Professional Documents
Culture Documents
1
Area : LPG storage, bottling & distribution
Area Code : 300
Course Code : 301
Intended For : Fresh Entrant Officers and Supervisors.
Duration : 3 days
Objective : To provide knowledge on the hazards associated with LPG operations /
maintenance and safe way to perform job. To evoke correct and prompt
response in any emergency situation.
Course Content:
I) Characteristics of LPG and Associated Hazards.
Commercial Butane also meets Indian Standard Code IS-4576 quality norms and can be
treated as LPG. LPG of mixtures 50% propane and 50% butane also meets Indian
Standard Code IS-4576 quality norms. It has been observed that Quality of LPG dealt in
India varies a lot depending on source of supply and number of constituents which
mainly consist of one or more of the following hydrocarbons:
a) Propane (C3H8)
b) Propylene (C3H6)
c) N-butane (C4H10)
d) Iso butane (C4H10)
e) Butylene (C4H8)
Currently LPG is being used for various applications like Cooking, Industrial applications
for heating, heat treatment, solvent & aerosol applications. LPG is also being used as
Automotive fuel. Specification of LPG used for cooking & Industrial applications is
governed by IS 4576 (1999) whereas LPG used for Automotive purpose is as per IS 14861
(2000)
IS 4576 specifications:
Table 1
OR
Volatility :
iii) Total volatile sulphur ppm, Max. 150 150 150 D 2784
D 3246
iv) Copper Strip Corrosion at 38 0C for 1 hour Not Worse than Not Worse than No. Not Worse D 1838
No. 1 1 than No. 1
(Note 3)
1.2.1 COLOUR
LPG is colourless both in liquid and vapour phase therefore, they cannot be seen.
However, when LPG, in liquid form, is released from a container or a pipe it
vapourizes almost immediately. This produces a cooling of the surrounding air
and may cause water vapour in the air to condense, freeze and become visible. In
this way a LPG leak may be detected even though the gas itself is invisible.
1.2.2 Smell
LPG is, in general, odourless and cannot be detected by human senses. When
odourization of LPG is required Ethyl Mercaptan ( C2H6S) is added to a min of 20
ppm.
1.2.3 Taste
LPG is tasteless and non-toxic, therefore, the presence of LPG vapours in the
atmosphere cannot be sensed by taste.
LPG in liquid form should not come in contact with surface of body. It is particularly
important that liqud propane or a product with relatively high vapour pressure be
avoided in the event that LPG in liquid form come in contact with the skin , the product
immediately vapourises. During this vapourisation process, heat will be absorbed
directly from the skin and flesh causing a freezing effect. The ultimate result of the
freezing is usually referred to as a cold burn. The results may be serious, therefore, if
the possibility of exposure to liquid LPG exists, suitable gloves and protective clothings
should be utilized.
1.2.5 TOXICITY
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however,
suffocate when in large concentrations due to the fact that it displaces oxygen. In view
of this the vapour possesses mild anaesthetic properties.
1.2.6 VISCOSITY
LPG liquid has low viscosity of around 0.3 CS @ 45 deg. C and can leak when other
petroleum products normally cannot, thus demanding a very high integrity in the
pressurised system to avoid leakage. It is also a poor lubricant and leaks are therefore
likely to occur at pump seals and glands. In view of this a special attention to be given,
for example to the selection of mechanical seals for pumps and also seals at the
carousel centre column.
1.2.7 DENSITY
Density means Mass or weight per unit volume. Unit used is gm/cm3 or Kg/m3. Since
the density of the liquid varies slightly with temperature, the latter must be indicated
in an exact statement of density. Normally density is expressed at 15 degrees
centigrade or 60 degrees F.
Since the density of water is 1.0 gm/cm3, and the density of liquid LPG is about 0.5
gms/cm3, the latter is about half as heavy as water.
================= ============================
===========================
In an exact statement of density of the gas, it is necessary to indicate not only the
temperature but also the pressure.
The usual form is to state the density of 1 m3 of the gas at 0 degrees centigrade & 760
mm Of Hg (Normal atmospheric pressure), this being known as a normal cubic metres,
abbreviated to m3 (n).
Relative density is used to indicate the density of a gas in relation to that of air at the
same temperature & pressure. If the relative density is greater than unity, the gas is
heavier than air. LPG is about 1.5 to 2 times as heavy as air.
Its value varies slightly with temperature, and the table therefore states the
coefficient for the two temperature ranges that may be encountered in practice.
The rate of expansion or contraction also varies depending upon the
composition of the product.
In the case of propane, the expansion rate between 0 °C and +40°C is
approximately 13.2%, whereas the expansion rate of butane for the same
temperature increase is approximately 8.0%.
In general, it may be said that the lower the density of the liquid the
greater the rate of expansion or contraction.
The normal boiling point is the temperature at which the vapour pressure
reaches
If, on the other hand, the liquid is in a closed container the motion of
the escaping molecules is confined to the vapour space above. As an
increasing number strike and re-enter the liquid, a point of equilibrium
is eventually reached when the rate of escape of molecules from the
liquid equals the rate of return to the liquid.
While LPG vapourization takes place, it takes latent heat from the body of the
container during change of phase from liquid to vapour. In case vapourization
rate is higher then the body temperature of the container is reduced resulting
in ice formation on the surface.
Flammability is defined by percentage by volume of the gas in mixture with air that forms a
flammable mixture at atmospheric pressure & ambient temperature. Flammability range is
difference between the minimum & maximum percentage by volume of the gas in mixture with
air .
The above indicates that in the event there is an insufficient supply of LPG vapour mixed with
air, the combination will not burn. Conversely, if an excessive amount of LPG vapour is mixed
in the atmosphere, combustion again can not be accomplished
Auto Ignition is the lowest temperature at which a material will ignite without an external
source of ignition. In case of LPG it is 410 to 580 degrees centigrade varying on account of
composition.
1.2.19 VOLATILITY
Volatility is the property of the substance to get converted into vapour phase from liquid phase
after absorbing latent heat of evaporation from surrounding at a certain pressure. In the case of
LPG , it is the temperature of residue LPG at balance quantity of 5 ml inside weathering tube of
100 ml capacity at atmospheric pressure. As per IS 4576 , the volatility of LPG can be of
maximum +2 Deg.C
1.3 COMBUSTION
Combustion may be defined as the oxidation of the product. In the context of LPG, combustion
is the combination of oxygen usually from air with LPG vapour to form carbon dioxide & water
vapour
As an example of the process, 0.4 volume of LPG when combined with 9.5 volume of air, after
combustion will produce 1.6 volume of water vapour, 1.2 volume of carbon dioxide and 7.5
volume of nitrogen.
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Flame temperature of LPG depends on the composition of the product. The maximum Flame
temperature of LPG attained is about 2000 degrees centigrade
The combustion reaction of LPG increases the volume of products in addition to the generation
of heat. LPG requires upto 50 times its own volume of air for complete combustion and at the
same time yields 3 or 4 times its own volume of carbon-dioxide yielding approx. 10,900 kcal to
16000 kcal heat per kg depending upon the composition.
Thus it is essential that adequate ventilation is provided when LPG is burnt in enclosed spaces
otherwise asphyxiation due to depletion of oxygen apart from the formation of carbon-dioxide
can occur.
Flame propagation is defined as the Flame velocity normal to the surface of the inner core of a
flame and is relative to the velocity of the unburned gases.
This property is one of the basis for Risk analysis of LPG facilities which influences site
selection & equipments layout, for efficient combustion of LPG for industrial /auto
application & mitigation measures to be adopted to ensure safety in case of any explosions
LPG contain some volatile sulphur which generates sulphur oxide during combustion.
