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LPG Installations - OISD STANDARD - 144
LPG Installations - OISD STANDARD - 144
Prepared by
FUNCTIONAL COMMITTEE ON
LIQUEFIED PETROLEUM GAS (LPG)
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil
and gas industry under Ministry of Petroleum & Natural Gas. These are the
property of Ministry of Petroleum & Natural Gas and shall not be reproduced or
copied and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby disclaims any liability or
responsibility for loss or damage resulting from their use.
These documents are intended to supplement rather than replace the prevailing
statutory requirements.
FOREWORD
The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies ,
operating and maintenance practices was hardly in existence at a national level.
This, coupled with feed back from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas
installations.
With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) for
formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of functional
committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.
Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as
well as with industrial applications due to its unique properties and environmental
benefits. The document on "LPG Bottling plant operations" was prepared in
1994. The present document "LPG Installations" has been prepared by the
functional based on the accumulated knowledge and experience of industry
members and updation of national and international codes and practices related
to LPG.
The Coordinator,
Committee on “LPG”
Oil Industry Safety Directorate,
7th floor, New Delhi House,
27, Barakhamba Road,
New Delhi – 110001
FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)
NAME ORGANISATION
LEADER
Sh. R. Krishnan Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS
Sh. A.N. Biswas Deptt. of Explosives, Nagpur
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
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
CONTENTS
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SR. No. ITEM PAGE NO
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1 Introduction
2 Scope
3 Definitions
4 Statutory Rules/ Regulations
5 Installation Layout
6 Design Considerations
7 Storage & Handling of Bulk LPG
8 Bottling Operations
9 Maintenance & Inspection
10 Statutory Testing of LPG Cylinders
11 Fire Protection Facilities
12 Gas Monitoring System
13 Emergency Management Plan
14 Safety Audit
15 References
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d) The availability of space for future e. Storage vessels shall be laid out in
extension of LPG facilities, if any, single row in each group.
shall also comply with the safety f. Storage vessels shall not be located
norms. one above the other.
5.5.10 LPG tank truck parking area Empty cylinders storage area
(Bulk/ Packed) shall be located in shall be properly segregated from
a secured area and provided with filling machines by 5 M (Min.).
adequate no. of hydrants / Cylinders shall always be stacked
monitors to cover the entire vertically with maximum stack
parking area. height of 1.5 m. For details of
cylinders stacking pattern refer
5.6 LPG BOTTLING FACILITIES Figure - I .
5.6.1 LPG bottling facilities shall be 5.6.4 LPG cylinder filling machines
located at a safe distance from and other related testing facilities
other facilities with minimum shall be provided in sequential
ingress of traffic and upwind order.
direction with respect to bulk
storage. 5.6.5 A separate shed shall be provided
for carrying out degassing of
There shall not be any deep defective cylinders.
ditches in the surrounding areas
at least within 15 M from storage 5.6.6 Cylinder storage shall be kept on
sheds to avoid settling of LPG or above grade and never below
vapour. grade in cellar or basement.
5.6.7 Filled cylinders shall not be 5.7.2 Proper industry type boundary
stored in the vicinity of cylinders wall atleast 3 M high with 0.6 M
containing other gases or barbed wire on top shall be
hazardous substances. provided around the installation
unless the bottling plant is
5.6.8 Escape routes shall be specified protected as a part of refinery
and marked in LPG sheds for complex.
evacuation of employees in
emergency. 5.7.3 Emergency exit with proper gate
shall be provided in the
5.6.9 There shall be sufficient no. of earmarked zone.
crossovers to avoid trapping of
personnel in LPG sheds by 5.7.4 In case provision for green belt is
conveyors, cylinders and other made, the same shall be
facilities. Further, sufficient no. segregated from hazardous area
of escape routes shall be by 1 M high wall / chain link
provided. fencing. Alternatively, it shall be
treated as a part of hazardous
5.6.10 All steps forming part of the area.
escape routes shall be minimum
1.2 M with treads 30 cms 5.8 UTILITIES
(minimum) and maximum rise of
15 cms. Utilities consisting of fire water pumps,
admin. building, canteen, motor control
5.7 PROTECTION OF FACILITIES centre, DG room, air compressors, dryers
etc. shall be separated from other LPG
5.7.1 Properly laid out roads around facilities and located as per the
various facilities shall be separation as specified in Table-I.
provided within the installation
area for smooth access of fire
tenders etc. in case of
emergency.
TABLE - I
---------------------------------------------------------------------------------------------------------------------------
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.
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
--------------------------------------------------------------------------------------------------------------------
ii. Material shall be in line with design Where ever extreme climatic conditions
code. ASTM A516 Gr. 60 shall be or security reasons warrants, suitable
used for refinery service (BS-5500 alterations in design can be made with
shall not be used for the same) and approval from statutory bodies.
for marketing installation where H2S
is not present ASTM A 516 Gr. 70 or 6.2.2 FITTINGS
A 537 CLASS 1 can be used. Micro-
alloyed steel containing Ni, Mo, Va Spheres/ bullets other than underground
shall not be considered. Maximum shall have a single nozzle at the bottom
specified tensile stress shall not be for liquid inlet as well as outlet. The
more than 80,000 psi. nozzle shall be full welded pipe, stress
relieved along with the vessel and shall
o
iii. Design temperature : (-) 27 C to extend minimum 3 meters from the
o
(+) 55 C. shadow of the sphere/ bullet. A remote
operated shutdown valve (ROV) shall be
2
iv. Design Pressure : 14.5 Kg/ cm g on provided on this bottom nozzle at a
top as per IS: 4576 at 55 oC. distance of at least 3 meters from the
shadow of sphere/ bullet. The nozzle
Marketable LPG conforming to IS: pipe shall have a minimum slope of 1.5
o
4576 can have a maximum vapour .
pressure of 16.87 Kg/ Sq.cm.g at 65 o
C temperature. LPG with higher There shall not be any other flanges,
vapour pressure are not expected to manhole, instrument tapping on this
be stored in bottling installations. 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 indicators and one independent high
the bottom nozzle shall be provided. level switch. High level alarms shall be
set at not more than 85% level of the
The top vapour zone of the vessel shall volumetric capacity of the vessel. Audio
be provided with nozzles for vapour visual indication shall be at local panel
outlet, recirculation wherever applicable. & control room. On actuation of high
These lines shall be provided with fire level alarm, the ROVs of the affected
safe ROV. vessel shall close.
