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NOTE

Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil
and gas industry under Ministry of Petroleum & Natural Gas. These are the
property of Ministry of Petroleum & Natural Gas and shall not be reproduced or
copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby disclaims any liability or
responsibility for loss or damage resulting from their use.

These documents are intended to supplement rather than replace the prevailing
statutory requirements.
 FOREWORD

The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies ,
operating and maintenance practices was hardly in existence at a national level.
This, coupled with feed back from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas
installations.

With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) for
formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of functional
committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.

Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as
well as with industrial applications due to its unique properties and environmental
benefits. The document on "LPG Bottling plant operations" was prepared in
1994. The present document "LPG Installations" has been prepared by the
functional based on the accumulated knowledge and experience of industry
members and updation of national and international codes and practices related
to LPG.

This document will be reviewed periodically for improvements based on the

new experiences and better understanding. Suggestions may be addressed
to :

The Coordinator,
Committee on “LPG”
Oil Industry Safety Directorate,
7th floor, New Delhi House,
27, Barakhamba Road,
New Delhi – 110001
 FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)

NAME ORGANISATION

LEADER
Sh. R. Krishnan Hindustan Petroleum Corporation Ltd., Mumbai

MEMBERS
Sh. A.N. Biswas Deptt. of Explosives, Nagpur

Sh. N. Rajkhowa, Engineers India Limited, New Delhi

Sh. B.S. Giridhar Indian Oil Corporation Ltd., - HQ, Mumbai

Sh. N. Dasgupta Bharat Petroleum Corporation Ltd., Mumbai

Sh. T.Koteeswaran Chennai Petroleum Corporation Ltd., Chennai

Sh. B.J. Phukan Numaligarh Refinery Ltd., Assam

Sh. P. Jaidevan Indian Oil Corporation Ltd., Calicut

Sh. S. Ramesh Bharat Petroleum Corporation Ltd., Noida

MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
 FUNCTIONAL COMMITTEE MEMBERS
( First Edition – April 1994 )

NAME ORGANISATION

LEADER
Sh. S.C. Tandon Indian Oil Corporation Ltd., ( Ref.)
MEMBERS
Sh. H.G. Bhinde Indian Oil Corporation Ltd., ( Mkt.)

Sh. A.C. Kelkar Indian Oil Corporation Ltd., ( Mkt.)

Sh. V. Narayana Rao Bharat Petroleum Corporation Ltd., (Mkt.)

Sh. P. Kumaraswamy Bharat Petroleum Corporation Ltd., ( Ref.)

Sh. P.P. Nadkarni Hindustan Petroleum Corporation Ltd., (Mkt.)

Sh. S. Mathur Engineers India Limited, New Delhi

MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
 CONTENTS
---------------------------------------------------------------------------------
SR. No. ITEM PAGE NO
---------------------------------------------------------------------------------

1 Introduction
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

---------------------------------------------------------------------------------
 LIQUEFIED PETROLEUM GAS (LPG)
INSTALLATIONS

1.0 INTRODUCTION • The pressure inside a LPG storage

vessel/ cylinder is equal to the
Liquefied Petroleum Gas (LPG) is a vapour pressure corresponding to the
mixture of light hydrocarbons primarily temperature of LPG in the storage
C3 & C4 derived from petroleum, which vessel. The restriction on vapour
is gaseous at ambient temperature and pressure is stipulated by IS-4576.
atmospheric pressure, is liquefied at
ambient temperature with application of • LPG has an explosive range of 1.8%
moderate pressure. LPG due to its to 9.5% volume of gas in air. This is
inherent properties is susceptible to fire, considerably narrower than other
explosion and other hazards. Such common gaseous fuels. This gives
hazards can have an impact on the an indication of hazard of LPG
property, equipment, plant personnel and vapour accumulated in low lying
public. area in the eventuality of the leakage
or spillage.
Liquefied Petroleum Gas (LPG)
handling, bottling and distribution throw
major challenges due to its inherent • Water, being insoluble in LPG, if
properties. Major incidents i.e. present in LPG can cause rust and
fires/explosions in LPG facilities in corrosion and freeze-up of valves,
world have underlined the need for total drain valves, excess-flow check
in depth review of design, procedures, valves, cylinder valves and
maintenance, fire fighting and safety regulators thereby affecting their
aspects in LPG handling. functioning and at times can lead to
leakage of LPG.
The oil and gas industry over the years
have learnt lessons from fires and • LPG liquid has low viscosity of
explosions and have been updating and around 0.3 CS @ 45 oC and can leak
standardising design, operations, bottling when other petroleum products
and distribution of LPG. normally cannot, thus demanding a
very high integrity in the pressurised
Some of the important properties of LPG system to avoid leakage.
are as below :
• LPG even though slightly toxic, is
• LPG at atmospheric pressure and not poisonous in vapour phase, but
temperature is a gas which is 1.5 to can, however, suffocate when in
2.0 times heavier than air. It is large concentrations due to the fact
readily liquefied under moderate that it displaces oxygen. In view of
pressures. The density of the liquid is this the vapour posses mild
approximately half that of water and anaesthetic properties.
ranges from 0.525 to 0.580 @ 15 oC.
• LPG is colourless both in liquid and 2.0 SCOPE
vapour phase. During leakage the
vapourisation of liquid cools the This standard lays down the minimum
atmosphere and condenses the water safety requirements on design, layout,
vapour contained in them to form a storage, loading / unloading, operation,
whitish fog which may make it inspection & maintenance, fire
possible to see an escape of LPG. protection, emergency planning and
safety audit systems of LPG
• The coefficient of expansion is Installations. This standard does not
around 0.00237 per oC. At liquid full cover process plants, the distribution of
condition any further expansion of LPG to domestic & non-domestic
the liquid, the container pressure will consumers and pipeline operations, road
rise by approx. 14 to 15 kg./sq.cm. / rail transportation, refrigerated and
for each degree centigrade. mounded storage facilities for LPG.

• LPG has only a very faint smell, This standard is not applicable to
therefore, ethyl mercaptan is bottling plants having a bulk LPG
normally used as stenching agent for inventory not exceeding 100 MT with
identifying the leakage as per IS : minimum two storage vessels and with
4576. LPG bottling a total quantity not
exceeding 20 MT per shift of 8 hrs. The
• The auto-ignition temperature of safety requirement for such LPG
LPG ranges from 410 to 580 oC. 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 Earthing : Earthing is the provision of
case may be. a safe path of electrical current to
ground, in order to protect structures,
Area Classification : It is a method of plant and equipment from the effects of
classifying an area zone wise/ group stray electrical current, and electrostatics
wise based on the presence of explosive discharge.
gas/ vapour - air mixture vis-a-vis the
requirement of precautions for Filling Ratio : It is the ratio of weight of
construction and use of electrical LPG in a container to the weight of
apparatus. water the same container can hold at 15
o
C.
Bonding : Bonding is the process by
which two electrical conducting bodies Fire safe : As applied to valves, it is the
are connected using a conductor to concept of controlling the leakage to an
maintain electrical continuity to prevent acceptable level after damage
sparking between two conducting encountered during and after the fire
bodies. achieved by dual seating.

Bulk Vessels : A pressure vessel used Fire proofing : It is an insulation that

for more than 1000 litres water capacity provides a degree of fire resistance to
for storage or transportation of LPG. protect substrates like vessels, piping
and structures for a predetermined time
Bullet : A horizontal cylindrical pressure period against fire.
vessel used for storage or transportation
of LPG by rail/ road. Flammability : It is the percentage of
volume of any flammable vapour in air-
Compressed Gas : Any permanent gas, vapour mixtures capable to form an
liquefiable gas or gas dissolved in liquid explosive mixture.
under pressure or gas mixture which in a
closed container exercises a pressure Flammable (or Inflammable) : Any
either exceeding 2.5 kg/sq.cm. abs @ 15 substance which when tested in a
o
C or a pressure exceeding 3.0 kg/Sq.cm. specified manner will ignite when mixed
abs @ 50 oC or both. with air on contact with a flame and will
support combustion.
Cylinders : A portable LPG container
upto 1000 litres water capacity used for Gas-Free : it means the concentration of
both domestic and industrial purposes. flammable or toxic gases or both in a
pressure vessel or pipeline is within the
Explosive mixture : It is a mixture of safe limits specified for persons to enter
combustion agent (oxidising product- and carryout hotwork in such vessels/
gas, vapour, liquid or solid) and a fuel pipelines.
(oxidisable product - gas, liquid or solid)
in such proportions that it could give rise Horton Sphere : A spherical pressure
to a very rapid and lively oxidisation vessel used for storage of LPG.
reaction liberating more energy than is
dissipated through conduction and Hot Work : It is an activity which may
convection. produce enough heat to ignite a
flammable air-hydrocarbon mixture or a
flammable substance.
Installation : The facilities where LPG
is stored or loading/ unloading Water Capacity : The maximum
operations or bottling operations are volume of water in litre that the a
carried out. container can hold at 15 oC.

Kerb Wall : A wall of appropriate 4..0 STATUTORY RULES /

height and size constructed of suitable REGULATIONS
material and designed to contain the
LPG spillage and to direct it to a safe The LPG installation & various facilities
location around the storage vessel. are covered under many regulations and
require specific approval / licence from
Liquefied Petroleum Gas (LPG) : The concerned statutory authorities. The
term applies to a mixture of certain light various regulations applicable to LPG
hydrocarbon predominately C3 & C4, installation facilities are as below :
derived from petroleum & natural gas
which are gaseous at ambient a. Gas Cylinders Rules, 1981 (under
temperature and pressure, may be Indian Explosives Act,1884)
condensed to a liquid state at normal
ambient temperature by the application b. Static & Mobile Pressure Vessels
of moderate pressure and conforming to (unfired) Rules-1981 (Under Indian
IS : 4576 or IS: 14861. Explosives Act 1884).