Presence of sulphur in LPG should be as minimum as possible. Free sulphur also reacts
with iron particle of vessel causing corrosion. As per IS-4576 sulphur content in LPG
should not exceed 150 PPM.
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Presence of the Sulphur in LPG will produce sulphur oxides ( Predominantly sulphur dioxide)
which inturn will produce acid which is highly corrosive in nature and may effect the
equipments in long term. In certain applications during combustion process, Sulphur oxides
will be a part of flue gas and will pollute environment. This may violate statuatory limits on
emission control set by Pollution Control Boards and hence the less presence of Sulphur in LPG
is desirable.
Presence of Hydrogen sulphide will generate sulphur and hydrogen ions. The sulphur inturn will
generate oxides and acids as explained above and leads to corrosion and environmental
pollution.
Pyrophoric Iron sulphide is a highly inflammable compound formed due to the reaction of
sulphur and its compounds with the loose iron/ iron oxide on a ferrous surface. Thus the
pyrophoric Iron Sulphide can be controlled by totally eliminating highly corrosive hydrogen
sulphide, limiting the total volatile sulphur to 0.02% by mass reducing the loose iron oxide by
thoroughly cleaning the storage vessels internally during the outage.
Pyrophoric Iron Sulphide will not ignite spontaneously in a sphere/ cylinder containing a
concentration of vapour of gas as long as the concentration is above the upper flammable range
limit. When the contents of the vessels come in contact of air (during opening to atmosphere or
air entrapped condition) within or below the range, Pyrophoric iron sulphide will ignite
spontaneously, unless water or steam is used to cut the sulphur iron reaction. The most
effective extinguishing agent is water spray or fog. Similar type of precaution is warranted
while opening of LPG pump strainers and any location where loose iron oxide is expected.
The hazards associated with the release to atmosphere of a boiling flammable liquid show
themselves disproportionately where large quantities are involved - they can give rise to two
phenomena which are highly hazardous ; (a) Unconfined Vapour Cloud Explosion (UVCE) and (b)
Boiling Liquid Expanding Vapour Explosion (BLEVE).
Vapour cloud can ignite and burn as deflagrations or fire balls causing lot of damage by
radiation starting secondary fires at some distance. Vapour cloud ignites and explodes causing
high over pressures and very heavy damage. The later is termed as `percussive unconfined
vapour cloud explosion' i.e. PUVCE in short. Even though large quantities of LPG emission is
necessary, only a fraction of this contributes to the percussive effect ( more reactive molecules
such as ethylene in much smaller quantities). Rare though PUVCE may be, their damage is large
and sometimes enormous.
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The boiling liquid expanding vapour explosion (BLEVE) is due to holding a pressurised flammable
liquid above its boiling point. This may result from inadequate vapour space for temperature
expansion of the contents or high temperature due to radiation heat from the adjacent vessel
fires or due to any mechanical damage. BLEVE even though not as serious as PUVCE, its
potential for spreading fire over a wide area makes them significant in terms of both life and
property damage.
Ejection of boiling liquid produces reaction rupturing the vessel causing the rocket
projectioning of dish ends. The released liquid flashes and atomizes immediately, often
resulting in a large fire ball. Although the fire ball lasts only a few seconds, its effect can be
devastating due to flame contact and thermal radiation.
2.0 GENERAL
LPG Bottling Plant / Installations can be termed as factories. Operations and administration of these
locations are governed by various applicable statutory guidelines. It is imperative that compliance to
the requirements of the applicable statutory guidelines to be ensured. Compliance of statutory
requirements plays important role towards safety , health and environment issues concerning not only
Corporation but Society as a whole.
Following are some of the important statutory Guidelines applicable to LPG Plants / Installaitons.
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Manufacture / Storage & Import of Hazardous Chemical Rules – 1989.
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Sudha Joshi Committee – 1987.
These Acts be referred for any issues pertaining to LPG Plant / Installation Operations. Salient features
of these Acts required to be complied and useful for LPG Plant Operations are given below.
Following three Explosive Licenses are required for LPG Bottling Plant :
I. License to store Bulk LPG in Storage Vessel (As per SMPV Rules)
II. License to Fill LPG in Cylinders (As per Gas Cylinder Rules)
III. License to Store Filled LPG Cylinders (As per Gas Cylinder Rules )
Rule 49 : Gives details of Application for obtaining of License. Application for obtaining new license for
storage of Bulk LPG to be submitted as per Form III and renewal application to be made in Form I.
Rule 50 : Specifies the period of licence. Licence shall remain in force from 01 st Oct. to 30th Sept. . The
licence can be renewed for a maximum period of 03 years.
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Applicable Rules 50,51,54 &55 of Gas Cylinder Rules 2004
Rule 51 ; Gives the period for renewal of licence which can be maximum 10 years. The licence shall be
granted for the period ending 30th Sept
Rule 55 : Specifies procedure for renewal of Licence which is applied for in Form E
Applicability of all rules is same for this licence as per licence to Fill LPG in cylinders except that the
renewal application to be made as per Form F
Every cylinder shall be labeled with the name of Gas & the name and address of person by whom the
cylinder is filled
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Rule 35 : Retesting of cylinders (Refer schedule IV for fetails)
Half yearly Return to Chief Inspector of Factory on or before 15th JUL in duplicate in FORM-22.
Muster Roll for all employees employed in a factory under Rule-110 in FORM-25.
Notice for change of Manager under Rule-15A in FORM-2A within 7days from the date of change.
Notice of Accident to Inspector & Chief Inspector of FACTORY within 12 hrs in FORM-18 under Rule-
103, with a copy to SDM, SHO & Relative of the injured.
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• Hoist & lift shall be examined once in six month by competent persons.
Competent PERSON must have a valid authorization from the Chief Inspector Of Factory of
CONCERNED state only
• Prior consent is required from concerned SPCB for discharge of effluent under Sect-25/26 of
above Act.
• Application for renewal of consent shall be made 30 days before the date of expiry of consent
along with required consent fees.
• Test reports by competent authorities for Effluent quality to be submitted during renewal of
license
In case effluent sample does not meet the specified norms, ETP has to be installed for treatment for
effluent. The sludge generated has to be disposed as per the following procedure:
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a) Sludge from LPG Bullets / Sphere testing and mandatory testing of cylinders
This is a heavy solid and must be collected in a container and should be buried to a depth of 2 m
depending upon the water table away from human settlement, water resources or agricultural fields.
2.5.1 Standards of Weights & Measures Act 1976 & Rules 1987)
• Every weights or measure used or intended to be used in any transaction shall be verified or re-
verified as prescribed by Controller of Weights & Measures ( Sect-24).
• Every weights or measures should be present for verification at the office of Inspector on or
before due date.
• For Every weights or measures which cannot be moved from its location, it shall be reported to
Inspector at least 30 days in advance for verification.
• The certificate of verification to be exhibited UNDER Sect-25 at a place where weights or
measures are used
a. Applicability :
Provided that the appropriate government may, after giving not less than two months notice of its
intention so to do, by notification in the Official Gazette, apply the provisions of this Act to any
establishment or contractor employing such number of workmen less than twenty as may be specified in
the notification.
Appropriate Government
Contract Labour
Contractor
Controlled Industry
Establishment
Principle Employer
Wages
Workmen
c. Compliance to be Made
Registration of Establishment for employing contract labour (Refer Section 6, 7,8 & 9)
Licensing of Contractors (Refer Section 11,12,13 & 14)
Welfare & Health of Contract Labour (Refer Section 16,17,18 & 19)
Responsibility of Payment of Wages (Refer Section 21)
Registers & Records to be maintained (Refer Section 29)
Returns as per Section 82
Registration of Establishment to be made as per Form I and Certificate of Registration to be issued
as per Form II.
