Liquefied Petroleum Gas (LPG) Installations: Oisd Standard - 144

OISD STANDARD - 144
Second Edition, October 2005

FOR RESTRICTED
CIRCULATION ONLY
LIQUEFIED PETROLEUM GAS (LPG)

INSTALLATIONS
Prepared by
FUNCTIONAL COMMITTEE ON
OIL INDUSTRY SAFETY DIRECTORATE

GOVERNMENT OF INDIA
MINISTRY OF PETROLEUM AND NATURAL GAS
7th Floor, New Delhi House

27, Barakhamba Road
Connaught Place, New Delhi 110 001
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 disclaims any liability or
responsibility for loss or damage resulting from their use.
These documents are intended to supplement rather than replace the prevailing
statutory requirements.
FOREWORD
The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies ,
operating and maintenance practices was hardly in existence at a national level.
This, coupled with feed back from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas
installations.
With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) for
formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of functional
committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.
Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as
well as with industrial applications due to its unique properties and environmental
benefits. The document on "LPG Bottling plant operations" was prepared in
1994. The present document "LPG Installations" has been prepared by the
functional based on the accumulated knowledge and experience of industry
members and updation of national and international codes and practices related
to LPG.
This document will be reviewed periodically for improvements based on the

new experiences and better understanding. Suggestions may be addressed
to :
The Coordinator,
Committee on LPG
Oil Industry Safety Directorate,
7th floor, New Delhi House,
27, Barakhamba Road,
New Delhi 110001
FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)
NAME
ORGANISATION
LEADER
Sh. R. Krishnan
Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS
Sh. A.N. Biswas
Deptt. of Explosives, Nagpur
Sh. N. Rajkhowa,
Engineers India Limited, New Delhi
Sh. B.S. Giridhar
Indian Oil Corporation Ltd., - HQ, Mumbai
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
MEMBER COORDINATOR
Sh. S. C. Gupta
Oil Industry Safety Directorate, New Delhi
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
Bharat Petroleum Corporation Ltd., ( Ref.)
Sh. P.P. Nadkarni
Hindustan Petroleum Corporation Ltd., (Mkt.)
Sh. S. Mathur
Engineers India Limited, New Delhi
MEMBER COORDINATOR
Sh. S. C. Gupta
Oil Industry Safety Directorate, New Delhi
CONTENTS
---------------------------------------------------------------------------------
SR. No.
ITEM
PAGE NO
--------------------------------------------------------------------------------1
Introduction
Scope
Definitions
Statutory Rules/ Regulations
Installation Layout
Design Considerations
Storage & Handling of Bulk LPG
Bottling Operations
Maintenance & Inspection
10
Statutory Testing of LPG Cylinders
11
Fire Protection Facilities
12
Gas Monitoring System
13
Emergency Management Plan
14
Safety Audit
15
References
---------------------------------------------------------------------------------

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, fire fighting 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
standardising design, operations, bottling
and distribution of LPG.
LPG has an explosive range of 1.8%

to 9.5% volume of gas in air. This is
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 posses mild
anaesthetic properties.
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.
LPG is colourless 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 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-4576.
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 stenching agent for
identifying the leakage as per IS :
4576.
Approved Type :
Any equipment
which has specific approval for use
under specified conditions by competent
authority or authorised person as the
case may be.
The auto-ignition temperature of

LPG ranges from 410 to 580 oC.
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.
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, refrigerated and
mounded storage facilities for LPG.
This standard is not applicable to
bottling plants having a bulk LPG
inventory not exceeding 100 MT with
minimum two storage vessels and with
LPG bottling a total quantity not
exceeding 20 MT per shift of 8 hrs. The
safety requirement for such LPG
Bottling plants are covered in OISDGDN-169.
Safety requirements for mounded
Storage facilities are covered in OISDSTD-150. The requirements for Auto
LPG Dispensing Stations are covered in
OISD-STD-210.
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.
3.0
DEFINITIONS
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 storage or transportation of LPG.
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
o
C 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 productgas, 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
convection.
conduction
and
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
stray electrical current, and electrostatics
discharge.
Filling Ratio : It is the ratio of weight of
LPG in a container to the weight of
water the same container can hold at 15
o
C.
Fire safe : As applied to valves, it is the
concept of controlling the leakage to an
acceptable
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 airvapour 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 hotwork 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 are
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.
Liquefied Petroleum Gas (LPG) : The
term applies to a mixture of certain light
hydrocarbon predominately C3 & C4,
derived from petroleum & natural gas
which are 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.
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.
Air (Prevention & Control of

Pollution) Act- 1981
Maximum Working Pressure : It is

saturated vapour pressure of LPG at 65
o
C for LPG cylinders and 55 oC for bulk
vessels.
The Environment (Protection)

Act 1986
Water Capacity :
The maximum
volume of water in litre that the a
container can hold at 15 oC.
Manufacture, storage & import of

Hazardous chemicals Rules 1989.
4..0 STATUTORY RULES /

REGULATIONS
The LPG installation & various facilities
are covered under many regulations and
require specific approval / licence from
concerned statutory authorities. The
various regulations applicable to LPG
installation facilities are as below :
a.
Gas Cylinders Rules, 1981 (under

Indian Explosives Act,1884)
b.
Static & Mobile Pressure Vessels

(unfired) Rules-1981 (Under Indian
Explosives Act 1884).
c.
The Factories Act, 1948.
d.
Indian Electricity Rules
e.
The Standards of Weight &

Measures Rules - 1987 Under
Weight & Measures Act - 1976.
Guidelines for Environmental

clearance of new projects - 1981.
In addition to the above Statutory
regulations,
there
are
various
recommended guidelines emerging out
of the various Committees set up by the
Govt. of India from time to time for
streamlining/ improving the safety
standards of LPG Bottling/ Distribution:
a.
Vasudevan Committee - 1983

Ministry of Energy (Department of
Petroleum).
b.
Expert Committee Review of Safety

and Operating Procedures in LPG
facilities - 1986, Ministry of
Petroleum
&
Natural
Gas
(Department of Petroleum)
c.
Sudha Joshi Committee for better

services to LPG users - 1987
(Ministry of Petroleum & Natural
Gas).
f.
The Standards of Weight &

Measures (Packaged Commodities
Rules-1977)
g.
Liquefied Petroleum Gas (Regulation

of supply and distribution Order 1993).
h.
The Motor Vehicles Act - 1988.
5.0 INSTALLATION LAYOUT
i.
Environmental Regulations :
5. 1 GENERAL
Water (Prevention & Control of

Pollution) Act, 1974.
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 effected by fire rapidly and
effectively. The layout shall permit
access from at least two 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
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.
LOCATION
While assessing the suitability of any

site for location of LPG installation, the
following aspects shall be considered :
a. The access of mobile fire fighting

equipment to the storage vessels
shall be at least from two sides.
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.
b. Longitudinal axis of static storage

vessels (bullets) shall not be pointed
towards
other
vessels,
vital
equipments e.g. LPG cylinder sheds,
tank lorry/tank wagon gantries, LPG
pump house and buildings wherein
control panels for fire and gas
detection/ actuation panels are
situated.
b) Adequate availability of water from a

reliable
source
or
alternate
arrangements proposed.
c. Storage vessels to be located

preferably in downwind of potential
ignition sources at lower elevation.
c) The topographical nature of the site

with specific reference to its effect
on the accidental release of LPG.
d. No foreign material / combustible

substances shall be stored in storage
area.
d) The availability of space for future

extension of LPG facilities, if any,
shall also comply with the safety
norms.
e. Storage vessels shall be laid out in

single row in each group.
f. Storage vessels shall not be located
one above the other.
e) The meteorological data of the

location including predominant wind
direction & velocity, high flood
level, temperatures etc.
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 atleast 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 not be
less than the diameter of the nearest
vessel or minimum 15 M. 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 shall be directed to
the main drainage through a water
seal to avoid the spread of LPG.
(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 and bullets shall be treated
as separate groups with minimum 30
M distance between two groups.
Top surfaces of all the vessels installed
in a group shall be on the same plane. It
is necessary to provide separate
manifolds preferably with independent
pumping facilities for bullets and
spheres.
Alternatively,
fail
safe
interlocks like two way valves shall be
provided so as to avoid any chances of
overfilling of adjacent vessels due to
gravitation.
5.5
LPG
BULK 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.
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 and
proper
maneuverability
for
vehicles.
5.5.9
5.6.2
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 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
filled
cylinders
storage,
valve
changing, degassing, if any, shall
be provided. Valve changing
unit without evacuation can be
provided in filling shed itself.
Tank truck shall be loaded/

unloaded
with
suitable
arrangement for cold flaring of
hose content, if used at the end of
the operations.
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 .
5.5.10 LPG tank truck parking area

(Bulk/ Packed) shall be located in
a secured area and provided with
adequate no. of
hydrants /
monitors to cover the entire
parking area.
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 from storage
sheds to avoid settling of LPG
vapour.
5.6.4
LPG cylinder filling machines

and other related testing facilities
shall be provided in sequential
order.
5.6.5
A separate shed shall be provided

for carrying out degassing of
defective cylinders.
5.6.6
Cylinder storage shall be kept on

or above grade and never below
grade in cellar or basement.
5.6.7
Filled cylinders shall not be

stored in the vicinity of cylinders
containing other gases or
hazardous substances.
5.6.8
Escape routes shall be specified

and marked in LPG sheds for
evacuation of employees in
emergency.
5.6.9
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.
5.6.10 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 case of
emergency.
5.7.2
Proper industry type boundary

wall atleast 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.
5.8 UTILITIES
Utilities consisting of fire water pumps,
admin. building, canteen, motor control
centre, 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
group of bldgs. not associated
with LPG installation
30
30
50
30
30
3.
Shed-LPG
30
30
15
30
50
30
15
60
4. Tank truck gantry - LPG
30
30
30
50
50
50
30
60
5. Tank wagon gantry
50
50
50
50
50
50
30
60
6. LPG/other rail spurs
30
30
30
50
50
50
30
60
7. Pump house/Comp.house
15
30
15
30
30
30
60
(LPG)
8. Fire Pump House/ storage tank 60
**
60
60
60
60
60
--------------------------------------------------------------------------------------------------------------------------Notes :
1.
2.
3.
4.
All distances are in metres. 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 centre of each bay and for storage vessels where the distance shall be
measured from the nearest point on the vertical shadow of the vessel.
Notation :
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.
Distance of stabling line shall be as per minimum Railway Standards.
Distance of stabling line shall be as per Railway guidelines.
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 metre )
--------------------------------------------------------------------------------------------------------------------------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

The minimum requirements w.r.t. design
considerations and various fitting to be
provided LPG storage vessels shall be as
under :
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
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.
A single code shall be adopted for
design, fabrication, inspection and
testing i.e. ASTM and BS shall not
be combined.
ii. Material shall be in line with design
code. ASTM A516 Gr. 60 shall be

used for refinery service (BS-5500
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. Microalloyed steel containing Ni, Mo, Va
shall not be considered. Maximum
specified tensile stress shall not be
more than 80,000 psi.
o
iii. Design temperature : (-) 27 C to

o
(+) 55 C.
2
iv. Design Pressure : 14.5 Kg/ cm g on
top as per IS: 4576 at 55 oC.