Purging : It is the act of replacing the c. The Factories Act, 1948.

atmosphere within a container by an
inert substance in such a manner as to d. Indian Electricity Rules
prevent the formation of explosive
mixture. e. The Standards of Weight &
Measures Rules - 1987 Under
Purging into Service : is the Weight & Measures Act - 1976.
replacement of air in a closed system by
an inert substance and replacement of f. The Standards of Weight &
the later by combustible gas, vapour, or Measures (Packaged Commodities
liquid. Rules-1977)

Purging out of service : is the g. Liquefied Petroleum Gas (Regulation

replacement of normal combustible of supply and distribution Order -
content of a closed system by an inert 1993).
substance, and replacement of the later
by air. h. The Motor Vehicles Act - 1988.

Tare Weight : The weight of the i. Environmental Regulations :

cylinder together with any fitting
permanently attached to it including the ¾ Water (Prevention & Control of
weight of valve. Pollution) Act, 1974.

Maximum Working Pressure : It is ¾ Air (Prevention & Control of

saturated vapour pressure of LPG at 65 Pollution) Act- 1981
o
C for LPG cylinders and 55 oC for bulk
vessels.
 ¾ The Environment (Protection) facilities have been detailed. The
Act – 1986 various facilities within LPG installation
shall be located based on Table-I and
¾ Manufacture, storage & import of Table-II.
Hazardous chemicals Rules -
1989. 5.2 LOCATION & SEPARATION
DISTANCES :
¾ Guidelines for Environmental
clearance of new projects - 1981. 5.2.1 LOCATION

In addition to the above Statutory While assessing the suitability of any

regulations, there are various site for location of LPG installation, the
recommended guidelines emerging out following aspects shall be considered :
of the various Committees set up by the
Govt. of India from time to time for a) The location of residential quarters,
streamlining/ improving the safety other industries, railways, roads,
standards of LPG Bottling/ Distribution: waterways, overhead power lines,
places of public assemblies etc.. This
a. Vasudevan Committee - 1983 shall be covered in risk analysis
Ministry of Energy (Department of study of the proposed site. The study
Petroleum). shall also be used to plan for
emergency measures.
b. Expert Committee Review of Safety
and Operating Procedures in LPG b) Adequate availability of water from a
facilities - 1986, Ministry of reliable source or alternate
Petroleum & Natural Gas arrangements proposed.
(Department of Petroleum)
c) The topographical nature of the site
c. Sudha Joshi Committee for better with specific reference to its effect
services to LPG users - 1987 on the accidental release of LPG.
(Ministry of Petroleum & Natural
Gas). d) The availability of space for future
extension of LPG facilities, if any,
shall also comply with the safety
5.0 INSTALLATION LAYOUT norms.

5. 1 GENERAL e) The meteorological data of the

location including predominant wind
The layout of the LPG facilities direction & velocity, high flood
including the arrangement and location level, temperatures etc.
of plant roads, walkways, doors and
operating equipment shall be designed to 5.2.2 SEPARATION DISTANCES
permit personnel and equipment to reach
any area effected by fire rapidly and The separation distances as given in
effectively. The layout shall permit Table- I & II are the distances in plane
access from at least two directions. between the nearest point on a vessel
other than the filling/ discharge line and
The general principles of layout of LPG a specified feature, e.g. adjacent vessel,
storage, bottling and bulk handling site boundary etc.
5.3 LAYOUT Grading of the ground underneath
should be levelled and directed to an
The following aspects shall be area connected with water seal away
considered while establishing layout of from the storage vessel.
LPG storage vessels. Bullets or spheres
are used for above ground storage of Kerb wall height shall be minimum
LPG. 30 cm but shall not exceed 60 cm
otherwise evaporation of spilled
a. The access of mobile fire fighting LPG may get affected.
equipment to the storage vessels
shall be at least from two sides. Spillage diversion area shall be
located at a distance where the
b. Longitudinal axis of static storage flames from fire will not impinge on
vessels (bullets) shall not be pointed the vessel. This distance shall not be
towards other vessels, vital less than the diameter of the nearest
equipments e.g. LPG cylinder sheds, vessel or minimum 15 M. No
tank lorry/tank wagon gantries, LPG accumulation of LPG should be
pump house and buildings wherein possible underneath the storage
control panels for fire and gas vessel in any condition.
detection/ actuation panels are
situated. (b) PIPING - Only piping associated
with the storage vessels shall be
c. Storage vessels to be located located within the storage areas or
preferably in downwind of potential between the storage area and the
ignition sources at lower elevation. manifold system.

d. No foreign material / combustible (c) SURFACE DRAINAGE - In order

substances shall be stored in storage to prevent the escape of spillage into
area. the main drainage system, surface
water from the storage area and from
e. Storage vessels shall be laid out in the manifold area shall be directed to
single row in each group. the main drainage through a water
f. Storage vessels shall not be located seal to avoid the spread of LPG.
one above the other.
(d) GROUPING - Vessels shall be
5.4 LPG STORAGE FACILITIES: arranged into groups, each having a
maximum of six vessels. There shall
(a) CONFINEMENT/ GRADING - be minimum spacing as specified in
Table-I between adjacent vessels.
Kerb wall shall be provided around Each group shall be separated by
all sides of the storage vessel with roads on all four sides for easy
concrete flooring of the ground access and emergency handling.
under vessel and extending upto
minimum distance of D/2 or 5M (e) Spheres and bullets shall be treated
whichever is higher and atleast 5 M as separate groups with minimum 30
(min.) from the edge of the storage M distance between two groups.
vessel with a slope of 1:100 (min.).
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 5.5.7 The layout of the unloading
pumping facilities for bullets and location shall be such that tank
spheres. Alternatively, fail safe truck being unloaded shall be in
interlocks like two way valves shall be drive out position.
provided so as to avoid any chances of
overfilling of adjacent vessels due to 5.5.8 The weigh bridge of adequate
gravitation. capacity shall be provided and
proper maneuverability for
5.5 LPG BULK LOADING / vehicles.
UNLOADING FACILITIES
5.5.9 Tank truck shall be loaded/
5.5.1 LPG tank lorry loading/ unloaded with suitable
unloading gantry shall be arrangement for cold flaring of
covered and located in a separate hose content, if used at the end of
block and shall not be grouped the operations.
with other petroleum products.
5.5.10 LPG tank truck parking area
5.5.2 LPG loading/ unloading rail (Bulk/ Packed) shall be located in
gantries shall have separate rail a secured area and provided with
spur and be grouped separately at adequate no. of hydrants /
least 50 M from other rail monitors to cover the entire
shunting facilities. parking area.

5.5.3 Space for turning with minimum 5.6 LPG BOTTLING FACILITIES
radius of 20 M for tank lorries
shall be provided commensurate 5.6.1 LPG bottling facilities shall be
with the capacities of the tank located at a safe distance from
trucks. other facilities with minimum
5.5.4 LPG tank wagon loading/ ingress of traffic and upwind
unloading shall be restricted to a direction with respect to bulk
maximum of half rake, not storage.
exceeding 600 tonnes. If full rake
loading/ unloading is envisaged There shall not be any deep
this shall be done on two separate ditches in the surrounding areas
rail gantries separated by a at least within 15 M from storage
minimum distance of 50M. sheds to avoid settling of LPG
vapour.
5.5.5 Maximum number of LPG tank
lorry bays shall be restricted to 8 5.6.2 LPG Bottling section shall be of
in one group. Separation single storey. Antistatic mastic
distance between the two groups flooring conforming to IS-8374
shall not be less than 30 M. shall be provided in the LPG
filling shed/ cylinder storage
5.5.6 For adequate permanent including valve changing shed to
protection for tank lorry avoid frictional sparks. The shed
discharge, pipeline island shall be shall be supported by RCC
provided. The minimum width of columns alternatively structure
such pipeline island shall be 1 M. steel columns shall be covered
 with concrete or fire-proofing 5.6.9 There shall be sufficient no. of
material upto full height of crossovers to avoid trapping of
columns. Anti static mastic personnel in LPG sheds by
coating upto 1.5 m (Min.) shall conveyors, cylinders and other
be done of the supporting facilities. Further, sufficient no.
columns of the shed. of escape routes shall be
provided.
5.6.3 The bottling operation shall be
carried out in the filling shed. 5.6.10 All steps forming part of the
Separate sheds for filled escape routes shall be minimum
cylinders storage, valve 1.2 M with treads 30 cms
changing, degassing, if any, shall (minimum) and maximum rise of
be provided. Valve changing 15 cms.
unit without evacuation can be
provided in filling shed itself. 5.7 PROTECTION OF FACILITIES

Empty cylinders storage area 5.7.1 Properly laid out roads around
shall be properly segregated from various facilities shall be
filling machines by 5 M (Min.). provided within the installation
Cylinders shall always be stacked area for smooth access of fire
vertically with maximum stack tenders etc. in case of
height of 1.5 m. For details of emergency.
cylinders stacking pattern refer
Figure - I . 5.7.2 Proper industry type boundary
wall atleast 3 M high with 0.6 M
5.6.4 LPG cylinder filling machines barbed wire on top shall be
and other related testing facilities provided around the installation
shall be provided in sequential unless the bottling plant is
order. protected as a part of refinery
complex.
5.6.5 A separate shed shall be provided
for carrying out degassing of 5.7.3 Emergency exit with proper gate
defective cylinders. shall be provided in the
earmarked zone.
5.6.6 Cylinder storage shall be kept on
or above grade and never below 5.7.4 In case provision for green belt is
grade in cellar or basement. made, the same shall be
segregated from hazardous area
5.6.7 Filled cylinders shall not be by 1 M high wall / chain link
stored in the vicinity of cylinders fencing. Alternatively, it shall be
containing other gases or treated as a part of hazardous
hazardous substances. area.

5.6.8 Escape routes shall be specified

and marked in LPG sheds for
evacuation of employees in
emergency.
 facilities and located as per the
5.8 UTILITIES separation as specified in Table-I.