Fire safe ROVs shall also be provided on ii) Each storage vessel shall have at
liquid line at TLD & Tank wagon gantry least two safety relief valves with
& isolation valve (quick closing type) on isolation arrangement set at different
the entry of liquid lines at LPG filling values and at not more than 110% of
shed at a safe location. design pressure of the vessel and each
having 100 % relieving capacity
Nozzles for two independent level adequate for limiting the pressure build
indicators of different type, a high level up in the vessel not more than 120% of
switch, two safety relief valves, pressure design pressure.
gauge and a manhole shall be provided
on top. The relieving load for the safety valves,
shall be based on fire condition and no
All the fittings shall be suitable for use at credit shall be taken for fire proofing on
the design parameters of the storage the vessel, if provided.
vessels and for the temperatures
appropriate to the worst operating The discharge of safety valves shall be
conditions. The remote operated valves connected to flare system, wherever
on the storage vessel connecting available. In this case, safety valves shall
pipelines shall be fire-safe type have lock open (or car seal open) type
conforming to API 607 or equivalent. isolation valves on both sides of safety
valves.
The flange joints of these valves shall
either have spiral wound metallic gaskets In case of non availability of flare
or ring joints. Plain asbestos sheet / system, the discharge from safety valve
reinforced gaskets shall not be used. shall be vented vertically upwards to
Gasket used shall conform to ASME atmosphere at an elevation of 3 meter
B16.20 or equivalent. The studs used (minimum) for effective dispersion of
shall conform to ASTM A 194 Gr 2 H/ hydrocarbons. In this case, isolation
ASTM A 193 Gr B7 or equivalent. valve on down stream of safety valve is
Flange connections shall be a minimum not required. A weep hole with a nipple
of 300 lb rating confirming to ANSI at low point shall be provided on the
B16.5 class 300 or equivalent. (pipe vent pipe in order to drain the rain water
flanges and flanged fittings. All tapings which may get accumulated otherwise.
or openings shall be of minimum 20 Weephole nipples shall be so oriented
mm thickness. that in case of safety valve lifting and
consequent fire, the flame resulting from
6.2.3 INSTRUMENTS LPG coming out from weephole does not
impinge on the sphere or structure. A
i) The storage vessel shall have loose fitting rain cap with a chain (non
minimum two independent level
sparking) fitted to vent pipe shall be
provided on top of safety valve. Unloading of LPG from tank truck is
carried out with vapour compressors
Typical safety fittings on a LPG storage using pressure differential method of
vessel are indicated in Figure-II. liquid transfer. The compressor used for
unloading shall be provided with the
6.3 LPG LOADING/ UNLOADING following facilities:
FACILITIES
(i) Vapour line with isolation valves
Each loading station shall consist
of the following : (ii) Excess flow check valve & non
return valve shall be provided in
i. Excess flow check valve & non LPG unloading lines with isolation
return valve shall be provided in valves
LPG loading lines.
(iii) Weigh bridge of suitable capacity
ii. A vapour return line with an
isolation valve connected back to the
storage vessel/ suction line with Additionally following shall be ensured.
NRV.
i. Suitable provision shall be made for
iii. Properly designed loading arm or evacuation of LPG from bulk storage
LPG hoses shall be provided at the vessels to tank truck or another
end of filling and vapour return lines vessel to empty the vessel in case of
for connecting to the tank truck emergency or for statutory testing.
vessel. The loading shall be
provided with break away couplings ii. Tank truck shall be loaded/ unloaded
or smart hoses shall be used. Loading with suitable arrangement for flaring
arm shall be of approved type and be of hose content at the end of the
tested as per OEM recommendations. operations.
In case, LPG hoses are used, it shall
conform to OISD-STD-135. iii. The unloading arms shall be used for
unloading the LPG TT at LPG
iv. The hose - coupling / flange joint installation. In case, LPG hose are
shall be of Class 300 lb rating with used, it shall conform to OISD-STD-
metallic gasket. The hose coupling 135 or equivalent as approved by
shall be provided with a cap or blind CCOE.
flange by which the nozzle can be
closed when not in use. iv. The hose - coupling / flange
joint shall be of 300 lb rating
v. Weigh bridges of suitable capacity with metallic gasket. The hose
for road / rail movements and mass coupling shall be provided with a
flow meters for pipeline transfers cap or blind flange by which the
shall be provided. The mass flow nozzle can be closed when not in
meters shall be certified for its use use.
with LPG.
6.4 CYLINDER FILLING
vi. A check valve shall be provided in FACILITIES
the vapour return line.
i) The cylinder filling area shall be vi) Cylinder storage area
completely open type and requirement shall be worked out
covered from top with roof based on the stacking pattern of
designed to ensure good natural filled and empty cylinders as
ventilation. RCC roofing shall described in Figure-I.
not be used. vii) The filling machines shall be
provided with auto cut-off system
The filling area shall not be on so that LPG supply is cut off
upper floors of building or in when the desired quantity of
cellars unless specifically product has been filled in the
required on account of extreme cylinders. The filling pressure
weather conditions. shall not be more than the design
pressure of the cylinders i.e. 16.9
ii) As far as possible, the floor area kg/sq.cm.g.
shall not have any channels or
pits. Where these are necessary viii) Filling machines in a
for conveyors or other equipment carousel/ stationary filling
like weigh machine etc., suitable machines shall not have a
gas detection system shall be weighment error of more than +
provided. Additionally, proper 150 gm of the net quantity of the
ventilation system through ducts LPG filled in the cylinder, with a
fitted with blowers shall be capacity of 14.2 kg or as
provided to release LPG outside specified in Weights and
of the shed at safe location. The Measures Rules.