Notice of commencement & completion of contract work ( As per Form VI B) Notice to be
submitted by principle employer (In our case Plant Manager/Occupier) to the office of LEO.
Principle Employer has to give a certificate in Form V to the contractor employing more than
specified number of contract labour.
The contractor has to apply in Form IV to obtain labour license, and license is issued in Form VI
Renewal of license under Form VII
The principal employer has to maintain Register of Contractors as per Form XII
Annual Return to be submitted by Principle Employer (Form No. XXV) by 15 th. Feb of next year.
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The principal employer has to ensure that the following registers are to be maintained by the
contractor:
Any person driving a goods carrying a goods carriage carrying goods of dangerous or hazardous nature to
human life shall in addition to being the holder of a driving license to drive a transport vehicle, also has the
ability to read and write at least one Indian Language out of those ( Specified in the VIII Schedule of the
Constitution ) and English and also possess a certificate of having successfully passed a course consisting of
following syllabus and periodicity with the transport of such goods.
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2.8 PUBLIC LIABILITY INSURANCE ACT ( 1991 )
Public Liability Insurance act ( 1991) Is valid for one year basis financial year effective 1 st april to 31st march.
As per the act, Insurance is to be obtained by HPCL for protecting the interest of the affected people and
to give immediate relief in case of accidents involving operations , transportation or handling of OIL
products.
Policy covers all operations of the ensured for all locations within Geographically limit including
refineries / road transportations / pipelines.
Maximum aggregate liability shall not exceed s 5 Crs for an accident and Rs 15 Crs in aggregate for more
than One Accident.
Any Claim Under this act is to be forwarded through the District Collector
On Occurrence of accidents, same shall be brought immediately to the notice of concerned District
Magistrate by HPCL.
FIR has to be lodged by the victims or affected person for furhet claim.
Claim application is to be made to the DM by the Victim / Relatives as per Form-1 of this ACT.
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2.9 EMPLOYEE STATE INSURANCE ACT ( 1948) :
This is a piece of social welfare legislation enacted primarily with the objecvtive to provide dcetial benefits
to employees in case of sickness, maternity , employment injuries and also to make provisions for certain
other matters .
This ACT applies to the employess, contract labours falling within the wage limit specified in the ACT from
time to time. Further, this ACT will be applicable if the factory falls within the area classification by ESIC
(Employees State Insurance Corporation) .
The contribution to be paid ESIC by the employee and the employer as per provisions of the ACT.
Employees are issued ESIC Card to get treatment for their self and family members in the nominated ESIC
hospitals.
In case of accidents or incidents, the act specifies accidents benefits / disebalement benfits , treatment
expenses etc.
Any person employed by or through a contractor in or in connection with the work of the establishment is
also an employee unless otherwise covered under the act and will be thus eligible to get the benefit of the
schemes framed under the act. Thus the employees engaged through the contractor will be liable to be
covered under the provisions of Employees Provident Fund Act.
Contractor has to obtain a separate identification code for the employees rendering services on contract
basis. On termination of the services, the amount can be withdrawn or continued with the new
contractor.
The principal employer shall be liable to pay any workman employed in the execution of the work any
compensation which he would have been liable to pay if that workman had been immediately employed
by him.
Act provides that the principal employer will ensure that the worker engaged thru the contractor will be
paid wages not less than minimum range as specified in that.
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The minimum wage rates are specified for different categories of jobs and skills of labour required to be
employed by the factory / establishments.
Act also specifies minimum wages will be applicable basis appropriate Governments for the establishment
i.e. in case of HPC minimum wages specified for Central Government will apply.
However, higher of the minimum wages notified by the sate / Central Government notifications shall be
payable .
Ministry of Petroleum & Chemicals had set up a high level committee in May, 1983 headed by Shri R.
Vasudevan, the then Joint Secretary, Deptt. of Petroleum to review all safety and operational
procedures adopted in LPG filling plants, transportation of LPG by rail/ road, and in the distribution/
delivery of LPG cylinders. Several recommendations for improvements in operations/ systems were
made by the committee for adoption/ implementation by the oil industry. Gist of key points pertaining
to the recommendations are given below :
i) Layout - Provision of 80 M wide green belt beyond perimeter wall, access roads etc.
iii) Cylinder Testing - Use of compact valve tester, water bath check for leaks.
iv) Cylinder Handling - Conveyor system, loading/ unloading at 15 M distance from shed.
v) Evacuation of leaky cylinders - Use of proper evacuation system and recovery of LPG, gas freeing
prior to repairs/ replacements of valve.
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vi) Cylinder Storage - Vertical stacking in small lots with min. separation distance of 1 metre
segregated storage for empty and filled cylinders, mastic flooring in the shed.
vii) Other Safety features/ practices - Fail-safe shut-off valves, extraction of gas/ air mixtures,
adequate communication facilities etc. One designated Safety Officer for each plant.
viii) Manpower & Training - LPG plants to be headed by Sr. Officers. Structured training/ refresher
courses for staff and officers on LPG operations, emergency handling etc. No contract labour on
shop floor for LPG operations.
ix) Fire Prevention/ Fire Fighting - Strict security check prevention of smoking, Gas detection/ alarms,
automatic Fire Water deluge/ sprinkler system. Automatic starting of Fire Water Pumps, fire drills
etc.
Standardisation and strict quality control in manufacture of cylinder and fittings, industry inspection
system for quality assurance etc.
i) Bulk by Rail - LPG movement in bulk rake of 68 wagons, unloading/ loading in lot of 34 (500 MT)
wagons. Provision of remote operated water sprinklers at Gantries.
ii) Bulk by Road - Safety training of Driver/ Attendant, special safety precautions during loading/
unloading LPG.
i) Distributor's godown - Properly designed distributor godowns with mastic covered flooring, fire
fighting equipment etc.
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ii) Delivery Equipment - Standardisation approach with cage design, use of 3 wheeler scooters/
delivery van.
iii) Training of delivery boys/ mechanics - suitable training programme by oil companies with
certification scheme.
iv) Customer Education - Audio Visual aids/ films on TV , booklets on LPG safety emergency complaint
cells etc.
v) Control and Supervision - System of periodic inspection to oversee and control the working of the
distributors by oil companies.
Ministry of Petroleum & Natural Gas in 1986 had set up a committee headed by Mrs. Sudha Joshi, the then
M.P. and Marketing Directors of Oil Companies as members with a view to provide better services to LPG
users with due regard to safety.
Brief summary of important recommendations w.r.t. safety aspects are outlined below :
-Streamlining of registration/ release of LPG connections, issuing booklet like ration card to each consumer
etc.
Distributors to check weight of at least 10% of cylinders before accepting deliveries. Oil
companies to ensure pre-delivery checks by the Distributors.
- Oil companies to use only aluminium/ PVC seals with different colour code of filling plant
embossed.
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Periodic safety inspection of equipment at consumer premises.
Emergency and complaint cells to be operated by oil companies in LPG marketed towns.
Consumer education in LPG SAFETY THROUGH TV media and curriculam to high school.
- Oil companies to strengthen the inspection system of LPG bottling plants and working of the
Distributors.
Establishment of more bottling plants near the consuming centre to the extent possible.
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iii) Safety Aspects in Design, Operation and Maintenance of LPG
Plants / Cylinders and Accessories.
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.
Notes :
1. 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.
2. 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.