Utilities consisting of fire water pumps,

admin. building, canteen, motor control
centre, DG room, air compressors, dryers
etc. shall be separated from other LPG

TABLE - I

INTERDISTANCE FOR LPG FACILITIES

---------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8
---------------------------------------------------------------------------------------------------------------------------

1. LPG Storage vessels * T-II 30 30 50 30 15 60

2. Boundary/property line/ T-II - 30 30 50 30 30 -

group of bldgs. not associated
with LPG installation

3. Shed-LPG 30 30 15 30 50 30 15 60

4. Tank truck gantry - LPG 30 30 30 50 50 50 30 60

5. Tank wagon gantry 50 50 50 50 50 50 30 60

6. LPG/other rail spurs 30 30 30 50 50 50 30 60

7. Pump house/Comp.house 15 30 15 30 30 30 - 60
(LPG)
8. Fire Pump House/ storage tank 60 ** 60 60 60 60 60 -
---------------------------------------------------------------------------------------------------------------------------
Notes :
1. 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
--------------------------------------------------------------------------------------------------------------------

6.0 DESIGN CONSIDERATIONS ii. Material shall be in line with design

code. ASTM A516 Gr. 60 shall be
6.1 GENERAL used for refinery service (BS-5500
shall not be used for the same) and
This section describes the design and for marketing installation where H2S
safety features required in a typical LPG is not present ASTM A 516 Gr. 70 or
bottling installation. A 537 CLASS 1 can be used. Micro-
alloyed steel containing Ni, Mo, Va
6.2 LPG STORAGE VESSELS shall not be considered. Maximum
specified tensile stress shall not be
The minimum requirements w.r.t. design more than 80,000 psi.
considerations and various fitting to be
o
provided LPG storage vessels shall be as iii. Design temperature : (-) 27 C to
o
under : (+) 55 C.
2
6.2.1 MECHANICAL DESIGN iv. Design Pressure : 14.5 Kg/ cm g on
top as per IS: 4576 at 55 oC.
i. The storage vessel shall be designed
in accordance with the codes i.e. Marketable LPG conforming to IS:
ASME SEC. VIII or IS-2825 or PD 4576 can have a maximum vapour
- 5500 or equivalent duly approved pressure of 16.87 Kg/ Sq.cm.g at 65 o
by CCE. Design shall take into C temperature. LPG with higher
account the Static and Mobile vapour pressure are not expected to
Pressure Vessels (Unfired) Rules be stored in bottling installations.
1981 also.
The recommended design pressure and
A single code shall be adopted for temperature shall be treated as
design, fabrication, inspection and MINIMUM requirement and other
testing i.e. ASTM and BS shall not design consideration and Statutory
be combined. requirements shall also be considered.

v. Other Design Considerations

 safe ROV. ROVs for vapour /
Corrosion Allowance : minimum 1.5 recirculation lines should be provided at
mm the ground level with an isolation valve
at top. In case, ROV is provided at top of
Radiography : Full the vessel, there is no need to provide an
isolation valve.
Stress Relieving : 100% irrespective of
thickness. Fire safe ROVs shall also be provided on
liquid line at TLD & Tank wagon gantry
Wind pressure : as per IS: 875 & isolation valve (quick closing type) on
the entry of liquid lines at LPG filling
Earthquake pressure : as per IS:1893 shed at a safe location.

Hydro test pressure : As per Design Nozzles for two independent level
Code indicators of different type, a high level
switch, two safety relief valves, pressure
Where ever extreme climatic conditions gauge and a manhole shall be provided
or security reasons warrants, suitable on top.
alterations in design can be made with
approval from statutory bodies. All the fittings shall be suitable for use at
the design parameters of the storage
6.2.2 FITTINGS vessels and for the temperatures
appropriate to the worst operating
Spheres/ bullets other than underground conditions. The remote operated valves
shall have a single nozzle at the bottom on the storage vessel connecting
for liquid inlet as well as outlet. The pipelines shall be fire-safe type
nozzle shall be full welded pipe, stress conforming to API 607 or equivalent.
relieved along with the vessel and shall
extend minimum 3 meters from the The flange joints of these valves shall
shadow of the sphere/ bullet. A remote either have spiral wound metallic gaskets
operated shutdown valve (ROV) shall be or ring joints. Plain asbestos sheet /
provided on this bottom nozzle at a reinforced gaskets shall not be used.
distance of at least 3 meters from the Gasket used shall conform to ASME
shadow of sphere/ bullet. The nozzle B16.20 or equivalent. The studs used
pipe shall have a minimum slope of 1.5 shall conform to ASTM A 194 Gr 2 H/
o
. ASTM A 193 Gr B7 or equivalent.
Flange connections shall be of minimum
There shall not be any other flanges, of 300 lb rating confirming to ANSI
manhole, instrument tapping on this B16.5 class 300 or equivalent. All
nozzle upto the ROV or on sphere/ bullet tapings or openings shall be of
bottom. In order to avoid stress on the minimum 20 mm thickness.
nozzle due to relative settling of support
and storage vessel, suitable supports for 6.2.3 INSTRUMENTS
the bottom nozzle shall be provided.
i) The storage vessel shall have
The top vapour zone of the vessel shall minimum two independent level
be provided with nozzles for vapour indicators and one independent high
outlet, recirculation wherever applicable. level switch. High level alarms shall be
These lines shall be provided with fire set at not more than 85% level of the
volumetric capacity of the vessel. Audio Typical safety fittings on a LPG storage
visual indication shall be at local panel vessel are indicated in Figure-II.
& control room. On actuation of high
level alarm, the ROVs of the affected 6.3 LPG LOADING/ UNLOADING
vessel shall close. FACILITIES

ii) Each storage vessel shall have at Each loading station shall consist
least two safety relief valves with of the following :
isolation arrangement set at different
values and at not more than 110% of i. Excess flow check valve & non
design pressure of the vessel and each return valve shall be provided in
having 100 % relieving capacity LPG loading lines.
adequate for limiting the pressure build
up in the vessel not more than 120% of ii. A vapour return line with an
design pressure. isolation valve connected back to the
storage vessel/ suction line with
The relieving load for the safety valves, NRV.
shall be based on fire condition and no
credit shall be taken for fire proofing on iii. Properly designed loading arm or
the vessel, if provided. LPG hoses shall be provided at the
end of filling and vapour return lines
The discharge of safety valves shall be for connecting to the tank truck
connected to flare system, wherever vessel. The loading shall be
available. In this case, safety valves shall provided with break away couplings
have lock open (or car seal open) type or smart hoses shall be used. Loading
isolation valves on both sides of safety arm shall be of approved type and be
valves. tested as per OEM recommendations.
In case, LPG hoses are used, it shall
In case of non availability of flare conform to OISD-STD-135.
system, the discharge from safety valve
shall be vented vertically upwards to iv. The hose - coupling / flange joint
atmosphere at an elevation of 3 meter shall be of Class 300 lb rating with
(minimum) for effective dispersion of metallic gasket. The hose coupling
hydrocarbons. In this case, isolation shall be provided with a cap or blind
valve on down stream of safety valve is flange by which the nozzle can be
not required. A weep hole with a nipple closed when not in use.
at low point shall be provided on the
vent pipe in order to drain the rain water v. Weigh bridges of suitable capacity
which may get accumulated otherwise. for road / rail movements and mass
Weephole nipples shall be so oriented flow meters for pipeline transfers
that in case of safety valve lifting and shall be provided. The mass flow
consequent fire, the flame resulting from meters shall be certified for its use
LPG coming out from weephole does not with LPG.
impinge on the sphere or structure. A
loose fitting rain cap with a chain (non vi. A check valve shall be provided in
sparking) fitted to vent pipe shall be the vapour return line.
provided on top of safety valve.
Unloading of LPG from tank truck is
carried out with vapour compressors
using pressure differential method of designed to ensure good natural
liquid transfer. The compressor used for ventilation. RCC roofing shall
unloading shall be provided with the not be used.
following facilities:
The filling area shall not be on
(i) Vapour line with isolation valves upper floors of building or in
cellars unless specifically
(ii) Excess flow check valve & non required on account of extreme
return valve shall be provided in weather conditions.
LPG unloading lines with isolation
valves ii) As far as possible, the floor area
shall not have any channels or
(iii) Weigh bridge of suitable capacity pits. Where these are necessary
for conveyors or other equipment
like weigh machine etc., suitable
Additionally following shall be ensured. gas detection system shall be
provided. Additionally, proper
i. Suitable provision shall be made for ventilation system through ducts
evacuation of LPG from bulk storage fitted with blowers shall be
vessels to tank truck or another provided to release LPG outside
vessel to empty the vessel in case of of the shed at safe location. The
emergency or for statutory testing. whole of the LPG filling shed
flooring shall be provided with
ii. Tank truck shall be loaded/ unloaded mastic flooring.
with suitable arrangement for flaring
of hose content at the end of the All carousels & leak detectors
operations. including electronic shall be of
approved type.
iii. The unloading arms shall be used for
unloading the LPG TT at LPG iii) Adequate lighting shall be
installation. In case, LPG hose are provided in the cylinder filling
used, it shall conform to OISD-STD- area. Emergency lighting shall
135 or equivalent as approved by also be provided at critical
CCOE. places.
iv. The hose - coupling / flange iv) Water drains from the cylinder
joint shall be of 300 lb rating filling area where they enter an
with metallic gasket. The hose outside drainage system, shall be
coupling shall be provided with a provided with vapour seals.
cap or blind flange by which the
nozzle can be closed when not in v) Proper access shall be made
use. available for other fire fighting
equipment i.e. fire tender, foam
6.4 CYLINDER FILLING
trolley etc.
FACILITIES
vi) Cylinder storage area
i) The cylinder filling area shall be
requirement shall be worked out
completely open type and
based on the stacking pattern of
covered from top with roof
 filled and empty cylinders as start without vapour extraction
described in Figure-I. unit being functional.
vii) The filling machines shall be
provided with auto cut-off system 6.5 UTILITIES
so that LPG supply is cut off
when the desired quantity of (A) Compressed air
product has been filled in the
cylinders. The filling pressure The quality of instrument air shall
shall not be more than the design conform to the requirements as
pressure of the cylinders i.e. 16.9 recommended by the manufacturers of
kg/sq.cm.g. instruments/ equipment:

viii) Filling machines in a If one compressor is envisaged to run

carousel/ stationary filling normally, another standby compressor of
machines shall not have a 100% capacity shall be provided. When
weighment error of more than + more than one compressor running is
150 gm of the net quantity of the envisaged, 50% standby capacity shall
LPG filled in the cylinder, with a be provided.
capacity of 14.2 kg or as
specified in Weights and (B) Service Water
Measures Rules.
Service water is required for the cylinder
ix) On-line check weigh scales with washing equipment and leak check bath,
a minimum of 50 gms. compressor cooling and in hose stations
graduation be installed so that all for washing etc.
the cylinders are check weighed
after filling. Water may be provided at a pressure of
about 3 Kg/sq.cm.g. If one pump is
x) Compact Valve Tester to check envisaged to run normally, another pump
valve and 'O" ring shall be with 100% capacity shall be provided as
installed on line. Alternatively a standby. Where more than one pump
electronic leak detectors shall be running is envisaged, 50% capacity as
provided. standby shall be provided.