whole of the LPG filling shed
flooring shall be provided with ix) On-line check weigh scales with
mastic flooring. a minimum of 50 gms.
graduation be installed so that all
All carousels & leak detectors the cylinders are check weighed
including electronic shall be of after filling.
approved type.
x) Compact Valve Tester to check
iii) Adequate lighting shall be valve and 'O" ring shall be
provided in the cylinder filling installed on line. Alternatively
area. Emergency lighting shall electronic leak detectors shall be
also be provided at critical provided.
places.
xi) Water test bath or electronic leak
iv) Water drains from the cylinder detectors shall be provided to
filling area where they enter an detect body and bung leak
outside drainage system, shall be cylinders.
provided with vapour seals.
xii) Vapour extraction system at
v) Proper access shall be made strategic locations near carousel,
available for other fire fighting cylinder evacuation unit, valve
equipment i.e. fire tender, foam changing unit, degassing shed
trolley etc. and at locations where leaking
LPG is expected to accumulate
shall be provided. Further, it shall
be interlocked with filling sprinkler system) and minimum lighting
machine so that filling do not during the grid power failure.
start without vapour extraction
unit being functional. 6.6 LPG PUMPS
Service water is required for the cylinder iv. Double Mechanical seal with seal
washing equipment and leak check bath, failure alarms shall be provided.
compressor cooling and in hose stations
for washing etc. v. A pressure switch actuating a low
pressure alarm in control room
Water may be provided at a pressure of and locally shall be provided,
about 3 Kg/sq.cm.g. If one pump is taken from discharge end.
envisaged to run normally, another pump
with 100% capacity shall be provided as vi. Pumps shall be designed to build
a standby. Where more than one pump a discharge pressure such that the
running is envisaged, 50% capacity as pressure at the carousel filling
standby shall be provided. machine is at least 5.0
kg/sq.cm.g. above the vapour
Water Quality pressure at the operating
temperature.
Water shall be of potable quality
conforming to IS : 10500 - Specification vii. Pumps shall have a by-pass valve
for Drinking Water. and other suitable protection
against high discharge pressure
(C) Emergency Power on the delivery side.
The installation shall be provided with viii. The electrical motor drive
battery / diesel generating set for and switchgear shall conform to
operating the essential systems such as area classification as per OISD
the instrumentation and safety systems Standard-113 / IS -5572. Belt
(gas detectors, automatic fire water
drives shall be of the anti-static Typical sketch of compressor
type. installation is enclosed as Figure-IV.
ii. The belts used in shall be of (ii) The material shall conform to API
antistatic type & fire resistant. 5L Gr. B / ASTM A106 Gr B or eqv.
- Pressure gauges in suction and (iv) Pipe joints should be welded as far as
discharge. practicable with full penetration
- Temperature gauge in discharge weld. Number of flanged or threaded
- Discharge safety valve and a vent joints should be kept to a minimum.
valve, their outlets leading to
flare/ safe height outside the (v) Low point drains and high point
shed. vents shall be plugged or capped
- Low Suction Pressure Trip suitably.
- Suction strainer
- High Discharge Pressure Trip (vi) Buried piping shall be protected
- High Temperature Trip against physical damage and
- Check valve in discharge corrosion with suitable sleeves,
- A discharge to suction recycle properly sealed at both the ends, at
valve for achieving capacity road crossings.
turndown during startup.
4. Stop the engine and switch off all 12. When the filling operation is in
electrical equipment. progress, the pressure within the tank
truck vessel shall be observed to
5. All persons should leave the driver's ensure that it does not approach the
cabin. start-to-discharge pressure of the
relief valve. Filling rate may be
6. Make earthing connections of the regulated as required.
vehicle at specified point to the fixed
grounding system. 13. The couplings may then be removed
and plugs/caps replaced on the tank
7. Connect liquid and vapour lines truck valves. Re-check tightness with
suitably with the loading point. soap solution.
Crack open valves on loading &
vapour return lines and inspect
hoses & connections for leakage. (b) Unloading Operations
Loading should start only when the
system is leak free. 1. Operations described under Item
1 through 6 in para 7.1.2(a)
8. Start the loading pump. should be carried out.
9. The quantity loaded into the truck 2. Liquid line and vapour line of the
can be determined by - tank truck shall be connected to
the respective hoses fixed to the
(i) Liquid level unloading point.
The quantity of LPG filled shall not 4. Start the LPG compressor.
exceed the RLW of the tank truck. Vapours will be sucked from the
receiving vessel and will be
10. Liquid level may be determined by discharged into the vapour space
roto-gauge or fixed liquid level of the tank truck vessel creating
gauge. Percentage volume to be pressure differential thereby
filled shall not exceed 85 % at 55OC pushing the liquid from the tank
i.e. the allowable filling limit as per truck vessel to the receiving
CMV Rules. vessel.
alternatively, mass flow meters can
5. Care should be exercised to see be used.
that the pressure created within
the delivering vessel does not Checklist for bulk LPG tank wagons
reach or exceed the set pressure at unloading locations is given at
of the relief valve. Annexure 7 –II.
10. Ensure that all fittings on the 10. Take the tare weight reading
wagons are checked physically. and set the pointer of the
scale to zero. Compare this
11. Hoses shall be tested as per with the marked tare weight
OISD-STD-135 and records on the wagon. Alternatively,
maintained. use mass flow meter to fill
12. The loading/unloading operation the wagons.
shall be carried out under close
supervision of authorised person. 11. Connect the filling hose or
loading arm and vapour
13. During unloading operation, after return line hose or arm to the
the liquid transfer is over, the wagon. Ensure that the flare
wagon pressure shall not be connection valves are closed.
reduced below 1.5 Kg/sq.cm.(g).
12. Ensure that the header is
7.2.2 OPERATING PROCEDURES charged with LPG and the
bulk loading pump is
(a) LOADING OPERATION running.