Marketable LPG conforming to IS:
4576 can have a maximum vapour
pressure of 16.87 Kg/ Sq.cm.g at 65 o
C temperature. LPG with higher
vapour pressure are not expected to
be stored in bottling installations.
Corrosion Allowance :
mm
minimum 1.5
Radiography : Full
Stress Relieving : 100% irrespective of
thickness.
Wind pressure : as per IS: 875
Earthquake pressure : as per IS:1893
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 have a minimum slope of 1.5
o
.
There shall not be any other flanges,
manhole, instrument tapping on this
nozzle upto 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.
Fire safe ROVs shall also be provided on
liquid line at TLD & Tank wagon gantry
& isolation valve (quick closing type) on
the entry of liquid lines at LPG filling
shed at a safe location.
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.
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 a minimum
of 300 lb rating confirming to ANSI
B16.5 class 300 or equivalent. (pipe
flanges and flanged fittings. All tapings
or openings shall be of minimum 20
mm thickness.
6.2.3 INSTRUMENTS
i)
The storage vessel shall have
minimum two independent level
indicators and one independent high

level switch. 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 safety
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 down stream 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.
Weephole nipples shall be so oriented
that in case of safety valve lifting and
consequent fire, the flame resulting from
LPG coming out from weephole does not
impinge on the sphere or structure. A
loose fitting rain cap with a chain (non
sparking) fitted to vent pipe shall be

provided on top of safety valve.
Typical safety fittings on a LPG storage
vessel are indicated in Figure-II.
6.3
LPG LOADING/ UNLOADING

FACILITIES
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 provided with the
following facilities:
(i) Vapour line with isolation valves
Each loading station

of the following :
shall
consist
i. Excess flow check valve & non

return valve shall be provided in
LPG loading lines.
(ii) Excess flow check valve & non

return valve shall be provided in
LPG unloading lines with isolation
valves
(iii)
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 shall be
provided with break away couplings
or smart hoses 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.
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
closed 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.
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 loaded/ unloaded
with suitable arrangement for flaring
of hose content at the end of the
operations.
iii. The unloading arms shall be used for
unloading the LPG TT at LPG
installation. In case, LPG hose are
used, it shall conform to OISD-STD135 or equivalent as approved by
CCOE.
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 closed when not in
use.
6.4
CYLINDER
FACILITIES
FILLING
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.
The filling area shall not be on
upper floors of building or in
cellars
unless
specifically
required on account of extreme
weather conditions.
ii) 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.
All carousels & leak detectors
including electronic shall be of
approved type.
iii)
Adequate lighting shall be

provided in the cylinder filling
area. Emergency lighting shall
also be provided at critical
places.
iv) Water drains from the cylinder

filling area where they enter an
outside drainage system, shall be
provided with vapour seals.
v) Proper access shall be made
available for other fire fighting
equipment i.e. fire tender, foam
trolley etc.
vi)
Cylinder storage
area
requirement shall be worked out
based on the stacking pattern of
filled and empty cylinders as
described in Figure-I.
vii) 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.
viii)
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.
ix) On-line check weigh scales with
a minimum of 50 gms.
graduation be installed so that all
the cylinders are check weighed
after filling.
x) Compact Valve Tester to check
valve and 'O" ring shall be
installed on line. Alternatively
electronic leak detectors shall be
provided.
xi) Water test bath or electronic leak
detectors shall be provided to
detect
body and bung leak
cylinders.
xii) Vapour extraction system at
strategic locations near carousel,
cylinder evacuation 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 do not
start without vapour extraction
unit being functional.
6.5
UTILITIES
(A)
Compressed air
The quality of instrument air shall

conform to the requirements as
recommended by the manufacturers of
instruments/ equipment:
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
withstand the maximum 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. A pressure switch actuating a low
pressure alarm in control room
and locally shall be provided,
taken from discharge end.
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
Typical sketch of compressor

installation is enclosed as Figure-IV.
drives shall be of the anti-static

type.
Typical sketch of a bottling pump
installation is enclosed as Figure-III.
6.7
LPG
COMPRESSOR
VAPOUR
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.
6.8
PIPING
Piping shall be designed for handling of

LPG. Piping that can be isolated and
need thermal safety valves shall have
minimum design pressure of 24 kg/cm2
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
provisions of ANSI B 31.3.
the
ii. The belts used in shall be of

antistatic type & fire resistant.
(ii) The material shall conform to API

5L Gr. B / ASTM A106 Gr B or eqv.
iii. Compressor shall be provided

with the following features as a
minimum :
(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.
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.
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.
(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.
6.9
THERMAL
RELIEF SYSTEM
PRESSURE
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
done in a safe manner.
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.
6.9 VALVES
Steel valves conforming to relevant
API standards shall be used. Cast
iron valves should not be used.
6.10 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.
(iv) All flanges shall be connected
for bonding for electrical
continuity.
6.10 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.
b. Each of cylinder emptying vessels

mentioned above shall be equipped
with the following :
-
Pressure gauge
Level gauge
high level alarm switch set at 85
% with trip / switchover
arrangement.
Pressure relief valves,
Vent valves discharging to 1.5 m
above the shed.
Other trims like drain valve,
utility connection.
Typical sketch of cylinder evacuation

facility is enclosed as Figure-V.
6.11
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 :
-
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.
stainless steel trim and stainless

or aluminized steel spring.
EQUIPMENT
FOR
ETHYL
MERCAPTAN
SERVICE
(iv) For transfer valves, stainless

steel
ball
valves
with
fluoroplastic seats and stainless
steel (SS316) trim or their
equivalent are recommended.
6.12
6.12.1 Material of Construction of

Ethyl Mercaptan containers
Stainless steel and copper free
steel alloys are the preferred
materials of construction of
equipment for mercaptan service.
Aluminium 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.
(v)
Rigid connection should be

welded or flanged joint type.
(vi) Fluoroplastics shall be used for

gasketing.
(vii) For pressure gauges, stainless
steel diaphragm type is
recommended with stainless
steel socket and tip.
(viii) Provision for analysis in line
with IS:4576 or IS14861 as
applicable shall be made.
6.13 SELECTION
OF ELECTRICAL
EQUIPMENT
6.12.2 Pumps for Mercaptan service

Only hermetically sealed pumps
shall be used.
6.12.3 Piping and Fittings
(i)
(ii)
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.
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
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 as 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-STD113,
OISD-RP-149, NEC 1985,
IS:2148, IS:5571, 5572, IS:
13408, Petroleum Rules, 2002
shall be referred.
6.14
water pumps,
stations etc.
fire
alarm
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 ON. During
power failure, battery bank shall
be used to provide power.
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 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 fire
fighting facilities such as fire
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-149.
vii. The lighting fixtures on various
circuits
shall
be
suitably
interlaced so that failure of any
one circuit do not result in
complete darkness.
viii.
Switches controlling the
lighting fixtures and exhaust fan
shall be installed outside 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.
Electrical equipment fencing

(e.g. transformer, yard etc.)
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 being
isolated by a removable link.
For details on inspection practices
OISD standard 147 to be referred..
6.15
i.
ii.
Installation Earthing
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.
Cable trays and

lighting mast and poles.
Spheres, Bullets etc.
loading
racks,
Flexible earth provision for

wagon, truck.
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.
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.
System neutral
Steel structures,
platform etc.
Cable shields and armour.
iii. Where installed, lightning protection

shall be provided as per the
requirements of IS:2309.
The earthing system shall have an

earthing network with required
number of earth electrodes connected
to it. The following shall be earthed:
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.
10 Ohms in the case of all noncurrent 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.
v. All
the
electrical
equipment
operating above 250 volts shall have
two separate and distinct connections
to earth grid.
vi. The main earthing network shall be

used for earthing of equipment to
protect it against static electricity.
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.
vii. 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.
viii. 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
just before the release of the

truck.
7.0 GENERAL
This section deals with the safe
practices and provisions applying to
unloading of bulk LPG and storage
of bulk LPG at installations. There
should be strict compliance w.r.t
selection, deployment of proper
skilled manpower for effective
operation and maintenance.
7.1 BULK HANDLING

MOVEMENT BY ROAD
OF BULK LPG
FOR
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 OISDSTD-159.
7.1.1 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
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 OISDSTD-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.
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.
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.
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 -
7.1.2
(i) Uncontrolled
leakage
occurring
(ii) A fire occurring in the
vicinity
(iii) Lightning and thunder
storm
PROCEDURES
FOR
OPERATION
pressure gauge, temperature

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.
Fitment of Spark arrestors
of approved quality.
No leakage in
silencer pipe exists.
exhaust
Manufacturer's name plate

with date of testing is fitted
on the vessel.
Valid Explosive Licence and
RTO certificate is available.
Approved drawings of vessel
are available.
Blind
flanges/caps
provided on vessel.
Availability
cable.
of
are
Earthing
Bonding between vessel and

chassis and between flanges
is satisfactory.
(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,
Earthing / bonding point is

available.
Third party inspection/test
certificates for vessel/fittings
are available.
Liquid / vapour line valves
are in good condition.
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.
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
hoses & connections for leakage.
Loading should start only when the
system is leak free.
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 volume to be
filled shall not exceed 85 % at 55OC
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-discharge pressure 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 tightness with
soap solution.
(b) Unloading Operations

1. Operations described under Item
1 through 6 in para 7.1.2(a)
should be carried out.
2. Liquid line and vapour line of the
tank truck shall be connected to
the respective hoses fixed to the
unloading point.
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 1.5
Kg/cm2g.
Checklist for bulk LPG tank Trucks
at unloading locations is given at
Annexure 7 I.
7.2
BULK
HANDLING
MOVEMENT BY RAIL
FOR
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 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.
7.2.1
SAFETY PRECAUTIONS
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 may be used to avoid
electric loco coming closer to the
gantry. Maintain the distance of
15 m from first fill point.
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
hoses, only non-sparking tools
shall be used.
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 all the wagons.
7. Do not use footwear
protruding nails.
with
8. Ensure that the lower portion of

flapper bridge at wagon side is
fitted with rubber or wooden
padding.
9. Ensure that electrical continuity

of the system is intact.
10. Ensure that all fittings on the
wagons are checked physically.
11. Hoses shall be
tested as per
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).
7.2.2 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.
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 the 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.
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 line slowly
to avoid ice formation. Thus,

the hoses are depressurised.
Then, close the flare line
connection valves.
18. Disconnect the filling and
vapour return line hose
connections from the wagon.
Replace and tighten the plugs
on filling and vapour return
lines.
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. With the plugs removed,
screw pipe nipples into the
outlets of the valves after 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 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 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
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 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.
20. After bleeding off the
pressure in the 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
connections.
bonding
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.
28. In the event of LPG received
on weight basis, the tank
wagon may require weighing
following the completion of
the unloading operation.
7.2.3
DEGASSING
SICK/LEAKY
WAGONS
OF
TANK
(a) Recommended Procedure

In the degassing system
recommended for LPG wagons,
vacuum
cycle
purging
technique should be followed
as outlined below :
- Vessel should be evacuated
repeatedly by a vacuum pump.
- 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.
7.3
BULK
HANDLING
MOVEMENT BY SEA
FOR
Transportation of LPG in bulk by

tankers may be carried out under
fully-pressurised, semi-pressurised
(semi-refrigerated)
or
fully
refrigerated
at
atmospheric
pressure conditions.
7.3.1 CARGO CARRIER DESIGN &
CONSTRUCTION
The design and construction of
cargo carrier is in line with
International
Maritime
Organisation (IMO) Gas code.
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.
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 gastight window at the top of and
outside the tank.
7.3.2 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 fullyrefrigerated 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:
f) Two sets of purge lines at the

top and bottom of the tank.
These are used to distribute
inert gas or vapour for gasfreeing or gassing-up of the
cargo tanks.
g) A vapour line for withdrawal of
vapour to the compressor.
h) Sample tubes.
Safety Devices
(a) Atleast 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.
pressure of the shore tank. A

suitable vapour recovery system or
re-liquefaction of the gas from the
receiving tank shall be provided.
7.3.5 UNLOADING OPERATIONS
It is essential that the ship and
terminal operators are familiar with
the basic 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.
7.3.3 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.)
7.3.6 COMMUNICATION
(b) Relief valves on liquid line to
surge vessel with an audible
alarm system connected to high
safe venting system
Reliable
and
effective
communications, irrespective of
whether these are directly between
the tanker and the terminal or
indirectly via third party, are prerequisites 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.
(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
7.3.4 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
7.3.7
PRE-CARGO
DISCUSSIONS
TRANSFER
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

discussions are as under :
(a) The names
terminal and
who will be
cargo transfer
be noted.
the
and roles of
ship personnel
responsible for
operations may
(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.
7.3.8 SHIP / SHORE
CHECKLIST
SAFETY
Checklist for Ship/Shore safety is

given in Annexure 7-III.
7.3.9 DISCONNECTION OF HOSE/
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.
7.4 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.
7.5 SAMPLING AND DRAINING
7.5.1 SAMPLING
Sampling is primarily required at
supply locations i.e. Refineries, Gas
Processing Plants, Import Terminals,
etc. Sampling of LPG for different
analytical tests shall be carried out in
accordance with IS:1448. During
handling of
LPG samples, the
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 minimises
flashing of sample during collection,
thereby
providing
a
truly
representative sample.
7.5.2 DRAINING
Storage vessel should be drained
regularly for its water content,
sediments, caustic 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) It shall be ensured that the drain
outlet is at a safe distance from the
vessel so that accidental ignition of
any escaping vapour would not
expose the vessel to flame
impingement.
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.
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
Height barrier provided as per specifications
ON THE TANK TRUCK :
Fuel tank is protected by means of stout

guard and fuel tank cap is locked.
Properly fitted spark arrestor of make and

design approved by CCE, Nagpur.
Paint of bullet is not peeling off.
Proper Fittings i.e. SRV, EFCV, temperature

& pressure gauges etc. as SMPV Rules &
OISD-STD-159.
TANK TRUCK
GENERAL
2 nos. 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.

ELECTRICALS :
First aid kit is available.
3.
CHECKS
REQUIRED
TO
BE
CARRIED OUT ON RANDOM BASIS MINIMUM ONE DAY, ONCE IN A
MONTH :
TANK TRUCK :
Internals of fire extinguishers in good

condition
Carries TREM CARD, instructions booklet

detailing
instructions
on
handling
emergencies en route.
All junction boxes are properly sealed
Any loose electrical wiring/ terminal
Carries route map
Electrical wiring is insulated and provided

with suitable over current protection.
Has valid CCE licence and authenticated

copy of drawing
Truck is self starting
Carries RTO permits
Readily accessible master switch for

switching off the engine is provided inside
the cabin.
RLW-ULW> Licenced capacity
HAZCHEM sign, name of contractor with

address and telephone No. displayed
prominently.
Bullet has no sign of external corrosion.
Dipole wiring. (Note 1)

TANK FITTINGS :
Leakage from any fittings or joints.
2.
CHECKS
REQUIRED
TO
BE
CARRIED OUT BEFORE ISSUING
LOADING MEMO (DURING THE
COURSE
OF
UNLOADING
OPERTIONS)
TANK FITTINGS :
-
Excess flow check valves are functioning.
Liquid / vapour lines are adequately

anchored and are well protected by means of
stout steel guard.
Following are available in Tank Truck :

-
Tools for all fittings
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.
Operative fittings like roto gauge, pressure
gauge and temperature gauge are
operational.
4 Nos. caution sign board with luminous

paint for stopping traffic in case of any
emergency.
GENERAL :
-
Flanges and bend pipe on liquid / vapour lines

should be of rating of 300.
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.
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.

