Professional Documents
Culture Documents
Number:OISD/DOC/2015/393
Page No.I
Prepared by
FUNCTIONAL COMMITTEE ON
LIQUEFIED PETROLEUM GAS (LPG)
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian
petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of
Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of
constantly updated world-scale standards for design, layout and operation of various equipment,
facility and activities involved in this industry. Moreover, OISD was also given responsibility of
monitoring implementation status of these standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts
and iterating through seeking & validating inputs from all stake-holders – operators, designers,
national level knowledge authorities and public at large – with a feedback loop of constant
updation based on ground level experience obtained through audits, incident analysis and
environment scanning.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in
the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not
affected implementation of the OISD standards. It also goes to prove the old adage that self-
regulation is the best regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides
other issues, calls for total engagement from all levels of the stake holder organizations, which
we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director
FOREWORD
The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies ,
operating and maintenance practices was hardly in existence at a national level.
This, coupled with feed back from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas
installations.
With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) for
formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of functional
committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.
Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as
well as with industrial applications due to its unique properties and environmental
benefits. The document on "LPG Bottling plant operations" was prepared in
1994. The present document "LPG Installations" has been prepared by the
functional based on the accumulated knowledge and experience of industry
members and updation of national and international codes and practices related
to LPG.
NOTE
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil
and gas industry under Ministry of Petroleum & Natural Gas. These are the
property of Ministry of Petroleum & Natural Gas and shall not be reproduced or
copied and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby disclaims any liability or
responsibility for loss or damage resulting from their use.
These documents are intended to supplement rather than replace the prevailing
statutory requirements.
Sr.Number:OISD/DOC/2015/393
Page No.V
FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)
NAME ORGANISATION
LEADER
Sh. R. Krishnan Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS
Sh. A.N. Biswas Deptt. of Explosives, Nagpur
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
Sr.Number:OISD/DOC/2015/393
Page No.VI
NAME ORGANISATION
LEADER
Sh. S.C. Tandon Indian Oil Corporation Ltd., ( Ref.)
MEMBERS
Sh. H.G. Bhinde Indian Oil Corporation Ltd., ( Mkt.)
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
Sr.Number:OISD/DOC/2015/393
Page No.VII
CONTENTS
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SL. NO. DESCRIPTION PAGE NO
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1 Introduction 1
2 Scope 2
3 Definitions 2
4 Statutory Rules/ Regulations 4
5 Installation Layout 5
6 Design Considerations 11
7 Storage & Handling of Bulk LPG 24
8 Bottling Operations 44
9 Maintenance & Inspection 48
10 Statutory Testing of LPG Cylinders 71
11 Fire Protection Facilities 77
12 Gas Monitoring System 91
13 Emergency Management Plan 94
14 Safety Audit 104
15 References 128
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Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 1
LIQUEFIED PETROLEUM GAS (LPG)
INSTALLATIONS
1.0 INTRODUCTION
Liquefied Petroleum Gas (LPG) handling, bottling and distribution throw major
challenges due to its inherent properties. Major incidents i.e. fires/explosions in LPG
facilities in world have underlined the need for total in depth review of design,
procedures, maintenance, fire fighting and safety aspects in LPG handling.
The oil and gas industry over the years have learnt lessons from fires and explosions and
have been updating and standardising design, operations, bottling and distribution of
LPG.
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times
heavier than air. It is readily liquefied under moderate pressures. The density of the
liquid is approximately half that of water and ranges from 0.525 to 0.580 @ 15 oC.
The pressure inside a LPG storage vessel/ cylinder is equal to the vapour pressure
corresponding to the temperature of LPG in the storage vessel. The restriction on
vapour pressure is stipulated by IS-4576.
LPG has an explosive range of 1.8% to 9.5% volume of gas in air. This is
considerably narrower than other common gaseous fuels. This gives an indication of
hazard of LPG vapour accumulated in low lying area in the eventuality of the leakage
or spillage.
Water, being insoluble in LPG, if present in LPG can cause rust and corrosion and
freeze-up of valves, drain valves, excess-flow check valves, cylinder valves and
regulators thereby affecting their functioning and at times can lead to leakage of LPG.
LPG liquid has low viscosity of around 0.3 CS @ 45 oC and can leak when other
petroleum products normally cannot, thus demanding a very high integrity in the
pressurised system to avoid leakage.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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LPG even though slightly toxic, is not poisonous in vapour phase, but can, however,
suffocate when in large concentrations due to the fact that it displaces oxygen. In
view of this the vapour posses mild anaesthetic properties.
LPG is colourless both in liquid and vapour phase. During leakage the vapourisation
of liquid cools the atmosphere and condenses the water vapour contained in them to
form a whitish fog which may make it possible to see an escape of LPG.
The coefficient of expansion is around 0.00237 per oC. At liquid full condition any
further expansion of the liquid, the container pressure will rise by approx. 14 to 15
kg./sq.cm. for each degree centigrade.
LPG has only a very faint smell, therefore, ethyl mercaptan is normally used as
stenching agent for identifying the leakage as per IS : 4576.
2.0 SCOPE
This standard lays down the minimum safety requirements on design, layout, storage,
loading / unloading, operation, inspection & maintenance, fire protection, emergency
planning and safety audit systems of LPG Installations. This standard does not cover
process plants, the distribution of LPG to domestic & non-domestic consumers and
pipeline operations, road / rail transportation, refrigerated and mounded storage facilities
for LPG.
This standard is not applicable to bottling plants having a bulk LPG inventory not
exceeding 100 MT with minimum two storage vessels and with LPG bottling a total
quantity not exceeding 20 MT per shift of 8 hrs. The safety requirement for such LPG
Bottling plants are covered in OISD-GDN-169.
Safety requirements for mounded Storage facilities are covered in OISD-STD-150. The
requirements for Auto LPG Dispensing Stations are covered in OISD-STD-210.
The green belt /buffer zone beyond the installation boundary is outside the scope of this
standard. Such provisions may be considered based on local environment / security
requirements.
The fire protection and fire fighting requirement for the combined POL and LPG
facilities in the same premised shall be as given in OISD-STD-117 under item 2.4.
3.0 DEFINITIONS
Approved Type : Any equipment which has specific approval for use under specified
conditions by competent authority or authorised person as the case may be.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Area Classification : It is a method of classifying an area zone wise/ group wise based
on the presence of explosive gas/ vapour - air mixture vis-a-vis the requirement of
precautions for construction and use of electrical apparatus.
Bonding : Bonding is the process by which two electrical conducting bodies are
connected using a conductor to maintain electrical continuity to prevent sparking between
two conducting bodies.
Bulk Vessels : A pressure vessel used for more than 1000 litres water capacity for
storage or transportation of LPG.
Bullet : A horizontal cylindrical pressure vessel used for storage or transportation of LPG
by rail/ road.
Compressed Gas : Any permanent gas, liquefiable gas or gas dissolved in liquid under
pressure or gas mixture which in a closed container exercises a pressure either exceeding
2.5 kg/sq.cm. abs @ 15 oC or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50 oC or both.
Cylinders : A portable LPG container upto 1000 litres water capacity used for both
domestic and industrial purposes.
Filling Ratio : It is the ratio of weight of LPG in a container to the weight of water the
same container can hold at 15 oC.
Flammable (or Inflammable) : Any substance which when tested in a specified manner
will ignite when mixed with air on contact with a flame and will support combustion.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Hot Work : It is an activity which may produce enough heat to ignite a flammable air-
hydrocarbon mixture or a flammable substance.
Kerb Wall : A wall of appropriate height and size constructed of suitable material and
designed to contain the LPG spillage and to direct it to a safe location around the storage
vessel.
Liquefied Petroleum Gas (LPG) : The term applies to a mixture of certain light
hydrocarbon predominately C3 & C4, derived from petroleum & natural gas which are
gaseous at ambient temperature and pressure, may be condensed to a liquid state at
normal ambient temperature by the application of moderate pressure and conforming to
IS : 4576 or IS: 14861.
Purging into Service : is the replacement of air in a closed system by an inert substance
and replacement of the later by combustible gas, vapour, or liquid.
Tare Weight : The weight of the cylinder together with any fitting permanently attached
to it including the weight of valve.
Water Capacity : The maximum volume of water in litre that the a container can hold at
15 oC.
The LPG installation & various facilities are covered under many regulations and require
specific approval / licence from concerned statutory authorities. The various regulations
applicable to LPG installation facilities are as below :
b. Static & Mobile Pressure Vessels (unfired) Rules-1981 (Under Indian Explosives Act
1884).
e. The Standards of Weight & Measures Rules - 1987 Under Weight & Measures Act -
1976.
i. Environmental Regulations :
In addition to the above Statutory regulations, there are various recommended guidelines
emerging out of the various Committees set up by the Govt. of India from time to time for
streamlining/ improving the safety standards of LPG Bottling/ Distribution:
c. Sudha Joshi Committee for better services to LPG users - 1987 (Ministry of
Petroleum & Natural Gas).
5. 1 GENERAL
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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The layout of the LPG facilities including the arrangement and location of plant roads,
walkways, doors and operating equipment shall be designed to permit personnel and
equipment to reach any area effected by fire rapidly and effectively. The layout shall
permit access from at least two directions.
The general principles of layout of LPG storage, bottling and bulk handling facilities have
been detailed. The various facilities within LPG installation shall be located based on
Table-I and Table-II.
5.2.1 LOCATION
While assessing the suitability of any site for location of LPG installation, the following
aspects shall be considered :
c) The topographical nature of the site with specific reference to its effect on the
accidental release of LPG.
d) The availability of space for future extension of LPG facilities, if any, shall also
comply with the safety norms.
e) The meteorological data of the location including predominant wind direction &
velocity, high flood level, temperatures etc.
The separation distances as given in Table- I & II are the distances in plane between the
nearest point on a vessel other than the filling/ discharge line and a specified feature, e.g.
adjacent vessel, site boundary etc.
5.3 LAYOUT
The following aspects shall be considered while establishing layout of LPG storage
vessels. Bullets or spheres are used for above ground storage of LPG.
a. The access of mobile fire fighting equipment to the storage vessels shall be at least
from two sides.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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b. Longitudinal axis of static storage vessels (bullets) shall not be pointed towards other
vessels, vital equipments e.g. LPG cylinder sheds, tank lorry/tank wagon gantries,
LPG pump house and buildings wherein control panels for fire and gas detection/
actuation panels are situated.
c. Storage vessels to be located preferably in downwind of potential ignition sources at
lower elevation.
Kerb wall shall be provided around all sides of the storage vessel with concrete
flooring of the ground under vessel and extending upto minimum distance of D/2 or
5M whichever is higher and atleast 5 M (min.) from the edge of the storage vessel
with a slope of 1:100 (min.).
Kerb wall height shall be minimum 30 cm but shall not exceed 60 cm otherwise
evaporation of spilled LPG may get affected.
Spillage diversion area shall be located at a distance where the flames from fire will
not impinge on the vessel. This distance shall not be less than the diameter of the
nearest vessel or minimum 15 M. No accumulation of LPG should be possible
underneath the storage vessel in any condition.
(b) PIPING - Only piping associated with the storage vessels shall be located within the
storage areas or between the storage area and the manifold system.
(c) SURFACE DRAINAGE - In order to prevent the escape of spillage into the main
drainage system, surface water from the storage area and from the manifold area shall
be directed to the main drainage through a water seal to avoid the spread of LPG.
(d) GROUPING - Vessels shall be arranged into groups, each having a maximum of six
vessels. There shall be minimum spacing as specified in Table-I between adjacent
vessels. Each group shall be separated by roads on all four sides for easy access and
emergency handling.
(e) Spheres and bullets shall be treated as separate groups with minimum 30 M distance
between two groups.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Top surfaces of all the vessels installed in a group shall be on the same plane. It is
necessary to provide separate manifolds preferably with independent pumping facilities
for bullets and spheres. Alternatively, fail safe interlocks like two way valves shall be
provided so as to avoid any chances of overfilling of adjacent vessels due to gravitation.
5.5.1 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.
5.6.1 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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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INSTALLATIONS
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
cylinders.
5.6.6 Cylinder storage shall be kept on or above grade and never below grade in cellar
or basement.
5.6.7 Filled cylinders shall not be stored in the vicinity of cylinders containing other
gases or hazardous substances.
5.6.8 Escape routes shall be specified and marked in LPG sheds for evacuation of
employees in emergency.
5.6.9 There shall be sufficient no. of crossovers to avoid trapping of personnel in LPG
sheds by conveyors, cylinders and other facilities. Further, sufficient no. of escape
routes shall be provided.