1. Place the wagon on weigh 13. Open the tanker filling line
bridge taking care to see that valve and vapour return line
all the four wheels are valve.
properly accommodated on
the platform. Engage hand 14. Check the system for leaks.
brakes.
15. Open the valve on the vapour
2. Ask loco to move away and return line. Now slowly open
exhibit caution sign at the valve on the filling line.
suitable distance away from Increase the valve opening
the wagons on both ends. and gradually open the valve
3. Switch off loco engine, if fully. Ensure filling is upto
parked nearby. safe filling level keeping in
view temperature factors.
4. Apply brakes on all wagons Take mass flow meter
readings if used.
5. Ensure fire system, safety
interlocks, communication 16. Once the filling is over, close
system are OK the wagon filling and vapour
return lines valves and also
6. Take loading advice. valves on filling and vapour
return lines at the loading
7. Connect earthing lugs to the point.
wagons.
17. Open the valve on flare line
8. Lower the flapper bridge connection to both feed line
slowly on the wagon. and vapour return line slowly
to avoid ice formation. Thus, be allowed to relieve itself
the hoses are depressurised. past the threads before the
Then, close the flare line plugs are entirely disengaged.
connection valves.
4. If the vapour discharge
18. Disconnect the filling and continues or if there is
vapour return line hose evidence of a liquid
connections from the wagon. discharge, the valves should
Replace and tighten the plugs be re-tightened.
on filling and vapour return
lines. 5. With the plugs removed,
screw pipe nipples into the
19. Close the top cover of the outlets of the valves after first
wagon and seal it properly. having applied a modest
Remove earthing quantity of sealant to the
connections. male threads, keeping the
sealant away from the end of
20. Release the hand brake of the the thread. Tighten nipples
wagon. with a pipe wrench.
21. Release all the wagons on the 6. Connect the two liquid
loading points in the lot. transfer unloading swing
arms or hoses to the nipples
22. Check the gross and net attached to the liquid
weight at the weigh bridge. discharge valves. Connect the
vapour or equalizing swing
Use loading arms for loading / arm or hose to the nipple
unloading operations. attached to the vapour valve.
In most of the cases, these
(b) Unloading Operations connections will be made by
means of either a ground joint
1. Ascertain that the liquid union or a hose coupling.
discharge valve and the
vapour valve within the tank 7. In the event, a ground joint
wagon cover are in the closed union is used, no gasket will
position. be required. If a hose
coupling is employed, ensure
2. Open the port covers in the that the appropriate gasket is
side of the dome shell, if in place. Make sure that they
exist. Unscrew the plugs in are secured tightly by
the outlets of the vapour appropriate means.
valve and the liquid valves
using a box wrench. This 8. After the vapour and liquid
must be done slowly. hoses have been connected
and before any valve is
3. If there is any sound of opened, the valves on the
escaping vapour or if there tank wagon are crack opened
seems to be pressure behind in order to apply pressure to
the plugs, the pressure must
the hoses / loading arms as a
test for leaks. 15. A flow of gas instead of
liquid through the sight-flow
9. If any leak appears, the valve glass in the unloading line
should be immediately closed indicates that the wagon is
and corrective measures empty of liquid. Recheck this
applied. by opening the sample valve
in the tank wagon dome.
10. Recheck the lines and
connections to make sure that 16. When the tank wagon is
they are connected correctly. emptied of all liquid, stop the
compressor and close the
11. After the liquid and vapour liquid valves beginning at the
lines have been secured and storage tank and progressing
tested, both liquid education to the tank wagon.
valves should be opened
slowly and completely. Then, 17. If the facilities are so
open all other valves in the arranged that vapours may be
liquid line working from the removed from the tank
tank wagon to the storage wagon, the pipeline at the
tank. compressor should be
arranged so that the
12. If the tank wagon pressure is compressor will draw vapour
higher than that in the storage from the tank wagon and
tank, do not open the valves force it into the storage tank.
in vapour line or operate the
compressor. When the rate of 18. In this operation, the vapour
liquid flow drops to an should be discharged below
unsatisfactory level with the the surface of the liquid in the
storage tank filling valve storage tank to hasten the
wide open, open the vapour liquefaction and, in turn, help
valves between the tank prevent excessive pressure in
wagon and the storage tank. the storage tank.
13. At this point, make sure that 19. Restart the compressor and
the control valves at the when the tank wagon
compressor are in a position pressure is reduced to about
which allow the compressor 1.5 - 2.0 Kg/ sq.cm., stop the
to draw vapours from the compressor and close all the
storage tank and force it into valves in the vapour line.
the tank wagon, then start the
compressor. 20. After bleeding off the
pressure in the hoses,
14. When the tank wagon is held disconnect both the liquid
at a pressure of 2.0 to 2.5 and vapour lines. Replace all
Kg/sq.cm. above the storage the plugs in the tank wagon
tank pressure, the tank wagon valves and the unloading
should be emptied into the fittings.
storage vessel.
21. Recheck sample valve,
gauging device and (a) Recommended Procedure
thermometer well to In the degassing system
determine that they have been recommended for LPG wagons,
returned to their original vacuum cycle purging
condition and are closed technique should be followed
tight. Lower the dome cover as outlined below :
carefully and lock it in place
with the locking pin or secure - Vessel should be evacuated
by appropriate means. repeatedly by a vacuum pump.
(d) Terminal representatives and c) All gauges, viz. High level alarm,
customs and/or independent measuring gauges, pressure gauges,
surveyors, where necessary, temperature gauges should be kept in
will be informed of the cargo operating condition at all times and
tank data e.g. temperature, be checked daily.
pressure, whether free of
cargo, liquid heel or arrival 7.5 SAMPLING AND DRAINING
dip, composition of tank 7.5.1 SAMPLING
vapour and quantity of cargo
on board. Sampling is primarily required at
supply locations i.e. Refineries, Gas
7.3.8 SHIP / SHORE SAFETY Processing Plants, Import Terminals,
CHECKLIST etc. Sampling of LPG for different
analytical tests shall be carried out in
Checklist for Ship/Shore safety is accordance with IS:1448. During
given in Annexure 7-III. handling of LPG samples, the
following safety precautions shall be
7.3.9 DISCONNECTION OF HOSE/ followed :
UNLOADING ARM
(i) Special sampling bombs shall be
On completion of unloading used for LPG sampling.
operation the tanker discharge Arrangement of rupture disc or any
pipeline need to be purged to push other suitable safety relief device
shall be incorporated in the sampling (i) The valve nearer to the vessel shall
bomb. be opened first and closed. Then,
draining shall be carried out by
(ii) Sampling bombs shall be inspected gradually opening the valve farther
periodically and tested from the vessel. The operation shall
hydrostatically at regular intervals. be repeated till LPG release starts.