The paint on the barrel is in good
condition and has not lost its
reflecting characteristics.
Y/N
The matter regarding tank wagon not complying with any of above checks shall be taken up with loading
location for corrective action.
ANNEXURE 7 - III
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
1.
Has information on cargo and shipshore connection been supplied ?
2.
Is the agreed ship-shore communic ation system operative ?
3.
Are fire and other

procedures agreed ?
4.
Are local
observed ?
5.
Has safe access been provided and

warning notices posted ?
6.
Are moorings secure and agreement

reached on the use of tension
winches ?
7.
Are emergency towing-off wires

correctly positioned ?
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 ?
emergency
regulations being
FOR SHORE
13.
Are ship's
main transmitting
aerials and radar switched off
and earthed ?
Counted....
S.NO
CHECK POINT
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 fire

fighting appliances
correctly
positioned and ready for immediate
use ?
19.
Is necessary protective clothing

available or being worn ?
20.
Are void spaces properly inerted ?
21.
Is
the required ventilation
equipment in operation ?
22.
Is the cargo system set for the

operation ?
23.
Are all remote control valves in

working order ?
24.
Are cargo tank relief valves

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 ?
FOR SHIP
FOR SHORE
29.
Are scuppers plugged and suitable

drip trays in position ?
Contd...
S.NO
CHECK POINT
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
system ?
35.
Are all personnel (including

supernumeraries and new arrivals)
aware that cargo transfer is to
begin ?
36.
Have all personnel been allocated

emergency stations ?
37.
Are non-essential personnel clear

of the cargo area ?
FOR SHIP
FOR SHORE
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)
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
at least once in a year by authorised
personnel.
(b) Filling operation - All cylinders shall

be filled on gross weight basis on
filling machine.
Maximum permissible errors on net
quantity declared by weight shall be
in accordance with the Standards of
Weights & Measures (Packaged
Commodities) Rules 1977 and
Amendment Rules, 1992. The filling
pressure
should
not
exceed
maximum working pressure of
cylinder i.e. 16.9 kg/cm2 at 65 deg.C.
Activity on bottling line including valve

change, shall be carried out by trained
personnel.
(c)
8.2 BOTTLING OPERATIONS

The Bottling Operations can
classified under following heads :
be
i) Receipt of LPG cylinders

ii) Filling & despatch of LPG Cylinders
iii)
Handling & storage of LPG

cylinders
iv) Auxiliary Operations

8.2.1
Receipt of LPG cylinders
Cylinders shall be received in capped

condition. Cylinder shall conform to
IS:3196.
8.2.2 Filling of LPG cylinders
(a)
Pre-filling operation : Cylinder

before filling shall be checked for
following :
- Visually inspected
IS:5845/ IS : 13258
as
per
Ò' Ring (joint packing) is

present and there
is
no
apparent damage to valve.
Tare weight is legible.
Post Filling Operation - Cylinder

shall be counter weighed with check
scale for accuracy of weight.
Variation of net weight. Variation of
net weight shall not exceed
permissible limits. All under-filled/
over-filled cylinders should be
corrected on correction scale.
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 removal machines
is used shall be checked for integrity
of the system with regard to proper
sealing. The machine shall be further
checked for leak tightness, torque

settings before being put in use
every day. The maintenance shall be
carried
out
as
OEM
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 Aluminium seal. Seal shall
have identification mark of oil
company, preferably name of plant
and period of filling.
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, 1981.
Following
observed :
safe
practices
shall
be
a) Handling of LPG Cylinders - LPG

cylinders shall not be dropped, rolled
on body 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.
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.
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 metres after
every 5 such lots. After each length
of 25 cylinders, there must be a
passage of 2 metres. The cylinder
storage space shall be properly
marked/ painted on the flooring.
Typical stacking arrangement for
14.2 kg cylinder is given in Figure-I.
Empty and filled cylinders shall be
demarcated clearly.
Minimum distance of 15 metres from
cylinder loading area and minimum
distance of 10 metres from filling
point shall be observed for all filled
cylinders stack.
of air prior to be taken up for

refilling with LPG. Following safe
procedure shall be observed for
purging of LPG cylinders :
8.2.4 Auxiliary Operations

a) Cylinder requiring valve removal
and valve fixing
-
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
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 degree C.
c)
Degassing of Cylinders :
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
valves. Teflon tape/ paste of suitable
valve
joining
material
are
recommended as jointing material.
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
MERCATAN 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.
b) Purging of cylinders
(ii) Treatment of Leaks and Spills
-
New cylinders and cylinders

degassed for repairs shall be purged
Leaks and spills of mercaptan can be

treated with commercially available
masking agents (e.g.Aldor and
Neutroleum Alpha etc.) to make
them odourless. 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.
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.
2. Electrical maintenance / inspection,

provisions of OISD-STD-137 shall
be adhered to.
9.5
INSPECTION
&
MAINTENANCE OF VARIOUS
FACILITIES
IN
LPG
INSTALLATIONS :
9.2 MAINTENANCE SCHEDULES :

9.5.1 STATIC EQUIPMENT :
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
equipments 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 system is under
pressure shall not be carried out without
a proper work permit and approved
procedure.
1. All Maintenance/ Inspection jobs
shall be carried out in line with OISD
Standard ; OISD-STD-105 on "Work
Permit System".
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
Fluoroscent 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 build up of grooves
so formed is essential wherever
depths of groove is more than
corrosion allowance.
b)
SHUT-OFF
VALVES,
CONTROL VALVES, NONRETURN 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 :
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.
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 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
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
thickness
externally.
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.
Inspection 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 bends 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
(i)
(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
taken
The details of thickness survey

shall be maintained on an
isometric sketch.
(iii)
Comprehensive inspection of
LPG pipelines shall be carried
out once in 6 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) Hydrotest
(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-to-soil voltage or pipeto-water voltage shall be
monitored once a month.
(vi)
All underground lines having

only wrapping and coating shall
be inspected once in three years
using Pearson Survey for
locating coating damage, if any.
Additionally, all these lines shall
be visually inspected at random
once in ten years by digging at a
PIPELINES
Inspection data as well as
thickness
data
of
newly
constructed pipelines shall be
collected at the earliest and with
in
two
years
of
their
commissioning to function as
base for establishment of
corrosion rates.
readings
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 ; OISDSTD-130 on "Inspection of Pipes and
Valves and Fittings" shall be followed.
9.5.4
HOSE
AND
CONNECTION :
FLEXIBLE
LPG hoses shall be inspected & tested at

maximum interval of 4 months as
detailed in OISD Standard ;. OISD-STD135 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%.
a) Gags, blinds do not exist.

b) Upstream and down stream 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
OISD Standard ;
OISD-STD-132 on "Inspection of
Pressure Relieving Devices" shall be
followed.
9.5.5 STRAINERS AND FILTERS :

Strainers & filters shall be inspected and
cleaned as per following frequency,
unless sluggish operation warrants
earlier inspection :
9.5.6 ROTARY EQUIPMENT :
TYPE / LOCATION FREQUENCY
a)
COMPRESSORS :
OISD
Standard No.
OISD-120 on
"Inspection of Compressors" shall
be followed. In addition, periodic
maintenance checks, as detailed in
Annexure-I to be followed.
b)
PUMPS : OISD Standard No.

OISD-110 on "Inspection of
Pumps" shall be followed.
In
addition, periodic checks as detailed
in Annexure-II to be followed.
c)
DIESEL ENGINES: OISD

Standard No. OISD-123 on
"Inspection and Maintenance of
Air filters
Strainers on evacuation
line
Pump Suction
Up stream of filling
carousel
up stream of PD-Meter
Weekly
Weekly
Quarterly
Quarterly
Quarterly
e) SAFETY RELIEF VALVES

Safety Relief valves shall be tested once
in a year. Further an on stream visual
inspection should be carried out at least
once in every 6 months to check the
following:
Rotating Equipment
shall be followed.
components
Pressure gauges shall be checked

daily for its proper functioning and
shall be calibrated once in 6 months.
9.5.7 FILLING EQUIPMENT

d) FLOW MEASURING DEVICES
It shall be ensured that the
equipment is in good working
condition to ensure quality output
and
also
safe
operation.
Inspection checks are given at
Annexure 9-III for the following
equipment:
a)
b)
c)
d)
e)
f)
g)
Ejection
Check Weigh Scales

Chain/ Roller conveyor
Drive Units for Conveyors
CVT-leak detector
Cylinder Test Bath
General
9.5.8 INSTRUMENTATION
a) TEMPERATURE INDICATING
DEVICES
Temperature indicating devices shall
be checked daily for its proper
functioning and shall be calibrated
once in 6 months.
b) LEVEL GUAGING 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
9.5.9 FIRE FIGHTING EQUIPMENT

Fire fighting equipment shall be
inspected and tested as per. OISDSTD-142 - "Inspection of Fire
Fighting Equipment".
CAROUSEL
i) Drive units
ii) Centre column
iii) Running Rail
iv) Introduction and
devices
v) Filling machines
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 ELECTRICAL EQUIPMENT

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
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
OISD-STD-137.
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 the
characteristic on which
approval has been granted
their
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
and 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 1 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.
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.
ANNEXURE 9-I
MAINTENANCE SCHEDULE
COMPRESSORS
-------------------------------------------------------------------------------------------------------------------------------Sr. Equipment Checks
PERIODICITY
-------------------------------------------------------------------------------------------------------------------------------Daily Weekly Monthly Qrtly
(1)
(2)
(3)
(4)
(5)
(6)
-------------------------------------------------------------------------------------------------------------------------------1. Check Lub. 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

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

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

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

a) Crank case
b) Pump chamber and fill fresh oil.
10.
Flush jacket water cooling system.
11.
Check alignment of compressor & 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.

*
--------------------------------------------------------------------------------------------------------------------------------

PERIODICITY
(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 Trips
21.
Pressure & Temperature Gauges
22.
Control Panel
*
*
23. Complete over-haul.

*
--------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-II
CENTRIFUGAL PUMP
PERIODICITY
Annually
Yrly
(1)
(2)
(3)
(4)
(5)
(6)
(7)
-------------------------------------------------------------------------------------------------------------------------------1.
Check lub 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.
Change lube oil every 800 running

hours.
6.
Check coupling and coupling bolts

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

a) Product pumps
b) Other pumps
9.
Check alignment of pump and motor.
10.
Overhaul.
11.
Greasing of Bearings.
12.
High Level Alarm
13.
Relief Valve
*
*
*
*
*
*
*
--------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-III
FILLING EQUIPMENTS
PERIODICITY
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.
Grease guide rollers.
5.
Check & adjust drive belt.
6.
Unscrew magnetic plug and clean.
7.
Change hydraulic oil &clean filter.
8.
Clean hydraulic oil tank.
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.
Grease bearing.
(C) RUNNING RAIL :

1.
Clean & apply graphite.
2.
Lubricate rail wheels.
3.
Check rail levels.
*
*
*
-------------------------------------------------------------------------------------------------------------------------------(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.
2.
Thoroughly cleaning by using

dry air.
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.
*
--------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------(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.
Clean suspension system bearings

knife edges etc.
7.
Check for wear & tear of knife edges

& replace if necessary.
8.
Complete overhauling.
II.
CHAIN CONVEYOR :
1.
Top up soap solution trays.
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.
*
*
-------------------------------------------------------------------------------------------------------------------------------(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.
CVT/ DCVT LEAK DETECTOR :
1.
Check for proper functioning.
2.
Top up kerosene
chamber.
3.
Check leakage rate thru verifier.
4.
Dismantle/ clean the interiors &

apply silicon grease to "O" ring.
Every shift
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 equipments.
5.
Check all fasteners and tighten.
6.
Paint tank walls from inside.
*
--------------------------------------------------------------------------------------------------------------------------------
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.
KNOW YOUR ENGINE'S CONDITION.
9.
CORRECT TROUBLES WHILE THEY ARE SIMPLE.
10.
SCHEDULE AND CONTROL YOUR MAINTENANCE.
DIESEL ENGINES
"A" CHECK EVERY DAY
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
CHECK PREVIOUS DAY'S

ENGINE LOG BOOK.
1A CORRECT AS REQUIRED
2.
DRAIN WATER AND SEDIMENT

FROM FUEL TANK AND FUEL
FILTER THROUGH DRAIN COCK.
2A
3.
CHECK ENGINE OIL LEVEL

AND TOP UP IF NECESSARY
3A MUST BE SLIGHTLY LESS THAN

OR 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 TREATED WATER
(CHROMATE CONCENTRATION
3500 PPM).
5A RADIATOR CAP MUST BE FIRMLY