xi) Water test bath or electronic leak Water Quality

detectors shall be provided to
detect body and bung leak Water shall be of potable quality
cylinders. conforming to IS : 10500 - Specification
for Drinking Water.
xii) Vapour extraction system at
strategic locations near carousel, (C) Emergency Power
cylinder evacuation unit, valve
changing unit, degassing shed The installation shall be provided with
and at locations where leaking battery / diesel generating set for
LPG is expected to accumulate operating the essential systems such as
shall be provided. Further, it shall the instrumentation and safety systems
be interlocked with filling (gas detectors, automatic fire water
machine so that filling do not sprinkler system) and minimum lighting
during the grid power failure.
 Typical sketch of a bottling pump
6.6 LPG PUMPS installation is enclosed as Figure-III.

i. LPG Pumps shall be designed for 6.7 LPG VAPOUR

handling of LPG and safely COMPRESSOR
withstand the maximum pressure
which could be developed by the i. Compressors shall be suitable for
product and / or transfer handling LPG and designed to
equipment. Pumps shall conform safely withstand the maximum
to API 610 or equivalent. outlet pressure to which these
will be subjected. Compressors
ii. Check valves shall be installed shall conform to API 618 or API
on the delivery side of all 619 or equivalent.
centrifugal pumps.
ii. The belts used in shall be of
iii. LPG Pumps shall be provided antistatic type & fire resistant.
with suction and discharge
pressure gauges, a high point iii. Compressor shall be provided
vent to safe height or flare, and a with the following features as a
suction strainer. minimum :

iv. Double Mechanical seal with seal - Pressure gauges in suction and
failure alarms shall be provided. discharge.
- Temperature gauge in discharge
v. A pressure switch actuating a low - Discharge safety valve and a vent
pressure alarm in control room valve, their outlets leading to
and locally shall be provided, flare/ safe height outside the
taken from discharge end. shed.
- Low Suction Pressure Trip
vi. Pumps shall be designed to build - Suction strainer
a discharge pressure such that the - High Discharge Pressure Trip
pressure at the carousel filling - High Temperature Trip
machine is at least 5.0 - Check valve in discharge
kg/sq.cm.g. above the vapour - A discharge to suction recycle
pressure at the operating valve for achieving capacity
temperature. turndown during startup.

vii. Pumps shall have a by-pass valve iv. A suitable size scrubber or liquid
and other suitable protection knockout drum shall be installed
against high discharge pressure upstream of the vapour
on the delivery side. compressor. It shall be equipped
with a gauge glass, safety relief
viii. The electrical motor drive valve, a drain and high liquid
and switchgear shall conform to level shut down device.
area classification as per OISD
Standard-113 / IS -5572. Belt Typical sketch of compressor
drives shall be of the anti-static installation is enclosed as Figure-IV.
type.
6.8 PIPING to atmosphere, the discharge shall be
done in a safe manner.
Piping shall be designed for handling of
LPG. Piping that can be isolated and 6.9 VALVES
need thermal safety valves shall have
minimum design pressure of 24 kg/cm2 Steel valves conforming to relevant
or the maximum pressure which could be API standards shall be used. Cast
developed by the transfer equipment or iron valves should not be used.
any other source etc, whichever is
higher and comply with the following : 6.10 FITTINGS

(i) Piping shall conform to the (i) Steel flanges and flanged fittings
provisions of ANSI B 31.3. conforming to API 105 Class 300
(forged) or eq. shall be used. Slip
(ii) The material shall conform to API on or weld neck flanges should
5L Gr. B / ASTM A106 Gr B or eqv. be used. Screwed flanges for
sizes 50 mm or smaller may be
(iii) Seamless pipes shall be used. used. Steel flanges should
Furnace butt welded or spiral welded conform to the applicable
pipes shall not be used. provisions of ANSI B 16.5.

(iv) Pipe joints should be welded as far as (ii) Steel screwed fittings and
practicable with full penetration couplings shall conform to ANSI
weld. Number of flanged or threaded B 16.11 or equivalent. Steel
joints should be kept to a minimum. unions shall have ground metal to
metal seats. Gasket type unions
(v) Low point drains and high point shall not be used.
vents shall be plugged or capped
suitably. (iii) Plugs shall be of steel.
Cast iron or brass plugs shall not
(vi) Buried piping shall be protected be used.
against physical damage and
corrosion with suitable sleeves, (iv) All flanges shall be connected
properly sealed at both the ends, at for bonding for electrical
road crossings. continuity.
6.10 EVACUATION FACILITY
FOR DEFECTIVE CYLINDERS
6.9 THERMAL PRESSURE
RELIEF SYSTEM a. The cylinder evacuation facility shall
consist of :
Any equipment or section of pipeline
in which liquid LPG may be trapped - Cylinder emptying vessel (s)
e.g. between shut off valves, shall be - Compressor
protected against excessive pressure - Four way valves or equivalent
developed by thermal expansion of - Cylinder rack, header to be provided
the LPG by providing suitable with pressure gauge and a strainer
thermal pressure relief valve(s). If with isolation valves.
pressure relieving devices discharge - The LPG line exit cylinder
evacuation area to be provided with a
 non-return valve before joining the 6.12 EQUIPMENT FOR
main LPG return header. ETHYL MERCAPTAN
- Independent earthing connections. SERVICE

b. Each of cylinder emptying vessels 6.12.1 Material of Construction of

mentioned above shall be equipped Ethyl Mercaptan containers
with the following :
Stainless steel and copper free
- Pressure gauge steel alloys are the preferred
- Level gauge materials of construction of
- high level alarm switch set at 85 equipment for mercaptan service.
% with trip / switchover Aluminium of desired pressure
arrangement. rating can also be used. Use of
- Pressure relief valves, Iron or carbon steel shall be
- Vent valves discharging to 1.5 m avoided as there is the hazard of
above the shed. formation of iron-sulphur
- Other trims like drain valve, complexes which are pyrophoric.
utility connection. Copper or copper bearing alloys
shall not be used for mercaptan
Typical sketch of cylinder evacuation service as mercaptan readily
facility is enclosed as Figure-V. attacks and contaminates them.

6.11 PURGING OF NEW 6.12.2 Pumps for Mercaptan service

CYLINDERS/ TANKERS
Only hermetically sealed pumps
(a) The new LPG cylinders containing shall be used.
air shall be evacuated with a vacuum
pump.. The evacuation facility shall 6.12.3 Piping and Fittings
consist of :
(i) Seamless stainless steel piping
- Vacuum pump (water/ oil / air shall be used. Threaded fittings
cooled type) can be used provided they meet
- Purging manifold the service requirement ratings.
- Vacuum receiver fitted with A fluoroplastic tape sealant is
vacuum gauge, vent and drain. recommended.
- LPG vapour header
- Purging adapters (ii) Flexible connections shall be
- Vacuum pump with suction seamless stainless steel with
strainer pipe nipples welded to each
- Pressure regulator, relief valves end.

Typical sketch of new cylinder purging (iii) Relief valves shall be full
system is enclosed as Figure-VI. nozzle, disc type, closed bonnet
(b) Purging of tankers/ vessels shall carbon steel body with 304
be done using either Nitrogen or stainless steel trim and stainless
by filling water and displacing or aluminized steel spring.
with LPG vapours.
(iv) For transfer valves, stainless
steel ball valves with
 fluoroplastic seats and stainless standard as per requirements of
steel (SS316) trim or their statutory authorities. All
equivalent are recommended. equipment used in hazardous
area shall be approved by Chief
(v) Rigid connection should be Controller of Explosives.
welded or flanged joint type.
iv. For details on hazardous area
(vi) Fluoroplastics shall be used for classification, enclosure
gasketing. protection etc., OISD-STD–113,
OISD-RP-149, NEC – 1985,
(vii) For pressure gauges, stainless IS:2148, IS:5571, 5572, IS:
steel diaphragm type is 13408, Petroleum Rules, 2002
recommended with stainless shall be referred.
steel socket and tip.
6.14 Installation Lighting
(viii) Provision for analysis in line
with IS:4576 or IS14861 as i) Sufficient lighting shall be
applicable shall be made. provided so as to enable plant
operators to move safely within
6.13 SELECTION OF ELECTRICAL the accessible areas of
EQUIPMENT installation and to perform
routine operations. In the event
i. Electrical equipment shall be of normal power failure,
selected, sized and installed so as emergency lighting shall be
to ensure adequacy of provided.
performance, safety and
reliability. The equipment in ii) Normal lighting system shall be
general shall conform to relevant on 415/ 240V AC supply,
Indian Standards and shall be whereas emergency lighting will
suitable for installation and be either on 220V or 110V DC.
satisfactory operation in the
service conditions envisaged. iii) Lighting requirements provided
during the failure of power
ii. All electrical equipment shall be supply for Normal lighting are
selected considering the system intended broadly,
neutral earthing.
a. to facilitate carrying out of
iii. Electrical equipment including specified operations, for safe
for lighting system shall conform shutdown of the installation.
to hazardous area classification
and be selected in accordance b. to gain access and permit
with IS:5571. These shall be ready identification of fire
tested by agencies such as fighting facilities such as fire
CMRI, ERTL, CPRI or water pumps, fire alarm
independent test laboratory of stations etc.
country of origin for such
equipment. Indigenous c. Escape route for safe
Flameproof equipment shall evacuation of operating
comply with relevant BIS personnel.
 only live poles, the neutral being
iv) Under normal operation, both isolated by a removable link.
emergency and normal lighting
shall be fed by normal power For details on inspection practices
source. On failure of normal OISD standard 147 to be referred..
supply, emergency lighting shall
be transferred to emergency 6.15 Installation Earthing
source until the start of D.G. set
within 15 seconds. Critical i. All electrical equipment shall be
lighting (D.C. supply based) shall suitably earthed. Earthing system
be normally kept ‘ON’. During shall cover the following:
power failure, battery bank shall
be used to provide power. ¾ Equipment earthing for personnel
safety.
v. Low pressure sodium vapour
lamps shall not be installed in ¾ System neutral earthing, and
hazardous areas.
¾ Protection against Static and
vi. The illumination levels in Lightning discharges.
different areas shall be as per
good engineering practice. The earthing system shall have an
Depending on the nature of job earthing network with required
activities to be carried out the number of earth electrodes connected
suggested minimum illumination to it. The following shall be earthed:
levels for various areas are
covered in OISD-STD-149. • System neutral