5.6.10 All steps forming part of the escape routes shall be minimum 1.2 M with treads 30
cms (minimum) and maximum rise of 15 cms.
5.7.1 Properly laid out roads around various facilities shall be provided within the
installation area for smooth access of fire tenders etc. in case of emergency.
5.7.2 Proper industry type boundary wall atleast 3 M high with 0.6 M barbed wire on
top shall be provided around the installation unless the bottling plant is protected
as a part of refinery complex.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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5.7.3 Emergency exit with proper gate shall be provided in the earmarked zone.
5.7.4 In case provision for green belt is made, the same shall be segregated from
hazardous area by 1 M high wall / chain link fencing. Alternatively, it shall be
treated as a part of hazardous area.
5.8 UTILITIES
Utilities consisting of fire water pumps, admin. building, canteen, motor control centre,
DG room, air compressors, dryers etc. shall be separated from other LPG facilities and
located as per the separation as specified in Table-I.
TABLE - I
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1 2 3 4 5 6 7 8
---------------------------------------------------------------------------------------------------------------------------
3. Shed-LPG 30 30 15 30 50 30 15 60
7. Pump house/Comp.house 15 30 15 30 30 30 - 60
(LPG)
8. Fire Pump House/ storage tank 60 ** 60 60 60 60 60 -
---------------------------------------------------------------------------------------------------------------------------
Notes :
1. 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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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TABLE - II
DISTANCE BETWEEN LPG STORAGE VESSELS AND PLANT BOUNDARY/GROUP OF
BUILDINGS NOT ASSOCIATED WITH LPG INSTALLATION
---------------------------------------------------------------------------------------------------------------------------
Capacity of each Distance
vessel (Cu.Mt. of water) ( in metre )
---------------------------------------------------------------------------------------------------------------------------
10-20 15
> 20-40 20
>40-350 30
>350-450 40
>450-750 60
>750-3800 90
> 3800 120
--------------------------------------------------------------------------------------------------------------------
6.1 GENERAL
This section describes the design and safety features required in a typical LPG bottling
installation.
The minimum requirements w.r.t. design considerations and various fitting to be provided
LPG storage vessels shall be as under :
i. The storage vessel shall be designed in accordance with the codes i.e. ASME SEC.
VIII or IS-2825 or PD - 5500 or equivalent duly approved by CCE. Design shall take
into account the Static and Mobile Pressure Vessels (Unfired) Rules 1981 also.
A single code shall be adopted for design, fabrication, inspection and testing i.e.
ASTM and BS shall not be combined.
ii. Material shall be in line with design code. ASTM A516 Gr. 60 shall be used for
refinery service (BS-5500 shall not be used for the same) and for marketing
installation where H2S is not present ASTM A 516 Gr. 70 or A 537 CLASS 1 can be
used. Micro-alloyed steel containing Ni, Mo, Va shall not be considered. Maximum
specified tensile stress shall not be more than 80,000 psi.
iv. Design Pressure : 14.5 Kg/ cm2g on top as per IS: 4576 at 55 oC.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Marketable LPG conforming to IS: 4576 can have a maximum vapour pressure of
16.87 Kg/ Sq.cm.g at 65 o C temperature. LPG with higher vapour pressure are not
expected to be stored in bottling installations.
Radiography : Full
Where ever extreme climatic conditions or security reasons warrants, suitable alterations
in design can be made with approval from statutory bodies.
6.2.2 FITTINGS
Spheres/ bullets other than underground shall have a single nozzle at the bottom for
liquid inlet as well as outlet. The nozzle shall be full welded pipe, stress relieved along
with the vessel and shall extend minimum 3 meters from the shadow of the sphere/ bullet.
A remote operated shutdown valve (ROV) shall be provided on this bottom nozzle at a
distance of at least 3 meters from the shadow of sphere/ bullet. The nozzle pipe shall
have a minimum slope of 1.5 o.
There shall not be any other flanges, manhole, instrument tapping on this nozzle upto the
ROV or on sphere/ bullet bottom. In order to avoid stress on the nozzle due to relative
settling of support and storage vessel, suitable supports for the bottom nozzle shall be
provided.
The top vapour zone of the vessel shall be provided with nozzles for vapour outlet,
recirculation wherever applicable. These lines shall be provided with fire safe ROV.
ROVs for vapour / recirculation lines should be provided at the ground level with an
isolation valve at top. In case, ROV is provided at top of the vessel, there is no need to
provide an isolation valve.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Fire safe ROVs shall also be provided on liquid line at TLD & Tank wagon gantry &
isolation valve (quick closing type) on the entry of liquid lines at LPG filling shed at a
safe location.
Nozzles for two independent level indicators of different type, a high level switch, two
safety relief valves, pressure gauge and a manhole shall be provided on top.
All the fittings shall be suitable for use at the design parameters of the storage vessels and
for the temperatures appropriate to the worst operating conditions. The remote operated
valves on the storage vessel connecting pipelines shall be fire-safe type conforming to
API 607 or equivalent.
The flange joints of these valves shall either have spiral wound metallic gaskets or ring
joints. Plain asbestos sheet / reinforced gaskets shall not be used. Gasket used shall
conform to ASME B16.20 or equivalent. The studs used shall conform to ASTM A 194
Gr 2 H/ ASTM A 193 Gr B7 or equivalent.
Flange connections shall be of minimum of 300 lb rating confirming to ANSI B16.5 class
300 or equivalent. All tapings or openings shall be of minimum 20 mm thickness.
6.2.3 INSTRUMENTS
i) The storage vessel shall have minimum two independent level indicators and one
independent high level switch. High level alarms shall be set at not more than 85% level
of the volumetric capacity of the vessel. Audio visual indication shall be at local panel &
control room. On actuation of high level alarm, the ROVs of the affected vessel shall
close.
ii) Each storage vessel shall have at least two safety relief valves with isolation
arrangement set at different values and at not more than 110% of design pressure of the
vessel and each having 100 % relieving capacity adequate for limiting the pressure build
up in the vessel not more than 120% of design pressure.
The relieving load for the safety valves, shall be based on fire condition and no credit
shall be taken for fire proofing on the vessel, if provided.
The discharge of safety valves shall be connected to flare system, wherever available. In
this case, safety valves shall have lock open (or car seal open) type isolation valves on
both sides of safety valves.
In case of non availability of flare system, the discharge from safety valve shall be
vented vertically upwards to atmosphere at an elevation of 3 meter (minimum) for
effective dispersion of hydrocarbons. In this case, isolation valve on down stream of
safety valve is not required. A weep hole with a nipple at low point shall be provided on
the vent pipe in order to drain the rain water which may get accumulated otherwise.
Weephole nipples shall be so oriented that in case of safety valve lifting and consequent
fire, the flame resulting from LPG coming out from weephole does not impinge on the
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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sphere or structure. A loose fitting rain cap with a chain (non sparking) fitted to vent pipe
shall be provided on top of safety valve.
i. Excess flow check valve & non return valve shall be provided in LPG loading lines.
ii. A vapour return line with an isolation valve connected back to the storage vessel/
suction line with NRV.
iii. Properly designed loading arm or LPG hoses shall be provided at the end of filling
and vapour return lines for connecting to the tank truck vessel. The loading shall be
provided with break away couplings or smart hoses shall be used. Loading arm shall
be of approved type and be tested as per OEM recommendations. In case, LPG hoses
are used, it shall conform to OISD-STD-135.
iv. The hose - coupling / flange joint shall be of Class 300 lb rating with metallic
gasket. The hose coupling shall be provided with a cap or blind flange by which the
nozzle can be closed when not in use.
v. Weigh bridges of suitable capacity for road / rail movements and mass flow meters
for pipeline transfers shall be provided. The mass flow meters shall be certified for its
use with LPG.
Unloading of LPG from tank truck is carried out with vapour compressors using pressure
differential method of liquid transfer. The compressor used for unloading shall be
provided with the following facilities:
(ii) Excess flow check valve & non return valve shall be provided in LPG unloading lines
with isolation valves
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 15
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ii. Tank truck shall be loaded/ unloaded with suitable arrangement for flaring of hose
content at the end of the operations.
iii. The unloading arms shall be used for unloading the LPG TT at LPG installation. In
case, LPG hose are used, it shall conform to OISD-STD-135 or equivalent as
approved by CCOE.
iv. The hose - coupling / flange joint shall be of 300 lb rating with metallic gasket.
The hose coupling shall be provided with a cap or blind flange by which the
nozzle can be closed when not in use.
i) The cylinder filling area shall be completely open type and covered from top with
roof designed to ensure good natural ventilation. RCC roofing shall not be used.
The filling area shall not be on upper floors of building or in cellars unless
specifically required on account of extreme weather conditions.
ii) As far as possible, the floor area shall not have any channels or pits. Where these
are necessary for conveyors or other equipment like weigh machine etc., suitable
gas detection system shall be provided. Additionally, proper ventilation system
through ducts fitted with blowers shall be provided to release LPG outside of the
shed at safe location. The whole of the LPG filling shed flooring shall be
provided with mastic flooring.
All carousels & leak detectors including electronic shall be of approved type.
iii) Adequate lighting shall be provided in the cylinder filling area. Emergency
lighting shall also be provided at critical places.
iv) Water drains from the cylinder filling area where they enter an outside drainage
system, shall be provided with vapour seals.
v) Proper access shall be made available for other fire fighting equipment i.e. fire
tender, foam trolley etc.
vi) Cylinder storage area requirement shall be worked out based on the stacking
pattern of filled and empty cylinders as described in Figure-I.
vii) The filling machines shall be provided with auto cut-off system so that LPG
supply is cut off when the desired quantity of product has been filled in the
cylinders. The filling pressure shall not be more than the design pressure of the
cylinders i.e. 16.9 kg/sq.cm.g.
viii) Filling machines in a carousel/ stationary filling machines shall not have a
weighment error of more than + 150 gm of the net quantity of the LPG filled in
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 16
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ix) On-line check weigh scales with a minimum of 50 gms. graduation be installed
so that all the cylinders are check weighed after filling.
x) Compact Valve Tester to check valve and 'O" ring shall be installed on line.
Alternatively electronic leak detectors shall be provided.
xi) Water test bath or electronic leak detectors shall be provided to detect body and
bung leak cylinders.
xii) Vapour extraction system at strategic locations near carousel, cylinder evacuation
unit, valve changing unit, degassing shed and at locations where leaking LPG is
expected to accumulate shall be provided. Further, it shall be interlocked with
filling machine so that filling do not start without vapour extraction unit being
functional.
6.5 UTILITIES
The quality of instrument air shall conform to the requirements as recommended by the
manufacturers of instruments/ equipment:
Service water is required for the cylinder washing equipment and leak check bath,
compressor cooling and in hose stations for washing etc.
Water Quality
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.
i. LPG Pumps shall be designed for handling of LPG and safely withstand the
maximum pressure which could be developed by the product and / or transfer
equipment. Pumps shall conform to API 610 or equivalent.
ii. Check valves shall be installed on the delivery side of all centrifugal pumps.
iii. LPG Pumps shall be provided with suction and discharge pressure gauges, a high
point vent to safe height or flare, and a suction strainer.
iv. Double Mechanical seal with seal failure alarms shall be provided.
v. A pressure switch actuating a low pressure alarm in control room and locally shall
be provided, taken from discharge end.
vi. Pumps shall be designed to build a discharge pressure such that the pressure at the
carousel filling machine is at least 5.0 kg/sq.cm.g. above the vapour pressure at
the operating temperature.
vii. Pumps shall have a by-pass valve and other suitable protection against high
discharge pressure on the delivery side.
viii. The electrical motor drive and switchgear shall conform to area
classification as per OISD Standard-113 / IS -5572. Belt drives shall be of the
anti-static type.
i. Compressors shall be suitable for handling LPG and designed to safely withstand
the maximum outlet pressure to which these will be subjected. Compressors shall
conform to API 618 or API 619 or equivalent.
ii. The belts used in shall be of antistatic type & fire resistant.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 18
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- Discharge safety valve and a vent valve, their outlets leading to flare/ safe height
outside the shed.
- Low Suction Pressure Trip
- Suction strainer
- High Discharge Pressure Trip
- High Temperature Trip
- Check valve in discharge
- A discharge to suction recycle valve for achieving capacity turndown during
startup.
iv. A suitable size scrubber or liquid knockout drum shall be installed upstream of the
vapour compressor. It shall be equipped with a gauge glass, safety relief valve, a
drain and high liquid level shut down device.