Record of such inspection/test shall (ii) It shall be ensured that the drain
be maintained. outlet is at a safe distance from the
vessel so that accidental ignition of
(iii) Sample bombs shall be earthed any escaping vapour would not
effectively before and during expose the vessel to flame
discharge of sample. impingement.
(iv) LPG samples shall be collected only It is important not to attempt removal of
in open/ventilated areas and the the entire quantity of water as
person taking the sample shall stand considerable liquid LPG may escape in
on the windward side. the process. At the first sign of
appearance of LPG, the operation shall
(v) The sampler shall wear protective be stopped. Escape of LPG may lead to
goggles, hand gloves, shoes etc. formation of ice block at the valve seat,
while taking samples. preventing closure of valve. This will
result in escape of uncontrolled vapour
(vi) Samples, after collection, shall be to the atmosphere causing a very serious
properly labeled and kept at hazard.
designated place.
The valve shall be operated slowly to
(vii) Sampling of LPG should avoid ice formation.
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
1. CHECKS REQUIRED TO BE
CARRIED OUT BEFORE ALLOWING TANK TRUCK
ENTRY OF TT INSIDE LICENCED
AREA - Height barrier provided as per specifications
- Properly fitted spark arrestor of make and - Paint of bullet is not peeling off.
design approved by CCE, Nagpur.
GENERAL
- Proper Fittings i.e. SRV, EFCV, temperature
& pressure gauges etc. as SMPV Rules & - First aid kit is available.
OISD-STD-159.
- Electrical wiring is insulated and provided - Has valid CCE licence and authenticated
with suitable over current protection. copy of drawing
- Liquid/ vapour pipe lines are in single piece - 4 Nos. caution sign board with luminous
from excess flow check valve to discharge paint for stopping traffic in case of any
valves - Safety fittings viz., safety valve, emergency.
roto-gauge, pressure gauge and temperature
gauge are adequately protected. Based on the nature of defects either all the
- Operative fittings like roto gauge, pressure deficiencies should be got corrected at the
gauge and temperature gauge are unloading location itself or the tanker should be
operational. allowed to get the repairs done en route and
submit the details at loading location.
GENERAL :
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
SHIP:_________________________________________DATE:______________
PORT &BERTH:_________________________________TIME:______________
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.
iii) Handling & storage of LPG Cylinder shall be checked for `O"
cylinders ring condition and for valve leak by
means of Compact valve Tester
iv) Auxiliary Operations (CVT) or electronic leak detector.
- Cylinder bung shall be cleaned with Valve shall be removed with suitable
3/4" NGT tap and cylinder bung torque wrench or by using online valve
threads checked with L1 and L9 changing machines. Cylinders shall be
gauge. filled with water fully and water should
be allowed to over flow. Thereafter,
- Only cylinders passing above tests cylinders shall be emptied out of water
shall be taken up for valve change and checked with explosimeter for
operation. degassing. Not more than 6 cylinders
shall be degassed at a time.
- Good valve shall be fixed using a
torque wrench. The torque shall not 8.3 DISPOSAL OF ETHYL
exceed 20 +/-2kg.m. Before fixing MERCATAN CONTAINERS
the valve suitable jointing compound
shall be used. Jointing compound It shall be ensured that the drums are
shall be compatible with LPG, water emptied of mercaptan to the extent
and metallurgy of cylinders and possible. The empty drums then can
valves. Teflon tape/ paste of suitable be washed with water and detergent,
valve joining material are followed by wash with a 5% bleach
recommended as jointing material. solution. After again washing with
copious amount of water, the drums
will be ready for disposal.
b) Purging of cylinders
(ii) Treatment of Leaks and Spills
- New cylinders and cylinders
degassed for repairs shall be purged
Leaks and spills of mercaptan can be the spill should then be washed with
treated with commercially available ordinary household bleach solution
masking agents (e.g.Aldor and and then thoroughly with water. Dry
Neutroleum Alpha etc.) to make bleaching powder should never be
them odourless. Large mercaptan used in treating mercaptan spills. A
spills shall be covered with sand or violent reaction could occur.
activated carbon or any other
absorbing material, which are then
buried or incinerated. The area over
9.0 MAINTENANCE & INSPECTION OF EQUIPMENT
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. *
MAINTENANCE SCHEDULE
CENTRIFUGAL PUMP
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Annually
Yrly
(1) (2) (3) (4) (5) (6) (7)
--------------------------------------------------------------------------------------------------------------------------------
10. Overhaul. *
--------------------------------------------------------------------------------------------------------------------------------
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. *
2. Air Filter :
a) Blow-out dirt & condensate. *
b) Clean. *
8. Complete overhauling. *
ANNEXURE 9-IV
DIESEL ENGINES
MAINTENANCE STEPS
7. PREVENT OVERSPEEDING.
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
8. REMOVE AND CLEAN AIR COM- 8A FILL WITH CLEAN OIL, UPTO
PRESSOR BREATHER, IF MARK.
EQUIPPED.
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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.
--------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
DIESEL ENGINES
"B" CHECK EVERY 250 HOURS
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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.