3. Distance of stabling line shall be as per minimum Railway Standards.
4. 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
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>450-750 60
>750-3800 90
> 3800 120
Top surfaces of all the vessels installed in a group shall be on the same plane. It is
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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 Tank truck shall be loaded/ unloaded with suitable arrangement for cold flaring of
hose content, if used at the end of the operations.
5.5.10 LPG tank truck parking area (Bulk/ Packed) shall be located in a secured area 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.
5.6.2 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.
Empty cylinders storage area shall be properly segregated from filling machines
by 5 M (Min.). Cylinders shall always be stacked vertically with maximum stack
height of 1.5 m. For details of cylinders stacking pattern refer Figure - I .
5.6.4 LPG cylinder filling machines and other related testing facilities shall be provided
in sequential order.
5.6.5 A separate shed shall be provided for carrying out degassing of defective
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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.
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iv. Design Pressure : 14.5 Kg/ cm2g on top as per IS: 4576 at 55 oC.
v. Marketable LPG conforming to IS: 4576 can have a maximum vapour
pressure of
vi. 16.87 Kg/ Sq.cm.g at 65 o C temperature. LPG with higher vapour
pressure are not
vii. expected to be stored in bottling installations.
viii. The recommended design pressure and temperature shall be treated as
MINIMUM
ix. requirement and other design consideration and Statutory requirements
shall also be
x. considered.
xi. v. Other Design Considerations
xii. Corrosion Allowance : minimum 1.5 mm
xiii. Radiography : Full
xiv. Stress Relieving : 100% irrespective of thickness.
xv. Wind pressure : as per IS: 875
xvi. Earthquake pressure : as per IS:1893
xvii. Hydro test pressure : As per Design Code
xviii. Where ever extreme climatic conditions or security reasons warrants,
suitable alterations
xix. in design can be made with approval from statutory bodies.
xx. 6.2.2 FITTINGS
xxi. Spheres/ bullets other than underground shall have a single nozzle at the
bottom for
xxii. liquid inlet as well as outlet. The nozzle shall be full welded pipe, stress
relieved along
xxiii. with the vessel and shall extend minimum 3 meters from the shadow of
the sphere/ bullet.
xxiv. A remote operated shutdown valve (ROV) shall be provided on this
bottom nozzle at a
xxv. distance of at least 3 meters from the shadow of sphere/ bullet. The nozzle
pipe shall
xxvi. have a minimum slope of 1.5 o.
xxvii. There shall not be any other flanges, manhole, instrument tapping on this
nozzle upto the
xxviii. ROV or on sphere/ bullet bottom. In order to avoid stress on the nozzle
due to relative
xxix. settling of support and storage vessel, suitable supports for the bottom
nozzle shall be
xxx. provided.
xxxi. The top vapour zone of the vessel shall be provided with nozzles for
vapour outlet,
xxxii. recirculation wherever applicable. These lines shall be provided with fire
safe ROV.
xxxiii. ROVs for vapour / recirculation lines should be provided at the ground
level with an
xxxiv. isolation valve at top. In case, ROV is provided at top of the vessel, there
is no need to
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xxxv. provide an isolation valve.
xxxvi. Fire safe ROVs shall also be provided on liquid line at TLD & Tank
wagon gantry &
xxxvii. isolation valve (quick closing type) on the entry of liquid lines at LPG
filling shed at a
xxxviii. safe location.
xxxix. Nozzles for two independent level indicators of different type, a high
level switch, two
xl. safety relief valves, pressure gauge and a manhole shall be provided on
top.
xli. All the fittings shall be suitable for use at the design parameters of the
storage vessels and
xlii. for the temperatures appropriate to the worst operating conditions. The
remote operated
xliii. valves on the storage vessel connecting pipelines shall be fire-safe type
conforming to
xliv. API 607 or equivalent.
xlv. The flange joints of these valves shall either have spiral wound metallic
gaskets or ring
xlvi. joints. Plain asbestos sheet / reinforced gaskets shall not be used. Gasket
used shall
xlvii. conform to ASME B16.20 or equivalent. The studs used shall conform to
ASTM A 194
xlviii. Gr 2 H/ ASTM A 193 Gr B7 or equivalent.
xlix. Flange connections shall be of minimum of 300 lb rating confirming to
ANSI B16.5 class
l. 300 or equivalent. All tapings or openings shall be of minimum 20 mm
thickness.
li. 6.2.3 INSTRUMENTS
lii. i) The storage vessel shall have minimum two independent level
indicators and one
liii. independent high level switch. High level alarms shall be set at not more
than 85% level
liv. of the volumetric capacity of the vessel. Audio visual indication shall be
at local panel &
lv. control room. On actuation of high level alarm, the ROVs of the affected
vessel shall
lvi. close.
lvii. ii) Each storage vessel shall have at least two safety relief valves with
isolation
lviii. arrangement set at different values and at not more than 110% of design
pressure of the
lix. vessel and each having 100 % relieving capacity adequate for limiting the
pressure build
lx. up in the vessel not more than 120% of design pressure.
lxi. The relieving load for the safety valves, shall be based on fire condition
and no credit
lxii. shall be taken for fire proofing on the vessel, if provided.
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lxiii. The discharge of safety valves shall be connected to flare system,
wherever available. In
lxiv. this case, safety valves shall have lock open (or car seal open) type
isolation valves on
lxv. both sides of safety valves.
lxvi. In case of non availability of flare system, the discharge from safety valve
shall be
lxvii. vented vertically upwards to atmosphere at an elevation of 3 meter
(minimum) for
lxviii. effective dispersion of hydrocarbons. In this case, isolation valve on down
stream of
lxix. safety valve is not required. A weep hole with a nipple at low point shall
be provided on
lxx. the vent pipe in order to drain the rain water which may get accumulated
otherwise.
lxxi. 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
i. shall be provided on top of safety valve.
Typical safety fittings on a LPG storage vessel are indicated in Figure-II.
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(ii) Excess flow check valve & non return valve shall be provided in LPG unloading
lines with isolation valves
(iii) Weigh bridge of suitable capacity
Additionally following shall be ensured.
i. Suitable provision shall be made for evacuation of LPG from bulk storage vessels to
tank truck or another vessel to empty the vessel in case of emergency or for
statutory testing.
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The hose coupling shall be provided with a cap or blind flange by which the nozzle
can be closed when not in use.
6.5 UTILITIES
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(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.
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.
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Typical sketch of a bottling pump installation is enclosed as Figure-III.
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/cm 2 or the
maximum pressure which could be developed by the transfer equipment or any
other source etc, whichever is higher and comply with the following :
(i) Piping shall conform to the provisions of ANSI B 31.3.
(ii) The material shall conform to API 5L Gr. B / ASTM A106 Gr B or eqv.
(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.
(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.
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If pressure relieving devices discharge to atmosphere, the discharge shall be done in
a safe manner.
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.
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- 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.
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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 -
(i) Uncontrolled leakage occurring
(ii) A fire occurring in the vicinity
(iii) Lightning and thunder storm
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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 55 OC 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.
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7.2 BULK HANDLING FOR MOVEMENT BY RAIL
LPG is moved in Tank Wagons by the Railways. These wagons are designed by RDSO
and are fitted with various devices as shown in Figure-VII.
The loading facilities are similar as for tank truck loading while unloading of LPG
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 with protruding nails. 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).
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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
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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.
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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 bonding connections.
23. Reverse or remove and replace the "Flammable" placard with "Dangerous -
Empty" placard.
24. Remove the "Stop - Tank Wagon Connected" sign and wheel blocks.
25. Any defect observed in the tank wagon should be noted on the appropriate
forms and routed in accordance with acceptable procedure.
26. Notify the railways in writing about release of wagon and ensure that it is
removed from the siding promptly.