6.8 PIPING
Piping shall be designed for handling of LPG. Piping that can be isolated and need
thermal safety valves shall have minimum design pressure of 24 kg/cm2 or the maximum
pressure which could be developed by the transfer equipment or any other source etc,
whichever is higher and comply with the following :
(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.
Any equipment or section of pipeline in which liquid LPG may be trapped e.g.
between shut off valves, shall be protected against excessive pressure developed by
thermal expansion of the LPG by providing suitable thermal pressure relief valve(s).
If pressure relieving devices discharge to atmosphere, the discharge shall be done in a
safe manner.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
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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.
b. Each of cylinder emptying vessels mentioned above shall be equipped with the
following :
- Pressure gauge
- Level gauge
- high level alarm switch set at 85 % with trip / switchover arrangement.
- Pressure relief valves,
- Vent valves discharging to 1.5 m above the shed.
- Other trims like drain valve, utility connection.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 20
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(a) The new LPG cylinders containing air shall be evacuated with a vacuum pump.. The
evacuation facility shall consist of :
(b) Purging of tankers/ vessels shall be done using either Nitrogen or by filling water
and displacing with LPG vapours.
Stainless steel and copper free steel alloys are the preferred materials of
construction of equipment for mercaptan service. Aluminium of desired pressure
rating can also be used. Use of Iron or carbon steel shall be avoided as there is the
hazard of formation of iron-sulphur complexes which are pyrophoric. Copper or
copper bearing alloys shall not be used for mercaptan service as mercaptan readily
attacks and contaminates them.
(i) Seamless stainless steel piping shall be used. Threaded fittings can be used
provided they meet the service requirement ratings. A fluoroplastic tape sealant
is recommended.
(ii) Flexible connections shall be seamless stainless steel with pipe nipples welded
to each end.
(iii) Relief valves shall be full nozzle, disc type, closed bonnet carbon steel body
with 304 stainless steel trim and stainless or aluminized steel spring.
(iv) For transfer valves, stainless steel ball valves with fluoroplastic seats and
stainless steel (SS316) trim or their equivalent are recommended.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
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(vii) For pressure gauges, stainless steel diaphragm type is recommended with
stainless steel socket and tip.
(viii) Provision for analysis in line with IS:4576 or IS14861 as applicable shall be
made.
ii. All electrical equipment shall be selected considering the system neutral earthing.
iii. Electrical equipment including for lighting system shall conform to hazardous
area classification and be selected in accordance with IS:5571. These shall be
tested by agencies such as CMRI, ERTL, CPRI or independent test laboratory of
country of origin for such equipment. Indigenous Flameproof equipment shall
comply with relevant BIS standard as per requirements of statutory authorities.
All equipment used in hazardous area shall be approved by Chief Controller of
Explosives.
iv. For details on hazardous area classification, enclosure protection etc., OISD-
STD–113, OISD-RP-149, NEC – 1985, IS:2148, IS:5571, 5572, IS: 13408,
Petroleum Rules, 2002 shall be referred.
ii) Normal lighting system shall be on 415/ 240V AC supply, whereas emergency
lighting will be either on 220V or 110V DC.
iii) Lighting requirements provided during the failure of power supply for Normal
lighting are intended broadly,
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 22
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b. to gain access and permit ready identification of fire fighting facilities such as
fire water pumps, fire alarm stations etc.
c. Escape route for safe evacuation of operating personnel.
iv) Under normal operation, both emergency and normal lighting shall be fed by
normal power source. On failure of normal supply, emergency lighting shall be
transferred to emergency source until the start of D.G. set within 15 seconds.
Critical lighting (D.C. supply based) shall be normally kept ‘ON’. During power
failure, battery bank shall be used to provide power.
v. Low pressure sodium vapour lamps shall not be installed in hazardous areas.
vi. The illumination levels in different areas shall be as per good engineering
practice. Depending on the nature of job activities to be carried out the suggested
minimum illumination levels for various areas are covered in OISD-STD-149.
vii. The lighting fixtures on various circuits shall be suitably interlaced so that failure
of any one circuit do not result in complete darkness.
viii. Switches controlling the lighting fixtures and exhaust fan shall be installed
outside the battery room.
ix. Switches of lighting panels installed in hazardous area, shall have a pole to break
the neutral in addition to the poles for phases.
When the means of isolation is located in a non-hazardous area, the switch shall break
all poles including neutral or alternatively may break only live poles, the neutral being
isolated by a removable link.
i. All electrical equipment shall be suitably earthed. Earthing system shall cover the
following:
The earthing system shall have an earthing network with required number of earth
electrodes connected to it. The following shall be earthed:
System neutral
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 23
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ii. Installation earthing design shall be carried out in accordance with the requirements
of Indian Electricity Rules and IS : 3043. All earth connections should be visible for
inspection to the extent possible.
iii. Where installed, lightning protection shall be provided as per the requirements of
IS:2309.
iv. The resistance values of an earthing system to the general mass of earth should be as
below:
For the electrical system and equipment a value that ensures the operation of the
protective device in the electrical circuit but not in excess of 4 Ohms.
10 Ohms in the case of all non-current carrying metallic parts of major electric
apparatus or any metallic object.
v. The earth conductor shall be adequately sized to carry the applicable maximum earth
fault current without undue temperature rise. All joints shall be protected against
corrosion.
v. All the electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grid.
vi. The main earthing network shall be used for earthing of equipment to protect it
against static electricity.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 24
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vii. Every Sphere/ bullet shall be electrically connected with the earth in an efficient
manner by not less than two separate and distinct connections. The connections
and the contacts required shall have as few joints as possible. All joints shall be
riveted, welded or bolted and also soldered to ensure both mechanical and
electrical soundness. The resistance to earth shall not exceed 7 Ohms and the
resistance to any part of the fitting to the earth plate or to any other part of fitting
shall not exceed 2 Ohms.
viii. All joints in pipelines, valves in installations, and associated facilities and
equipment for LPG shall be made electrically continuous by bonding or
otherwise; the resistance value between each joint shall not exceed 1 Ohm.
7.0 GENERAL
This section deals with the safe practices and provisions applying to unloading of
bulk LPG and storage of bulk LPG at installations. There should be strict compliance
w.r.t selection, deployment of proper skilled manpower for effective operation and
maintenance.
The tank truck for road movement shall be designed, constructed and tested in
accordance with the Static and Mobile Pressure Vessels (Unfired) Rules, 1981 and
OISD-STD-159.
2. Fire extinguishers shall be placed near the tank trucks during transfer
operations.
3. The first operation after positioning the truck should be to provide proper
earthing. Earthing shall be disconnected just before the release of the truck.
4. Before removing plugs or caps, always crack open to allow for release of
trapped LPG and further to ensure that the valves are effectively sealing.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
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5. Hoses shall be handled with care and inspected periodically as per OISD-STD-
135.
7. Do not expose hands, face or clothing to liquid LPG. Always use personal
protective equipment while making or breaking the connections to avoid cold
burns.
8. The master switch shall be put off immediately after parking the truck in
position. No electrical switch on the truck shall be turned " on" or " off" during
the transfer operation.
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.
Provision of two safety valves, level gauge, Excess flow check and control
valve on liquid and vapour lines, pressure gauge, temperature gauge on the
vessel / bullet.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
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Fire screen between cabin and vessel is provided. For this purpose, cabins
with metallic back cover without any opening will be considered as fire
screen.
2. Move truck to the loading bay/weigh bridge and record the weight of the empty tank
truck.
3. Place the truck on loading bay and place choke blocks at front and rear wheels. Keep
the truck in neutral mode with hand brakes "ON".
6. Make earthing connections of the vehicle at specified point to the fixed grounding
system.
7. Connect liquid and vapour lines suitably with the loading point. Crack open valves
on loading & vapour return lines and inspect hoses & connections for leakage.
Loading should start only when the system is leak free.
(ii) Weighment
The quantity of LPG filled shall not exceed the RLW of the tank truck.
10. Liquid level may be determined by roto-gauge or fixed liquid level gauge. Percentage
volume to be filled shall not exceed 85 % at 55OC i.e. the allowable filling limit as per
CMV Rules.
11. Where weigh bridge is used, it is necessary to determine the density of the product
being loaded to avoid excess filling in terms of volume. The weigh bridge shall be
periodically calibrated and stamped by Weights & Measures Authorities.
12. When the filling operation is in progress, the pressure within the tank truck vessel
shall be observed to ensure that it does not approach the start-to-discharge pressure
of the relief valve. Filling rate may be regulated as required.
13. The couplings may then be removed and plugs/caps replaced on the tank truck valves.
Re-check tightness with soap solution.
2. Liquid line and vapour line of the tank truck shall be connected to the respective
hoses fixed to the unloading point.
3. Test the connections for leaks by slightly opening the valves for pressurising.
When satisfied, valves on the tank truck and the receiving vessel shall be opened.
4. Start the LPG compressor. Vapours will be sucked from the receiving vessel and
will be discharged into the vapour space of the tank truck vessel creating pressure
differential thereby pushing the liquid from the tank truck vessel to the receiving
vessel.
5. Care should be exercised to see that the pressure created within the delivering
vessel does not reach or exceed the set pressure of the relief valve.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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6. An authorised person of the company shall supervise the transfer operation and
respond immediately in the event of an emergency.
7. After the liquid has been expelled, the vapour recovery operation may be started.
Care should be taken not to bring down the pressure of the delivering vessel
below 1.5 Kg/cm2g.
Checklist for bulk LPG tank Trucks at unloading locations is given at Annexure 7 –I.
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.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 29
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8. Ensure that the lower portion of flapper bridge at wagon side is fitted with rubber
or wooden padding.
10. Ensure that all fittings on the wagons are checked physically.
13. During unloading operation, after the liquid transfer is over, the wagon pressure
shall not be reduced below 1.5 Kg/sq.cm.(g).
1. Place the wagon on weigh bridge taking care to see that all the four wheels are
properly accommodated on the platform. Engage hand brakes.
2. Ask loco to move away and exhibit caution sign at suitable distance away
from the wagons on both ends.
3. Switch off loco engine, if parked nearby.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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13. Open the tanker filling line valve and vapour return line valve.
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.
21. Release all the wagons on the loading points in the lot.
22. Check the gross and net weight at the weigh bridge.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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5. With the plugs removed, screw pipe nipples into the outlets of the valves after
first having applied a modest quantity of sealant to the male threads, keeping
the sealant away from the end of the thread. Tighten nipples with a pipe
wrench.
6. Connect the two liquid transfer unloading swing arms or hoses to the nipples
attached to the liquid discharge valves. Connect the vapour or equalizing
swing arm or hose to the nipple attached to the vapour valve. In most of the
cases, these connections will be made by means of either a ground joint union
or a hose coupling.
7. In the event, a ground joint union is used, no gasket will be required. If a hose
coupling is employed, ensure that the appropriate gasket is in place. Make sure
that they are secured tightly by appropriate means.
8. After the vapour and liquid hoses have been connected and before any valve is
opened, the valves on the tank wagon are crack opened in order to apply
pressure to the hoses / loading arms as a test for leaks.
9. If any leak appears, the valve should be immediately closed and corrective
measures applied.
10. Recheck the lines and connections to make sure that they are connected
correctly.
11. After the liquid and vapour lines have been secured and tested, both liquid
education valves should be opened slowly and completely. Then, open all
other valves in the liquid line working from the tank wagon to the storage
tank.
12. If the tank wagon pressure is higher than that in the storage tank, do not open
the valves in vapour line or operate the compressor. When the rate of liquid
flow drops to an unsatisfactory level with the storage tank filling valve wide
open, open the vapour valves between the tank wagon and the storage tank.
13. At this point, make sure that the control valves at the compressor are in a
position which allow the compressor to draw vapours from the storage tank
and force it into the tank wagon, then start the compressor.
14. When the tank wagon is held at a pressure of 2.0 to 2.5 Kg/sq.cm. above the
storage tank pressure, the tank wagon should be emptied into the storage
vessel.
15. A flow of gas instead of liquid through the sight-flow glass in the unloading
line indicates that the wagon is empty of liquid. Recheck this by opening the
sample valve in the tank wagon dome.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
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16. When the tank wagon is emptied of all liquid, stop the compressor and close
the liquid valves beginning at the storage tank and progressing to the tank
wagon.
17. If the facilities are so arranged that vapours may be removed from the tank
wagon, the pipeline at the compressor should be arranged so that the
compressor will draw vapour from the tank wagon and force it into the storage
tank.