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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
"C" CHECK EVERY 1500 HOURS
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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
"D" CHECK EVERY 4500 HOURS
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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.
e) Weighing scale error should not be This is done primarily to facilitate easy
greater than 1.0%. segregation of cylinders for repairs at
installations without going through the
f) The tare weight should be recorded test date of manufacturing dates punched
with an accuracy of +/-50 gms. and on each and every cylinder. Currently,
rounded off as per IS:2. the following colour codes have been
selected for easy identification of
10.1.10 PUNCHING OF cylinders and the same shall be repeated
MARKS : after every five/ seven years cycle.
Colour coding is done on the inside of
In addition to punching of revised one of the Stay Plates and the same is
tare weight/ gross weight wherever given below:
applicable, following details should
also be punched on the cylinder
COLOUR CODING SCHEME
--------------------------------------------------------------------------------------------------------------------------------
Cylinder Cylinder Next Background Shade as Lettering
Manufactured retested/hot Retesting colour IS:5 colour
in the repaired Date
year in the year
-------------------------------------------------------------------------------------------------------------------------------
10.1.12 CERTIFICATION :
k) External
A detailed record of each cylinder tested
at the installation or at the repairer's l) Whether passed/ rejected
premises should be maintained. The
record should include the minimum 10.1.13 HYDROSTATIC TEST/
following details : HYDROSTATIC STRETCH
TEST :
a) Running serial number
- Whether passed/ rejected
b) Date of testing
- Condition of bung threads (internal)
c) Serial number of cylinder & name of - Whether satisfactory/ rejected
manufacturer Pneumatic Test
d) Month and year of test - Whether passed/ rejected
j) Internal
(The Remarks columns should indicate The test certificate issued by the Plant or
whether the cylinder has been finally by the Repairers should include :
passed or rejected besides any other
relevant details not covered above). - Running Serial Number of cylinder
- Cylinder Serial Number
- Date of testing
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
FIRE PROTECTION FACILITIES
ii) All LPG storage Vessels, Cylinder The Fire Water pumping requirement for
Storage/ Filling/ Repair Sheds, LPG medium velocity spray system shall be
Pump / compressor Houses, remote calculated based on minimum spray
operating valves /motor operating density as 10.2 LPM/Sq.M of the
valves on LPG lines Bulk Lorry and exposed surface or area to be cooled, in
Tank Wagon Gantries shall be fully case of LPG Pump/ compressor it shall
covered by medium velocity water be 20.4 LPM/Sq.M .
spray system.
a. Storage Vessels
iii) Fire Protection Facilities shall have
fire fighting access, means of escape MV sprinkler system with automatic
in case of fire and also segregation of heat detection having remote/ local
facilities so that the adjacent operated Deluge valve with spray
facilities are not endangered during density of Minimum 10.2 LPM/ Sq.M
the fire. shall be provided on all above ground
storage vessels.
iv) Heat Detectors for detection of fire
for automatic actuation of medium For water flow calculations aggregate
velocity water sprinkler system shall surface area of all vessels within
be provided. The QB/EP detectors distance of 30 Mts. from the periphery
shall be placed directly overhead or of the affected LPG vessel shall also
inside the hazard. In areas without be considered as single risk .
specific hazard, detectors shall be
placed evenly across the ceiling or b) Sheds
with maximum spacing of 3 meter
inside the shed. Any other detectors MV sprinkler system with automatic
if provided shall comply with the heat detection having remote/ local
design requirements. operated Deluge valve with spray
density of minimum 10.2 LPM/Sq.M
11.3 FIRE WATER SYSTEM shall be provided in the entire shed
including the loading / unloading
fingers.
For spray water calculations, the shed MV sprinkler system with automatic
can be divided into suitable number of heat detection having remote/ local
zones, each served by independent operated deluge valve with effective
deluge system. The adjacent zones shall spray density of 10.2 LPM/Sq.M shall be
be operative around the zone under fire provided. The gantry can be divided into
and the same shall be considered as a suitable number of zones with minimum
single risk. The width of a zone shall zone length of 30 meters and adjacent
not be less than 10 meter except of the zones shall operate around zone under
zone on either end of the shed. As there fire and same shall be considered as
is no storage of cylinders in the loading single risk. The spray system shall
/ unloading fingers, spray system can cover tank wagons surface on either side
be taken as separate zone with of tank wagon gantry atleast in two tiers
independent deluge valve to optimise as well as the associated LPG pipelines
the fire water requirement . in the gantry.
c) LPG Pump / Compressor House The fire water system in the plant shall
be designed to meet the highest fire
MV sprinkler system with automatic water flow requirement of a single
heat detection having remote/ local largest risk of any of the above cases at a
operated Deluge valve with spray time plus 288 Cu.M/Hr. for operating 2
density of Minimum 20.4 LPM/Sq.M Nos. Fire water Monitors/
shall be provided. Supplementary Hose requirements.
ix) Monitors shall be located to direct xiv) The fire water deluge valves shall
water on the object as well as to be kept outside the kerb wall at a
provide water shield to firemen safe distance in case of sphere/
approaching a fire. bullet, and located 15 M away from
limits of other sheds or shadows of
spheres. A fire wall shall be
The requirement of monitors shall be provided for the protection of the
established based on hazards deluge valve and for personal
involved and layout considerations. protection of the operator.
ii) The hoses shall be of 15 Meters 10. Fire proximity suit Min. 1 No.
standard length and shall be provided
with Gun metal/ Aluminium alloy 11. Resuscitator Min. 2 No.
male & female couplings of
instantaneous pattern. 12. Red/Green Flags As reqd
The fire protection equipment shall be i) All deluge valves and sprinkler
kept in good operating condition all the system shall be operated and checked
time. once in a quarter for correct remote
operation performance of each
The fire fighting system shall be nozzle and effectiveness of system in
periodically tested for proper functioning total.
and logged for record and corrective
actions. In addition to routine daily ii) Testing of sprinkler system in the
checks/ maintenance the following sheds shall be carried out by closing
periodic inspection/ testing shall be the outlet of the deluge valve for
ensured. correct remote operation once in a
quarter.
