STD 162
STD 162
STD 162
For Restricted
Circulation only
No.
SAFETY IN INSTALLATION
AND MAINTENANCE OF
LPG CYLINDERS MANIFOLD
OISD-STANDARD-162
First Edition, July 1995
For Restricted
Circulation only
No.
SAFETY IN INSTALLATION
AND MAINTENANCE OF
LPG CYLINDERS MANIFOLD
Prepared By
COMMITTEE ON LPG CYLINDERS MANIFOLD
Oil Industry in India is more than 100 years old. Over the years a
variety of practices have been in vogue because of
collaboration/association with different foreign companies and
governments. Standardisation in design, operating and maintenance
practices was hardly in existence at a national level. This lack of
uniformity, 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) staffed from within the industry in 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.
The present document on ‘Safety in installation and maintenance
of LPG cylinders manifold’ was prepared by the functional committee
on LPG Cylinders Manifold. This document was prepared based on
the accumulated knowledge and experience of industry members and
the various national and international codes and practices.
This document will be reviewed periodically for improvements
based on the new experiences and better understanding.
Suggestions from industry members/users may be addressed to :
The Coordinator
Committee on
LPG Cylinders Manifold
Oil Industry Safety Directorate,
2nd Floor ‘Kailash’
26, Kasturba Gandhi Marg,
New Delhi - 110 001
COMMITTEE
ON
LPG CYLINDERS MANIFOLD
Members Representing
In addition to the above, several other experts from industry contributed in the preparation,
review and finalisation of this document.
SAFETY IN
INSTALLATION AND MAINTENANCE
OF LPG CYLINDERS MANIFOLD
CONTENTS
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SECTION
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1.0 INTRODUCTION
2.0 SCOPE
3.0 LAYOUT
ANNEXURES
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SAFETY IN INSTALLATION AND MAINTENANCE
OF LPG CYLINDERS MANIFOLD
There are a number of LPG cylinders 3.1 General guidelines for manifolded
manifolded installations existing in Hotels, LPG cylinders shall be followed from IS :
Hospitals, Nursing Homes etc. Apart from a 6044 (Part I) - 1971. The additional safety
BIS code, there is no detailed code which can measures need to be taken are as under:
be followed by the Oil Industry (through
their approved contractors). In view of the 3.2 The site for LPG cylinder manifold
potential hazards of such manifold shall be located away from the kitchen.
installations, the need was felt to develop a Installation shall be slightly raised from the
standard code of practice in addition to BIS ground level. Cylinders shall not be installed
code IS:6044 (Part I)-1971. In the Liquefied below ground level in cellars or basement.
Petroleum Gas trade, commercial/Industrial The cylinders shall be stored in dry, cool and
cylinders installations relate to the larger well ventilated room.
type catering/production arrangements such
as Restaurants and Canteens located in 3.3 Cylinders installation should not be
Hotels, Hospitals, Nursing Homes and located close to steam pipes and boilers etc.
Industrial Establishments such as Textiles, to prevent cylinders from getting affected due
Baking, Glass factory etc. to radiant heat.
3.15 The storage room shall have caution 4.2.4 Size of the cylinder storage room shall
signs such as “DANGER”, “HIGHLY depend upon the number of installed
INFLAMMABLE GAS SHED”. “NO cylinders designed for the layout of the
SMOKING” etc. painted in luminous red manifold (parallel or linear) and the cylinder
paint outside at a prominent place. arrangement in the storage room (Standard
or staggered). Enough room shall be
3.16 A minimum distance of 1 mt. shall be provided for easy access to each and every
maintained between the cylinder installation cylinder.
and the surface water drain, if any.