TIGHTENED BACK INTO THE
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 AND CHANGE OIL, IF
REQUIRED (IF OIL BATH
TYPE) CLEAN DUST PAN AND
PRECLEANER OF DAY TYPE
AIR CLEANER.
6A
7.
CHECK AIR LINE CONNECTIONS

FOR LEAKS.
7A CORRECT AS REQUIRED
8.
REMOVE AND CLEAN AIR COMPRESSOR BREATHER, IF

EQUIPPED.
9.
DRAIN AIR RECEIVER TANK

AT THE BEGINNING OF EACH
SHIFT AND THEN CLOSE THE
DRAIN COCK.
BEFORE STARTING ENGINE.
USE CLEAN ENGINE OIL.
8A FILL WITH CLEAN OIL, UPTO

MARK.
DIESEL ENGINES
"A" CHECK EVERY DAY
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------10. CLEAN CRANKCASE BREATHER
10A
DISCARD PAPER TYPE ELEMENT,

IF CLOGGED.
11. CHECK OIL LEVEL IN

HYDRAULIC GOVERNOR,IF
PROVIDED.
11A
CHECK FOR LEAKS, USE SPECIFIED ENGINE OIL FOR TOPPING

UP.
12. START THE ENGINE AND NOTE

THE OIL PRESSURE BOTH AT
IDLING AND MAXIMUM SPEED.
12A
13.
RECORD OIL PRESSURE
13A
14. FILL FUEL TANK AT THE

END OF THE SHIFT.
14A
IF THERE IS A CHANGE IN OIL

PRESSURE FROM THAT RECORDED
IN THE LONG 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 PRESSURE
CALL YOUR SERVICE
REPRESENTATIVE IF NECESSARY.
REFER O&M MANUAL FOR LUB.
OIL PRESSURE LIMITS.
USE CLEAN FUEL AND A STRAINER. ALSO CLEAN THE CAP AND
SURROUNDING AREA BEFORE
OPENING THE FILLER CAP.
--------------------------------------------------------------------------------------------------------------------------
"B" CHECK EVERY 250 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
REPEAT ALL MAINTENANCE

STEPS OF CHECK "A" 1 TO 14.
1B
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.)
DIESEL ENGINES
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------3.
FIT NEW LUBRICATING OIL

FULL FLOW FILTER ELEMENT
3B INSPECT THE CHANGED FILTER

ELEMENTS AND CHECK FOR METAL
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, CHECK GASKETS
AND "O" RINGS FOR DAMAGE
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 SOLUTION OF
WARM WATER (120-140 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 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

TRAY SCREEN
5B
6.
CHANGE LUBRICATING OIL

BY-PASS FILTER ELEMENT
AND GASKET, IF PROVIDED.
6B RECORD OIL PRESSURE.
7.
CLEAN FLOAT TANK AND/OR

MAIN FUEL TANK BREATHER.
7B
8.
CHECK COOLANT PH VALUECONCENTRATION OF DCA/

CHROMATE CONCENTRATION
(3500 PPM).
8B CHANGE CORROSION PRESISTER

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

IN ASSEMBLY CORROSION
REGISTER CHANGE WATER
9B CHECK MAGNESIUM PLATE FOR

PITTING OR BEING EATEN AWAY
CHANGE IF MORE THAN 50% OF
DIESEL ENGINES

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------FILTER ELEMENT.
OF AREA IS LOST. USE DCA

SERVICE ELEMENT OR CHROMATE
ELEMENT OR CHROMATE ELEMENT
BAGS (AR95679) IF CONCENTRATION IS LOW.
10. CHANGE FUEL FILTER ELE

MENT WASHER AND "O" RING
ON MOUNTING BOLT.
10B
CLEAN SHELL FUEL FILTER
CHANGE ELEMENT WHEN RESTRICTION EXCEEDS VACUUM 200MM
OR MERCURY.
11. CHECK OIL IN ANEROID

CONTROL, IF REQUIRED.
11B
USE SAME OIL AS USED IN OIL

PAN.
12. CHECK & ADJUST BELTS.NEW

BELTS WILL STRETCH WITHIN
ONE HOUR OR USE THEY MUST
BE READJUSTED.
12B
TIGHTEN BELT TENSION REFER

MAINTENANCE MANUAL.
13B
CORRECT AS REQUIRED.
13. TIGHTEN FOUNCTION BOLTS AND

FLEXIBLE COUPLING BOLTS OF
ENGINE AND ALTERNATOR.
14. CHECK ALL AIR CLEANER CONNECTIONS FOR CRACKS.
CHAFING ETC. TIGHTEN ALL
AIR INTAKE CONNECTIONS.
15. CHECK FAN HUB AND DRIVE.
14B USE SPECIAL TOOL FOR

TIGHTENING THE FAN HUB NUT.
16. CLEAN/CHANGE AIR COMPRESSOR BREATHER ELEMENT.
15B
17. CHECK THROTTLE LINKAGE.
CHANGE ELEMENT FOR NATURALLY

ASPIRATED ENGINE CLEAN SCREEN
FOR TURBO ENGINE.
DIESEL ENGINES
"C" CHECK EVERY 1500 HOURS
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
REPEAT ALL MAINTENANCE

STEPS 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

BEARING
3C
CHECK MOUNTING BOLTS AND

END PLAY.
4.
CHECK IMPLELLER WATER PUMP

FOR PLAY.
4C
CORRECT IF NECESSARY.
5.
CHECK FOR TURBOCHARGER

OIL LEAKS.
5C
CORRECT AS REQUIRED.
6.
TIGHTEN TURBOCHARGER
MOUNTING NUTS.
6C
TIGHTEN TO THE SPECIFIED TORQUE

DO NOT TIGHTEN WHEN ENGINE IS
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
FITTED.
8.
CLEAN OIL BATH AIR CLEANER
8C
REMOVE COMPLETE ASSEMBLY AND

CLEAN INCLUSIVE OF FIXED
SCREENS.
9.
CLEAN AND TIGHTEN ALL ELECTRICAL CONNECTIONS.
10.
CHECK GENERATOR BRUSHES AND

COMMUTATOR.
11.
CLEAN ENTIRE ENGINE
9C
10C
REPLACE AND CLEAN AS REQUIRED.
11C
HIGH PRESSURE AND SOAP WATER

MIXTURE PREFERRED AFTER
SPRAYING ENGINE WITH CLEANSER
DIESEL ENGINES
"C" CHECK EVERY 1500 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------TAKING CARE OF PROTECTING

ELECTRICAL SYSTEM.
12. TIGHTEN ALL MOUNTING BOLTS
AND NUTS.
12C TIGHTEN AS REQUIRED. OVER TIGHTENNING MAY RESULT IN DISTORTION OR

DAMAGE.
13. CLEAN ANEROID AIR BREATHER.
13C REPLACE BREATHER IF NECESSARY.
14. CHECK SEA WATER PUMP

(MARINE APPLICATION ONLY)
14C CHECK FOR LEAKS/ OPERATION/

PERFORMANCE.
15. CHECK HEAT EXCHANGER ELEMENT 15C CLEAN ELEMENT TUBES/CHANGE

ZINC PLUG (MARINE APPLICATION)
PLUGS.
16. CHECK EXHAUST AND INLET MANI- 16C
FOLD NUTS AND CAPSCREWS.
17. CHECK ENGINE BLOWER.
17C
READINGS IN EXCESS OF RECOMMENDED

LIMITS. CORRECTIVE ACTION MUST BE
TAKEN. THOROUGH ANALYSIS WITH THE
HELP OF TROUBLE SHOOTING CHART.
18. CLEAN RADIATOR
18C
BLOW AIR THROUGH THE RADIATOR CORE

IN OPPOSITE DIRECTION TO THE NORMAL
FLOW OF AIR, IF WORKING UNDER
DUSTRY/ DIRTY CONDITIONS.
(REVERSE FLUSHING OPERATION)
19. CHECK AIR COMPRESSOR
19C
CHECK SHAFT END CLEARANCE.
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

OIL/ ANEROID OIL.
22C USE ENGINE LUBRICATING OIL.
23. CHECK VIBRATION DAMPER.
23C
CHECK WOBBLE AND ECCENTRICITY

ALIGNMENT MARKS ON RUBBER TYPE.
DISCARD DAMPER IF MISALIGNMENT
IF MORE THAN 1/16 IN.
DIESEL ENGINES
"D" CHECK EVERY 4500 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
----------------------------------------------------------------------------------------------------------------------------
1.
REPEAT ALL MAINTENANCE STEPS

OF CHECKS "A", "B" & "C".
1D
2.
CHECK EXHAUST AND INLET

2D
MANIFOLD NUTS AND CAPSCREWS.
3.
TIGHTEN ALL MOUNTING BOLTS

AND NUTS.
3D
4.
CLEAN TURBOCHARGER DIFFUSER

AND IMPELLER AND CHECK END
FLOAT.
4D
5.
CHECK TURBOCHARGER REARING

CLEARANCES
5D ONLY END FLOT ON SEMI FLOATING

BEARINGS IF IN EXCESS OF LIMITS,
REPLACE.
6.
CHECK CRANKSHAFT END FLOAT
6D IF IN EXCESS OF RECOMMENDED LIMITS.

CORRECTIVE ACTION IS INDICATED.
7.
CLEAN INJECTOR INLET SCREENS.
8.
CLEAN AND CALIBRATE ALL

INJECTORS.
MUST BE DONE ONLY IF A PERFORMANCE

DETERIORATION IS EVIDENT.
SOME OF THE INDICATIONS FOR
PERFORMANCE DETERIORATION ARE:
9.
CHECK FUEL PUMP CALIBRATION
10.
REPLACE ANEROID BELLOWS AND

CALIBRATE ANEROID.
1
2
3
4
11.
REPLACE FUEL PUMP FILTER

SCREEN AND MAGNET.
12.
STEAM CLEAN ENGINE
BLACK SMOKE.
CHANGE IN FUEL MANIFOLD PRESSURE
LOSS OF POWER
MALFUNCTION OF ANEROID.
12D IF STEAM IS NOT AVAILABLE, THEN

USE CLEAN SOAP WATER SOLUTION
AS OUTLINED IN "C" CHECK ITEM-11C.
È' CHECK EVERY 8000 HOURS
1.
REPEAT ALL MAINTENANCE STEPS OF CHECK À', `B', `C' & `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 LUB. OIL PRESSURE (5) UNUSUAL NOISE & VIBRATIONS.
THE È' MAINTENANCE CHECK IS A METHODOLOGY FOR INSPECTION OF WEAR OR
ASSEMBLY DETRIORATION OF PARTS AND ASSEMBLIES, AND SHOULD BE
RESORTED TO ONLY WHEN TROUBLE SHOOTING IN ADDITION TO PERFORMING
A,B,C AND D MAINTENANCE CHECKS, WHICH MAY 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 25000 HOURS BEFORE THAT THE ENGINE MUST BE
DISMANTLED FOR INSPECTION PRELUDE TO A MAJOR OVERHAUL. THE TIME
INTERNAL OF 8000 HOURS IS A PERIOD AT WHICH THE ENGINE MAY DEVELOP
SYMPTOMS ASCRIBED ABOVE 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 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 INFORMATIONIS
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).
10.0 STATUTORY TESTING OF LPG CYLINDERS
10.0
STATUTORY TESTING OF
LPG CYLINDERS
All cylinders used for filling LPG
are required to be tested periodically
to ensure fitness of the cylinders for
further service. First re-testing is
required to be done after 7 years and
subsequent re-testing after every 5
years interval. Such tests are to be
conducted by the CCE approved
parties only.
10.1 TESTING PROCEDURE

10.1.1
DEGASSING
CYLINDERS
OF
LPG
cleaning by immersing the cylinder

in the caustic soda bath and soap
water and the same is then rinsed
with water.
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.
10.1.4 VISUAL INSPECTION :
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)
b)
After depressurising the cylinder

and emptying out the water, the
same is kept in inverted position and
stroked gently with a non-sparking
hammer such as wooden mallet to
remove any dust, rust or any loose
remnants in the cylinders.
The depressurized cylinder bung is
plugged and is taken up for surface
a) The detailed visual inspection of the

cylinder body shall be carried out as
per IS:5845/ IS : 13258.
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
examined by means of infra low
voltage FLP lamp. The internal
examination shall be carried out as
per IS:5845 / IS : 13258.
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 LPG cylinders shall be taken
up for hydrostatic test at an interval
of 7 years for first testing and
subsequent testing after every 5 years
in accordance with IS:8868. 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
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.
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 7
kg/sq.cm. for a minimum of 60
seconds as per IS:3196. This is
basically to check the tightness of the
valve cylinder joints.
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 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 :
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
a) To enhance the life of the cylinder

and to project a better image to the
customers, 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
shade 575). 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
stencilled with paint on the shoulder
and as well as on inside of one of the
vertical stay.
c) Gross weight punched/ stencilled on
the cylinder should be changed in
case of change of tare weight.
-
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.
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
MARKS :
PUNCHING
OF
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 stencilled 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 stencilled 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.
Sequence of operations for
statutory pressure testing of LPG
Cylinders is given at Annexure
10-I.
10.1.11 COLOUR
CYLINDER
CODING
OF
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 have been
selected for easy identification of
cylinders and the same shall be repeated
after every five/ seven years cycle.
Colour coding is done on the inside of
one of the Stay Plates and the same is
given below:
COLOUR CODING SCHEME