18. In this operation, the vapour should be discharged below the surface of the
liquid in the storage tank to hasten the liquefaction and, in turn, help prevent
excessive pressure in the storage tank.
19. Restart the compressor and when the tank wagon pressure is reduced to about
1.5 - 2.0 Kg/ sq.cm., stop the compressor and close all the valves in the vapour
line.
20. After bleeding off the pressure in the hoses, disconnect both the liquid and
vapour lines. Replace all the plugs in the tank wagon valves and the unloading
fittings.
21. Recheck sample valve, gauging device and thermometer well to determine that
they have been returned to their original condition and are closed tight. Lower
the dome cover carefully and lock it in place with the locking pin or secure by
appropriate means.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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-Vapour should be discharged through high rise vent, keeping the steam on.
-Between the two vacuum cycles, nitrogen/inert gas should be used for breaking
the vacuum.
- Cycle should be repeated till the LPG concentration is found below the
end point of LPG (for butane, it is 4% by volume when purging is done by
nitrogen). Periodically, samples should be drawn from suitable location and
analysed for LPG concentration.
-Finally the vessel should be flushed with air to displace the nitrogen. Barrel
should be tested finally with explosive meter to ensure that hydrocarbon
concentration is below 10% of LEL.
The design and construction of cargo carrier is in line with International Maritime
Organisation (IMO) Gas code.
The deep well pump supplies liquid to the booster pump to send the product ashore.
In pressurised ship, liquid is withdrawn by pressurising the tank through vapour
compression from other tanks. All semi and fully-refrigerated tankers are provided
with cargo heaters to enable the vessels to discharge into pressure storage ashore
and a booster pump if the discharge pressure is significantly above 9 bars. Each
cargo tank is provided with the following equipment:
a) Two cargo pumps, one each on either side of the longitudinal bulk head.
b) Liquid discharge line from the tank dome, connected to the main liquid line.
e) Two liquid level indicating devices one on each side. These usually consist of a
float attached to a self winding tape which moves up and down, either on guide
wires or inside a guide tube. The liquid level is read off the tape through a gas-
tight window at the top of and outside the tank.
f) Two sets of purge lines at the top and bottom of the tank. These are used to
distribute inert gas or vapour for gas-freeing or gassing-up of the cargo tanks.
h) Sample tubes.
Safety Devices
(c) Overfill alarm. When actuated, this will shuttle main loading valve and sound
an alarm.
However, the design of the tankers with regard to provision of facilities, equipment,
accessories and safety features must be in accordance with the IMO requirements.
The following facilities on transfer piping between Terminal and Shore tanks should
be provided:
(a) ROVs at both the ends of transfer line.(Additional ROV at critical locations in
the pipe line route.)
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(b) Relief valves on liquid line to surge vessel with an audible alarm system
connected to high safe venting system
(d) Protection of pipeline against corrosion, particularly when the pipeline passes
under public road way, which is likely to be water-logged
(e) Pipe work passing public road way be designed to acceptable public highway
authority standard in terms of roadway axle weights
Transfer of LPG from ship to terminal and vice versa is accomplished using
loading arms of approved type as per OCIMF guidelines. Provision of vapour return
facility shall be made.
In case of pressurised gas transfer, it is observed that the pumping rate falls off
gradually due to back pressure of the shore tank. A suitable vapour recovery system
or re-liquefaction of the gas from the receiving tank shall be provided.
It is essential that the ship and terminal operators are familiar with the basic
characteristics of each other's facilities, are aware of the precise division of
responsibilities and are able to communicate effectively during the time they are
together involved in the joint operation of cargo handling.
7.3.6 COMMUNICATION
Before any cargo transfer operation, it is imperative that the intended procedures are
thoroughly discussed between the responsible personnel from the tanker and the
terminal with a view to make both sides fully conversant with the characteristics of
the tanker and shore cargo handling systems, the envisaged operational and safety
procedures and requirements and the parameters to be adhered to during the
transfer.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(a) The names and roles of terminal and ship personnel who will be responsible for
cargo transfer operations may be noted.
(b) The terminal representatives shall check that pre-arrival instructions to the ship
on cargo, cargo disposition and cargo conditioning have been carried out. They
also shall check that all necessary tanker equipment inspection and tests have
been performed.
(c) Similarly, the tanker's officers shall satisfy themselves that the relevant
terminal equipment and inspection checks have been carried out satisfactorily.
a) Liquid level in the vessel shall not exceed the permissible limits. Filling shall not
exceed safe permissible filling ratio.
b) Vessel shall be inspected daily for any LPG leakage and corrective action taken.
c) All gauges, viz. High level alarm, measuring gauges, pressure gauges, temperature
gauges should be kept in operating condition at all times and be checked daily.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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carried out in accordance with IS:1448. During handling of LPG samples, the
following safety precautions shall be followed :
(i) Special sampling bombs shall be used for LPG sampling. Arrangement of rupture disc
or any other suitable safety relief device shall be incorporated in the sampling bomb.
(ii) Sampling bombs shall be inspected periodically and tested hydrostatically at regular
intervals. Record of such inspection/test shall be maintained.
(iii) Sample bombs shall be earthed effectively before and during discharge of sample.
(iv)LPG samples shall be collected only in open/ventilated areas and the person taking
the sample shall stand on the windward side.
(v) The sampler shall wear protective goggles, hand gloves, shoes etc. while taking
samples.
(vi)Samples, after collection, shall be properly labeled and kept at designated place.
(vii) Sampling of LPG should preferably be done in bombs with provision of pre-
charge at one end. This will not only eliminate the possibility of undesirable presence
of air in the bomb, which may become a safety hazard, but also minimises flashing of
sample during collection, thereby providing a truly representative sample.
7.5.2 DRAINING
Storage vessel should be drained regularly for its water content, sediments, caustic
contents etc. Draining operation should be carried out under the supervision of an
authorised person.
For draining of water from LPG vessels , following procedure shall be followed :
(i) The valve nearer to the vessel shall be opened first and closed. Then, draining shall
be carried out by gradually opening the valve farther from the vessel. The operation
shall be repeated till LPG release starts.
(ii) It shall be ensured that the drain outlet is at a safe distance from the vessel so that
accidental ignition of any escaping vapour would not expose the vessel to flame
impingement.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ANNEXURE - 7 - I
- Properly fitted spark arrestor of make and design approved by CCE, Nagpur.
- Proper Fittings i.e. SRV, EFCV, temperature & pressure gauges etc. as SMPV Rules & OISD-STD-
159.
- 2 nos. 10 kg. DCP extinguishers in easily accessible and removable position with Truck No. date of
checking and charging painted on it.
- Provision of quick closing manifold valve with lever indicating close and open status.
ELECTRICALS :
- Electrical wiring is insulated and provided with suitable over current protection.
- Readily accessible master switch for switching off the engine is provided inside the cabin.
TANK FITTINGS :
TANK TRUCK
- Fuel tank is protected by means of stout guard and fuel tank cap is locked.
GENERAL
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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TANK TRUCK :
- Carries TREM CARD, instructions booklet detailing instructions on handling emergencies en route.
- HAZCHEM sign, name of contractor with address and telephone No. displayed prominently.
TANK FITTINGS :
- Liquid / vapour lines are adequately anchored and are well protected by means of stout steel guard.
- Liquid/ vapour pipe lines are in single piece from excess flow check valve to discharge valves - Safety
fittings viz., safety valve, roto-gauge, pressure gauge and temperature gauge are adequately protected.
- Operative fittings like roto gauge, pressure gauge and temperature gauge are operational.
GENERAL :
- 4 Nos. caution sign board with luminous paint for stopping traffic in case of any emergency.
Based on the nature of defects either all the deficiencies should be got corrected at the unloading location
itself or the tanker should be allowed to get the repairs done en route and submit the details at loading
location.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ANNEXURE - 7- II
CHECKLIST AT UNLOADING LOCATION FOR BULK LPG TANKWAGONS
The matter regarding tank wagon not complying with any of above checks shall be taken up with loading
location for corrective action.
ANNEXURE 7 - III
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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SHIP:_________________________________________DATE:______________
PORT &BERTH:_________________________________TIME:______________
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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We have checked with each other the items on the above check list and have satisfied ourselves
that the entries we have made are correct to the best of our knowledge.
8.1 GENERAL
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.
(a) Pre-filling operation : Cylinder before filling shall be checked for following :
(b) Filling operation - All cylinders shall be filled on gross weight basis on filling
machine.
(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
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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.
Handling and storage of LPG cylinders shall be governed by Gas Cylinders Rules, 1981.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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All above cylinders shall be clearly identified, with markers, to their nature of defects
and shall be kept capped during storage.
c) LPG cylinder storage - All cylinders shall be stacked vertically (with valve in
upright position) in not more than 1.5 m.
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.
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.
Cylinder having defective valve and with bung leak shall have to undergo valve
removal and valve refixing 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.
- 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
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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
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.
It shall be ensured that the drums are emptied of mercaptan to the extent possible. The
empty drums then can be washed with water and detergent, followed by wash with a
5% bleach solution. After again washing with copious amount of water, the drums
will be ready for disposal.
Leaks and spills of mercaptan can be treated with commercially available masking
agents (e.g.Aldor and Neutroleum Alpha etc.) to make them odourless. Large
mercaptan spills shall be covered with sand or activated carbon or any other
absorbing material, which are then buried or incinerated. The area over the spill
should then be washed with ordinary household bleach solution and then thoroughly
with water. Dry bleaching powder should never be used in treating mercaptan spills.
A violent reaction could occur.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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9.1 GENERAL :
This section covers the maintenance and inspection practices to be followed to ensure
safe and trouble free operation of various equipment.
Necessary personal protection equipments such as Hand gloves, Safety shoes, Helmets,
Safety belts, Safety goggles etc. shall be used ( for details refer OISD- STD-155).
Any maintenance, inspection, disassembly or removal of fittings while any part of the
system is under pressure shall not be carried out without a proper work permit and
approved procedure.
1. All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard ;
OISD-STD-105 on "Work Permit System".
Weld cracking has been experienced in the lower half portions of LPG vessels.
Small amounts of wet H2S present in LPG is supposed to be responsible for this
in service stress corrosion cracking of welds. LPG vessels made from micro-
alloyed high tensile steels have shown greater susceptibility to such cracking.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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.
Gate valves, which have been used for throttling, shall be measured for thickness at the
bottom between the seats, as serious deterioration may have occurred because of
turbulence. This is particularly weak point because of the wedging action of the disc
when the valve is closed. The seating surface shall be inspected visually for defects
which might cause leakage. The wedging guides shall be inspected for corrosion and
erosion. The stem and threads on the stem and in the bonnet of valves shall be examined
for corrosion which might cause failure., The connection between stem and disc shall be
inspected to assure that the disc will not detach from the stem during operating.
Swing check valves shall be inspected by removing the cover or cap. The clapper or disc
shall be checked for freedom of rotation and the nut holding it to the arm shall be checked
for security and presence of a locking pin, lock washer, or tack weld. The arm should be
free to swing and the anchor pin shall be inspected for wear. Also the seating surface on
both the disc and valve body shall be checked for deterioration by feeling them with the
fingers. After the valve has been reassembled, it shall be hydrostatically and/or
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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
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.
(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
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.
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%.
Strainers & filters shall be inspected and cleaned as per following frequency, unless
sluggish operation warrants earlier inspection :
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:
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.
a) CAROUSEL
i) Drive units
ii) Centre column
iii) Running Rail
iv) Introduction and Ejection devices
v) Filling machines
9.5.8 INSTRUMENTATION
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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a) TEMPERATURE INDICATING
DEVICES
Temperature indicating devices shall be checked daily for its proper functioning and
shall be calibrated once in 6 months.
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.
All flow measuring devices shall be checked daily for proper functioning and
calibration shall be carried out monthly and quarterly as applicable.
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.
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”
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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i. No Flame proof or intrinsically safe apparatus shall be opened and no work likely
to impair the safety characteristics of such apparatus or electric wiring connected
thereto shall be carried out until all voltage has been cut off from said apparatus
or wiring. The voltage shall not be restored thereto until the work has been
completed and the safety characteristics provided in connection with the apparatus
and wiring have been fully restored.
ii. Use of soldering apparatus or other means involving flame, fire or heat or use of
industrial type of apparatus in a zone “1” area shall be permitted for the purposes
of effecting repairs and testing and alterations, provided that the area in which
such apparatus or wiring has been installed, has first been made safe and certified
by a competent person after testing with an approved gas – testing apparatus to be
safe and free from inflammable vapours, gases or liquids and is maintained in
such conditions, so long as the work is in progress.
iii. No alteration that might invalidate the certificate or other document relating to the
safety of the apparatus, shall be made to any apparatus.