11.15.1 FIRE WATER PUMPS
iii) The strainers provided in the Fire
i) Every Pump shall be in test run for water sprinkler system shall be
atleast 10 minimum twice in a week cleaned once in a quarter and records
at the rated conditions. maintained.
ii) Once in a month each pump shall be 11.15.4 FIRE WATER RESERVOIR
checked and tested and the shut-off
pressure observed and logged. Also In case of a Reservoir the same shall be
the pump performance shall be cleaned once in 6 months or earlier as
ascertained. and when needed so that there shall not
be any foreign particles/ fungus/
iii) The Jockey pump operation shall be vegetation in the reservoir.
checked periodically. Frequent start/
stop condition of Jockey pump 11.16 MAKE UP WATER
indicates that there are water leaks in
the system. Facilities to make up water during fire
fighting shall be provided.
11.15.2 FIRE WATER RING
MAIN
i) The ring main shall be kept
pressurised at 7 kg/sq.cm.g with the
help of one or more jockey pumps.
CHAPTER 12
i) The detectors for the gas monitoring iv) The control equipment should be
system shall be strategically located able to generate at least two alarms at
in LPG Bottling Plant at all different levels of LEL concentration
facilities close to the potential of gas.
source of leakage.
v) The control equipment is not
ii) The detection control equipment required to have automatic corrective
should be provided in the control action capabilities on sensing
room for continuous monitoring leakages as this is basically a
even during power failure. warning device. However, in case of
any specific recommendations made
12.2 DETECTORS in the risk analysis / HAZOP studies,
the same should be implemented.
Amongst the various methods of
detection available, the following 12.4 ANNUNCIATION SYSTEMS
proven systems for LPG can be
considered. Appropriate annunciation system shall
be available to ensure that all the alarms
i) Catalytic detectors generated, both, audio and visual are
ii) Infra-red detectors reported to the plant personnel, who are
authorized to take corrective action.
12.3 CONTROL SYSTEMS Depending on the manning practice of
the plant, the alarms both, audio and
i) This is a critical equipment for visual can be repeated at additional
plant’s safety. Hence, the system location to ensure corrective action is
should have independent control taken.
equipment, power supply, UPS to
ensure that the system remains in 12.5 LOCATION OF DETECTORS
operation even if the plant DCS or
i) The behaviour of the gas leakage TLD – one at each manifold and at
governs the positioning of the gas ends.
detector. As LPG is heavier than air,
the height of the detector should not Tank wagon gantry – 1 no. for every
be more than 0.3 M from the two bays or 30 m whichever is less
mounting level. at bottom. Additionally, some
detectors at selected locations shall
ii) The pre-dominant wind direction be provided at the top of platform.
should be considered with respect to
the potential source of leakage to The number and location of the
ensure positioning of the detector on detectors required over and above the
the down stream side of the wind minimum requirements specified
direction. above shall be as per the specific
requirements identified in the risk
iii) The detectors especially the catalytic analysis / HAZOP study report.
type should not be positioned very
close to the potential source of The location can be decided by
leakage to avoid poisoning of the assessing the behaviour of gas drift
detectors(temporary malfunctioning). and consequential safety risk.
The detectors should be located at
least 0.3 mtrs. away from the vi) Inspection and testing
potential source of leakage.
The gas monitoring system shall be
iv) In case of infra-red detectors, the kept in good operating condition all
same shall be installed on the down the time.
wind side ensuring the path is free The inspection of the system shall be
from obstructions. In case any done at an interval of 1 month in
additional expansion/ construction if which the gas shall be released at all
undertaken, the detectors will have to the detectors and the performance of
be pre-positioned. the systems shall be established.
iii) Spark from the loose contact on b) Initiate action as per Fire
vehicle batteries. Organisation Plan or Disaster
Management Plan, based on
iv) Spark from exhaust of railway gravity of the emergency.
engine.
c) Stop all operations and ensure
v) Cinders from the steam closure of all ROVs and isolation
locomotives. valves.
iii) Spark from studed shoes, with f) Plant personnel without specific
steel button by friction against duties should assemble at the
ground/ metal. nominated place.
i) If the feed to the fire cannot be cut e) Fire fighters should advance
off, the fire must be controlled and towards a fire down wind if
not extinguished. possible.
After the fire is extinguished, if the 13.2.5 Fire Fighting Organisation Plan
leakage cannot be stopped the
cylinder should be moved carefully (a) A plan of action for use in the event
to a safe location to vent out the of a major LPG product leakage
contents under controlled with a fire or risk of fire is
conditions. essential. Such a plan must be
carefully prepared for each plant.
(iv) Fire of LPG vapour escaping It should be fully understood by all
from a damaged vessel fitting LPG plant supervisory personnel
(flame not playing on vessel) and other personnel responsible for
action as per plan. It shall be based
Allow fire to continue till exhaustion. on the following :
Spray vessel with water to cool it, if (i) Plant personnel shall be fully
vessel is being heated by radiation from trained for the specialized
the flame or if flame is endangering techniques necessary for
other plant equipment. combating LPG leakages and LPG
fires.
Cool adjacent vessels and structures.
(ii) If leakage and/ or fire occurs, all
(v) Fire at Safety Relief Valves of personnel should use the
vessels exposed to adjacent fire. equipment provided and to carry
out their allotted tasks as detailed
(vi) Fire in Oil storage area adjacent in the fire fighting organisation
to LPG storage : plan.
Start water sprays only on those
LPG vessels exposed to fire/ heat. (iii) All personnel should be conversant
with fire control equipment and
Isolate affected vessels and run out also its location.
fire water hoses in case hose
stream cooling becomes necessary. (iv) LPG plant personnel should know
the position and method of
operation of all Remove Operation
valves (ROVs) in the plant. (ix) Preventing all sources of ignition in
case of LPG leakage.
(v) Plant personnel should be familiar
with the standard recognition (x) Evacuation of vehicles.
markings of fire control, first aid
and all safety equipment, must (xi) Evacuation and mustering of
know the location of emergency personnel.
exits, and they should know the
location of water hydrant points/ (xii) Establishing an emergency fire-
monitors and must be familiar with control centre.
the sound of the emergency (fire)
alarm. (xiii) Traffic control.