-------------------------------------------------------------------------------------------------------------------------------Cylinder
Cylinder
Next
Background
Shade as
Lettering
Manufactured retested/hot
Retesting
colour
IS:5
colour
in the
repaired
Date
year
in the year
------------------------------------------------------------------------------------------------------------------------------1997
1999
2004
Dove grey
694
Black
1998
2000
2005
Aircraft Blue
108
White
1999
2001
2006
Salmon Pink
443
Black
2000
2002
2007
Black
521
White
2001
2003
2008
Yellow
355
Black
2002
2004
2009
White
127
Black
2003
2005
2010
Sea Green
217
Black
--------------------------------------------------------------------------------------------------------------------------------
10.1.12
CERTIFICATION :
k) External
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 :
l) Whether passed/ rejected

10.1.13
HYDROSTATIC TEST/
HYDROSTATIC STRETCH
TEST :
a) Running serial number

- Whether passed/ rejected
b) Date of testing
Condition of bung threads (internal)
c) Serial number of cylinder & name of

manufacturer
Whether satisfactory/ rejected

Pneumatic Test
d) Month and year of test
Whether passed/ rejected
e) Weight of cylinder
Quarter/ year of retest punched on

the cylinder
Stencilling/ colour coding for age

profile
Relevant test certificate number
f) Punched on cylinder
g) Observed weight
h) Whether satisfactory/ rejected

i) Visual defects
j) Internal
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
ANNEXURE - 10- I
SEQUENCE OF OPERATIONS FOR STATUTORY
PRESSURE TESTING OF LPG CYLINDERS
1.
Receipt of Cylinders
2.
Depressurising
3.
Recording details
(like Sr.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.
Internal cleaning and checking
12.
Primer coating
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 cylinders,

stencilling new tare weight, new 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 despatches.
CHAPTER 11
FIRE PROTECTION FACILITIES

The main components of the fire
water system are :
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 :
Fire Water Storage
Fire Water Pumps
Fire
Hydrant/
Monitor
distribution piping network.
Water Sprinkler/ Deluge system.
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 operating
valves on LPG lines Bulk Lorry and
Tank Wagon Gantries shall be fully
covered by medium velocity water
spray system.
11.4
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.
iii) Fire Protection Facilities shall have

fire fighting 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 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.
11.3 FIRE WATER SYSTEM
FLOW RATE DESIGN
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
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 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 optimise
the fire water requirement .

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. The spray system shall
cover tank wagons surface on either side
of tank wagon gantry atleast in two tiers
as well as the associated LPG pipelines
in the gantry.
c) LPG Pump / Compressor House
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.

density of Minimum 20.4 LPM/Sq.M
shall be provided.
The entire pump /compressor house
shall be considered as single risk area :
alternatively it can be divided into
suitable number of zones with minimum
10 meter width.
d) Tank Lorry Gantry
In case of Tank Lorry Gantry, automatic
detection of heat for automatic actuation
of MV sprinkler system having remote/
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 shall be atleast 3 tiers of
MV sprinkler system and heat detectors
uniformly cool the top , middle and the
bottom of the tank lorry.
e)
Tank Wagon Gantry
11.5
FIRE
WATER
DESIGN
SYSTEM
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.
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 masonary. 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 type fire water pumps

shall be installed to meet the
designed fire water flow rate and
head. These pumps shall have a
flooded suction,
alternatively
suitable arrangement for auto
priming shall be provided.
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.
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. Each engine shall
have an independent fuel tank of
suitable size for 6 Hrs. continuous
running.
In refineries / gas processing plants,
where reliable source of electric
power is available electrical driven
centrifugal pumps can be used upto a
maximum of 50 % of total pumping
capacity. Power supply to the pump
motors should be from two separate
feeders.
iv) At least one standby fire water pump
shall be provided upto 2 nos of main
pumps For main pumps 3 and more,
minimum two standby pumps of the
same capacity as the main pumps
shall be provided.
iv)
v)
Fire water pumps shall be

used exclusively for Fire
protection and prevention
purpose only.
Suction and discharge valves
of fire water pump shall be
kept open all the time.
The fire water pumps shall be provided

with automatic starting facilities which
shall function with specified logic even

if initial pump does not start or having
started , fails to build up the required
pressure in the fire water ring main
system within 20 seconds.
iii) For Fire water ring main laid

underground the following shall be
ensured :
a)
11.8
FIRE HYDRANT NETWORK
i) Fire hydrant ring main shall be laid

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 analysed 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 vehicle movement.
c) Places where above ground piping is
likely to get damaged mechanically,
particularly in 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.
The Ring main shall have at least

one meter earth cushion in open
ground, 1.2 meters 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.
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 a
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.
vii) 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.
viii) Double headed hydrants with two

separate landing valves on 3"/ 4"
standpost shall be used. All hydrant
outlets shall be 1.2 mtrs. above
ground level.
ix) 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.
x) Hydrants and monitors shall not be
installed inside the dyked areas.
xi) 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.
xii) 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
deluge valves shall be
located out side the kerb wall at a
safe distance in case of LPG spheres/
bullets and 15 meters away from the
limits of LPG cylinder sheds. A fire
wall shall be provided for the
protection of deluge valve and for
operating personnel.
xiv) 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.
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 (CS)

per IS:3589/IS:1239
ii) Isolation Valves Carbon Steel
iii) Deluge valve
Carbon Steel
iv) Hydrant
Standpost
CS
Outlet valves Gunmetal/ Aluminium
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 masonary chamber.
vii) The above ground fire water main
and the fire hydrant standpost 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
The medium velocity spray system
shall be provided in all critical areas
like LPG Storage Area, Sheds, LPG
Pump/Compressor House, Tank
truck/ wagon loading / unloading
areas, valve manifolds etc.
i) 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
nozzles shall at least meet.
Where projections (manhole flanges,
pipe flanges, staircase, 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.
Horizontal dry piping down stream
of the block valve and after deluge
valve shall be 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. In LPG storage area, such
detectors shall be provided
encircling each vessel, equispaced with a maximum spacing
of 1 meter at an elevation of
about 1.5 to 2.0 meter from
bottom of vessel. Also minimum
2 nos. detectors shall be provided
at the top of the vessel and atleast
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.
b. Detectors shall be placed at
critical locations in LPG sheds
(filling, cylinder storage, testing,
evacuation,
etc.)
loading/
unloading
gantries,
LPG
compressor
house,
piping
manifold, repair sheds etc. Upon
actuation there shall be alarm in
control panel, LPG pumps and
compressors would trip, ROVs
(wherever provided) on LPG
supply and return lines would trip
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 air through one
Quartzoid Bulb will depressurise the
system to actuate the deluge valves.
iii) In case of Electro pneumatic (E.P)
heat detectors, it shall actuate the
deluge valve in any of the following
conditions :
a) Rate of rise
of temp.
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.
The actuation of detectors shall
initiate the following :
i) Opening of deluge valve of the
affected zone as well as adjacent
zones.
ii)
iii)
Closure of
all Remote
Operated Valves in affected
facility.
v)
Tripping of main power

supply barring the emergency
power
vi)
The water spray from all

nozzles within 30 seconds.
vii) The fire water pump(s) shall start

based on their set pressure to
supplement/ to maintain the fire
water pressure in the ring main.
- 10 oC/min
b) At 79 deg. C (max.)
iv)
iv)
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.
Fire siren of l km range
Additionally 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, air release valves etc
shall also be provided in the field at safe
location for enabling manual actuation
by an operator. In case, the zoning
concept is used for MV sprinkler system,
the operations of sprinklers in various
zones shall be clearly earmarked on 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.
11.12 FIRST AID FIRE FIGHTING
EQUIPMENT
11.12.1
PORTABLE
EXTINGUISHERS
FIRE
i) Portable fire extinguishers shall be

located at convenient locations and
shall at all times be readily
accessible and clearly visible.
Other Pump Houses 2 Nos. 10 kg

DCP
extinguisher
Office/Canteen/
Stores
2 X 10 kg DCP
extinguishers in
each building
MCC/
DG Room/
HT Room
At 2 x. 4.5 kg
CO2 extinguisher
in each room or
for floor Area of
about 100 Sq.m.&
4 sand buckets &
a stand shall be
provided in MCC/
DG Room.
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
Extinguisher
Portable Fire
LPG Storage
Vessel(Each)
2 Nos. 10
kg DCP
extinguisher.
LPG cylinder
sheds
2 Nos. 10 kg DCP
extinguisher per
200 Sq.M.Area.
LPG Pump
houses
2 Nos.10 kg. DCP

extinguisher per
50 Sq.m. Area.
Tank Truck loading/ 1 No. 10 kg.

loading gantries DCP Extinguisher
in each bay.
Tank Wagon loading/ 1 No. 10kg
unloading gantries DCP Extinguisher
for every 15/20
meters of gantry.
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/
FIRE
FIGHTING
EQUIPMENT
MOBILE
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
AND
HOSES,
NOZZLES
ACCESSOREIS
i) Reinforced rubber lined hoses

(63mm) conforming to IS : 636 (type
A or B) shall be provided.
8. Low tem. protective Min. 2 sets

clothing for LPG
emergency.
ii)
10. Fire proximity suit
Min. 1 No.
11. Resuscitator
Min. 2 No.
12. Red/Green Flags
As reqd
iii)
The hoses shall be of 15 Meters

standard length and shall be provided
with Gun metal/ Aluminium alloy
male & female couplings of
instantaneous pattern.
Minimum of two or 25% spare
Hoses shall be stored in the LPG
plant.
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 Tripple 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.)
13. Self contained

Min. 1 No.
breathing apparatus
with one spare cyl.
(Cap. 30 minutes)
14. Water jel blankets
Min. 2 nos.
15. Portable Gas detectors min. 2.

/ Explosimeter
The above are guidelines and
minimum requirements of each item
and can be 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
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 Min. 2 pairs
for electrical
(BIS approved)
purpose.
7. Low temperature
4 pairs
rubber hand gloves
for LPG emergency
as per OISD-GDN-115
i) Manual call points near to filling

shed, storage area, tank truck/ wagon
gantry, pump house, etc. shall be
provided and clearly marked in the
installation. Operation of these points
shall raise audio visual alarm in
control room.
ii) Electricity operated Fire Siren shall
be audible to the farthest distance in
the plant (1 K.M. from the periphery
of the plant).
iii) Manually operated fire sirens shall be
provided at strategic places.
iv) For fire condition the siren shall be

wailing sound for minimum `2
minutes and for all clear signal it
shall be straight run siren for 2
minutes.
v) For Disaster condition the wailing
sound given shall be repeated thrice
with a minimum 10 seconds gap.
11.13.2 COMMUNICATION
SYSTEM
i) Communication
system
like
telephone/ PA or paging or walkietalkie 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/ near by major Industries
shall be provided.
iv) Plant shall have a ` Mutual Aid'

arrangement with near by industries.
fire fighting measures like starting

pumps, organising people, opening
valves etc. This will also take care
automation failure wherever it
provided.
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 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 1 hr.
lines upto the fire safe ROVs
Supporting legs of all above
11.14
SPECIAL
PROTECTION
of
of
of
is
2 hr.
FIRE
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
Fire proofing is not required for diagonal