Replacement fasteners, nuts, studs and bolts shall be of the type specified by the
manufacturer for the particular apparatus. No attempt shall be made to replace or
repair a glass in a flameproof enclosure e.g. in a luminaire or other enclosures,
except by replacement with the complete assembly or part obtainable from the
manufacturer, complying with the approval certificate.
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.
vi. A system shall be established to record the results of all inspections and the action
taken to correct defects.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ANNEXURE 9-I
MAINTENANCE SCHEDULE
COMPRESSORS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
1. Check Lub. Oil Level of plunger *
pump unit & top up if necessary.
12. Change lube oil filter and clean LPG Suction filter. *
--------------------------------------------------------------------------------------------------------------------------------
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ANNEXURE 9-II
MAINTENANCE SCHEDULE
CENTRIFUGAL PUMP
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Annually
Yrly
(1) (2) (3) (4) (5) (6) (7)
--------------------------------------------------------------------------------------------------------------------------------
10. Overhaul. *
--------------------------------------------------------------------------------------------------------------------------------
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ANNEXURE 9-III
MAINTENANCE SCHEDULE
FILLING EQUIPMENTS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half Annually
Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
I. CAROUSEL :
(A) DRIVE UNIT :
2 Grease bearing. *
--------------------------------------------------------------------------------------------------------------------------------
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(1) (2) (3) (4) (5) (6) (7) (8)
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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2. Air Filter :
a) Blow-out dirt & condensate. *
b) Clean. *
8. Complete overhauling. *
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(1) (2) (3) (4) (5) (6) (7) (8)
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 61
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ANNEXURE 9-IV
DIESEL ENGINES
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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MAINTENANCE STEPS
7. PREVENT OVERSPEEDING.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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DIESEL ENGINES
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MAINTENANCE STEPS REMARKS
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8. REMOVE AND CLEAN AIR COM- 8A FILL WITH CLEAN OIL, UPTO
PRESSOR BREATHER, IF MARK.
EQUIPPED.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 64
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DIESEL ENGINES
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MAINTENANCE STEPS REMARKS
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11. CHECK OIL LEVEL IN 11A CHECK FOR LEAKS, USE SPECI-
HYDRAULIC GOVERNOR,IF FIED ENGINE OIL FOR TOPPING
PROVIDED. UP.
12. START THE ENGINE AND NOTE 12A IF THERE IS A CHANGE IN OIL
THE OIL PRESSURE BOTH AT PRESSURE FROM THAT RECORDED
IDLING AND MAXIMUM SPEED. IN THE LONG BOOK ON EARLIER
OCCASION THEN STOP ENGINE
AND CHECK THROUGH TROUBLE
SHOOTING TECHNIQUE THE CAUSE
FOR OIL PRESSURE CHANGE AND
CORRECT IF NECESSARY (FOR
ASSISTANCE IN DIAGNOSING THE
CHANGE IN OIL PRESSURE
CALL YOUR SERVICE
REPRESENTATIVE IF NECESSARY.
13. RECORD OIL PRESSURE 13A REFER O&M MANUAL FOR LUB.
OIL PRESSURE LIMITS.
14. FILL FUEL TANK AT THE 14A USE CLEAN FUEL AND A STRAI-
END OF THE SHIFT. NER. ALSO CLEAN THE CAP AND
SURROUNDING AREA BEFORE
OPENING THE FILLER CAP.
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MAINTENANCE STEPS REMARKS
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DIESEL ENGINES
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MAINTENANCE STEPS REMARKS
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DIESEL ENGINES
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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10. CHANGE FUEL FILTER ELE 10B CLEAN SHELL FUEL FILTER
MENT WASHER AND "O" RING CHANGE ELEMENT WHEN RESTRI-
ON MOUNTING BOLT. CTION EXCEEDS VACUUM 200MM
OR MERCURY.
11. CHECK OIL IN ANEROID 11B USE SAME OIL AS USED IN OIL
CONTROL, IF REQUIRED. PAN.
12. CHECK & ADJUST BELTS.NEW 12B TIGHTEN BELT TENSION REFER
BELTS WILL STRETCH WITHIN MAINTENANCE MANUAL.
ONE HOUR OR USE THEY MUST
BE READJUSTED.
15. CHECK FAN HUB AND DRIVE. 14B USE SPECIAL TOOL FOR
TIGHTENING THE FAN HUB NUT.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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DIESEL ENGINES
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MAINTENANCE STEPS REMARKS
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10. CHECK GENERATOR BRUSHES AND 10C REPLACE AND CLEAN AS REQUIRED.
COMMUTATOR.
11. CLEAN ENTIRE ENGINE 11C HIGH PRESSURE AND SOAP WATER
MIXTURE PREFERRED AFTER
SPRAYING ENGINE WITH CLEANSER
DIESEL ENGINES
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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MAINTENANCE STEPS REMARKS
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12. TIGHTEN ALL MOUNTING BOLTS 12C TIGHTEN AS REQUIRED. OVER TIGHTEN-
AND NUTS. NING MAY RESULT IN DISTORTION OR
DAMAGE.
14. CHECK SEA WATER PUMP 14C CHECK FOR LEAKS/ OPERATION/
(MARINE APPLICATION ONLY) PERFORMANCE.
18. CLEAN RADIATOR 18C BLOW AIR THROUGH THE RADIATOR CORE
IN OPPOSITE DIRECTION TO THE NORMAL
FLOW OF AIR, IF WORKING UNDER
DUSTRY/ DIRTY CONDITIONS.
(REVERSE FLUSHING OPERATION)
20. ADJUST INJECTORS AND VALVES. 20C FINAL ADJUSTMENTS MUST BE CARRIED
OUT WITH ENGINE HOT AND WITH
CORRECT TORQUE AS SPECIFIED
(REFR O&M MANUAL).
DIESEL ENGINES
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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MAINTENANCE STEPS REMARKS
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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1. REPEAT ALL MAINTENANCE STEPS OF CHECK `A', `B', `C' & `D'.
2. THE `E' MAINTENANCE CHECK IS NECESSARY ONLY WHEN THE ENGINE OPERATING
CONDITIONS SIGNIFY DETERIORATION IN PERFORMANCE AS CAN BE ASCERTAINED
BY THE SYMPTOMS :
(1) HEAVY SMOKE (2) LOSS OF POWER (3) HIGH OIL TEMPERATURE HIGH WATER
TEMPERATURE (4) LOSS OF LUB. OIL PRESSURE (5) UNUSUAL NOISE & VIBRATIONS.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 71
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All cylinders used for filling LPG are required to be tested periodically to ensure
fitness of the cylinders for further service. First re-testing is required to be done after
7 years and subsequent re-testing after every 5 years interval. Such tests are to be
conducted by the CCE approved parties only.
All the LPG cylinders are depressurised in the approved premises by opening valves
by means of suitable adapters to ensure that the internal cylinder pressure is reduced
to atmospheric pressure. Only after depressurising the cylinder, cylinder valve is
removed and LPG cylinder is taken up for water filling and water is overflown and
retained in the cylinder for not less than one hour to remove any traces of LPG.
Degassing can also be achieved by stripping, Nitrogen purging, etc.
a) After depressurising the cylinder and emptying out the water, the same is kept in
inverted position and stroked gently with a non-sparking hammer such as wooden
mallet to remove any dust, rust or any loose remnants in the cylinders.
b) The depressurized cylinder bung is plugged and is taken up for surface cleaning by
immersing the cylinder in the caustic soda bath and soap water and the same is then
rinsed with water.
All the LPG cylinders shall be weighed and if the loss in tare weight is more than
5% of original weight such cylinders shall be segregated and scrapped. At the
time of weighing the weight of valve is also accounted.
a) The detailed visual inspection of the cylinder body shall be carried out as per IS:5845/
IS : 13258.
b) Depending upon the visual inspection, cylinders are segregated for scrapping, for cold
repairs and for hot repairs in case required.
c) The interior of the cylinder shall be examined by means of infra low voltage FLP
lamp. The internal examination shall be carried out as per IS:5845 / IS : 13258.
d) LPG cylinders selected at random may be cut into two holes for assessing internal
corrosion.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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e) In case of dented/ buckled cylinders, visual inspection of welds needs to be done more
carefully since the welds are more susceptible to cracking. Denting or buckling by
more than nominal plate thickness may be attended by repairs/ replacement.
a) All the LPG cylinders shall be taken up for hydrostatic test at an interval of 7 years
for first testing and subsequent testing after every 5 years in accordance with IS:8868.
Only water should be used as a medium for hydrostatic testing and the pressure to be
applied should be the test pressure marked on the cylinder body (25.35 kg/sq.cm) and
the same should be retained for a minimum period of 30 seconds. Any reduction in
pressure noticed during the test, any leakage, visible bulge or deformation should be
treated as a case of failure. Such cylinders should be properly marked, observation
recorded and segregated for scrapping and disposal.
b) Pressure Gauges shall be calibrated at least once a week and the Pressure Gauges used
for verification should be tested once in every three months.
a) Before commencing the fitting of valve operation, all the water inside the cylinder
should be drained and the cylinder should be made dry with the use of hot air jet.
Before refitting the valve, internal threads of the cylinder bung should be cleaned with
3/4" NGT thread tap and checked against thread damage. In case old valves are being
refitted the same should be tested by compressed air at 7 kg/sq.cm for leakage from
seat.
b) Teflon paste/ suitable sealing compound should be used as a sealing material for
tightening the valve and the torque of 20+/-2 kg. m. should be applied. In no case
spanners and ordinary wrenches be used for tightening the valves.
a) The Pneumatic test should be applied to the cylinder at a pressure of 7 kg/sq.cm. for a
minimum of 60 seconds as per IS:3196. This is basically to check the tightness of the
valve cylinder joints.
b) With the cylinder under pressure, a soap solution should be applied to the cylinder
valve bung joint to ensure that there is no leak. The same can be checked by dipping
the cylinders in water bath. Depressurise the cylinders. All the Pressure Gauges used
for Pneumatic test shall be calibrated at least once in 3 weeks and the Pressure Gauge
used for verification should be tested once in every three months.
a) To enhance the life of the cylinder and to project a better image to the customers,
maintaining a well painted surface of cylinder is most desirable.
b) All LPG cylinders are painted with one coat of zinc chromate primer and a coat of
super synthetic enamel paint of signal red colour (IS:2932 shade 575). Special care
should be taken to paint the cylinders in vulnerable areas like underneath the foot
ring.
a) Tare Weight of the cylinder should be ascertained and if in variance with the original
tare weight (this could be as a result of change of cylinder valves ) the observed tare -
weight should be punched as close to the original tare weight marking as recorded in
the register maintained.
b) The observe tare weight should be stencilled with paint on the shoulder and as well as
on inside of one of the vertical stay.
c) Gross weight punched/ stencilled on the cylinder should be changed in case of change
of tare weight.
- Weighing machines used for checking the tare weight should be duly certified by
Weights & Measures Authority. The machine should be tested daily with the
standard weights to verify accuracy. The test used for checking should be tested
against standard weights and the same must be stamped periodically by Weights
and Measures Authority. The minimum graduations of 50 gms. must be available.
f) The tare weight should be recorded with an accuracy of +/-50 gms. and rounded off as
per IS:2.
a) Date of retest
c) Tare weight of the cylinder should be stencilled with black paint within the V.P.
Ring circle diameter at 3 places for easy identification by filling operators. The
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 74
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d) It is also recommended that the net weight of LPG to be filled should be stencilled
on the body of the cylinders outside the V.P. Ring diameter. The size of the
lettering recommended is 18 mm and the thickness of the numerals is 4-5 mm.
This is done primarily to facilitate easy segregation of cylinders for repairs at installations
without going through the test date of manufacturing dates punched on each and every
cylinder. Currently, the following colour codes have been selected for easy identification
of cylinders and the same shall be repeated after every five/ seven years cycle. Colour
coding is done on the inside of one of the Stay Plates and the same is given below:
--------------------------------------------------------------------------------------------------------------------------------
Cylinder Cylinder Next Background Shade as Lettering
Manufactured retested/hot Retesting colour IS:5 colour
in the repaired Date
year in the year
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10.1.12 CERTIFICATION :
A detailed record of each cylinder tested at the installation or at the repairer's premises
should be maintained. The record should include the minimum following details :
b) Date of testing
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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e) Weight of cylinder
f) Punched on cylinder
g) Observed weight
i) Visual defects
j) Internal
k) External
REMARKS :
(The Remarks columns should indicate whether the cylinder has been finally passed or
rejected besides any other relevant details not covered above).