27. Gauge the storage tanks, within the installation, which have received the LPG
to determine that the liquid level is appropriate.
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
OF SICK/LEAKY TANK WAGONS
(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
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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.
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(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.
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.
Activity on bottling line including valve change, shall be carried out by trained
personnel.
8.2 BOTTLING OPERATIONS
The Bottling Operations can be classified under following heads :
i) Receipt of LPG cylinders
ii) Filling & 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 as per IS:5845/ IS : 13258
- `O' Ring (joint packing) is present and there is no apparent damage to valve.
- Tare weight is legible.
(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
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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.
(c) 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 `O" 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 `O' ring defect, the `O' 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 safe practices shall be observed :
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
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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.
8.2.4 Auxiliary Operations
a) Cylinder requiring valve removal and valve fixing
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.
b) Purging of cylinders
- New cylinders and cylinders degassed for repairs shall be purged of air prior to be
taken up for refilling with LPG. Following safe procedure shall be observed for
purging of LPG cylinders :
- Connect the cylinder valve to vacuum pump and evacuate air so that the pressure
in
cylinder is brought down to maximum 0.35 kg/cm2 absolute. Inject LPG vapour in
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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 :
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.
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1. All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard ;
OISD-STD-105 on "Work Permit System".
2. Electrical maintenance / inspection, provisions of OISD-STD-137 shall be adhered
to.
9.5 INSPECTION & MAINTENANCE OF VARIOUS FACILITIES IN LPG
INSTALLATIONS :
9.5.1 STATIC EQUIPMENT :
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 microalloyed
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, NON-RETURN VALVES,
EXCESS CHECK VALVES, PIPELINES, VALVES AND FITTINGS :
All new valves shall be inspected and tested to ensure conformation to required
specifications and for leak tightness. All new valves shall be inspected and tested
as per requirements of API-598. The closure torque during testing for hand wheel
and gear operated valves shall not be greater than that obtainable by hand
tightening. Further fire safe valves shall comply with following :
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
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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 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
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condition. Permanently deformed flanges must be replaced.
9.5.3 PIPELINES
(i) Inspection data as well as thickness data of newly constructed pipelines shall be
collected at the earliest and with in two years of their commissioning to function
as base for establishment of corrosion rates.
(ii) External inspection of LPG pipelines within the installation shall be carried out
once in three years which shall include both visual inspection and ultrasonic
thickness readings taken externally.
The details of thickness survey shall be maintained on an isometric sketch.
(iii) Comprehensive inspection of LPG pipelines shall be carried out once in 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
pipe-to-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 few locations. Pipelines crossing the roads and dykes shall be
inspected once in ten years by digging and exposing the line completely.
Provisions of OISD Standard ; OISD-STD-130 on "Inspection of Pipes and Valves and
Fittings" shall be followed.
9.5.4 HOSE AND FLEXIBLE CONNECTION :
LPG hoses shall be inspected & tested at maximum interval of 4 months as detailed
in
OISD Standard ;. OISD-STD-135 on "Inspection of Loading and Unloading Hoses for
petroleum products" and records maintained thereof.
LPG hoses shall be discarded after 3 years of service or earlier in case the permanent
elongation exceeds 5%.
9.5.5 STRAINERS AND FILTERS :
Strainers & filters shall be inspected and cleaned as per following frequency, unless
sluggish operation warrants earlier inspection :
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TYPE / LOCATION FREQUENCY
Air filters Weekly
Strainers on evacuation Weekly
line
Pump Suction Quarterly
Up stream of filling Quarterly
carousel
up stream of PD-Meter Quarterly
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:
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.
9.5.6 ROTARY EQUIPMENT :
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 Rotating Equipment components shall be followed.
9.5.7 FILLING EQUIPMENT
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) CAROUSEL
i) Drive units
ii) Centre column
iii) Running Rail
iv) Introduction and Ejection devices
v) Filling machines
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b) Check Weigh Scales
c) Chain/ Roller conveyor
d) Drive Units for Conveyors
e) CVT-leak detector
f) Cylinder Test Bath
g) General
9.5.8 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
Pressure gauges shall be checked daily for its proper functioning and shall be
calibrated once in 6 months.
d) FLOW MEASURING DEVICES
All flow measuring devices shall be checked daily for proper functioning and
calibration shall be carried out monthly and quarterly as applicable.
9.5.9 FIRE FIGHTING EQUIPMENT
Fire fighting equipment shall be inspected and tested as per. OISD-STD-142 -
"Inspection of Fire Fighting Equipment".
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 their approval has been granted”
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
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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.
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iv) Fire Protection Facilities /Equipment.
LPG Bottling Plants are generally located away from populated areas in view of
hazardous nature of product. With the passage of time these plants get surrounded by
settlements/ residential localities in the absence of any statutory regulations prohibiting
their construction.
Due to large quantities of highly inflammable product stored in the Bottling Plants these
pose safety risk to the plant as well as to the surrounding environment. Therefore, it is
very much essential that elaborate in-built Fire Protection Facilities are installed at the
LPG Bottling Plants.
Specific norms of various types of fire extinguishers and equipments to be kept at plant
has been stipulated in the OISD 144.
In case of fire fighting system detailed design and operating parameters has been
defined.
Provisions for fire fighting facilities for plants construction as per OISD 144 is different
from plant constructed as per OISD 169. Majority of plants are as per OISD 144 . Details
of Fire fighting facilities as per OISD 144 are as below.
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8.2 DESIGN CRITERIA FOR FIRE FIGHTING SYSTEM
i) Facilities shall be preferably designed on the basis of plant area , LPG handled,
Inhibition around the plant and availability of Auxiliary source of water and other
facilities near the plant.
iii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump Houses,
Bulk Lorry and Tank Wagon Gantries shall be fully covered by medium velocity water
spray system.
iv) 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. The layout shall permit access from at least two directions.
v) Detection of fire for automatic actuation of medium velocity water sprinkler system
shall be provided at all critical places like LPG Bulk Storage, Tank Truck/ Tank Wagon
Gantry, near Carousal, LPG pump/ Compressor House, Evacuation, Valve Change
Shed etc.
Water is used for fire extinguishment, fire control, cooling of vessels/ equipment and
exposure protection of equipment and personnel from heat radiation.
The Fire Water pumping requirement shall be calculated based on minimum spray
density as under :
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LPG Shed - 10.2 LPM/Sq.M
House
a) Storage Vessels
In case of Bulk Storage of LPG, automatic detection of heat for automatic actuation of
medium velocity (MV) sprinkler system having remote/ local operated deluge valve with
spray density of 10.2 LPM/Sq.M. of surface area shall be provided. For water flow
calculations adjoining vessels within distance of R+30 Mts. (Where R is the Radius of the
LPG vessel and 30 Mts. shall be measured from the periphery of the LPG vessel), water
density for cooling shall be considered at the rate of 10.2 LPM/Sq.M. surface area.
b) Sheds
MV sprinkler system having remote operated deluge valve and at critical places like near
carousal, evacuation, valve change shed, automatic detection of heat for automatic
operation of sprinkler system with spray density 10.2 LPM/Sq.M. shall be provided. The
shed has to be divided into suitable number of zones, each served by independent
deluge system. The adjacent zones are required to be operative around the zone under
fire and the same shall be considered as a single risk. (Note 1)
MV sprinkler system with automatic heat detection having remote/ local operated
Deluge valve with spray density of Max. 20.4 LPM/Sq.M shall be provided. (Note 1)
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 7 bays shall be considered
as single risk area. (Note 1)
MV sprinkler system with automatic heat detection having remote/ local operated
deluge valve with effective spray density of 10.2 LPM/Sq.M shall be provided. A
minimum of one gantry (600 MTs) shall be considered as single risk. The spray system
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shall cover tank wagons surface on either side of tank wagon gantry as well as the
associated LPG pipelines in the gantry.