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 sandblasting
and
corrosion-protective
primers. Particular attention shall be
given to the top junction of the fireproofing 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 fire fighting 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.
ii) The ring main shall be inspected for

any visual leaks, detects, damage and
corrosion at least once in week and
records maintained thereof.
iii) All valves on the ring main/ hydrant/
monitor valves shall be checked for
leaks/ operation and lubricated once
in a month.
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.
11.15.1 FIRE WATER PUMPS

i) Every Pump shall be in test run for
atleast 10 minimum twice in a week
at the rated conditions.
ii) Once in a month each pump shall be
checked and tested and the shut-off
pressure observed and logged. Also
the pump performance shall be
ascertained.
iii) The Jockey pump operation shall be
checked periodically. Frequent start/
stop condition of Jockey pump
indicates that there are water leaks in
the system.
11.15.2
FIRE WATER RING
MAIN
i) The ring main shall be kept
pressurised at 7 kg/sq.cm.g with the
help of one or more jockey pumps.
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 fire
fighting shall be provided.
CHAPTER 12
GAS MONITORING SYSTEM
12.0 GENERAL
The best method of prevention of
explosion is to avoid basic build up
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 build up 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, TSVs relief
discharge in manifold area, filling/
evacuation hoses leakage.
12.1
i)
APPLICATION
The detectors for the gas monitoring
system shall be strategically located
in LPG Bottling Plant at all
facilities close to the potential
source of leakage.
ii) The detection control equipment

should be provided in the control
room for continuous monitoring
even during power failure.
12.2 DETECTORS
Amongst the various methods of
detection available, the following
proven systems for LPG can be
considered.
i)
ii)
12.3
Catalytic detectors
Infra-red detectors
CONTROL SYSTEMS
i) This is a critical equipment for

plants 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.
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.
12.4
ANNUNCIATION SYSTEMS
Appropriate annunciation system shall

be available to ensure that all the alarms
generated, both, audio and visual are
reported to the plant personnel, who are
authorized to take corrective action.
Depending on the manning practice of
the plant, the alarms both, audio and
visual can be repeated at additional
location to ensure corrective action is
taken.
12.5 LOCATION OF DETECTORS
i) The behaviour 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 down stream 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.
iv) In case of infra-red detectors, the
same shall be installed on the down
wind side ensuring the path is free
from obstructions. In case any
additional expansion/ construction if
undertaken, the detectors will have to
be pre-positioned.
v) The minimum detectors facilitieswise are as given below:
Storage vessels (above ground) 1
No. top and 1 No. near bottom ROV.
LPG pump house 1 No. in pump
house and 1 No. in manifold.
Filled cylinder shed - 2 No.
Valve change shed 1 No.
Empty-cum-filling shed 2 Nos.
near carousel, 1 No. near evacuation
unit tank, 1 No. weight correction
unit.
TLD one at each manifold and at

ends.
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 behaviour 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 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.
CHAPTER 13
EMERGENCY MANAGEMENT PLAN
13.0 GENERAL
13.1 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.
agencies, such as local administration,

Police authorities, Fire Brigade, hospital
authorities, home guards, neighbouring
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.
13.1.3 CHECK
FOR
LPG
LEAKAGE AT FOLLOWING
LOCATIONS
b) Careful selection and correct

use of equipment.
a)
Through water drain valve while

draining.
c) Observance of safety
security regulations.
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 sviwel joints of
body arms.
g)
Leakage from the filling guns.
h)
Escape of liquid/ vapour LPG

during maintenance/ repairs.
and
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
alertness.
supervision
and
13.1.2 EMERGENCY PLANS :

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 organisation
chart/ posters not only for fire-fighting
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 outside
13.1.4 SOME OF THE COMMON

CAUSES OF FIRE :
(a)
ELECTRICAL :
i) Short circuiting due to loose
wiring including that of
automobile moving in the area.
ii) 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 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.)
iii) 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.
the
v)
Excessive release of vapour

beyond safe limit and fire due to
outside source of ignition.
vi)
Lighting
vii)
Smoking.
13.2
ACTION
EMERGENCY
DURING
13.2.1 Immediate action is the most

important factor in emergency
control because the first 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

Organisation Plan or Disaster
Management Plan, based on
gravity of the emergency.
c)
Stop all operations and ensure

closure of all ROVs and isolation
valves.
v)
Cinders
from
locomotives.
steam
(c)
OTHERS
d)
All out effort should be made to

contain the spread of leakage/ fire.
i)
Landing of crackers (flying type )

in hazardous areas.
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
ii)
Chiselling/ hammering.
iii)
Spark from studed shoes, with

steel button by friction against
ground/ metal.
iv)
Lighted agarbatti in a truck.
area, in an orderly manner at prenominated route.
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.
h)
Electrical system except for control

supplies, utilities, lighting and fire
fighting system, should be isolated.
i)
If the feed to the fire cannot be cut

off, the fire must be controlled and
not extinguished.
e)
Fire fighters should

towards a fire down
possible.
j)
Start water spray system at areas

involved in or exposed to fire risks.
f)
k)
In case of leakage of LPG without

fire and inability to stop the flow,
take all precautions to avoid source
of ignition.
Cylinder fire should be approached

using proper barricades/ protection
to avoid direct hit from flying
cylinders.
g)
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.
The person attempting the closure
should be continuously protected
by means of water spraying
(through fog nozzles), fire entry
suit, water jel 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 pressurisation.
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.
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 neighbouring 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)
Fire Fighting 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.
advance
wind if
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.
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 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)
Fire fighting procedure - Fire

fighting procedures would vary
depending upon various factors

such as nature, sources, size,
location, etc. of fire. Basic fire
fighting techniques have been
explained earlier in section 13.2.2.
However, for the purpose of
guidelines, fire fighting techniques
for few common cases are as
follows :
(i) Cylinder Fire : If a filled cylinder
is involved in fire, internal pressure
may start rising and if not relieved
the built up pressure could rise
above 70 kgf/cm2g 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. Bus
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)
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 water
coverage, through fixed monitors
or other equipment. Cooling the
Water pressure in LPG vessels.
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)
If LPG vessel's SRVs have started

blowing vapour, take no further
action (apart from cooling) unless
vessel pressure continues to rise.
Leakage of LPG burning at the

outlet of a cylinder valve:
Extinguish the fire by means of a
portable fire extinguisher, or
smoothening with a thick nonsynthetic cloth (preferably wet) or
sand/ earth etc.
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.
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)
13.2.5 Fire Fighting Organisation 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 occurs, all

personnel
should
use
the
equipment provided and to carry
out their allotted tasks as detailed
in the fire fighting organisation
plan.
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.
(iii) All personnel should be conversant

with fire control equipment and
also its location.
(iv) LPG plant personnel should know
the position and method of
operation of all Remove Operation

valves (ROVs) in the plant.
(v)
Plant personnel should be familiar

with the standard recognition
markings of fire 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 Organisation Plan

together with layout of fire fighting
and safety devices shall be
displayed at prominent places and
explained to all personnel. It shall
include the following functions,
expanded to suit the location
facilities/ requirement:(i)
(ix) Preventing all sources of ignition in

case of LPG leakage.
(x)
(xi)
Evacuation and mustering of

personnel.
(xii)
Establishing an emergency firecontrol centre.
(xiii) Traffic control.

(xiv)
Shutting off the LPG supply to any

leakage point/ fire.
(iii)
Summoning the fire brigade/

police.
Fire control, with first aid, fire
fighting 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.
(xvii)
(viii) Closing down all operations in the

plant including closure of valves
and stopping of pumps.
Display of fire brigade,

ambulance,
Police
telephone
numbers etc.
(xviii) All clear signal by competent

person.
Liaison with local fire brigade :
Close co-operation with the local fire

authorities is essential and shall take the
following form :
(i)
(vii) Cooling of vessels/ cylinders and

other equipment/ facilities.
Policing of affected areas.
(xvi) Any other specialised duties.
(c)
(iv)
Stations and duties of all

personnel.
(xv)
Sounding the emergency (fire)

alarm.
(ii)
Evacuation of vehicles.
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) Fire fighting equipment at the plant

shall be compatible with the fire
brigade equipment, otherwise
adapters shall be kept ready for
hoses, hydrants etc.
(iii) The fire brigade shall be aware of

the plant's fire fighting organisation
plan and the views held at the plan
regarding the most effective LPG
fire control methods.
f)
Protective clothing, breathing

apparatus and any other specialised
safety equipment available shall be
tried out during drills to train all
concerned in their application.
(iv) 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.
stocks of filled cylinders at that
particular point of time.
g)
The local fire brigade should be

encouraged to participate in fire
drills periodically.
h)
Any shortcoming, noticed during

the drill shall be rectified.
13.2.6 Disaster Management Plan :

(d)
Fire Drills & Training :

ON- SITE
a)
b)
c)
Drills for all Plant personnel,

making use of the "Fire fighting
Organisation Plan" and practicing
the specialised techniques required
for fighting LPG fires or
dispensing/ diluting LPG vapour
clouds shall be held minimum once
in a month.
The drills should cover various
types of incidents, e.g. major
spillage, LPG bulk lorry fire,
cylinder fire etc.
Extinguishers due for recharging/
due for hydrotesting shall be
discharged during drills and
replenished subsequently 50%
(Min.) stock of refills as
replenishment for FEs should be
maintained.
d)
The fire pump should be run,

sprinkler
system
activated,
emergency systems tested, water
hoses run out and spray/ set
techniques practiced during drills.
e)
Fire alarms shall be sounded/

tested
(neighbouring
plants/
factories and the fire brigade shall
be warned in advance of this test).
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
(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
organisation,
preliminary meeting shall be conducted
with the representatives from local fire
services, police authorities, voluntary
organisations like ambulance service/
Govt. medical service/ contractors and
even Home Guards and defence
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) 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:
(i)
(ii)
Identify Disaster scenario i.e. the

situation under which the plan
would become operational. Plan for
the worst possible scenario.
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.
(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 organisation.
(vii)
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
organisation to mobilise support and to
consider alternatives for maintaining
essential supplies.
CHAPTER 14 : SAFETY AUDIT

14.1 GENERAL:
Safety audit is a well recognised tool to
improve the effectiveness of safety
programme
and
loss
prevention
measures by carrying out systematic and
critical appraisal of potential safety
hazards involving personnel, plants and
equipments.
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 equipments,
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.
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-I, II, III, IV.
These check lists 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/ safety practices. Reports of
audit shall be reviewed by the Plant
Manager on daily basis and corrective
action be undertaken on priority
wherever required.
General guidelines on safety audit

methodologies and techniques are also
given in OISD - GDN- 145.
----------------------------------------------------------------------------------------------------------------------------S.No. Type of Safety
By
Frequency
Checklist
Audit
(Annexure)
----------------------------------------------------------------------------------------------------------------------------1
2
3
4
5
----------------------------------------------------------------------------------------------------------------------------1.
Inspection Safety
LPG Plant
Daily
14-I
audit of LPG Installation Safety Officer
2.
Electrical audit of
Authorised
Annual
14-II
LPG Installation
electrical Engineer
3.
Detailed safety audit
Multi disciplinary
Annual
14-III
of LPG Installation
team of region/ HQ
4.
Inspection and
Personnel from
Annual
14-IV
maintenance audit of
Inspection/ Maintenance
LPG Installation
5.
External safety audit
OISD
of LPG Installation
--------------------------------------------------------------------------------------------------------------------------------
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 alongwith 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
complied in totality.
In case of external safety audit,
following areas besides the points given
in check list of Annexure 14- III shall be
covered.
1.
Safety Organisation
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.
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
1
2
3
4
5
6
(status)
-------------------------------------------------------------------------------------------------------------------------------A. SAFETY/ FIRE PROTECTION SYSTEM
A-01
Water level in static

water tank is satisfactory.
Yes/No
A-02
Hydrant pressure
maintained with jockey pump.
Record Pressure.
Yes/No
A-03
Fire water pumps/engines
Yes/No
a) Are the batteries in good condition.

b) Are the diesel tanks full
c) Start one pump, record pressure developed.
d) Whether auto start system working.
A-04
Fire alarm/
communication system in working order.
Yes/No
A-05
Automatic Gas Detection

system operating.
Yes/No
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

being done at gate/ at the plant.
Yes/No
A-10
Direction of wind
(specify in remarks column by
observing wind sock).
Yes/No
-------------------------------------------------------------------------------------------------------------------------------S.No.
Item
Observation*
1
2
3
4
5
6
(status)
-------------------------------------------------------------------------------------------------------------------------------A-11
Caution signs displayed

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

B-01
Whether water draining

sampling done under constant
supervision.
Yes/No
B-02
Earthing connection
apparently sound.
Yes/No
a) Whether level instruments are working.

b) High level alarm in working condition (test check).
B-04
Portable fire
extinguishers in position.
Yes/No
B-05
Water spray/ sprinkler

system apparently O.K.
Yes/No
B-06
Housekeeping is in order
Yes/No
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 on remote mode
Yes / no
B-12
Pressure and temperature gauge

Functional
Yes/ no
B- 13
Bonding across flanges visible
Yes / no
B-14
-----------
C.
TANK WAGON UNLOADING
-------------------------------------------------------------------------------------------------------------------------------S.No.
Item
Observation*
1
2
3
4
5
6
(status)
-------------------------------------------------------------------------------------------------------------------------------C-01
Any visible sign of LPG leakage
Yes/No
C-02
Earthing connection apparently sound
Yes/No
C-03
a) Whether hose condition/

connections are proper
Yes/No
b) Are these properly

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

system apparently O.K.
Yes/No
C-07
Housekeeping is in order
Yes/No
C-08
Condition of Water seal
Yes / no
C-09
Gas detectors functional
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
Yes / no
C-13
-----------
D. BULK TRUCK UNLOADING

--------------------------------------------------------------------------------------------------------------------------------
S.No.
1
Item
2
Observation*
3

4
5
6
(status)
-------------------------------------------------------------------------------------------------------------------------------D-01
Are all vehicles allowed in licensed Yes/No

area permanently fitted with CCE
approved spark arrestors on exhaust
pipe (Random check)
D-02
Is the vehicle engine and master

switch being shut off during
unloading bulk LPG (site check)
Yes/No
D-03
Are the earthing connection

properly made before connecting
hoses to tank trucks.
Yes/No
D-04
Rotogauge, Fixed level instrument