The test certificate issued by the Plant or by the Repairers should include :
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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INSTALLATIONS
ANNEXURE - 10- I
1. Receipt of Cylinders
2. Depressurising
3. Recording details
(like Sr.No., Test Dates, Tare weight, Manufacturer's name)
4. Valve Removal
5. Degassing
17. Tapping the bung thread, cleaning the same by brass wire
brush and checking the bung threads by L-1 & L-9 plug gauges.
CHAPTER 11
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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11.1 GENERAL
LPG Installations shall have well defined in-built fire prevention and protection system
to mitigate any exigency. The requirements of fire prevention and protection system shall
be as under :
ii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump /
compressor Houses, remote operating valves /motor operating valves on LPG lines
Bulk Lorry and Tank Wagon Gantries shall be fully covered by medium velocity
water spray system.
iii) Fire Protection Facilities shall have fire fighting access, means of escape in case of
fire and also segregation of facilities so that the adjacent facilities are not endangered
during the fire.
iv) Heat Detectors for detection of fire for automatic actuation of medium velocity water
sprinkler system shall be provided. The QB/EP detectors shall be placed directly
overhead or inside the hazard. In areas without specific hazard, detectors shall be
placed evenly across the ceiling or with maximum spacing of 3 meter inside the
shed. Any other detectors if provided shall comply with the design requirements.
The Fire Water pumping requirement for medium velocity spray system shall be
calculated based on minimum spray density as 10.2 LPM/Sq.M of the exposed surface or
area to be cooled, in case of LPG Pump/ compressor it shall be 20.4 LPM/Sq.M .
a. Storage Vessels
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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MV sprinkler system with automatic heat detection having remote/ local operated Deluge
valve with spray density of Minimum 10.2 LPM/ Sq.M shall be provided on all above
ground storage vessels.
For water flow calculations aggregate surface area of all vessels within distance of 30
Mts. from the periphery of the affected LPG vessel shall also be considered as single
risk .
b) Sheds
MV sprinkler system with automatic heat detection having remote/ local operated Deluge
valve with spray density of minimum 10.2 LPM/Sq.M shall be provided in the entire shed
including the loading / unloading fingers.
For spray water calculations, the shed can be divided into suitable number of zones, each
served by independent deluge system. The adjacent zones shall be operative around the
zone under fire and the same shall be considered as a single risk. The width of a zone
shall not be less than 10 meter except of the zone on either end of the shed. As there is
no storage of cylinders in the loading / unloading fingers, spray system can be taken as
separate zone with independent deluge valve to optimise the fire water requirement .
MV sprinkler system with automatic heat detection having remote/ local operated Deluge
valve with spray density of Minimum 20.4 LPM/Sq.M shall be provided.
The entire pump /compressor house shall be considered as single risk area : alternatively
it can be divided into suitable number of zones with minimum 10 meter width.
In case of Tank Lorry Gantry, automatic detection of heat for automatic actuation of MV
sprinkler system having remote/ local operated deluge valve with spray density 10.2
LPM/Sq.M of surface area shall be provided. A maximum of 8 bays shall be considered
as single risk area. In addition to the tank lorry surface, MV spray system shall
effectively cover the tyres, manifold and dish ends of various size of tank lorries. There
shall be atleast 3 tiers of MV sprinkler system and heat detectors uniformly cool the top
, middle and the bottom of the tank lorry.
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. The gantry can
be divided into suitable number of zones with minimum zone length of 30 meters and
adjacent zones shall operate around zone under fire and same shall be considered as
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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single risk. The spray system shall cover tank wagons surface on either side of tank
wagon gantry atleast in two tiers as well as the associated LPG pipelines in the gantry.
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 kg/ cm2 g at the remotest place of application in the plant.
ii) A fire water ring main shall be provided all around perimeter of the LPG Plant
facilities with hydrants/ monitors spaced at intervals not exceeding 30 M when
measured aerially. Fire hydrants and monitors shall not be installed within 15 Meters
from the facilities/ equipment to be protected.
iii) Fire hydrant network shall be in closed loops to ensure multidirectional flow in the
system. Isolation valves shall be provided to enable isolation of any section of the
network without affecting the flow in the rest. The isolation valves shall be located
normally near the loop junction. Additional isolation valves shall be provided in the
segments where, the length of the segment exceeds 300 Mts.
i) Water for the hydrant service shall be stored in any easily accessible surface or
underground lined reservoir or above ground tanks of steel, concrete or masonary.
The effective capacity of the reservoir above the level of suction point shall be
minimum 4 hours aggregate working capacity of pumps. Where make up water
supply system is 50% or more this storage capacity may be reduced to 3 hours
aggregate rated capacity of pumps.
Large natural reservoirs having water capacity exceeding 10 times the aggregate
water requirement of fire pumps may be left unlined.
ii) Storage tank/ reservoir shall be in two inter connected compartments to facilitate
cleaning and repairs. In case of steel tanks there shall be a minimum of two tanks.
i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head. These pumps shall have a flooded suction, alternatively suitable
arrangement for auto priming shall be provided.
ii) The system pressure has to be maintained at 7 kg/cm2g at the farthest end of the
hydrant system with the help of Jockey Pump operating automatically.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 80
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A standby jockey pump shall be provided if the number of hydrant points is more than
100. One monitor shall be considered as equivalent to 4 hydrant points.
iii) The fire water pump(s) including the stand by pump(s) shall be diesel engine driven .
The pumps shall be capable of discharging 150% of its rated discharge at a minimum
of 65% of the rated head. Each engine shall have an independent fuel tank of suitable
size for 6 Hrs. continuous running.
iv) At least one standby fire water pump shall be provided upto 2 nos of main pumps For
main pumps 3 and more, minimum two standby pumps of the same capacity as the
main pumps shall be provided.
iv) Fire water pumps shall be used exclusively for Fire protection and prevention
purpose only.
v) Suction and discharge valves of fire water pump shall be kept open all the
time.
The fire water pumps shall be provided with automatic starting facilities which shall
function with specified logic even if initial pump does not start or having started , fails to
build up the required pressure in the fire water ring main system within 20 seconds.
i) Fire hydrant ring main shall be laid above ground ensuring that :
a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground
level.
b) The mains shall be supported at regular intervals not exceeding 6 meters or as per
design approved.
c) The system for above ground portion shall be analysed for flexibility against
thermal expansion and necessary expansion loops where called for shall be
provided.
ii) However the ring main may be laid underground at the following places :
a) Road crossings.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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. Alternatively, for above ground pipelines, water circulation to be carried
out.
iii) For Fire water ring main laid underground the following shall be ensured :
a) The Ring main shall have at least one meter earth cushion in open ground, 1.2 meters
cushion under the road crossings and in case of rail crossing, provisions stipulated
by Indian Railways shall be complied.
iv) Fire water ring main shall be sized for 120% of the design water flow rate. The
velocity of water shall not exceed 5 meter per second in fire water ring main. Design
flow rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.
In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally or other suitable coating material shall be used.
vii) Hydrants shall be located at a minimum distance of 15 mtrs. from the periphery of
storage tank or equipment under protection. In case of buildings this distance shall not
be less than 2 mtrs. and not more than 15 mtrs. from the face of building. Provision of
hydrants within the building shall be provided in accordance with IS : 3844.
Hydrant/Monitors shall be located along road side berms for easy accessibility.
viii) Double headed hydrants with two separate landing valves on 3"/ 4" standpost shall
be used. All hydrant outlets shall be 1.2 mtrs. above ground level.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 82
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ix) Monitors shall be located to direct water on the object as well as to provide water
shield to firemen approaching a fire.
The location of the monitors shall not exceed 45 mtrs from the hazard to be protected.
x) Hydrants and monitors shall not be installed inside the dyked areas.
xi) LPG tank wagon Loading/ unloading facility and Tank Truck gantry area should be
provided hydrants having multipurpose combination nozzles for jet spray & fog
arrangement and fire hydrants located at a spacing of 30 mtrs. on both sides of the
gantry. The hydrants & monitors shall be located at a minimum distance of 15 mtrs.
from the Tank Wagon/Tank Trucks measured from edge of the facilities.
xii) Fire water monitors shall be provided with independent isolation valves.
xii) Hose box with 2 nos. hoses and a nozzle shall be provided at each hydrant points.
xiii) The deluge valves shall be located out side the kerb wall at a safe distance in case
of LPG spheres/ bullets and 15 meters away from the limits of LPG cylinder sheds. A
fire wall shall be provided for the protection of deluge valve and for operating
personnel.
xiv) The fire water deluge valves shall be kept outside the kerb wall at a safe distance
in case of sphere/ bullet, and located 15 M away from limits of other sheds or
shadows of spheres. A fire wall shall be provided for the protection of the deluge
valve and for personal protection of the operator.
All the materials used in fire water system using fresh water shall be of type as indicated
below.
Equivalent or superior materials meeting the design requirements can also be used .
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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vi) In case of underground mains the isolation valves shall be located in RCC/ brick
masonary chamber.
vii) The above ground fire water main and the fire hydrant standpost shall be painted with
corrosion resistant "Fire Red" paint as per IS : 5.
viii)Water monitor, hydrant point and hose box shall be painted "Luminous Yellow' IS :
5.
The medium velocity spray system shall be provided in all critical areas like LPG
Storage Area, Sheds, LPG Pump/Compressor House, Tank truck/ wagon loading /
unloading areas, valve manifolds etc.
i) Spray nozzles shall be directed radially to the vessel at a distance not exceeding 0.6 m
from the equipment surface. Only one type and size of spray nozzle shall be used in
a particular facility. The horizontal extremities of water flow from spray nozzles
shall at least meet.
Horizontal dry piping down stream of the block valve and after deluge valve shall
have adequate drain facilities at selected locations.
i. Automatic fire protection (Fixed) system based on heat detection through thermal
fuses/ quartz bulbs/ EP detectors shall be employed. Sensors shall be installed at all
critical places wherever medium velocity spray system has been installed as described
below :
a. In LPG storage area, such detectors shall be provided encircling each vessel, equi-
spaced with a maximum spacing of 1 meter at an elevation of about 1.5 to 2.0
meter from bottom of vessel. Also minimum 2 nos. detectors shall be provided at
the top of the vessel and atleast one near the liquid line ROV to take care of
failure of flanges. In case of an automatic thermal fuse based fire protection
system the instrument air supply pressure to thermal fuses shall be maintained
through a pressure control valve and a restriction orifice.
provided) on LPG supply and return lines would trip and the deluge valves on fire
water sprinkler system will get actuated.
ii) In case, Quartzoid Bulbs are used for detection, the same shall be designed to blow at
79 deg. centigrade (max.) and Quartzoid Bulb network shall be maintained with plant
air at a pressure not more than 3.5 kgs/sq.cm.g and shall be such that the discharge of
air through one Quartzoid Bulb will depressurise the system to actuate the deluge
valves.
iii) In case of Electro pneumatic (E.P) heat detectors, it shall actuate the deluge valve in
any of the following conditions :
b) At 79 deg. C (max.)
The EP detectors shall be divided in groups and alternate detectors shall be connected
in one circuit. Two detectors from two different groups shall function/ operate for
actuation of sprinkler system.
iv) Water spray nozzles and heat detection system shall be of approved type and duly
certified for the performance.
0i) Opening of deluge valve of the affected zone as well as adjacent zones.
ii) Audio-visual alarm indicating the affected zone at the fire pump house and
manned control panel. The control panel shall also have status indications for
deluge valves with facility for actuation.
vii) The fire water pump(s) shall start based on their set pressure to supplement/ to
maintain the fire water pressure in the ring main.
Additionally suitable systems like push buttons etc. for initiating all the above actions
shall be provided on remote operating panel. Further similar system like push buttons, air
release valves etc shall also be provided in the field at safe location for enabling manual
actuation by an operator. In case, the zoning concept is used for MV sprinkler system, the
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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operations of sprinklers in various zones shall be clearly earmarked on the push buttons.
In the field, manual bypass valves of fire water deluge valves shall also be provided.
The performance test certificates after installation in respect of spray density, flow rate,
response time for each facility to be protected provided by manufacturer shall be
maintained at the LPG Installations and verified once in 6 months and records
maintained thereof. Further, all spray nozzles shall be inspected for proper positioning,
corrosion and cleaned if necessary at intervals of not more than 12 months or earlier
based on actual experience.