The fire water system in the plant shall be designed to meet the highest fire water flow
requirement of a single largest risk of any of the above cases at a time plus 288 Cu.M/Hr.
for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
i) The Fire Water pressure system shall be designed for a minimum residual pressure of
7.0 kgs/ Sq.cm 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 30 M centre to centre. 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.
i) Water for the hydrant service shall be stored in any easily accessible surface of
underground concrete reservoir or above ground tank of steel or concrete. However,
above ground tanks shall be preferred in view of the availability of flooded suction
condition for easy start of fire water engines. The effective storage capacity shall be
not less than 4 Hrs. aggregate working capacity of Fire Water pumps.
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.
i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head. These pumps preferably should have a flooded suction.
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ii) There shall be jockey pump of capacity so designed to achieve a pressure of 7
kg./cm2 at the farthest end of the hydrant system . The system pressure has to be
maintained at 7 kg/cm2g with the help of Jockey Pump operating automatically.
The Jockey Pump shall be quick auto start-stop type with the help of pressure
switches.
A standby jockey pump shall be provided if the number of hydrant points are more
than 100.
iii) The fire water pump(s) including the stand by pump(s) shall be of diesel engine driven
type. 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.
a) Minimum 1 no.
v) Fire water pump house/ Fire water tanks or reservoir shall be located atleast 60 M
(minimum) away from LPG facilities.
vi) Fire water pumps shall be exclusively used for Fire Fighting purpose only.
i) Fire hydrant ring main should be normally laid above ground. Following precautions
should be taken if fire water ring main laid above ground:
a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground
level.
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 shall be laid underground at the following places :
a) Road crossings.
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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.
iii) If Fire water ring main laid underground the following precautions shall be taken :
a) The Ring main shall have at least one meter earth cushion in open ground and 1.2
meters cushion under the road crossings.
b) The Ring main shall be provided with protection against soil corrosion by suitable
coatings/ wrappings.
iv) Fire water ring main shall be sized for 120% of the design water rate. Design flow
rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.
v) The fire water network shall be kept pressurised to a pressure of about 7 kg/sq.cm.g
with the help of one or more Jockey pumps.
vi) Hydrants/ monitors shall be located bearing in mind the fire hazards at different
sections of the premises to be protected and to give most effective service.
vii) Hydrant/ monitors shall be provided for every 30 meters in case of hazardous areas
and may be spaced 45 meters in other areas.
viii) Connections for fire water monitors shall be provided with independent isolation
valves.
ix) Hose boxes with 2 nos. hoses and a nozzle shall be provided between the hydrant
points.
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x) Considering radiation levels in the event of a fire hydrants/ Monitors/ Control valves
shall be located at a safe distance (minimum distance of 15 mts.) and from hazardous
equipment/ buildings.
xi) 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.
All the materials used in fire water system using fresh water shall be of approved type as
indicated below.
In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally.
iv) Hydrant
Standpost C.S.
v) Monitors C.S.
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.
viii) Water monitor and hose box shall be painted "Luminous Yellow'.
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8.3.8 MEDIUM VELOCITY SPRAY SPRINKLER SYSTEM
i) Medium velocity sprinkler system based on heat and other detection shall be
employed.
ii) Quartzoid Bulb protection can be provided in open areas or in the sheds. The
Quartzoid Bulbs are designed to blow at 79 deg. centigrade (max.) and Quartzoid
Bulb network shall be maintained with plant air at a pressure of about 3.5
kgs/sq.cm.g through a restriction orifice and is such that the discharge of air through
one Quartzoid Bulb will depressurise the down stream side of the restriction orifice.
iii) The Electro pneumatic (E.P) heat detectors can be provided in the sheds and they
work on the following principle :
b) At 79 deg. C(max.)
The EP detectors are divided into groups and alternate detectors are connected in
one circuit. Two detectors from two different groups shall function/ operate for
actuation of sprinkler system.
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c) Fire siren.
d) The diesel pump will start based on their set pressure to supplement/ to maintain the
fire water pressure in the ring main.
The following areas shall be covered with the medium velocity spray system in the
LPG Bottling Plants :
MV sprinkler system having remote/ local operated deluge valves shall be provided.
Tank wagon loading/ unloading area shall be divided into six zones and one deluge
valve shall cover 12 LPG tank wagons at a time (60 Meters long on each spur).
Detection of heat for automatic actuation of MV sprinkler system having remote/ local
operated deluge valve shall be provided. One deluge valve shall be provided for a
maximum of 4 bays.
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d) LPG Sheds:
MV sprinkler system having remote/ local operated deluge valve and at critical places
like carousal, evacuation, valve change shed, automatic detection of heat for automatic
operation of sprinkler system shall be provided.
Based on heat detection automatic MV sprinkler system having remote/ local operated
deluge valves shall be provided.
i) Portable fire extinguishers shall be located at convenient locations and shall at all
times be readily accessible and clearly visible.
ii) The maximum running distance to locate an extinguisher in working areas shall not
exceed 15 meters.
iii) The top surface of the extinguisher shall not be more than 1.5 meter high.
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Area Portable Fire Extinguisher
Vessel(Each) extinguisher.
Tank Truck loading/ 1 No. 10 kg. DCP loading gantries Extinguisher in each bay.
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& 4 sand buckets & a stand shall be
provided in MCC/DG Room.
v) 100% spre CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher
Capacities) shall be stored in the LPG plant.
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 IS:4308. Nitrogen/ Carbon Dioxide shall be used as
expellent gas.
iii) Considering the large area, and no. of operations involved in Mega LPG Plants,
special fire fighting facilities like DCP fire tenders should preferably be provided.
iv) A trolley with suitable first aid fire protective accessories shall be readily available in
the LPG plant.
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ii) The hoses shall be of 15 Meters standard length and shall be provided with Gun
metal/ Aluminium alloy male & female couplings of instantaneous pattern.
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 :
blankets.
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purpose.
emergency.
breathing apparatus
(Cap. 30 minutes)
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15. Water jet blankets Min. 2 nos.
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.
ii) Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1
K.M. from the periphery of the plant).
iv) For fire condition the siren shall be walling 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.
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8.7 COMMUNICATION SYSTEM
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.
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 fighting
measures like starting of pumps, organising people, opening of valves etc. This will also
take care of automation failure wherever it is 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.
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Since the risk of BLEVE get reduced to insignificant level with the provision of mounded
storage, all new facilities for storage of LPG/ Propane should preferably be of mounded
type.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect
the shell material from overheating and consequent failure. The material provided for fire
proofing purpose shall be good enough to provide this protection for the initial 30-60
minutes. Based on this it is recommended to provide the minimum rating for fire
proofing as follows :
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.
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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.
i) Every Pump shall be in test run for atleast 10 min. 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.
i) The ring main shall be kept pressurised at 7 kg/sq.cm.g with the help of one or more
jockey pumps.
ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion.
iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/
operation and lubricated once in a month.
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(c ) 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) The sprinkler system in the sheds shall be tested by closing the outlet of the deluge
valve for correct remote operation once in a quarter.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.
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.
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8.10 CHANGES IN FIRE FIGHTING FACILITIES REQUIREMENTS PLANTS CONSTRUCTED
AS PER OISD 169 WHEN COMPARED TO OISD 144
(R + 15)
Fixed water system with manually operated isolation valve located at a safe distance of
15 meters shall be provided. For water flow calculations adjoining vessels within
distance of R + 15 Mts. (Where R is the radius of the LPG Vessels) shall be considered.