4.3 CONNECTION CRITERIA OF LPG
4.0 DESIGN CRITERIA OF CYLINDERS TO MANIFOLD :
INSTALLATION
4.3.1 All The cylinders at the customers’
premises shall always be connected to the
4.1 In order to meet the larger manifold wherever the installed cylinders at
requirement of commercial customers it is the premises are more than four. The
necessary to connect a number of cylinders to cylinders should not be left unconnected or
a manifold so that the required quantity of stored elsewhere. Should there be
gas at requisite pressure can be obtained. requirement of additional cylinders which are
The multi cylinder installations shall be to be kept loose, the customer can store
designed as per IS:6044 (part I) - 1971. them within stipulations as provided for in
Gas Cylinders Rules, 1981. However
4.1.1 It is required to visit the customer’s such cylinders should not be stored in
premises and select a suitable site for manifolded room. Each arm of the manifold
cylinder storage room as per the layout shall have a control valve. To each arm of
considerations. In order to ascertain the the cylinder manifold, cylinders shall be
requirement complete details shall be connected through a pigtail. For ‘SC’ type
collected and noted in the format as given in valve cylinders it is necessary to use an
annexure - I. adaptor to connect the cylinder pigtail. The
distance between the nipples on the manifold
to which pigtails are attached, depends upon 5.1 GENERAL :
the type of cylinder arrangement required i.e.,
standard or staggered. The staggered 5.1.1 For safe efficient performance of
arrangement is to be used when any LPG installation, all equipments,
availability of space is limited. appliances and accessories shall conform to
the laid down standards and specifications.
4.3.2 The flexible hose/pigtail shall be in the For quality control more and more items are
same room and its length shall not exceed 2 being covered by BIS. In case of BIS
M. Flexible hose/ pigtail shall not pass covered items, items approved by BIS only
through doors, windows, walls, ceiling (or) shall be used. In case any component is not
floors. The pigtails shall be accessible for covered by BIS Standard, then the same shall
inspection. have Oil Industry’s approval.
4.6 The manifold (header) pipeline shall 5.3.1 Copper, steel and mild steel tubes to
not have any joints to extend its length. be used in LPG service shall be as specified
in IS:6044 (Part I) - 1971.
5.0 SPECIFICATIONS FOR
EQUIPMENTS, APPLIANCES AND 5.3.2 Steel pipes, cold steel drawn
ACCESSORIES seamless or electric resistance welded
(ERW) conforming to IS:3601 shall only be These have a spreading ring flame profile
used. and are good for cooking purpose. These
burners are referred to as ‘M’ type burners.
5.3.3 Copper tubes shall be solid drawn with There are no BIS specifications so far. Hence,
outside diameter of 10, 12, 20 mm as suitable Oil industry approved make shall only be
conforming to IS:2501. used.
5.4.1 The following types of valves are These are long burners used horizontally and
normally used in the LPG installations: named ‘V’ burners due to their shape.
i) Needle control valves These burners are used for heating long,
ii) Fire control valves broad containers mussel ovens etc. The
iii) Quick shut-off valves burner flame impinges on the bottom of the
iv) Main shut-off valves vessel or plate at an angle of 45 degrees.
The burner shall be so chosen such that the
5.4.2 The valves designed to work on LPG flame does not enter beyond the
shall only be used. Materials used in these circumference of bottom plate of vessel.
valves should not be affected by LPG. Type
of valves to be used on LPG service should 5.5.7 CANTEEN BURNERS
be of proper pressure rating and meet oil
industry specifications since BIS or equivalent 5.5.7.1 These burners are low pressure
standards are presently not available. appliances widely used in commercial
installations. These are similar to the
5.4.3 Cast iron and aluminum valves shall domestic burner but of larger size.
not be used.
5.5.7.2 Canteen burners shall conform to
IS:5517 - 1969.
5.5 BURNERS :
5.5.7.3 High pressure canteen burners as
5.5.1 The burners used in commercial may be required by end users can be custom -
installations are normally high pressure built and used.
burners. These burners work at a pressure of The heat efficiency of all the burners
0.315 kg/cm2 (4.5 PSIG) and above. Of the mentioned above should be a minimum of
various models currently in use, from types 40% when tests are conducted as per BIS
which find the maximum applications are Standard No. IS:5117-1969.