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

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

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

Yes/No
TREMCARD available. Record
any abnormality/discrepancies observed.
D-07
e) Wheel choke used
Yes/No
a) Portable extinguisher
available in nominated places.
Yes/No
b) Sprinkler system in
working condition.
Yes/No
D-08
House keeping in order
Yes/No
D-09
Bonding of flange connection given
Yes/No
D-10
Hose test date
Yes /No
D-11
-----------
E. PUMP HOUSE/ COMPRESSOR ROOM
-------------------------------------------------------------------------------------------------------------------------------S.No.
Item
Observation*
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

in working condition, record pressure.
Yes/No
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
Yes/No
E-08 Any visible sign of LPG leak or any

unsafe conditions observed (record
under remarks column).
Yes/No
E-09 Housekeeping in order.
Yes/No
E-10 Gas detection system working.
Yes/No
E-11
-----------
F. FILLING SHED
F-01 No ignition sources visible in operating
areas or area in vicinity.
Yes/No
F-02 Are the LPG cylinders empty or empty

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

carousel properly made.
Yes/No
F-04 Are the cylinder chain conveyors adequately

Yes/No
lubricated to avoid metallic rubbing and friction.
F-05 Water in test bath is clean and maintained
upto the required level.
Yes/No
F-06 Any sign of leakage of unsafe condition

Yes/No
None of the filling guns or adapters used
for cylinder filling/emptying are leaking.
-------------------------------------------------------------------------------------------------------------------------------S.No.
Item
Observation*
1
2
3
4
5
6
(status)
-------------------------------------------------------------------------------------------------------------------------------F-07 Are all the fire extinguishers available
Yes/No
in accessible location.
F-08 All electrical connection apparently
intact & safe.
Yes/No
F-09
Is the concentration level of gas checked

Yes/No
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
F-15
Last fire drill in the area
F-16
Vapour extraction system functional
Yes / no
F-17
Emergency trip at Carousel functional
Yes/ No
Yes/ No
-----------
G.
CYLINDER STORAGE/ HANDLING
G-01
Are cylinders stacked properly in

demarcated areas.
Yes/No
G-02
Any leaky overfilled cylinder kept at

the end of the day. Record No. if any,
of the leaky unevacuated cylinder.
Yes/No
G-03
Safety cap fixed on cylinders in stock.
Yes/No
G-04
Sprinklers functional
G-05
Cylinders loaded in to trucks through

conveyors.
Yes/No
G-06
Rubber mats are used for unloading

empty cylinders from tank trucks and
are in good condition.
Yes/No
G-07
Last fire drill in the area
-----------
* Put specific observation wherever the conditions are not in line with specified
requirement levels.
ANNEXURE 14 - II.
ELECTRICAL AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________
Dated ____________
AUDIT/ INSPECTION BY ______________________

-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------A. ELECTRICAL SUBSTATION/ SWITCH ROOM
A-01 Is painted line diagram of power/ lighting distribution provided.

A-02 Is the equipment easily accessible for operation, inspection & maintenance.
A-03 MCC Panel condition :
a) Doors okay and closed
b) Dust/soot/ cobwebs not existed
c) Lugs existing at each cable, termination not loose.
d) Visual condition of switch contact fuse etc. O.K.
e) Control wiring condition satisfactory.
f) Jumper condition between bus and distribution okay.
g) Grounding OK
h) Alarm/ trip circuit working.
A-04 Live parts of equipment made inaccessible by barriers/ shrouds.
A-05 No temporary electrical connection existing.
A-06 Condition of cable duct
a) Cables are on rack
b) Cable deck clear
c) Sealing of duct
d) Cable identification tags.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------A-07 Rubber mats (with ISI mark) existing are enough in number.
A-08 Protective relays set at recommended values.
A-09 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/ wtiches etc.)
A-12 Emergency lighting system in order.
A-13 All energised equipment provided with caution boards.
A-14 Condition of transformer :
a) Grounding OK
b) No oil leak
c) Silica gel OK
d) Oil level OK
e) Terminal box earthing OK
f) Oil/winding temp. OK
g) Periodic oil quality test conducted.
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-01 Is double independent earthing connection for all motors provided.
B-02 Is grounding wire OK (not loose).
B-03 a) Is terminal box and gland OK
Flame-proofness maintained and not tampered.
b) Existing cable termination are proper
B-04 a) Is push button earthed properly and flame proof condition not tampered.
b) General condition of push button good.
B-05 Ground resistance at motor/ push button measured and found okay.
B-06 No motor abnormality

- Vibration/ bearing condition, faulty guard, fan condition,
excessive noise, high body temperature.
B-07 Existing preventive maintenance schedule OK.
B-08 a) Earthing resistance test schedules/ records satisfactory.
b) Earthing pit condition OK
B-09 i) Carousel machine frame to filling gun earthing continuity maintained.
ii) 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-01 All lighting fixture flame proof as per area classification.
C-02 Whether flame proof condition of fixtures ensured ?
C-03 Whether proper earthing of fixture provided ?
C-04 Condition of wiring good.
C-05 Does water enter and accumulate in fixture distribution boxes etc ?
C-06 Whether lighting DB, switches, MCB well maintained ?
C-07 Any other unsafe point observed.
D. MAST LIGHTS (AREA LIGHTING)

D-01 Whether grounding of mast OK ?
D-02 Condition of junction boxes, switch board, fuses etc. OK
D-03 Approach to electrical installation and ladder good and safe.
D-04 Condition of flood lights :
a) Is gasket present ?
b) Is glass cover in good condition ?
c)
Is control gear condition OK
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------D-05 Is earthing electrode of mast OK and its
connection with mast proper ?
E. TANKAGE AREA, PIPELINES, LOADING/

UNLOADING GANTRY
E-01 Are LPG pipelines provided with flange earth jumper connection
for electrical continuity?
E-02 Are earthing provision on LPG storage vessel well maintained ?
E-03 Condition of grounding electrode OK
E-04 Continuity of location, hoses maintained.
E-05 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.)
E-06 Connection of earth-bonding of railway track OK.
F. GENERAL
F-01 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.
F-02 Certificate in respect of FLP for each electrical equipment- records maintained.
F-03 Earthing network diagram available and site checks done from time to time.
F-04 Records for electrical testing/ checks maintained upto date.
F-05 Work permit system is effective and records are maintained.
Note : For developing a detailed check list refer OISD-GDN-145-09 document on safety audit check list for
electrical system.
ANNEXURE 14- III
DETAILED SAFETY AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________
Dated ____________
AUDIT/ INSPECTION BY ______________________
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------A. BULK STORAGE AREA
A-01 Area under the sphere is having concrete pavement with proper
slope leading to shallow sumps.
A-02 a) Water drain chamber provided away from shadow of sphere.
b) Double valves on water drain line provided: the first one
(near to chamber) of quick shut off type and the other are
throttle type (Globe valve).
c) Safety instructions for draining operations displayed prominently
and water draining is done under supervision.
A-03 a) Relief valves provided with isolation valves.
b) Isolation valves in locked open condition.
A-04 Last safety valve test done as per statutory requirement and record maintained.
A-05 Remote operated valves provided on liquid inlet/outlet lines with push
buttons/ indication control and located at safe distance.
A-06 Two independent level instruments and high level alarm provided in
storage vessels and are in working condition.
A-07 All leg supports of Horton spheres/ vessels encased in concrete with
fire proof coating/ motor.
A-08 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-09 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.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------A-11 Statutory inspection/ hydro test records maintained.
B. PUMPS/ COMPRESSORS AREA
B-01 a) All electrical motors/ push buttons properly earthed and flame proofness maintained.
b) Flame proof light fittings provided.
c) Earthing resistance test conducted periodically and record maintained.
B-02 Venting through high rise vents or flare systems only.
B-03 a) No leakage from mechanical seals.
b) Double seal provided to minimise chances of leakage.
c) No abnormal sound and vibration from motor and bearings condition OK.
d) Coupling guards in position.
B-04 Drain points/ vent points/ sample points capped when not in use.
B-05 Operating instructions Do's and Don'ts displayed.
B-06 Long range monitors/ fixed water spray with proper throw/ sprinkler system
installed and in good condition.
C.
CYLINDER FILLING/ STORAGE AREA
C-01 LPG bottling facilities located at safe distance from other facilities with
minimum ingress to trucking traffic.
C-02 Facilities provided for positioning of trucks 15 m away from storage shed
for receipt/ loading of cylinders.
C-03 Transfer of cylinders from truck to conveyor.
- Telescopic conveyor
- Trolley use
C-04 Proper purging facilities provided for new/ retested/ reconditioned cylinders
C-05 a) Inspection/ visual checks followed for spurious/ defective cylinders and
record maintained.
b) Segregated storage marked for i) Spurious
ii) Hot repairs

iii) 5/7 years testing due cylinders
iv) Other defects
C-06 Gross weight filling :
- Auto cut off after completion of filling
C-07 Hoses are of approved quality and periodically tested.
C-08 Vapour extraction system provided for carousel and system is working satisfactorily.
C-09 100% 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.
- Aluminium foil
- PVC sealing
C-16 Neck label being put
- Plastic
- Paper
C-17 Quality control checks (SQC) carried out/ records maintained.
C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily.
C-19 Cold repairs facilities evacuation for evacuated depressurized cylinders.
-
Valve removal/ replacement by use of torque wrench with proper settings.
--------------------------------------------------------------------------------------------------------------------------------
S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------- PTFE tape/ paste or other suitable sealing compound used.
C-20 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys.
C-21 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.
D. BULK LPG UNLOADING FACILITIES
D-01 Whether the location and layout of the facilities meet statutory distances/ design guidelines.
D-02 Effective earthing system provided and working satisfactorily.
D-03 a) Hoses used are of approved quality standard.
b) They are periodically tested and replaced after prolonged use.
D-04 Hose contents after unloading are released to high vent located at safe distance.
D-05 Blocked hoses/ pipelines provided with TSVs.
D-06 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-07 Remote operated valves provided on liquid loading headers.
D-08 a) Weigh bridge provided on liquid loading headers.
b) Calibration certificate obtained from Weights & Measures Authorities available.
D-09 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 licence, safety certificate, fitness certificate.
d) Proper earthing cable with clamps.
D-10 Loading/ unloading procedures along with safety precautions prominently displayed.
--------------------------------------------------------------------------------------------------------------------------------
S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------E. SAFETY/ FIRE PROTECTION SYSTEM
E-01 Fire organisation chart prepared, updated and displayed.
E-02 Contingency plan updated for tackling major emergencies.
E-03 Important telephone Nos. of State Fire Services, Police, District Admn./
other offices etc. displayed.
E-04 Are fire emergency mock drills conducted periodically and records maintained.
E-05 Work permit system for repairs/ hot jobs etc. followed and records maintained.
E-06 a) Fire water network (layout displayed)
- above ground/ under ground
- corrosion protection
- material of construction
b) Pressure at farthest end and flow
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.
- Defective nozzles to be identified for replacement.
- Deluge valve operation satisfactory.
e) Strainers provided at inlet of deluge/ sprinkler water supply main piping. Strainers are
cleaned periodically and records maintained.
E-07 Fire Water Pumps :
- Adequacy of capacity, nos. discharge pressure etc.
- Auto starting (system security logic) provided.
- Working jockey pump operating parameters maintained.
E-08 Static water storage tank - capacity and adequacy
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------- Source of water supply and rate of replenishment.
E-09 a) Fire vehicles well maintained.

b) Mutual aid scheme with neighbouring industries/ district
authorities existing.
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 fire fighting suits (Aluminised suits)
- Breathing apparatus & its upkeep
- Water jel blankets.
- Use of nylon clothes prohibited.
E-13 Automatic Gas Detection System :
- Working satisfactorily
- Regularly tested.
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.
b) Flame-proof torches available
F. MANPOWER AND TRAINING
F-01 Supervisory/ managerial cadre staff fully trained in all aspects of LPG plant
operations, Disaster control/ emergency handling.
F-02 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------F-03 Training programmes are organised periodically in LPG operations;
fire fighting/ emergency handling etc. for

a) Regular staff
b) Contractor workmen
c) Security staff
d) Tank truck operators/ drivers
F-04 All activities are effectively supervised with available manpower.
F-05 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.
F-06 Important Do's and Don'ts displayed prominently in operation areas.
G. GENERAL
G-01 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-02 a) Strict security checks employed for compliance to safety regulations.
b) Spot checks being done.
G-03 a) Valid CCE licences available for :
- Storage of LPG
- Storage of LPG cylinders
- 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-04 Accident records maintained and updated.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------G-06 Hot work permit/ clearance issued - proper procedures followed and
documents maintained.
G-07 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, 1981, SMPV Rules 1981 and other relevant
BIS Standards with latest amendments.
G-08 a) Records of periodic testing of hoses/ replacement.
b) Testing records of Pn relief valves/ pop action valves.
c) Inspection records of underground pipelines etc.
d) Weights & Measures certificates.
G-09 Updated P&I Diagrams, drawing of layout and other facilities available.
G-10 Records of "Daily Safety Audits" reviewed. Corrective action taken.
G-11 General housekeeping standards : area/ facility wise.
G-12 Pipeline colour code system maintained.
ANNEXURE 14- IV
INSPECTION & MAINTENANCE SYSTEM AUDIT