vii. The lighting fixtures on various • Metallic non-current carrying

circuits shall be suitably parts of all electrical apparatus
interlaced so that failure of any such as transformers,
one circuit do not result in switchgears, motors, lighting /
complete darkness. power panels, terminal boxes,
control stations, lighting fixtures,
viii. Switches controlling the receptacles etc.
lighting fixtures and exhaust fan
shall be installed outside the • Steel structures, loading
battery room. platform etc.

ix. Switches of lighting panels • Cable trays and racks,

installed in hazardous area, shall lighting mast and poles.
have a pole to break the neutral
in addition to the poles for • Spheres, Bullets etc.
phases.
• Electrical equipment fencing
When the means of isolation is (e.g. transformer, yard etc.)
located in a non-hazardous area, the
switch shall break all poles including • Cable shields and armour.
neutral or alternatively may break
 • Flexible earth provision for two separate and distinct connections
wagon, truck. to earth grid.

ii. Installation earthing design shall be vi. The main earthing network shall be
carried out in accordance with the used for earthing of equipment to
requirements of Indian Electricity protect it against static electricity.
Rules and IS : 3043. All earth
connections should be visible for An independent earthing network
inspection to the extent possible. shall be provided for lightning
protection and this shall be
bonded with the main earthing
iii. Where installed, lightning protection network below ground, minimum
shall be provided as per the at two points.
requirements of IS:2309.
vii. Every Sphere/ bullet shall be
iv. The resistance values of an earthing electrically connected with the
system to the general mass of earth earth in an efficient manner by
should be as below: not less than two separate and
distinct connections. The
¾ For the electrical system and connections and the contacts
equipment a value that ensures required shall have as few joints
the operation of the protective as possible. All joints shall be
device in the electrical circuit but riveted, welded or bolted and
not in excess of 4 Ohms. also soldered to ensure both
mechanical and electrical
¾ 10 Ohms in the case of all non- soundness. The resistance to
current carrying metallic parts of earth shall not exceed 7 Ohms
major electric apparatus or any and the resistance to any part of
metallic object. the fitting to the earth plate or to
any other part of fitting shall not
v. The earth conductor shall be exceed 2 Ohms.
adequately sized to carry the
applicable maximum earth fault viii. All joints in pipelines, valves
current without undue temperature in installations, and associated
rise. All joints shall be protected facilities and equipment for LPG
against corrosion. shall be made electrically
continuous by bonding or
v. All the electrical equipment otherwise; the resistance value
operating above 250 volts shall have between each joint shall not
exceed 1 Ohm.
 7.0 STORAGE AND HANDLING OF BULK LPG

7.0 GENERAL
4. Before removing plugs or
This section deals with the safe caps, always crack open to
practices and provisions applying to allow for release of trapped
unloading of bulk LPG and storage LPG and further to ensure that
of bulk LPG at installations. There the valves are effectively
should be strict compliance w.r.t sealing.
selection, deployment of proper
skilled manpower for effective 5. Hoses shall be handled with
operation and maintenance. care and inspected
periodically as per OISD-
STD-135.
7.1 BULK HANDLING FOR
MOVEMENT BY ROAD 6. While disconnecting
hoses/arm, connections shall
The tank truck for road movement be loosened only slightly at
shall be designed, constructed and first to allow release of
tested in accordance with the Static trapped pressure, if any.
and Mobile Pressure Vessels
(Unfired) Rules, 1981 and OISD- 7. Do not expose hands, face or
STD-159. clothing to liquid LPG.
Always use personal
7.1.1 SAFETY PRECAUTIONS protective equipment while
making or breaking the
Following precaution should be connections to avoid cold
taken due to associated hazards burns.
during transfer of LPG to or from
a tank truck. 8. The master switch shall be put
off immediately after parking
1. No source of ignition must be the truck in position. No
allowed in the area where electrical switch on the truck
product transfer operations are shall be turned " on" or " off"
carried out. during the transfer operation.

2. Fire extinguishers shall be 9. No repairs shall be made on

placed near the tank trucks the truck while it is in the
during transfer operations. loading area.

3. The first operation after 10. Availability of wheel chokes.

positioning the truck should be
to provide proper earthing. 11. New tank trucks vessels or
Earthing shall be disconnected vessels received after repair
just before the release of the shall be purged as per laid
truck. down procedure.
 ¾ Fire screen between cabin
12. In case, the receiving vessel is and vessel is provided. For
having a pressure of less than this purpose, cabins with
1 Kg/sq.cm.g, it shall not be metallic back cover without
filled. Such vessel shall be any opening will be
taken for filling only after considered as fire screen.
detailed safety checks.
¾ Provision of 2 nos. of 10 Kgs.
13. Venting and purging of LPG DCP Fire Extinguishers.
during transfer operation shall
not be carried out in open ¾ Fitment of Spark arrestors
atmosphere. It shall be piped of approved quality.
to a suitable flare system.
Where such facility does not ¾ No leakage in exhaust
exist, vent pipes shall be silencer pipe exists.
provided to carry the vented
product to a safe distance and ¾ Manufacturer's name plate
released at a height not less with date of testing is fitted
than 1.5 m above the eves of on the vessel.
the structure.
¾ Valid Explosive Licence and
14. Filling/transfer operations RTO certificate is available.
should be stopped
immediately in the event of - ¾ Approved drawings of vessel
are available.
(i) Uncontrolled leakage
occurring ¾ Blind flanges/caps are
(ii) A fire occurring in the provided on vessel.
vicinity
(iii) Lightning and thunder ¾ Availability of Earthing
storm cable.
7.1.2 PROCEDURES FOR
OPERATION ¾ Bonding between vessel and
chassis and between flanges
(a) LOADING OPERATIONS is satisfactory.

1. Check for following in a tank ¾ Earthing / bonding point is

truck as per statutory available.
regulations before accepting
it for filling: ¾ Third party inspection/test
certificates for vessel/fittings
¾ Provision of two safety are available.
valves, level gauge, Excess
flow check and control valve ¾ Liquid / vapour line valves
on liquid and vapour lines, are in good condition.
pressure gauge, temperature
gauge on the vessel / bullet. 2. Move truck to the loading
bay/weigh bridge and record the
weight of the empty tank truck.
 the product being loaded to avoid
3. Place the truck on loading bay and excess filling in terms of volume.
place choke blocks at front and rear The weigh bridge shall be
wheels. Keep the truck in neutral periodically calibrated and stamped
mode with hand brakes "ON". by Weights & Measures Authorities.

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.

(ii) Weighment 3. Test the connections for leaks by

slightly opening the valves for
(iii) Positive displacement meter pressurising. When satisfied,
valves on the tank truck and the
(iv) Mass flow meter receiving vessel shall be opened.

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.

11. Where weigh bridge is used, it is 5. Care should be exercised to see

necessary to determine the density of 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.

6. An authorised person of the 7.2.1 SAFETY PRECAUTIONS

company shall supervise the
transfer operation and respond 1. Do not allow the locomotive to
immediately in the event of an come on the weigh bridge unless
emergency. its capacity is designed to take
the locomotive load.
7. After the liquid has been
expelled, the vapour recovery 2. Sufficient number of dummy
operation may be started. Care wagons may be used to avoid
should be taken not to bring electric loco coming closer to the
down the pressure of the gantry. Maintain the distance of
delivering vessel below 1.5 15 m from first fill point.
Kg/cm2g.
3. The first operation after
Checklist for bulk LPG tank Trucks positioning the wagon shall be to
at unloading locations is given at provide for proper earthing.
Annexure 7 –I. Earthing shall be disconnected
just before the release of the
7.2 BULK HANDLING FOR wagon.
MOVEMENT BY RAIL
4. For connecting and disconnecting
LPG is moved in Tank Wagons by hoses, only non-sparking tools
the Railways. These wagons are shall be used.
designed by RDSO and are fitted
with various devices as shown in 5. After the wagons are placed on
Figure-VII. weigh bridge and before the loco
is detached, the hand brakes on
The loading facilities are similar as each and every wagon shall be
for tank truck loading while applied.
unloading of LPG from tank wagons
shall be done with the help of 6. Like-wise, before the wagons are
compressor. The compressor is used moved from the weigh bridge,
to create a differential pressure release brakes on all the wagons.
between the receiving and
discharging vessels by withdrawing 7. Do not use footwear with
vapors from the receiving vessel protruding nails.
and forcing it at high pressure into
the discharging vessel thereby 8. Ensure that the lower portion of
establishing a smooth flow. The flapper bridge at wagon side is
content of tank wagons can be fitted with rubber or wooden
ascertained by weighment on weigh padding.
bridge before and after emptying or,
alternatively, mass flow meters can 9. Ensure that electrical continuity
be used. of the system is intact.
 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,
9. Open the lid of the wagon. the hoses are depressurised.
 Then, close the flare line past the threads before the
connection valves. plugs are entirely disengaged.