outlined below:
5.6 CYLINDERS MANIFOLD :
5.5.2 T-TYPE BURNERS OR
TORCH BURNERS 5.6.1 Cylinder manifold is very important
because of the fact that it is subjected to full
These give a concentrated flame and are cylinder pressure at all times. The fabrication/
good for water heating and deep frying. The welding of the manifold should be of the
vessels used in this type of burners should best available quality. All such manifolds
preferably have concave bottom. shall be designed to a pressure equivalent
to the maximum possible cylinder pressure
5.5.3 These are vertical burners and height (assessed at 65 degree C) of LPG i.e. at 16.87
can be varied. kgf/cm2. The test pressure should be 1.5
times the maximum pressure (assessed at 65
5.5.4 There are mainly two sizes in this type degree C) i.e. 25.35 kgf/cm2.
of burners i.e. T22 and T35 with consumption
of 1 kg/hr and 1.6 kg/hr LPG respectively. 5.6.2 The control valve (‘F’ type ) used in
These burners are also called as T1 and T2. the cylinder manifold arm shall be of the type
Higher capacity burners are also available. used for LPG cylinders. Valves manufactured
There are no BIS specifications so far. Hence by approved valve manufacturers of oil
oil industry approved make shall only be industry shall only be used in manifold.
used.
5.6.3 All joints in the manifold should be
5.5.5 ‘M’ TYPE BURNERS welded (except for valve fixation) and be
easily accessible for inspection/ repairs etc.
5.6.4 Each manifold arm shall be fabricated 6.0 INSTALLATION OF PIPING AND
out of a single length of pipe. Joints to APPLIANCES
lengthen the arm, are not permitted.
6.1 In fabrication of LPG installation
5.7 CYLINDER PIGTAILS : general guidelines shall be drawn from code
of practice for LPG storage installation IS :
Normally copper pigtails are used to connect 6044 (Part I)-1971.
cylinders to the manifold. However, flexible
reinforced synthetic rubber pipes are also 6.2 Those responsible for the installation
being used. The quality of braided synthetic of LPG equipment and piping etc. should
rubber tubes shall be such that it is least understand the characteristics of LPG very
affected by LPG. The reinforcement i.e. clearly and shall be trained in proper
braiding should be able to withstand the same handling, installing and maintaining
pressure as that of cylinder manifold. The installations.
design and test criteria shall be same as
that of cylinder manifold. Test pressure shall 6.3 Detailed drawings giving
not be less than 25.35 /cm2. The free nut at specifications of the equipment used and
the end shall be of noncorrosive metal. layout of the entire installation must be
approved by concerned Oil Co. before
5.8 ADAPTOR : undertaking work.
This device is used to connect the pigtails 6.4 The route of pipeline which is spelt out
to the cylinder valves (self-closing) of the very clearly in the approved drawing, shall not
LPG cylinders. This device shall have non- deviate while laying down the pipelines. If
return device and shall have prior approval of need be the original drawings can be got
the oil industry. revised duly approved by Oil Cos.
5.9 NEEDLE CONTROL VALVE : 6.5 All pipelines must be either welded
or brazed so as to ensure that no leakage
These are normally used to control the flow can take place even at pressures much higher
of gas to the burners. These valves should than the working pressures. Use of threading
be of approved type of oil industry. and jointing the pipeline through jointing
compound shall not be resorted to.
5.10 PRESSURE GAUGE :
6.6 The welding/brazing of the pipeline
A good quality pressure gauge with a range of joints shall be done by a trained and qualified
0-3 kgf/cm2 (0-40 PSI) shall be provided in welder.
the pipeline after the first stage pressure
regulator. The joint at which pressure gauge is 6.7 If the pipeline diameter is more than
fixed shall be thoroughly checked for leakage. 50 mm, it should be welded and/or flanged.
Similar type of pressure gauges shall be Smaller diameter pipelines should only be
provided in the pipelines after II stage welded/brazed.
regulation.
6.8 The piping joints shall not be placed
5.11 EXCESS FLOW VALVE : embedded in floors in inaccessible places.
Wherever it cannot be helped, welding and
The excess flow check valve shall be provided prior pressure testing of pipeline shall be
on each arm of the manifold to ensure done. Wherever the pipes are buried they
stoppage of LPG supplies in case of heavy shall not have any flange joints in the buried
leakage/damage to the pipeline in the portion.
downstream facilities. The capacity of the
excess flow valve shall be 50% more than 6.9 Joints other than welded, if any, are
the maximum designed flow rate required to be so placed that they shall be readily
through the manifold. accessible, so that leakage tests can be
conducted without any difficulty.