LOCAL _______________
DATED: _________
AUDIT/ INSPECTION BY ________________

-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------A. GENERAL
A-01 Whether standard system of inspection/ maintenance schedule
developed and followed and records maintained.
A-02 Whether equipment documents supplied by vendors are readily
available and recommended maintenance procedures are strictly
adhered to.
A-03 Whether spare parts for different equipment/ machinery are maintained.
A-04 Whether data card/ history records of static and rotary equipment are
maintained (as per OISD Std.127/28).
A-05 Whether proper work permit system is followed for maintenance jobs and
records maintained.
A-06 Whether personnel protective equipment such as hand gloves, safety shoes,
safety helmet etc. provided to the concerned workmen and their use is ensured
(OISD Std.-155).
A-07 Fire fighting equipment and portable fire extinguishers periodically checked /
tested as per maintenance schedules & records maintained (OISD Std.-142).
A-08 Fire alarm/ communication system scheduled testing & maintenance ensured.
A-09 Whether Explosimeters are periodically checked and calibrated.
A-10 Whether continuous monitoring devices are periodically checked and calibrated.
A-11 Whether exhaust fans and other ventilation devices are properly maintained and
regularly used.
A-12 Whether inspection/ testing of pressure vessels carried out periodically as per statutory
requirements and records maintained.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
--------------------------------------------------------------------------------------------------------------------------------
B. BULK STORAGE HANDLING FACILITIES

B-01 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-02 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-03 Annual inspection and testing of safety valves carried out at proper set
pressure and records maintained.
B-04 All instruments, level indicators, pressure and temperature gauges, ROVs
are maintained in working condition following daily scheduled checks,
periodic calibration and preventing maintenance schedule.
B-05 Regular operation checks are carried out on pumps/ compressors
(condition of bearings/ mechanical seal/ abnormal sound etc. as
per OISD STD-119, 120).
B-06 Preventive maintenance and servicing schedules for pumps and
compressors for daily/ weekly/ monthly/ yearly are checked and
records maintained.
B-07 Gas detection system is checked and calibrated periodically. Audio
visual alarm/ security logic system maintained in working condition.
B-08 Fire water system & sprinkler spray system checked/ tested periodically
and maintenance jobs carried out and records maintained.
B-09 LPG bullets/ spheres having fire proofing are periodically checked for cracks,
spalling/ 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.
Records of resistance testing as outlined in OISD Std-137 maintained.
B-11 Foundation/ Anchor bolts, ladders, stairways, platforms/ structurals checked periodically
for any corrosion/damage etc.
B-12 Annual testing of chain pulley blocks and other tool tackles is carried out by certified agency.
B-13 Weigh bridges calibration and certification done once in a year.
-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------C. CYLINDER FILLING
C-01 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-02 Introduction/ Ejection devices and filling machines are checked daily and
scheduled maintenance/ overhaul work carried out.
C-03 Checking of pin travel done regularly and records maintained.
C-04 Check scales are well maintained and calibrations carried out on daily basis
with standard weights.
C-05 Calibration of CVT/DCVT detectors being done regularly and maintenance
schedule followed.
15.0 REFERENCES
15.1 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:1432-1959
GENERAL REQUIREMENTS FOR WEIGHING

INSTRUMENTS
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:2148-1981
FLAMEPROOF ENCLOSURES FOR ELECTRICAL

APPRATUS
IS:2206
FLAME PROOF ELECTRIC LIGHT FITTINGS
IS:2206(PART 1)-1984
WELL GLASS AND BULKHEAD TYPES
IS:2206(PART 2)-1976
FITTINGS USING GLASS TUBES
IS:2808-1964
METHOD FOR COMPUTATION OF CAPACITY TABLES

FOR PRESSURIZED STORAGE TANKS
-------------------------------------------------------------------------------------------------------------------------------CODE NO.
NAME
-------------------------------------------------------------------------------------------------------------------------------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.
IS:3465-1966
JOINTING COMPOUND FOR USE IN LPG APPLIANCES

AND INSTALLATIONS
IS:3710-1978
FILLING RATIOS FOR LOW PRESSURE LIQUEFIABLE

GAS.
IS:4093-1981
NON-REFILLABLE LPG CONTAINERS
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:4784-1968
LOW PRESSURE REGULATORS FOR USE WITH

BUTANE GASES
IS:4785-1968

PROPANE GAS
IS:4786-1968
VARIABLE HIGH PRESSURE REGULATORS FOR USE

WITH LPG
IS:4991-1968
CRITERIA FOR BLAST RESISTANT DESIGN OF

STRUCTURES FOR EXPLOSIONS ABOVE
IS:5116-1985
GENERAL REQUIREMENT FOR DOMESTIC AND

COMMERCIAL EQUIPMENT FOR USE WITH LPG
IS:5571-1979
GUIDE FOR SELECTION OF ELECTRICAL EQUIPMENT

FOR HAZARDOUS AREAS
IS:5572
CLASSIFICATION OF HAZARDOUS AREAS (OTHER

THAN MINES) FOR ELECTRICAL INSTALLATIONS
GROUND
-------------------------------------------------------------------------------------------------------------------------------CODE NO.
NAME
-------------------------------------------------------------------------------------------------------------------------------IS:5572(PART 1)-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 TORAGE

INSTALLATIONS
IS:6044(PART 1)-1971
COMMERCIAL AND INDUSTRIAL CYLINDER

INSTALLATIONS
IS:6044(PART 2)-1972
INDUSTRIAL, COMMERCIAL AND DOMESTIC BULK

STORAGE INSTALLATIONS
IS:6539-1972
INSTRINSICALLY SAFE MAGNETO TELEPHONES FOR

USE IN HAZARDOUS ATMOSPHERES
IS:6665-1972
CODE OF PRACTICE FOR INDUSTRIAL LIGHTING
IS:7142-1974
WELDED LOW CARBON STEEL GAS CYLINDER FOR

LOW PRESSURE LIQUEFIABLE GASES, NOT
EXCEEDING 5 LT WATER CAPACITY
IS:7145-1973
TECHNICAL SUPPLY CONDITION FOR TORQUE

WRENCHES
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 GAS
(LPG)
IS:8374-1977
SPECIFICATION FOR BITUMEN MASTIC, ANTI STATIC

ELECTRICALLY CONDUCTING GRADE
IS:8451-1984
CODE OF PRACTICE FOR VISUAL INSPECTION OF

HIGH PRESSURE GAS CYLINDERS
-------------------------------------------------------------------------------------------------------------------------------CODE NO.
NAME
-------------------------------------------------------------------------------------------------------------------------------IS:8737
VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF
MORE THAN 5 LIT. WATER CAPACITY
IS:8737(PART 1)-1979
VALVE FITTINGS FOR REPLACEMENT PURPOSES
IS:8737(PART 2)-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 CAPACITY
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
IS:9121-1979
INSPECTION GAUGES FOR CHECKING TYPE 1 (SIZE 2)

TAPER THREADS OF GAS CYLINDER VALVES, TAPER
1 IN 16
IS:9122-1979
INSPECTION GAUGES FOR CHECKING TYPE 2 TAPER

THREADS OF GAS CYLINDER VALVES, TAPER 3 IN 25
IS:9199-1979
INSPECTION GAUGES FOR CHECKING TAPER

THREADS OF GAS CYL. VALVES, TAPER 60 DEGREE
INCLUDED ANGEL
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
-------------------------------------------------------------------------------------------------------------------------------CODE NO.
NAME
-------------------------------------------------------------------------------------------------------------------------------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
CODE OF PRACTICE FOR VISUAL INSPECTION

OF LOW PRESSURE WELDED STEEL GAS
CYLINDERS IN USE
IS:9777-1981
DATA SHEET FOR SELECTION OF

WEIGHBRIDGES FOR BULK HANDLING
EQUIPMENT
IS:9798-1981

LPG
IS:9902-1982
RECOMMENDED PRACTICE FOR LEAK

TESTING
IS:9975
Ò' RINGS
IS:9975(PART 1)-1981
DIMENSIONS
IS:9975(PART 2)-1984
MATERIAL SELECTION & QUALITY

ACCEPTANCE CRITERIA
IS:9975(PART 3)-1984
SEAL HOUSING DIMENSIONS AND

TOLERENCES
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
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
-------------------------------------------------------------------------------------------------------------------------------CODE NO.
NAME
-------------------------------------------------------------------------------------------------------------------------------IS:13258-1991
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
PART I MECHANICAL TYPE

--------------------------------------------------------------------------------------------------------------------------------
ii.
The Static and Mobile Pressure Vessels (Unfired) Rules-1981
iii.
LPG (Regulation of use in Motor Vehicles) Order 2001
iv.
Gas Cylinder Rules, 2003
v.
API Standard 25 Design and Construction of LP Gas Installations
vi.
ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American

Society of Mech.Engrs., New York
vii.
NFPA 58
Storage and Handling of Liquefied Petroleum Gases
viii.
NEPA 59
LP Gases at Utility Gas Plants
ix.
OISD-STD-105
Work Permit System.
x.
OISD-STD-113
xi.
OISD-STD-135
Classification of Areas for Electrical Installations at

Hydrocarbon processing and handling facilities
Inspection of Loading/Unloading
Petroleum Products.
hoses
for
xii.
OISD-STD-144
Liquefied Petroleum Gas (LPG) Bottling Plant

Operations
xiii.
OISD-STD-150
Design and Layout of Liquefied Petroleum Gas

Mounded Storage Vessels
xiv.
OISD-STD-158
xv.
OISD-STD-159
Recommended Practices on Storage and Handling

of Bulk Liquefied Petroleum Gas (LPG)
LPG Tank Trucks Requirements of Safety on
Design/ Fabrication & Fittings
xvi.
OISD-STD-179
Requirement of Safety for Compression, Storage,

Handling & Refueling of Natural Gas for Use in
Automotive Sector.
xvii.
ASME B - 31.3
Chemical Plant and Petroleum Refinery Piping
xviii. ASME B - 31.4
Liquid Transportation Systems for Hydrocarbons,

Liquid Petroleum Gas, Anhydrous Ammonia and
Alcohols
xix.
Specification for unfired fusion welded pressure

vessels
PD-5500

Liquefied Petroleum Gas (LPG) Installations: Oisd Standard - 144

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

Liquefied Petroleum Gas (LPG) Installations: Oisd Standard - 144

Uploaded by

Copyright:

Available Formats

OISD STANDARD - 144

Second Edition, October 2005

LIQUEFIED PETROLEUM GAS (LPG)

OIL INDUSTRY SAFETY DIRECTORATE

7th Floor, New Delhi House

This document will be reviewed periodically for improvements based on the

Hindustan Petroleum Corporation Ltd., Mumbai

Deptt. of Explosives, Nagpur

Engineers India Limited, New Delhi

Sh. B.S. Giridhar

Indian Oil Corporation Ltd., - HQ, Mumbai

Bharat Petroleum Corporation Ltd., Mumbai

Chennai Petroleum Corporation Ltd., Chennai

Sh. B.J. Phukan

Numaligarh Refinery Ltd., Assam

Indian Oil Corporation Ltd., Calicut

Bharat Petroleum Corporation Ltd., Noida

Oil Industry Safety Directorate, New Delhi

FUNCTIONAL COMMITTEE MEMBERS

( First Edition April 1994 )

Indian Oil Corporation Ltd., ( Ref.)

Indian Oil Corporation Ltd., ( Mkt.)

Sh. A.C. Kelkar

Indian Oil Corporation Ltd., ( Mkt.)

Sh. V. Narayana Rao

Bharat Petroleum Corporation Ltd., (Mkt.)

Bharat Petroleum Corporation Ltd., ( Ref.)

Sh. P.P. Nadkarni

Hindustan Petroleum Corporation Ltd., (Mkt.)

Engineers India Limited, New Delhi

Oil Industry Safety Directorate, New Delhi

Statutory Rules/ Regulations

Storage & Handling of Bulk LPG

Maintenance & Inspection

Statutory Testing of LPG Cylinders

Fire Protection Facilities

Gas Monitoring System

Emergency Management Plan

LIQUEFIED PETROLEUM GAS (LPG)

LPG has an explosive range of 1.8%

Water, being insoluble in LPG, if

LPG liquid has low viscosity of

LPG even though slightly toxic, is

Some of the important properties of LPG

LPG at atmospheric pressure and

LPG is colourless both in liquid and

The pressure inside a LPG storage

The coefficient of expansion is

LPG has only a very faint smell,

The auto-ignition temperature of

Area Classification : It is a method of

This standard lays down the minimum

Bonding : Bonding is the process by

Earthing : Earthing is the provision of

Hot Work : It is an activity which may

Air (Prevention & Control of

Maximum Working Pressure : It is

The Environment (Protection)

Manufacture, storage & import of

4..0 STATUTORY RULES /

Gas Cylinders Rules, 1981 (under

Static & Mobile Pressure Vessels

The Factories Act, 1948.