18. Disconnect the filling and 4. If the vapour discharge

vapour return line hose continues or if there is
connections from the wagon. evidence of a liquid
Replace and tighten the plugs discharge, the valves should
on filling and vapour return be re-tightened.
lines.
5. With the plugs removed,
19. Close the top cover of the screw pipe nipples into the
wagon and seal it properly. outlets of the valves after first
Remove earthing having applied a modest
connections. quantity of sealant to the
male threads, keeping the
20. Release the hand brake of the sealant away from the end of
wagon. the thread. Tighten nipples
with a pipe wrench.
21. Release all the wagons on the
loading points in the lot. 6. Connect the two liquid
transfer unloading swing
22. Check the gross and net arms or hoses to the nipples
weight at the weigh bridge. attached to the liquid
discharge valves. Connect the
Use loading arms for loading / vapour or equalizing swing
unloading operations. arm or hose to the nipple
attached to the vapour valve.
(b) Unloading Operations In most of the cases, these
connections will be made by
1. Ascertain that the liquid means of either a ground joint
discharge valve and the union or a hose coupling.
vapour valve within the tank
wagon cover are in the closed 7. In the event, a ground joint
position. union is used, no gasket will
be required. If a hose
2. Open the port covers in the coupling is employed, ensure
side of the dome shell, if that the appropriate gasket is
exist. Unscrew the plugs in in place. Make sure that they
the outlets of the vapour are secured tightly by
valve and the liquid valves appropriate means.
using a box wrench. This
must be done slowly. 8. After the vapour and liquid
hoses have been connected
3. If there is any sound of and before any valve is
escaping vapour or if there opened, the valves on the
seems to be pressure behind tank wagon are crack opened
the plugs, the pressure must in order to apply pressure to
be allowed to relieve itself the hoses / loading arms as a
test for leaks.
 15. A flow of gas instead of
9. If any leak appears, the valve liquid through the sight-flow
should be immediately closed glass in the unloading line
and corrective measures indicates that the wagon is
applied. empty of liquid. Recheck this
by opening the sample valve
10. Recheck the lines and in the tank wagon dome.
connections to make sure that
they are connected correctly. 16. When the tank wagon is
emptied of all liquid, stop the
11. After the liquid and vapour compressor and close the
lines have been secured and liquid valves beginning at the
tested, both liquid education storage tank and progressing
valves should be opened to the tank wagon.
slowly and completely. Then,
open all other valves in the 17. If the facilities are so
liquid line working from the arranged that vapours may be
tank wagon to the storage removed from the tank
tank. wagon, the pipeline at the
compressor should be
12. If the tank wagon pressure is arranged so that the
higher than that in the storage compressor will draw vapour
tank, do not open the valves from the tank wagon and
in vapour line or operate the force it into the storage tank.
compressor. When the rate of
liquid flow drops to an 18. In this operation, the vapour
unsatisfactory level with the should be discharged below
storage tank filling valve the surface of the liquid in the
wide open, open the vapour storage tank to hasten the
valves between the tank liquefaction and, in turn, help
wagon and the storage tank. prevent excessive pressure in
the storage tank.
13. At this point, make sure that
the control valves at the 19. Restart the compressor and
compressor are in a position when the tank wagon
which allow the compressor pressure is reduced to about
to draw vapours from the 1.5 - 2.0 Kg/ sq.cm., stop the
storage tank and force it into compressor and close all the
the tank wagon, then start the valves in the vapour line.
compressor.
20. After bleeding off the
14. When the tank wagon is held pressure in the hoses,
at a pressure of 2.0 to 2.5 disconnect both the liquid
Kg/sq.cm. above the storage and vapour lines. Replace all
tank pressure, the tank wagon the plugs in the tank wagon
should be emptied into the valves and the unloading
storage vessel. fittings.
 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.

22. Remove bonding - Vapour should be discharged

connections. through high rise vent, keeping
the steam on.
23. Reverse or remove and
replace the "Flammable" - Maximum possible vapours
placard with "Dangerous - should be sucked out in first
Empty" placard. step depending on the
capacity of vacuum
24. Remove the "Stop - Tank pump/compressor. As per
Wagon Connected" sign and RDSO, vessel can sustain the
wheel blocks. full vacuum also.

25. Any defect observed in the - Between the two vacuum

tank wagon should be noted cycles, nitrogen/inert gas
on the appropriate forms and should be used for breaking the
routed in accordance with vacuum.
acceptable procedure.
- Cycle should be repeated
26. Notify the railways in writing till the LPG concentration is
about release of wagon and found below the end point of
ensure that it is removed from LPG (for butane, it is 4% by
the siding promptly. volume when purging is done
by nitrogen). Periodically,
27. Gauge the storage tanks, samples should be drawn from
within the installation, which suitable location and analysed
have received the LPG to for LPG concentration.
determine that the liquid level
is appropriate. - Finally the vessel should be
flushed with air to displace the
28. In the event of LPG received nitrogen. Barrel should be
on weight basis, the tank tested finally with explosive
wagon may require weighing meter to ensure that
following the completion of hydrocarbon concentration is
the unloading operation. below 10% of LEL.

7.2.3 DEGASSING OF (b) Alternate Procedure

SICK/LEAKY TANK
WAGONS
 Alternately, wagons may be a) Two cargo pumps, one each on
degassed by steaming or filling either side of the longitudinal
with water. However, it should bulk head.
be ensured that wagon is made
water free after degassing. b) Liquid discharge line from the
tank dome, connected to the
7.3 BULK HANDLING FOR main liquid line.
MOVEMENT BY SEA
c) All emergency pump trunk
Transportation of LPG in bulk by way.
tankers may be carried out under
fully-pressurised, semi-pressurised d) A liquid loading line connected
(semi-refrigerated) or fully to the main liquid line.
refrigerated at atmospheric
pressure conditions. e) Two liquid level indicating
devices one on each side. These
7.3.1 CARGO CARRIER DESIGN & usually consist of a float
CONSTRUCTION attached to a self winding tape
which moves up and down,
The design and construction of either on guide wires or inside a
cargo carrier is in line with guide tube. The liquid level is
International Maritime read off the tape through a gas-
Organisation (IMO) Gas code. tight window at the top of and
outside the tank.
7.3.2 TANKER FACILITIES
f) Two sets of purge lines at the
The cargo handling equipment in a top and bottom of the tank.
tanker usually comprise of Cargo These are used to distribute
pumps (submersible and booster), inert gas or vapour for gas-
Compressors, Condensers, Heat freeing or gassing-up of the
Exchangers, Vapourisers, Cargo cargo tanks.
heaters etc.
g) A vapour line for withdrawal of
The deep well pump supplies vapour to the compressor.
liquid to the booster pump to send
the product ashore. In pressurised h) Sample tubes.
ship, liquid is withdrawn by
pressurising the tank through Safety Devices
vapour compression from other
tanks. All semi and fully- (a) Atleast two safety valves in
refrigerated tankers are provided each cargo tank
with cargo heaters to enable the
vessels to discharge into pressure (b) High and Low level alarms
storage ashore and a booster pump
if the discharge pressure is (c) Overfill alarm. When actuated,
significantly above 9 bars. Each this will shuttle main loading
cargo tank is provided with the valve and sound an alarm.
following equipment:
 However, the design of the tankers pressure of the shore tank. A
with regard to provision of suitable vapour recovery system or
facilities, equipment, accessories re-liquefaction of the gas from the
and safety features must be in receiving tank shall be provided.
accordance with the IMO
requirements. 7.3.5 UNLOADING OPERATIONS

7.3.3 TRANSFER PIPING It is essential that the ship and

terminal operators are familiar with
The following facilities on transfer the basic characteristics of each
piping between Terminal and other's facilities, are aware of the
Shore tanks should be provided: precise division of responsibilities
and are able to communicate
(a) ROVs at both the ends of effectively during the time they are
transfer line.(Additional ROV together involved in the joint
at critical locations in the pipe operation of cargo handling.
line route.)
7.3.6 COMMUNICATION
(b) Relief valves on liquid line to
surge vessel with an audible Reliable and effective
alarm system connected to high communications, irrespective of
safe venting system whether these are directly between
the tanker and the terminal or
(c) Physical protection against indirectly via third party, are pre-
impact to vent/drain pipes requisites of safe and efficient
cargo operations before the tanker
(d) Protection of pipeline against comes alongside and during the
corrosion, particularly when the period of cargo operations and
pipeline passes under public until the tanker departs. Terminal
road way, which is likely to be communication shall be compatible
water-logged with tanker's system.

(e) Pipe work passing public road 7.3.7 PRE-CARGO TRANSFER

way be designed to acceptable DISCUSSIONS
public highway authority
standard in terms of roadway Before any cargo transfer
axle weights operation, it is imperative that the
intended procedures are thoroughly
7.3.4 TERMINAL FACILITIES discussed between the responsible
personnel from the tanker and the
Transfer of LPG from ship to terminal with a view to make both
terminal and vice versa is sides fully conversant with the
accomplished using loading arms characteristics of the tanker and
of approved type as per OCIMF shore cargo handling systems, the
guidelines. Provision of vapour envisaged operational and safety
return facility shall be made. procedures and requirements and
In case of pressurised gas transfer, the parameters to be adhered to
it is observed that the pumping rate during the transfer.
falls off gradually due to back
 The broad outlines for the liquid LPG to the receiving tank.
discussions are as under : Purging may be done by LPG
vapour, inert gas or water as per
(a) The names and roles of the design of the system. However,
terminal and ship personnel before disconnecting hoses or
who will be responsible for unloading arm, it is to be ensured
cargo transfer operations may that there is no liquid LPG left
be noted. between the tanker main valve and
shore isolation valve. Product from
(b) The terminal representatives this length of pipeline is to be
shall check that pre-arrival safely vented.
instructions to the ship on
cargo, cargo disposition and 7.4 STORAGE OF BULK LPG
cargo conditioning have been
carried out. They also shall Precautions for storage of LPG in
check that all necessary tanker bulk :
equipment inspection and tests
have been performed. a) Liquid level in the vessel shall not
exceed the permissible limits. Filling
(c) Similarly, the tanker's officers shall not exceed safe permissible
shall satisfy themselves that filling ratio.
the relevant terminal
equipment and inspection b) Vessel shall be inspected daily for
checks have been carried out any LPG leakage and corrective
satisfactorily. action taken.