Care shall be taken in positioning nozzles so that water spray does not miss the
targeted surface and reduce the efficiency or calculated discharge rate.
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.
Office/Canteen/ 2 X 10 kg DCP
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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v) 100% spare 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 OISD-GDN-115. Nitrogen/ Carbon Dioxide shall be used
as expelling gas.
iii) A trolley containing first aid fire protective accessories shall be readily available in
the LPG plant.
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.
iii) Minimum of two or 25% spare Hoses shall be stored in the LPG plant.
iv) In addition to the nozzles provided in the hose boxes there shall be at least 2 Nos.
spare nozzles in each category viz. Jet Nozzles with branch pipes, Fog Nozzles,
universal Nozzles, water curtain Nozzles, Spray Nozzles and Tripple purpose nozzles
in the plant.
v) The following accessories/ first aid items shall be provided in the plant :
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.
i) Manual call points near to filling shed, storage area, tank truck/ wagon gantry, pump
house, etc. shall be provided and clearly marked in the installation. Operation of these
points shall raise audio visual alarm in control room.
ii) Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1
K.M. from the periphery of the plant).
iv) For fire condition the siren shall be wailing sound for minimum `2 minutes and for all
clear signal it shall be straight run siren for 2 minutes.
v) For Disaster condition the wailing sound given shall be repeated thrice with a
minimum 10 seconds gap.
ii) In the hazardous areas, flame-proof / intrinsically safe telephones shall be provided.
iii) Wherever possible Hot line connection between City Fire Brigade/ near by major
Industries shall be provided.
iv) Plant shall have a ` Mutual Aid' arrangement with near by industries.
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.
The fireproofing of LPG storage vessel shall be decided based on the fire safety analysis
keeping in view local considerations, population density, availability of water, societal
risk and fire protection measures provided.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect the
shell material from overheating and consequent failure. The minimum rating for fire
proofing shall be as under :
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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Fire proofing is not required for diagonal bracing, including tie rods, or redundant
members that are not necessary for supporting the static loads.
Before fire-proofing application, protected metal surfaces shall be prepared through such
means as sand-blasting and corrosion-protective primers. Particular attention shall be
given to the top junction of the fire-proofing with the protected metal to prevent water
ingress. OISD-STD-164 on "Fire proofing" shall be referred for details on fire proofing.
Fire water line to each sphere should be so routed that it is not exposed to direct fire.
This is to protect it from failure in the initial period when water flow has not commenced.
It is recommended that riser should be located away from bottom ROV. The horizontal
run of the Fire Water line may be buried if fire engulfment cannot be avoided otherwise.
Fire proofing shall include connected LPG lines and pipe supports within 15 M of a
storage vessel or in the drainage paths.
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 minimum twice in a week at the rated
conditions.
ii) Once in a month each pump shall be checked and tested and the shut-off pressure
observed and logged. Also the pump performance shall be ascertained.
iii) The Jockey pump operation shall be checked periodically. Frequent start/ stop
condition of Jockey pump indicates that there are water leaks in the system.
ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion at
least once in week and records maintained thereof.
iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/
operation and lubricated once in a month.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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i) All deluge valves and sprinkler system shall be operated and checked once in a
quarter for correct remote operation performance of each nozzle and effectiveness of
system in total.
ii) Testing of sprinkler system in the sheds shall be carried out by closing the outlet of
the deluge valve for correct remote operation once in a quarter.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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CHAPTER 12
12.0 GENERAL
The Gas Monitoring system shall provide early warning on build up of dispersed gas
concentration below the LFL limits.
The system shall be designed considering small leaks (leaks which have secondary
closures) such as mechanical seals failure, sampling point left open, gasket leaks, hose
pinholes, valves gland leakage, drain point left partially open, TSV’s relief discharge
in manifold area, filling/ evacuation hoses leakage.
12.1 APPLICATION
i) The detectors for the gas monitoring system shall be strategically located in LPG
Bottling Plant at all facilities close to the potential source of leakage.
ii) The detection control equipment should be provided in the control room for
continuous monitoring even during power failure.
12.2 DETECTORS
Amongst the various methods of detection available, the following proven systems
for LPG can be considered.
i) Catalytic detectors
ii) Infra-red detectors
i) 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.
ii) In case of failure or during maintenance when the system is not in operation, the plant
safety officer should keep the plant personnel on alert to be more vigilant during
operations and night security patrolling.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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iii) The control equipment should have data logging facilities to provide print outs of the
history of the events with date and time of leakages.
iv) The control equipment should be able to generate at least two alarms at different
levels of LEL concentration of gas.
v) The control equipment is not required to have automatic corrective action capabilities
on sensing leakages as this is basically a warning device. However, in case of any
specific recommendations made in the risk analysis / HAZOP studies, the same
should be implemented.
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 side of the
wind direction.
iii) The detectors especially the catalytic type should not be positioned very close to the
potential source of leakage to avoid poisoning of the detectors(temporary
malfunctioning). The detectors should be located at least 0.3 mtrs. away from the
potential source of leakage.
iv) In case of infra-red detectors, the same shall be installed on the down wind side
ensuring the path is free from obstructions. In case any additional expansion/
construction if undertaken, the detectors will have to be pre-positioned.
Storage vessels (above ground) – 1 No. top and 1 No. near bottom ROV.
Empty-cum-filling shed – 2 Nos. near carousel, 1 No. near evacuation unit tank, 1 No.
weight correction unit.
Tank wagon gantry – 1 no. for every two bays or 30 m whichever is less at bottom.
Additionally, some detectors at selected locations shall be provided at the top of
platform.
The number and location of the detectors required over and above the minimum
requirements specified above shall be as per the specific requirements identified in the
risk analysis / HAZOP study report.
The location can be decided by assessing the behaviour of gas drift and consequential
safety risk.
The gas monitoring system shall be kept in good operating condition all the time.
The inspection of the system shall be done at an interval of 1 month in which the gas
shall be released at all the detectors and the performance of the systems shall be
established.
The calibration of the equipment shall coincide with the monthly inspection schedule
every three months for calibration of the gas detectors the calibrated gas with known
and certified level of concentration shall be used.
The drift in the sensitivity of the individual detectors shall be recorded in maintenance
history log book during calibration and the detectors with abnormal or wide drift in
sensitivity.
The plants should have at least 2 Nos. spare detectors for each system maintained at
all times to facilitate immediate replacement of defective detectors.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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CHAPTER 13
13.0 GENERAL
13.1 The best way to manage any emergency is to prevent it. Following guidelines for
emergency prevention shall be followed :
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.
Plant Manager shall ensure that suitable instructions are issued to both Corporation's and
contractor's personnel identifying the action to be taken by each one in an emergency.
This should be achieved by display of organisation chart/ posters not only for fire-
fighting but also for other likely emergencies. Likewise, for emergencies of large
magnitude Emergency Response Plan (or Disaster Management Plan) to be drawn out in
coordination with related outside 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.
f) Leakage due to bursting/ rupture of hose or through sviwel joints of body arms.
(a) ELECTRICAL :
i) Short circuiting due to loose wiring including that of automobile moving in the
area.
ii) Use of non-flame proof fittings such as lights, torch, motors, fan, telephone,
temporary lighting etc. (Note : Flameproof fittings become non-flame proof due
to poor maintenance e.g. increase in gap in junction boxes, due to missing nuts
and bolts or improper glands used for connection to junction box, or sealing
compound not used in junction boxes etc.)
(b) VEHICLE :
(c) OTHERS
iii) Spark from studed shoes, with steel button by friction against ground/ metal.
v) Excessive release of vapour beyond safe limit and fire due to outside source of
ignition.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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vi) Lighting
vii) Smoking.
13.2.1 Immediate action is the most important factor in emergency control because the
first few seconds count, as LPG fires develop and spread very quickly unless
prompt and efficient action is taken. In the event of fire/ gas leak within LPG Plant
the following action shall be taken as quickly as possible:
a) Take immediate steps to stop LPG leakage/ fire and raise alarm simultaneously.
b) Initiate action as per Fire Organisation Plan or Disaster Management Plan, based on
gravity of the emergency.
c) Stop all operations and ensure closure of all ROVs and isolation valves.
d) All out effort should be made to contain the spread of leakage/ fire.
f) Plant personnel without specific duties should assemble at the nominated place.
g) All vehicles except those required for emergency use should be moved away from
the operating area, in an orderly manner at pre-nominated route.
h) Electrical system except for control supplies, utilities, lighting and fire fighting
system, should be isolated.
i) If the feed to the fire cannot be cut off, the fire must be controlled and not
extinguished.
k) In case of leakage of LPG without fire and inability to stop the flow, take all
precautions to avoid source of ignition.
l) Block all roads in the adjacent area and enlist Police support for the purpose if
warranted.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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.
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.
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.
b) If escaping LPG is not on fire, close any valve which will stop the flow.
c) In some cases like the leakage from a pressure vessel without a fire (such as leak
from tank truck bullet or overturning) it may be desirable to move the vessel to
some remote area such as block of isolated roadway or open field where it can be
allowed to leak safely without a source of ignition nearby. However, if this is to be
done, the vessel must be moved in an upright position. Never drag the vessel in a
manner which might damage valve or pipeline. Any attempt to turn a vessel back
upright to move it to some remote location should be done carefully to avoid
damage to valve and pipelines.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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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/cm2g and
ultimately rupture the container. Ignition of the escaping gas would aggravate the
fire but the release of pressure would reduce the possibility of rupture of the
container. No attempt should be made to extinguish the burning gas. Bus the
container and other containers in the vicinity should be kept cool by water sprays
until the contents of the container have burnt away. If the gas leakage does not
ignite, the container should be approached from upwind (if in the open air) and be
removed to a place of safety remote from sources of ignition. Cylinders not directly
involved in the fire should be moved away from heat exposure, while applying
cooling water sprays on cylinders directly involved.
(ii) Fire on storage vessel : If a pressure vessel is exposed to radiant heat from
external fire, it should be kept cool by water sprays to prevent excessive pressure
rise in the vessel. Cooling water sprays must be applied without delay to the heat
affected area using fixed water sprinkler system or equivalent spray water coverage,
through fixed monitors or other equipment. Cooling the 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.
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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(iv) Fire of LPG vapour escaping from a damaged vessel fitting (flame not playing
on vessel)
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.
Isolate affected vessels and run out fire water hoses in case hose stream cooling
becomes necessary.
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.
(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.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(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:-
(ii) Shutting off the LPG supply to any leakage point/ fire.
(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.
(viii) Closing down all operations in the plant including closure of valves and stopping of
pumps.
Close co-operation with the local fire authorities is essential and shall take the following
form :
(i) The fire brigade should be made familiar with the layout of the plant and the location
of important equipment/ facilities provided, and their method of use. Mock fire
drills/ exercise jointly by plant personnel and local fire brigades shall be planned.
(ii) 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.
a) Drills for all Plant personnel, making use of the "Fire fighting Organisation Plan"
and practicing the specialised techniques required for fighting LPG fires or
dispensing/ diluting LPG vapour clouds shall be held minimum once in a month.
b) The drills should cover various types of incidents, e.g. major spillage, LPG bulk
lorry fire, cylinder fire etc.
c) Extinguishers due for recharging/ due for hydrotesting shall be discharged during
drills and replenished subsequently 50% (Min.) stock of refills as replenishment for
FEs should be maintained.
d) The fire pump should be run, sprinkler system activated, emergency systems tested,
water hoses run out and spray/ set techniques practiced during drills.
e) Fire alarms shall be sounded/ tested (neighbouring plants/ factories and the fire
brigade shall be warned in advance of this test).
f) Protective clothing, breathing apparatus and any other specialised safety equipment
available shall be tried out during drills to train all concerned in their application.
g) The local fire brigade should be encouraged to participate in fire drills periodically.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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ON- SITE
(iii) Lightning
The objective of the plan shall be to reduce the probability of serious loss/ damage to
general stock, plant and machinery, documents etc. utilizing combined resources of the
location itself and the outside agencies. In order to have an effective organisation,
preliminary meeting shall be conducted with the representatives from local fire services,
police authorities, voluntary organisations like ambulance service/ Govt. medical service/
contractors and even Home Guards and defence personnel. In the course of the meeting,
there should be exchange of knowledge, training and plans for development of expertise
and skills to gain knowledge about the plant layout/ facilities, potential of likely hazards/
risks, likely emergencies that may arise. This group should draw out modalities of the
exercises in the given situation and arrive at an agreed action plan which should be
updated from time to time and put to test in the form of periodical mock drills.