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 72 Cu. M
(i) Water for the hydrant service shall be stored preferably in above ground tanks for
availing the advantage of flooded suction to enable easy start of fire water pump. The
effective storage capacity shall be for two hours aggregate working capacity of fire
water pumps
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(i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head.
(ii) Atleast one fire water pump shall be of diesel engine driven type.
(iii) Pumps shall be capable of discharging 150% of its rated discharge at a minimum of
65% of the rated head.
(iv) Fire water pumps shall be exclusively used for fire fighting purposes only.
The fire water hydrant system is to be maintained in pressurized condition with water
pressure of 7 Kg/cm2 at Farthest end. Fire Fighting system is provided with Jockey
pump to keep the system in pressurized condition in Auto mode through pressure
switch.
Jockey pump is generally set to operate at minimum of 7 kg/cm2 and cut off pressure
at 8 kg/cm2 or more based on the pipeline network. A standby jockey pump is also to
be maintained.
Principle of Operation of Fire Fighting System in Auto Mode: In case jockey pump fails
to maintain pressure due to opening of outlets from the hydrant network, Fire Engines
are set logically with set pressure as below .
First Engine will start immediately on dropping the pressure below 7 Kg/cm2. In case
the Engine is able to maintain the pressure at 7 Kg/cm2 , next pump will not start. In
case the pump is not able to maintain the pressure, then subsequent pumps will start
one by one till it maintains the hydrant pressure of 7 Kg/cm2. Standby pumps shall not
be kept in Auto mode as long as the main pumps are in working order.
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Fire water network operates in Auto mode basis signal it receives from area under
emergency either through communication as below
In any of above case, logic shall be such that solenoid valve at the DV station gets
deactivated opening the sprinkler line.
After the Emergency is over, the effected Deluge valve shall be isolated by opening the
water balancing line which balances the inlet pressure and pressure of the deluge valve
thereby closing the deluge valve. Then reset the Fire Fighting panel alarm system and
reset the deluge valve at field.
8.12.1 GENERAL:
8.12.2 APPLICATION:
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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
The detection control equipment should be provided in the control room for
continous monitoring even during power failure.
(A) DETECTORS:
Amongst the various methods of detection available, the following proven systems for
LPG can be considered.
i) Catalytic detectors
ii) Infra-red detectors
a. This is a critical equipment for plant’s 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
b. 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
c. The control equipment should have data logging facilities to provide print
outs of the history of the events with date and time of leakages
d. The control equipment should be able to generate at least two alarms at
different levels of LEL concentration of gas.
e. 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
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(C) 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.
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
of the wind direction
iii) The detectors especially the catalytic type should be positioned very close to the
potential source of leakage to avoid poisioning 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 pre-poritioned.
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Storage vessels ( above ground ) – 1 No. top and 1 No. near bottom ROV
Hot Work & Cold Work to be carried out with proper Work Permit system as per
OISD -105
Plant Should ensure closure of the permit on completion of job and maintain records
for future reference
Identity card should be issued to all the contractor employees by the contractor
authorizing their entry to the Work area
Safety shoes, hand gloves, helmets etc. and other related protective equipments shall
be used while carrying out the specified job.
Specific care shall be taken while working at heights and entry to a vessel .
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Explosimeter to be used to ensure that the working araea is free from LPG before
commencing any hot work.
Earthling of all electrical equipments to be checked for its connectivity and earth
resistance on regular intervals.
Welding Job shall not be carried out in explosive area unless or otherwise it is
unavoidable. However, In case it is to be carried out , specific permission must be
taken from the location incharge .
Floor area in all the operating sheds shall be maintained clean and free from foreign
materials like soap solution, oil spillage, cotton waste etc.
Cylinder handling shall be carried out on the conveyor . No rolling of cylinder should
be allowed. In case it is not possible for handle the cylinders ( due to its shape &
Size ) in conveyors then mechanized trolleys / puller or pusher to be used to handle
such cylinders.
Maintain the speed of carrousel at its optimum i.e. 66 to 72 seconds per revolution.
Use proper Non sparking tools and tackles for M&R jobs involving LPG equipments.
Use proper earthings while loading / Unlaoding tank truck / tank wagons .
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Stacking of cylinders shall be made as per VSCR recommendations with identified
lots.
De-pressurize the defective cylinders before opening the valves for replacement.
Use Torque wrench for fixing valve in the cylinders with allowable torque.
Vapour extraction system should be inter-locked with the operation of the carrousel.
Ensure proper setting of relays for all motors connected with conveyors, compressors
, pumps etc.
Ensure use of recommended Oil, Greases for use in mechanical equipments and chain
conveyor.
Trained operator should carry out connection and disconnection of tank trucks hoses
/ arms and supervise the loading / unloading operation.
Ensure working condition of ELD, OLD on daily basis thru test cylinders.
Ensure use of rubber mats while loading / unloading of cylinders at the platform
from the trucks and in front of electrical panels.
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Medical facilities to be kept ready.
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v) Safety in Transportation of LPG in Bulk, Emergency Rescue
Systems.
The road transport of Petroleum products has significant presence and needs
special attention. Complete details of treatment for handling emergency
arising out of road transportations have been provided below:
(b) Copies of the ERDMP shall be made available by the Industry to all
the field locations i.e.Plants, Installations, POL Depots, Terminals /
Installations, Refineries, Gas Processing Plants, Dispatch units of
etc., the concerned District Administration, Police Stations and Fire
Brigades en-route and within vicinity of specified tank truck routes,
oil industry sales personnel of concerned area as may be required.
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TREM Card format including sample as per details shown in
Schedule-IX and Route Map shall be provided to the Tank Truck
Crew which should be referred in case of an emergency.
(a) rush fire tender to the incident site with all necessary fire fighting
equipments;
(b) prepare a contingency plan for removal of tank truck, if not
leaking, in consultation with installation personnel;
(c) dispersal of vapours by water spray away from inhabited area, in
case of leakage. Extinguish the fire, in case leakage source cannot
be stopped;
(d) allow the fire to burn under controlled conditions if isolation is
not possible in case of gaseous fuels;
(e) save human lives and salvage material from incident affected
truck;
(f) liaise with fire brigade in the adjoining town for additional help, if
necessary;
(g) arrange water through muni
(h) cipal water tanker or any other source;
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In addition to the above, the Schedule-V shall be followed.
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(a) to keep watch on the overall situation.
(b) rush ambulance to the incident site if casualties are reported.
(c) direct cranes or any other such equipment to carry out rescue
operations.
(d) issue warning messages to people through public address
system, if any evacuation is required.
(e) arrange emergency vehicles for evacuation purposes.
(f) give direction to hospitals having burns injury ward for readiness
to receive patient in case of incident involving fire.
(g) provide basic amenities, e.g., water, electricity, food and shelter
to the affected people as required.
A. In-Plant Resources
Mechanical Equipment:
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15. Spark-proof wrenches, hammer and tools.
16. Barricading masts and ropes / tapes
17. hoses
18. Chain pulley blocks and stay pipes
19. Small valve keys for operating valves in the tank truck
Electrical Equipment :
1. Gas Explosi-meter
2. Flame-proof torches
1. Gloves:
i) Rubber gloves
2. Face shields
3. Soap
4. Blanket.
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5. Water Gel Blanket
6. Breathing Apparatus (With spare filled cylinder and Canister gas masks)
2. Fire-water Hoses
Communication Equipment :
2. Whistles
2. Area maps
3. Diversion Boards
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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.
b) Careful selection and correct use of equipment.
c) Observance of safety and security regulations.
d) Proper and constant training and guidance to all personnel working in the Plant,
with particular reference to product knowledge and maintenance practices.
e) Good House-keeping.
f) Constant supervision and alertness.