(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

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 :
 ANNEXURE - 7 - I

CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION

1. CHECKS REQUIRED TO BE
CARRIED OUT BEFORE ALLOWING TANK TRUCK
ENTRY OF TT INSIDE LICENCED
AREA - Height barrier provided as per specifications

ON THE TANK TRUCK : - Fuel tank is protected by means of stout

guard and fuel tank cap is locked.

- Properly fitted spark arrestor of make and - 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.

- 2 nos. 10 kg. DCP extinguishers in easily 3. CHECKS REQUIRED TO BE

accessible and removable position with CARRIED OUT ON RANDOM BASIS -
Truck No. date of checking and charging MINIMUM ONE DAY, ONCE IN A
painted on it. MONTH :

- Provision of quick closing manifold valve TANK TRUCK :

with lever indicating close and open status.
- Internals of fire extinguishers in good
- No visible dent on the bullet. condition

ELECTRICALS : - Carries TREM CARD, instructions booklet

detailing instructions on handling
- All junction boxes are properly sealed emergencies en route.

- Any loose electrical wiring/ terminal - Carries route map

- Electrical wiring is insulated and provided - Has valid CCE licence and authenticated
with suitable over current protection. copy of drawing

- Truck is self starting - Carries RTO permits

- Readily accessible master switch for - RLW-ULW> Licenced capacity

switching off the engine is provided inside
the cabin. - HAZCHEM sign, name of contractor with
address and telephone No. displayed
- Dipole wiring. (Note 1) prominently.

TANK FITTINGS : - Bullet has no sign of external corrosion.

- Leakage from any fittings or joints.

TANK FITTINGS :
2. CHECKS REQUIRED TO BE
CARRIED OUT BEFORE ISSUING - Excess flow check valves are functioning.
LOADING MEMO (DURING THE
COURSE OF UNLOADING
OPERTIONS)
- Liquid / vapour lines are adequately Following are available in Tank Truck :
anchored and are well protected by means of
stout steel guard. - Tools for all fittings

- 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 :

- Flanges and bend pipe on liquid / vapour lines

should be of rating of 300.
 ANNEXURE - 7- II
CHECKLIST AT UNLOADING LOCATION FOR BULK LPG TANKWAGONS

VISUAL EXAMINATION OF WAGON FOR

- POH/ ROH OVERDUE : FOR BARREL Y/N

- FOR UNDERFRAME Y/N

- Damage to Tank Barrel Y/N

- Damage/ missing tank fittings Y/N

- Leakage from dome fittings Y/N

- Seal intact Y/N

- All valves, fittings are in working order Y/N

- The surface is free from rust. Y/N

The paint on the barrel is in good
condition and has not lost its
reflecting characteristics.

The matter regarding tank wagon not complying with any of above checks shall be taken up with loading
location for corrective action.
 ANNEXURE 7 - III

LIQUEFIED GAS-CARGO TRANSFER CHECK LIST

(Items to be checked before cargo transfer begins)

SHIP:_________________________________________DATE:______________

PORT &BERTH:_________________________________TIME:______________

S.NO CHECK POINT FOR SHIP FOR SHORE

1. Has information on cargo and ship-

shore connection been supplied ?

2. Is the agreed ship-shore communic -

ation system operative ?

3. Are fire and other emergency

procedures agreed ?

4. Are local regulations being

observed ?

5. Has safe access been provided and

warning notices posted ?

6. Are moorings secure and agreement

reached on the use of tension
winches ?

7. Are emergency towing-off wires

correctly positioned ?

8. Is the ship ready to move under its

own power ?

9. Are smoking restrictions in force

and notices posted ?

10. Are naked light restrictions being

observed ?

11. Are portable electrical equipment

cables disconnected ?

12. Are all hand torches and portable

R/T sets of approved type ?
 13. Are ship's main transmitting
aerials and radar switched off
and earthed ?
Counted....

S.NO CHECK POINT FOR SHIP FOR SHORE

14. Some doors and ports have to be

closed : are they actually shut ?

15. Are all air conditioning intakes

correctly trimmed and window type
units closed ?

16. Is the water main ready for

immediate use ?

17. Is the water spray system ready

for immediate use ?

18. Are dry powder and all other fire

fighting appliances correctly
positioned and ready for immediate
use ?

19. Is necessary protective clothing

available or being worn ?

20. Are void spaces properly inerted ?

21. Is the required ventilation

equipment in operation ?

22. Is the cargo system set for the

operation ?

23. Are all remote control valves in

working order ?

24. Are cargo tank relief valves

correctly set and in good order ?

25. Are the required cargo pumps and

compressors in good order ?

26. Is reliquefaction or boil-off

control equipment in good order ?

27. Is gas detection equipment set for

the cargo, calibrated and in good
order ?

28. Are cargo system gauges and alarms

correctly set and in good order ?
29. Are scuppers plugged and suitable
drip trays in position ?
Contd...

S.NO CHECK POINT FOR SHIP FOR SHORE

30. Are cargo and bunker hoses in good

condition and properly rigged, have
certificates being checked ?

31. Are unused bunker connections

blanked and bunker tank lids
closed ?

32. Are unused cargo connections

(including inert gas line)securely
blanked ?

33. Are automatic shutdown systems

working properly ?

34. Does shore know the closing rate

of ship's automatic valve at
operating temperature ; does ship
have a similar details of shore
system ?

35. Are all personnel (including

supernumeraries and new arrivals)
aware that cargo transfer is to
begin ?

36. Have all personnel been allocated

emergency stations ?

37. Are non-essential personnel clear

of the cargo area ?

38. Are those directly involved aware

of the agreed cargo transfer
sequence ?
========================================================================
REMARKS :

We have checked with each other the items on the above check list and have satisfied ourselves
that the entries we have made are correct to the best of our knowledge.

CHECKED BY______________________ _______________________

(For Ship) (For Terminal)
 8.0 BOTTLING OPERATIONS

- `O' Ring (joint packing) is

8.1 GENERAL present and there is no
apparent damage to valve.
This section covers the operations in the - Tare weight is legible.
LPG bottling plants,
(b) Filling operation - All cylinders shall
Safe work practices shall be established be filled on gross weight basis on
to ensure safe operation, maintenance, filling machine.
and modification activities while
carrying out various jobs. These Maximum permissible errors on net
practices shall be documented and quantity declared by weight shall be
approved. The manuals shall be updated in accordance with the Standards of
at least once in a year by authorised Weights & Measures (Packaged
personnel. Commodities) Rules 1977 and
Amendment Rules, 1992. The filling
Activity on bottling line including valve pressure should not exceed
change, shall be carried out by trained maximum working pressure of
personnel. cylinder i.e. 16.9 kg/cm2 at 65 deg.C.

8.2 BOTTLING OPERATIONS (c) Post Filling Operation - Cylinder

shall be counter weighed with check
The Bottling Operations can be scale for accuracy of weight.
classified under following heads : Variation of net weight. Variation of
net weight shall not exceed
i) Receipt of LPG cylinders permissible limits. All under-filled/
over-filled cylinders should be
ii) Filling & despatch of LPG Cylinders corrected on correction scale.

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.

8.2.1 Receipt of LPG cylinders CVT or electronic leak detector shall

be calibrated to detect leakage
Cylinders shall be received in capped beyond 0.5 gm/hr. For cylinders
condition. Cylinder shall conform to found with `O' ring defect, the `O'
IS:3196. ring shall be replaced with a new
one. Further all "O" ring or valve
8.2.2 Filling of LPG cylinders change cylinders shall be rechecked
for leakage with CVT or electronic
(a) Pre-filling operation : Cylinder leak detectors.
before filling shall be checked for
following : The on line valve removal machines
is used shall be checked for integrity
- Visually inspected as per of the system with regard to proper
IS:5845/ IS : 13258 sealing. The machine shall be further
 checked for leak tightness, torque leak, bulge, fire ravaged or spurious
settings before being put in use shall be evacuated immediately.
every day. The maintenance shall be
carried out as OEM Any cylinder with valve leak shall be
recommendation. immediately capped and thereafter
evacuated immediately.
Cylinder shall be checked for body
leak and bung leak by dipping in Cylinders requiring repairs other
water test bath or by an established than valve leak shall be degassed for
electronic leak detection system. repairs.
Cylinder shall be capped prior to
dipping in test bath water. All above cylinders shall be clearly
identified, with markers, to their
Only those cylinders found passing nature of defects and shall be kept
all above checks shall be processed capped during storage.
further for sealing.
c) LPG cylinder storage - All
Cylinders shall be sealed with PVC cylinders shall be stacked vertically
seal or Aluminium seal. Seal shall (with valve in upright position) in
have identification mark of oil not more than 1.5 m.
company, preferably name of plant
and period of filling. Cylinders of different capacity and
type shall be stacked separately.
No bypassing of safety interlocks,
fire water system, gas detection All cylinders shall be capped during
system, vapour extraction system and storage.
heat detection system shall be
permitted unless authorised by plant The cylinders shall be stacked in
manager in writing. small lots of 4 rows and 25 cylinders
length. A minimum access path of 1
8.2.3 Handling & Storage of LPG mtrs. must be maintained on both
sides of 4 rows and 2 metres after
Handling and storage of LPG cylinders every 5 such lots. After each length
shall be governed by Gas Cylinders of 25 cylinders, there must be a
Rules, 1981. passage of 2 metres. The cylinder
storage space shall be properly
Following safe practices shall be marked/ painted on the flooring.
observed :
Typical stacking arrangement for
a) Handling of LPG Cylinders - LPG 14.2 kg cylinder is given in Figure-I.
cylinders shall not be dropped, rolled
on body and shall not be subjected to Empty and filled cylinders shall be
any violent contact with any other demarcated clearly.
cylinder or object cylinder shall be
moved by rolling on its foot ring or Minimum distance of 15 metres from
on conveyors or hand trolleys. cylinder loading area and minimum
distance of 10 metres from filling
b) Defective filled cylinders - Any point shall be observed for all filled
cylinder having body leak, bung cylinders stack.
 of air prior to be taken up for
8.2.4 Auxiliary Operations refilling with LPG. Following safe
procedure shall be observed for
a) Cylinder requiring valve removal purging of LPG cylinders :
and valve fixing
- Connect the cylinder valve to
Cylinder having defective valve and vacuum pump and evacuate air so
with bung leak shall have to undergo that the pressure in cylinder is
valve removal and valve refixing brought down to maximum 0.35
operation. kg/cm2 absolute. Inject LPG vapour
in the cylinder so that pressure is
Following safe procedures shall be minimum 1 kg/cm2 and not above
observed for the operation : working pressure of cylinder i.e. 16.9
kgf/cm2 at 65 degree C.
- Cylinder shall be evacuated of its
product upto pressure, 1.5 kg/cm2 or c) Degassing of Cylinders :
less, thereafter depressurised to near
atmospheric pressure through cold Cylinders shall be evacuated and
flare before opening the defective depressurised to near atmospheric
valve. pressure. The residual LPG in the
cylinder should be cold flared in the
- The valve of cylinders with bung / atmosphere at a vent outside the shed at
valve leak shall be replaced. 1.5 m height above the eves of the shed.