(b) Due to varying risk potentials and also varying hazards at/ around each location
`Disaster Management Plan' for each location shall be drawn up individually based
on the outline given below:
(i) Identify Disaster scenario i.e. the situation under which the plan would become
operational. Plan for the worst possible scenario.
(iii) Establish outside agencies, role of each agency and obtain their commitment for
rendering the assistance in crisis situation as per the agreed plan.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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(vi) Furnish detailed data and drawings relevant for the crisis management.
(vii) Establish channel of communication at the local level to Statutory Authorities and
higher authorities within the organisation.
(ix) Modify the plan based on the experience gained through mock drills and try out the
modified plan through subsequent mock drills.
(x) The plan shall be updated as and when the changes recorded in the plan occur and
communication sent to all concerned.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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14.1 GENERAL:
Safety audit is a well recognised tool to improve the effectiveness of safety programme
and loss prevention measures by carrying out systematic and critical appraisal of potential
safety hazards involving personnel, plants and equipments.
For a structured and systematic safety audit of any plant/ facility, check lists are the most
important prerequisite. Check lists should cover all the operational areas, major
equipments, operating/ maintenance procedures, safety practices, fire prevention/
protection systems etc. Observations/ recommendations of safety audit team should be
presented in the form of a formal report and action plan for corrective measures should be
prepared and subsequently monitored for implementation.
General guidelines on safety audit methodologies and techniques are also given in OISD
- GDN- 145.
In view of the high hazard potential of LPG, safety audits at frequent intervals by the
teams/ personnel of various levels are advocated, Broad check lists for different
recommended safety audits are given in the Annexure 10-I, II, III, IV. These check lists
can be further supplemented and modified suitably to meet the specific requirements of
individual plant. Recommended minimum safety audits at different levels, their
frequencies and broad check lists to be used are indicated below :-
Daily audit essentially shall cover the compliance of recommended operating procedures/
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken on priority wherever required.
-----------------------------------------------------------------------------------------------------------------------------
S.No. Type of Safety By Frequency Checklist
Audit (Annexure)
-----------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5
-----------------------------------------------------------------------------------------------------------------------------
1. Inspection Safety LPG Plant Daily 14-I
audit of LPG Installation Safety Officer
2. Electrical audit of Authorised Annual 14-II
LPG Installation electrical Engineer
3. Detailed safety audit Multi disciplinary Annual 14-III
of LPG Installation team of region/ HQ
4. Inspection and Personnel from Annual 14-IV
maintenance audit of Inspection/ Maintenance
LPG Installation
5. External safety audit OISD
of LPG Installation
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 105
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Daily audit essentially shall cover the compliance of recommended operating procedures/
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken alongwith the target dates shall be done immediately.
The compliance to other audit recommendations along with target schedules shall be
monitored on monthly basis. Alternate, safety measures shall be taken till the
recommendations are complied in totality.
In case of external safety audit, following areas besides the points given in check list of
Annexure 14- III shall be covered.
1. Safety Organisation
2. Security System
4. Preparedness to handle any emergency --Disaster control plan and mock drills.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 106
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ANNEXURE 14- I
LOCATION ______________
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S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 107
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 108
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S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 109
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 110
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S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 111
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F. FILLING SHED
F-01 No ignition sources visible in operating Yes/No
areas or area in vicinity.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 112
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* Put specific observation wherever the conditions are not in line with specified
requirement levels.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 113
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ANNEXURE 14 - II.
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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A-02 Is the equipment easily accessible for operation, inspection & maintenance.
g) Grounding OK
c) Sealing of duct
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 114
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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A-07 Rubber mats (with ISI mark) existing are enough in number.
A-09 All fuses are of proper type and rating as specified in single line diagram.
A-10 Fire extinguishers are of proper type and are in working condition.
a) Grounding OK
b) No oil leak
c) Silica gel OK
d) Oil level OK
f) Oil/winding temp. OK
B-04 a) Is push button earthed properly and flame proof condition not tampered.
b) General condition of push button good.
B-05 Ground resistance at motor/ push button measured and found okay.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 115
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B-11 First-aid chart for treating electrical shocks displayed prominently in MCC room.
C. UNIT LIGHTING
C-05 Does water enter and accumulate in fixture distribution boxes etc ?
a) Is gasket present ?
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 116
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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E-01 Are LPG pipelines provided with flange earth jumper connection
for electrical continuity?
E-05 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.)
F. GENERAL
F-02 Certificate in respect of FLP for each electrical equipment- records maintained.
F-03 Earthing network diagram available and site checks done from time to time.
Note : For developing a detailed check list refer OISD-GDN-145-09 document on safety audit check list for
electrical system.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 117
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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A-01 Area under the sphere is having concrete pavement with proper
slope leading to shallow sumps.
A-04 Last safety valve test done as per statutory requirement and record maintained.
A-05 Remote operated valves provided on liquid inlet/outlet lines with push
buttons/ indication control and located at safe distance.
A-06 Two independent level instruments and high level alarm provided in
storage vessels and are in working condition.
A-07 All leg supports of Horton spheres/ vessels encased in concrete with
fire proof coating/ motor.
A-08 a) Sprinkler system provided on all vessels and are in working condition.
b) Deluge valve is remote operated and is located at safe distance from storage vessels.
A-09 Gas detection system provided and in good working condition (To be checked).
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 118
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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B-01 a) All electrical motors/ push buttons properly earthed and flame proofness maintained.
c) No abnormal sound and vibration from motor and bearings condition OK.
B-04 Drain points/ vent points/ sample points capped when not in use.
B-06 Long range monitors/ fixed water spray with proper throw/ sprinkler system
installed and in good condition.
C-01 LPG bottling facilities located at safe distance from other facilities with
minimum ingress to trucking traffic.
C-02 Facilities provided for positioning of trucks 15 m away from storage shed
for receipt/ loading of cylinders.
- Telescopic conveyor
- Trolley use
C-04 Proper purging facilities provided for new/ retested/ reconditioned cylinders
C-05 a) Inspection/ visual checks followed for spurious/ defective cylinders and
record maintained.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 119
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i) Spurious
C-08 Vapour extraction system provided for carousel and system is working satisfactorily.
C-10 Accuracy of check scales being checked daily and records maintained.
C-12 Check facilities provided for valve seat leakage and working satisfactorily.
- Electronic
C-13 Proper facilities/ correction conveyor loops are provided for defective cylinders
(`O' ring & weight correction).
C-14 Bung leak/ body leak check are done through in-line water bath with caps in position.
- Aluminium foil
- PVC sealing
- Plastic
- Paper
C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 120
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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- PTFE tape/ paste or other suitable sealing compound used.
C-20 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys.
C-21 Mastic flooring provided on the floor storage area to avoid accidental sparks.
C-23 Cylinders are inspected for leakage with explosimeter or portable leak detector.
C-24 Sprinkler system provided in the storage shed and in working condition.
D-01 Whether the location and layout of the facilities meet statutory distances/ design guidelines.
D-04 Hose contents after unloading are released to high vent located at safe distance.
D-06 a) Sprinkler system provided on the railway siding/ tank truck loading/
unloading area are and working satisfactorily.
D-09 a) Vehicles are properly checked for any sign of leak, proper fittings and
other valid documents.
D-10 Loading/ unloading procedures along with safety precautions prominently displayed.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 121
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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E-03 Important telephone Nos. of State Fire Services, Police, District Admn./
other offices etc. displayed.
E-04 Are fire emergency mock drills conducted periodically and records maintained.
E-05 Work permit system for repairs/ hot jobs etc. followed and records maintained.
- corrosion protection
- material of construction
e) Strainers provided at inlet of deluge/ sprinkler water supply main piping. Strainers are
cleaned periodically and records maintained.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 122
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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- Working satisfactorily
- Regularly tested.
E-14 No smoking cautions/ signs in Hindi/ English local languages displayed at prominent places.
E-16 a) Emergency lighting system provided in strategic locations and system working satisfactorily.
F-01 Supervisory/ managerial cadre staff fully trained in all aspects of LPG plant
operations, Disaster control/ emergency handling.
F-02 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 123
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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a) Regular staff
b) Contractor workmen
c) Security staff
G. GENERAL
G-01 a) Plant approach/ access roads well maintained and at least two emergency
exits are there.
- Storage of LPG
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 124
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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G-06 Hot work permit/ clearance issued - proper procedures followed and
documents maintained.
e) Gas Cylinders Rules, 1981, SMPV Rules 1981 and other relevant
BIS Standards with latest amendments.
G-09 Updated P&I Diagrams, drawing of layout and other facilities available.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 125
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ANNEXURE 14- IV
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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A. GENERAL
A-03 Whether spare parts for different equipment/ machinery are maintained.
A-04 Whether data card/ history records of static and rotary equipment are
maintained (as per OISD Std.127/28).
A-05 Whether proper work permit system is followed for maintenance jobs and
records maintained.
A-06 Whether personnel protective equipment such as hand gloves, safety shoes,
safety helmet etc. provided to the concerned workmen and their use is ensured
(OISD Std.-155).
A-07 Fire fighting equipment and portable fire extinguishers periodically checked /
tested as per maintenance schedules & records maintained (OISD Std.-142).
A-08 Fire alarm/ communication system scheduled testing & maintenance ensured.
A-10 Whether continuous monitoring devices are periodically checked and calibrated.
A-11 Whether exhaust fans and other ventilation devices are properly maintained and
regularly used.
A-12 Whether inspection/ testing of pressure vessels carried out periodically as per statutory
requirements and records maintained.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 126
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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B-03 Annual inspection and testing of safety valves carried out at proper set
pressure and records maintained.
B-04 All instruments, level indicators, pressure and temperature gauges, ROVs
are maintained in working condition following daily scheduled checks,
periodic calibration and preventing maintenance schedule.
B-08 Fire water system & sprinkler spray system checked/ tested periodically
and maintenance jobs carried out and records maintained.
B-09 LPG bullets/ spheres having fire proofing are periodically checked for cracks,
spalling/ bulging and suspected area are further inspected for presence of corrosion
etc. and corrective steps taken.
B-10 Earthing connections are periodically checked and good electrical contact is maintained.
Records of resistance testing as outlined in OISD Std-137 maintained.
B-11 Foundation/ Anchor bolts, ladders, stairways, platforms/ structurals checked periodically
for any corrosion/damage etc.
B-12 Annual testing of chain pulley blocks and other tool tackles is carried out by certified agency.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 127
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S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
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C. CYLINDER FILLING
C-01 LPG filling carousel - Drive unit, central column, running rails, etc.
are daily checked, scheduled maintenance (weekly, monthly, quarterly,
annual) are carried out and records maintained.
C-02 Introduction/ Ejection devices and filling machines are checked daily and
scheduled maintenance/ overhaul work carried out.
C-04 Check scales are well maintained and calibrations carried out on daily basis
with standard weights.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 128
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15.0 REFERENCES
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CODE NO. NAME
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IS:1436-1991 - WEIGHBRIDGES
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 129
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CODE NO. NAME
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 130
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CODE NO. NAME
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
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OISD – STD – 144 Page No. 131
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CODE NO. NAME
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IS:8737 - VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF
MORE THAN 5 LIT. WATER CAPACITY
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 132
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CODE NO. NAME
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 133
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CODE NO. NAME
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IS:13258-1991 - WELDED LOW CARBON STEEL CYLINDERS
EXCEEDING 5 LT WATER CAPACITY FOR
LOW PRESSURE LIQUEFIED PETROLEUM GAS
CODE OF PRACTICE FOR INSPECTION AND
RECONDITIONING OF USED LPG CYLINDERS
vi. ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American
Society of Mech.Engrs., New York
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 134
LIQUEFIED PETROLEUM GAS (LPG)
INSTALLATIONS
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 135
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INSTALLATIONS
Figure I
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 136
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INSTALLATIONS
Figure
Figure II
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 137
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INSTALLATIONS
Figure III
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 138
LIQUEFIED PETROLEUM GAS (LPG)
INSTALLATIONS
Figure IV
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 139
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INSTALLATIONS
Figure V
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 140
LIQUEFIED PETROLEUM GAS (LPG)
INSTALLATIONS
Figure VI
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
Sr.Number:OISD/DOC/2015/393
OISD – STD – 144 Page No. 141
LIQUEFIED PETROLEUM GAS (LPG)
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“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”