13.1.2 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 firefighting
but also for other likely emergencies. Likewise, for emergencies of large
magnitude Emergency Response Plan (or Disaster Management Plan) to be drawn out in
coordination with related outside 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
a) Through water drain valve while draining.
b) Leaking sample valve.
c) Breakage of glass on Sight Flow Indicator on the pipeline.
d) Opening of pop-off valve, gland/ packing etc.
e) Leakage through LPG compressor/ pump.
f) Leakage due to bursting/ rupture of hose or through sviwel joints of body arms.
g) Leakage from the filling guns.
h) Escape of liquid/ vapour LPG during maintenance/ repairs.
(b) VEHICLE :
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i) Exhaust of vehicle, if effective spark arrestors are not provided.
ii) Operation of non-FLP electrical switches such as vehicle ignition.
iii) Spark from the loose contact on vehicle batteries.
iv) Spark from exhaust of railway engine.
v) Cinders from the steam locomotives.
(c) OTHERS
i) Landing of crackers (flying type ) in hazardous areas.
ii) Chiselling/ hammering.
iii) Spark from studed shoes, with steel button by friction against ground/ metal.
iv) Lighted agarbatti in a truck.
v) Excessive release of vapour beyond safe limit and fire due to outside source of
ignition.
vi) Lighting
vii) Smoking.
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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.
d) Exercise care to ensure that static charge is not generated in LPG vapour cloud. For
this purpose solid jets of water must be avoided, instead fog nozzles should be used. e)
Fire fighters should advance towards a fire down wind if possible.
f) 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.
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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/cm 2g 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 vessel with water sprays reduces the heat
input to the vessel and thereby reduces the pressure, thus, reducing the rate of
discharge from the relief valves.
(iii) Leakage of LPG burning at the outlet of a cylinder valve: Extinguish the fire by means
of a portable fire extinguisher, or smoothening with a thick non-synthetic cloth
(preferably wet) or sand/ earth etc.
Fix safety cap on the valve to prevent further leakage.
After the fire is extinguished, if the leakage cannot be stopped the cylinder should be
moved carefully to a safe location to vent out the contents under controlled conditions.
(iv) Fire of LPG vapour escaping from a damaged vessel fitting (flame not playing
on vessel)
Allow fire to continue till exhaustion.
Spray vessel with water to cool it, if vessel is being heated by radiation from the flame or
if flame is endangering other plant equipment.
Cool adjacent vessels and structures.
(v) Fire at Safety Relief Valves of vessels exposed to adjacent fire.
(vi) Fire in Oil storage area adjacent to LPG storage :
Start water sprays only on those LPG vessels exposed to fire/ heat.
Isolate affected vessels and run out fire water hoses in case hose stream cooling
becomes necessary.
Water pressure in LPG vessels.
If LPG vessel's SRVs have started blowing vapour, take no further action (apart from
cooling) unless vessel pressure continues to rise.
If fire enters LPG storage area, concentrate available cooling water on LPG vessels, most
affected.
Do not try to empty LPG vessels exposed to fire. They become more vulnerable to
overheating as their liquid content decreases.
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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.
(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) Sounding the emergency (fire) alarm.
(ii) Shutting off the LPG supply to any leakage point/ fire.
(iii) Summoning the fire brigade/ police.
(iv) Fire control, with first aid, 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.
(vii) Cooling of vessels/ cylinders and other equipment/ facilities.
(viii) Closing down all operations in the plant including closure of valves and stopping of
pumps.
(ix) Preventing all sources of ignition in case of LPG leakage.
(x) Evacuation of vehicles.
(xi) Evacuation and mustering of personnel.
(xii) Establishing an emergency fire-control centre.
(xiii) Traffic control.
(xiv) Stations and duties of all personnel.
(xv) Policing of affected areas.
(xvi) Any other specialised duties.
(xvii) Display of fire brigade, ambulance, Police telephone numbers etc.
(xviii) All clear signal by competent person.
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(i) The fire brigade should be made familiar with the layout of the plant and the location
of important equipment/ facilities provided, and their method of use. Mock fire drills/
exercise jointly by plant personnel and local fire brigades shall be planned.
(ii) 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.
(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.
1. SAFETY POLICY
2. SAFETY COMMITTEES
3. EMPLOYEE PARTICIPATION
6. OPERATING PROCEDURES
7. TRAINING
8. CONTRACTORS
SAFETY POLICY
DEPOT/TERMINAL.
SAFETY COMMITTEE
EMPLOYEE PARTICIPATION
OPERATING TECHNOLOGY
OPERATING PROCEDURES
MECHANICAL INTEGRITY
COLD WORK
ELECTRICAL JOBS
GRINDING / EXCAVATION
FIRE ENGINE
GRASS CUTTING
PAINTING OF P/Ls
GUIDELINES
TO BE TAGGED
RESPONSIBILITIES - ISSUER
AREA TO BE INSPECTED
WORKING CONDITIONS
RESPONSIBILITIES - RECEIVER
CLOTHING OF WORKERS
FIRST AID:
· Preserve life - the overriding aim of all medical care, including first aid, is to save
lives
· Prevent further harm - also sometimes called prevent the condition from
worsening,or danger of further injury, this covers both external factors, such as
moving a patient away from any cause of harm, and applying first aid techniques to
prevent worsening of the condition, such as applying pressure to stop a bleed
becoming dangerous.
· Promote recovery - first aid also involves trying to start the recovery process from
the illness or injury, and in some cases might involve completing a treatment, such as
in the case of applying a plaster to a small wound
Disposable gloves.
Cotton buds - for cleaning small wounds or removing obvious foreign objects.
Sterile eye pads - as a temporary dressing and cover for injured eyes.
Cling film - for applying over serious burns to keep air out. This helps relieve
pain and prevents infection. As it won't stick to the burn, it can also be easily
removed later by medical staff treating the burn.
Antacid : Indigestion
Constipation : Laxative
HANDLING EMERGENCIES
STEP 2 In case, phone facility is not available in the vicinity, TT crew should send the
message through any other means such as any other truck / TT or any volunteer to
the nearest Bottling Plant, Retail Outlet, Oil Installation of any Oil Company, Police
Post and Fire Brigade, (All Retail Outlets, Oil Installations, Fire Brigade & Police
Station should be provided with telephone nos. of the nearest LPG Installation).
STEP 3 In case the message is received first by Police Post or Fire Brigade or Depot /
Installation of any Oil company, they should inform the nearest Bottling Plant of any
company.
STEP 4 While conveying the information to LPG Installation by TT Crew, Fire Brigade,
Police Post, Depot / Installation as may be the case, the following information should
be collected and relayed :
a) Location of incident, milestone no., Highway No., nearest village / town and any
other easily identifiable landmark.
b) Registration No. of TT, name of the Transporter. c) Date and time of incident. d) TT
empty or full and the quantity. e) Proceeding from/ on way to.
j : Help required (tools & tackles, i.e., jacks etc., crane, transfer of product, towing of
vehicle, fire tender, fire fighting equipment, ambulance etc).
x) Electrical Safety
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.
STATIC ELECTRICITY
GENERATION OF SPARKS
MOVING VEHICLES
BONDING
GROUNDING
xi) Housekeeping
Blocked pathway .
• TOOLS
• *Properly stored
• AISLES
• *Clear marking
FLOORS
GROUND
• Good Order
• Water
• Electricity
House Keeping :-
d) Record Keeping.
WASTE MANAGEMENT
v) The following accessories/ first aid items shall be provided in the plant :