5.12 PIPING TUBING AND FITTINGS :
6.10 Piping both embedded in floor and
Proper record of suppliers of equipments, its above ground shall be protected against
installation and Standard used shall be physical damage and corrosion. These shall
maintained. be covered with bituminous wrap coating at
the buried portion for LPG.
6.11 Cast iron and aluminum pipe fittings 7.1 Every multi-cylinder installation
shall not be used. essentially consists of the following:
1. Cylinders
6.12 All materials including non-metallic 2. Manifold
parts for valves, seals, gaskets and 3. Valves
diaphragms shall be resistant to the action 4. Pigtails
of the LPG under the service conditions to 5. Regulators
which they are subjected. 6. Burners
It shall be ensured that all the above
6.13 Plugs shall be solid steel plugs or equipments conforms to a approved layout
steel ball plugs. Cast iron or brass plugs shall drawing and other specifications as mentioned
not be used. in the foregoing sections.
9.1 All the safety precautions outlined in iv) Sliding, dropping or playing with
the Gas Cylinder Rule 1981 shall be complied cylinders is prohibited.
with.
v) Liquefied Petroleum Gas cylinders
9.1.1 Storage of Cylinders shall always be kept in an upright position and
i) The storage of cylinders is governed shall be so placed that they cannot be
by the Gas Cylinders Rules - 1981 and the knocked over.
appropriate safety distances as given in the
rule should be complied with. vi) Open flames, lights, lighting of fires,
welding and smoking shall be
ii) Cylinders shall be stored in a cool, prohibited in close proximity.
dry, well ventilated place under cover, away Cylinder should not be lifted with magnets
from boilers open flames, steam pipes or and chains should not be used for
any potential sources of heat and such place slinging.
of storage shall be easily accessible.
vii) Cylinders shall not be stored along 9.2.2 Detection of Gas Leakages
with any combustible material.
Gas leakage can be easily detected by its
viii) Unconnected cylinders shall be kept characteristic smell and more positively
away from the LPG cylinder manifold. located by means of a soap solution.
ix) All electric meters, distribution boards, 9.2.3 For pinpointing the source of leakage
switches, fuses, plugs and sockets, electric only soap solution shall be used. A NAKED
fixed lamps, portable hand lamps and motors FLAME MUST NEVER BE USED because
shall be of flame-proof construction. there is risk of causing fire accident.
M 22
Category : Hotel/School/Hospital/
M 35
Laboratory/Other/College
(Specify) /Mess V 300/600/900
Type of Hotel: 5* 4* 3* 2* Other
(Specify)
Canteen burner
Type : New Hotel/unit
M 100/140
: Existing unit using other fuels converting to LPG
Usage:
: Existing unit using LPG and requires
enhancement Intermittent :
Adequate space available for
cylinder storage : Yes/No Continuous :
Coffee/Tea Date :
Snacks
Sweets
Meals
b. If so, Floor area as per norms Yes/No b. All materials, fittings etc. used
in cylinder manifold comply
c. Adequate ventilation at low level with BIS stipulation. Yes/No
to directly outside air provided
Yes/No c. In case of pressure regulator
and automatic change over
d. Minimum distance of 3m is Yes/No device connected by semi
maintained between installation flexible connectors and are
and any building, public place,
roadway and other surroundings
rigidly supported. Yes/No
provided Yes/No
4. Pressure Regulators :
e. Not twisted - looped or
a. PR comply BIS stipulation kinked Yes/No
(IS:4786-1968) Yes/No
f. Joints are accessible for
b. PR fitted with a relief valve and inspection Yes/No
positioned to avoid
hazards Yes/No g. Piping and electric wiring
are at least 60 mm
c. PR and other control devices away and is fixed below
adequately supported Yes/No electric wiring Yes/No
Action to be taken: