly disclaims any liability or responsibility for loss or damage resulting

shall be provided on top of saf ety valve. L

Typical safety fittings on a LPG storage vessel are indicated in Figure-II.

expressly disclaims any liability or responsibility for loss or damage resulting

provided with the following facilities:

expressly disclaims any liability or responsibility for loss or damage resulting

If one compressor is envisaged to run normally, another standby compressor of 100%

expressly disclaims any liability or responsibility for loss or damage resulting

pressure which could be developed by the product and / or transfer equipment.

panel provided in the LPG pump house. L

Typical sketch of a bottling pump installation is enclosed as Figure-III.

expressly disclaims any liability or responsibility for loss or damage resulting

expressly disclaims any liability or responsibility for loss or damage resulting

Typical sketch of cylinder evacuation facility is enclosed as Figure-V.

expressly disclaims any liability or responsibility for loss or damage resulting

2. Boundary/property line/ T-II 30 30 50 30 30