(b) The Fire Fighting Organisation Plan (xiv) Stations and duties of all
together with layout of fire fighting personnel.
and safety devices shall be
displayed at prominent places and (xv) Policing of affected areas.
explained to all personnel. It shall
include the following functions, (xvi) Any other specialised duties.
expanded to suit the location
facilities/ requirement:- (xvii) Display of fire brigade,
ambulance, Police telephone
(i) Sounding the emergency (fire) numbers etc.
alarm.
(xviii) All clear signal by competent
(ii) Shutting off the LPG supply to any person.
leakage point/ fire.
(c) Liaison with local fire brigade :
(iii) Summoning the fire brigade/
police. Close co-operation with the local fire
authorities is essential and shall take the
(iv) Fire control, with first aid, fire following form :
fighting equipment.
(i) The fire brigade should be made
(v) LPG vapour dispersal. familiar with the layout of the plant
and the location of important
(vi) Operation of LPG vessel's fixed equipment/ facilities provided, and
water sprinkler system, starting of their method of use. Mock fire
fire pump (s) and application of drills/ exercise jointly by plant
water hose jets/ sprays for personnel and local fire brigades
containing/ extinguishing fires. shall be planned.
(vii) Cooling of vessels/ cylinders and (ii) Fire fighting equipment at the plant
other equipment/ facilities. shall be compatible with the fire
brigade equipment, otherwise
(viii) Closing down all operations in the adapters shall be kept ready for
plant including closure of valves hoses, hydrants etc.
and stopping of pumps.
(iii) The fire brigade shall be aware of f) Protective clothing, breathing
the plant's fire fighting organisation apparatus and any other specialised
plan and the views held at the plan safety equipment available shall be
regarding the most effective LPG tried out during drills to train all
fire control methods. concerned in their application.
(iv) In the event of an emergency/ fire, g) The local fire brigade should be
the plant manager and/ or his encouraged to participate in fire
representative shall advise the Fire drills periodically.
Officer about particular or potential
hazards that may be present e.g. h) Any shortcoming, noticed during
stocks of filled cylinders at that the drill shall be rectified.
particular point of time.
13.2.6 Disaster Management Plan :
(d) Fire Drills & Training :
ON- SITE
a) Drills for all Plant personnel,
making use of the "Fire fighting a) It is basically a pre-plan to handle
Organisation Plan" and practicing any emergency situation of a
the specialised techniques required higher magnitude arising out of
for fighting LPG fires or factors listed below:
dispensing/ diluting LPG vapour
clouds shall be held minimum once (i) Major fire/ explosions
in a month.
(ii) Uncontrollable leakage of LPG
b) The drills should cover various
types of incidents, e.g. major (iii) Lightning
spillage, LPG bulk lorry fire,
cylinder fire etc. (iv) Heavy floods
14.1 GENERAL:
14.2 TYPE OF SAFETY AUDIT AND
Safety audit is a well recognised tool to PERIODICITY :
improve the effectiveness of safety
programme and loss prevention In view of the high hazard potential of
measures by carrying out systematic and LPG, safety audits at frequent intervals
critical appraisal of potential safety by the teams/ personnel of various levels
hazards involving personnel, plants and are advocated, Broad check lists for
equipments. different recommended safety audits are
given in the Annexure 10-I, II, III, IV.
For a structured and systematic safety These check lists can be further
audit of any plant/ facility, check lists supplemented and modified suitably to
are the most important prerequisite. meet the specific requirements of
Check lists should cover all the individual plant. Recommended
operational areas, major equipments, minimum safety audits at different
operating/ maintenance procedures, levels, their frequencies and broad check
safety practices, fire prevention/ lists to be used are indicated below :-
protection systems etc. Observations/
recommendations of safety audit team Daily audit essentially shall cover the
should be presented in the form of a compliance of recommended operating
formal report and action plan for procedures/ safety practices. Reports of
corrective measures should be prepared audit shall be reviewed by the Plant
and subsequently monitored for Manager on daily basis and corrective
implementation. action be undertaken on priority
wherever required.
General guidelines on safety audit
methodologies and techniques are also
given in OISD - GDN- 145.
-----------------------------------------------------------------------------------------------------------------------------
S.No. Type of Safety By Frequency Checklist
Audit (Annexure)
-----------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5
-----------------------------------------------------------------------------------------------------------------------------
1. Inspection Safety LPG Plant Daily 14-I
audit of LPG Installation Safety Officer
2. Electrical audit of Authorised Annual 14-II
LPG Installation electrical Engineer
3. Detailed safety audit Multi disciplinary Annual 14-III
of LPG Installation team of region/ HQ
4. Inspection and Personnel from Annual 14-IV
maintenance audit of Inspection/ Maintenance
LPG Installation
5. External safety audit OISD
of LPG Installation
--------------------------------------------------------------------------------------------------------------------------------
Daily audit essentially shall cover the
compliance of recommended operating 1. Safety Organisation
procedures/ safety practices. Reports of
audit shall be reviewed by the Plant 2. Security System
Manager on daily basis and corrective
action be undertaken alongwith the 3. Fire prevention/ protection system
target dates shall be done immediately.
The compliance to other audit 4. Preparedness to handle any
recommendations along with target emergency --Disaster control plan
schedules shall be monitored on monthly and mock drills.
basis. Alternate, safety measures shall be
taken till the recommendations are 5. Skill level and training needs for
complied in totality. HRD.
LOCATION ______________
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
* Put specific observation wherever the conditions are not in line with specified
requirement levels.
ANNEXURE 14 - II.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-02 Is the equipment easily accessible for operation, inspection & maintenance.
g) Grounding OK
c) Sealing of duct
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.
B-06 No motor abnormality
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 ?
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.
ANNEXURE 14- III
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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).
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.
i) Spurious
ii) Hot repairs
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.
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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.
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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.
- 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.
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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
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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.
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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.
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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.
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.
IS:1436-1991 - WEIGHBRIDGES
vi. ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American
Society of Mech.Engrs., New York