- 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

9.1 GENERAL : pressure shall not be carried out without

a proper work permit and approved
This section covers the maintenance and procedure.
inspection practices to be followed to
ensure safe and trouble free operation of 1. All Maintenance/ Inspection jobs
various equipment. shall be carried out in line with OISD
Standard ; OISD-STD-105 on "Work
9.2 MAINTENANCE SCHEDULES : Permit System".

To facilitate the maintenance service to 2. Electrical maintenance / inspection,

be rendered in a planned manner, a provisions of OISD-STD-137 shall
preventive maintenance schedule be adhered to.
covering the necessary work to be done, 9.5 INSPECTION &
mentioning the periodicity i.e. daily, MAINTENANCE OF VARIOUS
weekly, monthly, half yearly and yearly FACILITIES IN LPG
schedules, must be worked out. While INSTALLATIONS :
basic recommendations given by the
manufacturers should be considered and 9.5.1 STATIC EQUIPMENT :
modified bearing in mind the local
conditions (refer Annexure 9- I-IV). a) PRESSURE VESSELS &
STORAGE FACILITIES :
9.3 PERSONAL PROTECTIVE
EQUIPMENT : OISD Standard OISD-STD-128
on "Inspection of Pressure
Necessary personal protection Vessels shall be followed.
equipments such as Hand gloves, Safety
shoes, Helmets, Safety belts, Safety Weld cracking has been
goggles etc. shall be used ( for details experienced in the lower half
refer OISD- STD-155). portions of LPG vessels. Small
amounts of wet H2S present in
9.4 WORK PERMIT SYSTEM : LPG is supposed to be
responsible for this in service
Any maintenance, inspection, stress corrosion cracking of
disassembly or removal of fittings welds. LPG vessels made from
while any part of the system is under micro-alloyed high tensile steels
 have shown greater susceptibility ™ The high pressure seat test is not
to such cracking. Wet required except for threaded and
Fluoroscent Magnetic Particle valves.
Testing (WFMPT) is considered
the most reliable test method for ™ No leakage shall be permitted.
detecting these micro-cracks.
WFMPT should be carried out ™ Fire-safe test shall be carried out
prior to hydraulic test wherever as per API : 607.
cracks are found, their depths
should be assessed by ultrasonic Valves shall be dismantled at the time of
testing. All cracks having depths specified comprehensive inspection or
less than corrosion allowance during the shutdown of the line to permit
may be removed by grinding, examination of all internal parts. Body
edges smoothened and areas left thickness measurements shall be made at
as such after final WFMPT locations inaccessible before,
check. Weld build up of grooves dismantling, particularly at locations
so formed is essential wherever showing evidence of erosion. Bodies of
depths of groove is more than valves operating in severe cyclic
corrosion allowance. temperature service shall be checked
internally for cracks.
b) SHUT-OFF VALVES,
CONTROL VALVES, NON- Gate valves, which have been used for
RETURN VALVES, EXCESS throttling, shall be measured for
CHECK VALVES, thickness at the bottom between the
PIPELINES, VALVES AND seats, as serious deterioration may have
FITTINGS : occurred because of turbulence. This is
particularly weak point because of the
All new valves shall be inspected wedging action of the disc when the
and tested to ensure valve is closed. The seating surface
conformation to required shall be inspected visually for defects
specifications and for leak which might cause leakage. The
tightness. All new valves shall wedging guides shall be inspected for
be inspected and tested as per corrosion and erosion. The stem and
requirements of API-598. The threads on the stem and in the bonnet of
closure torque during testing for valves shall be examined for corrosion
hand wheel and gear operated which might cause failure., The
valves shall not be greater than connection between stem and disc shall
that obtainable by hand be inspected to assure that the disc will
tightening. Further fire safe not detach from the stem during
valves shall comply with operating.
following :
Swing check valves shall be inspected
™ Low pressure seat test shall be by removing the cover or cap. The
conducted with the ball and seat clapper or disc shall be checked for
dry and free of oil, grease or any freedom of rotation and the nut holding
lubricant. 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 will reveal this condition.
seating surface on both the disc and Permanently deformed flanges
valve body shall be checked for must be replaced.
deterioration by feeling them with the
fingers. After the valve has been
reassembled, it shall be hydrostatically 9.5.3 PIPELINES
and/or pneumatically tested for tightness.
If tested pneumatically, a soap solution (i) Inspection data as well as
shall be applied to the edges of the thickness data of newly
seating surface and observed for any constructed pipelines shall be
evidence of leakage. collected at the earliest and with
in two years of their
9.5.2 Flanges, Gaskets and Bolts commissioning to function as
base for establishment of
The gasket faces of flanged joints, which corrosion rates.
have been opened, shall be inspected
visually for corrosion and for defects (ii) External inspection of LPG
such as scratches, cuts and gouges which pipelines within the installation
might cause leakage. The gasket faces shall be carried out once in three
shall be checked for true flatness or years which shall include both
warping by placing a straight edge visual inspection and ultrasonic
across the diameter of the face of the thickness readings taken
flange and rotating it about an axis externally.
through the center line of the flange.
Grooves and rings of ring joints shall be The details of thickness survey
checked for defects. shall be maintained on an
isometric sketch.
Flanges bolts should be inspected
for stretching. Where excessive (iii) Comprehensive inspection of
bolt loading is indicated or where LPG pipelines shall be carried
flanges are deformed, nuts may out once in 6 years which shall
be rotated along the entire length cover the following :
of the stud. If studs are stretched,
thread pitch will be changed and i) Visual inspection
nuts will not turn freely. ii) Hammer test
Inspection involve checking to iii) Ultrasonic thickness
determine whether bolts of the measurement
proper specification have been iv) Dye penetration test or
used and may involves chemical Magnetic particle test
analyse or physical tests to v) Hydrotest
determine the yield point and the
ultimate strength of the material. (iv) Piping in coastal installations and
If flanges are bolted too tightly, in corrosive environment shall be
they may bends until the outer visually inspected once a year.
edges of the flanges are in Years of inspection experience
contact. When this occurs, there have revealed that failures of
may be insufficient pressure on most of the Offsite pipelines are
the gasket to assure a tight joint. due to external corrosion and that
Visual inspection of the gasket
 internal corrosion failures are Strainers & filters shall be inspected and
minimum. cleaned as per following frequency,
unless sluggish operation warrants
(v) The underground lines having earlier inspection :
wrapping and coating as well as
cathodic protection shall be TYPE / LOCATION FREQUENCY
inspected whenever current leaks
are observed and/or any damage Air filters Weekly
to the coating is suspected. Strainers on evacuation Weekly
Parameters of cathodic protection line
like pipe-to-soil voltage or pipe- Pump Suction Quarterly
to-water voltage shall be Up stream of filling Quarterly
monitored once a month. carousel
up stream of PD-Meter Quarterly
(vi) All underground lines having
only wrapping and coating shall e) SAFETY RELIEF VALVES
be inspected once in three years
using Pearson Survey for Safety Relief valves shall be tested once
locating coating damage, if any. in a year. Further an on stream visual
Additionally, all these lines shall inspection should be carried out at least
be visually inspected at random once in every 6 months to check the
once in ten years by digging at a following:
few locations. Pipelines crossing
the roads and dykes shall be a) Gags, blinds do not exist.
inspected once in ten years by b) Upstream and down stream isolation
digging and exposing the line valves, if any, are opened and sealed.
completely. c) Seals protecting the spring setting
have not been broken.
Provisions of OISD Standard ; OISD- d) Relief device is not leaking. This
STD-130 on "Inspection of Pipes and may be checked visually and by
Valves and Fittings" shall be followed. thermography, contact thermometers
or by hand touch at outlet nozzle
9.5.4 HOSE AND FLEXIBLE wherever practicable.
CONNECTION : e) The continuous operation of heat
tracing provision, if any, provided
LPG hoses shall be inspected & tested at for low temperature application on
maximum interval of 4 months as valve and discharge piping.
detailed in OISD Standard ;. OISD-STD-
135 on "Inspection of Loading and f) Condition of insulation and cladding
Unloading Hoses for petroleum on the heat traced piping and valves.
products" and records maintained
thereof. a) Inspection and test of the valve shall
be done in as received condition.
LPG hoses shall be discarded after 3 This is important and helps in
years of service or earlier in case the establishing the frequency of
permanent elongation exceeds 5%. inspection.

9.5.5 STRAINERS AND FILTERS : Provisions of OISD Standard ;

OISD-STD-132 on "Inspection of
 Pressure Relieving Devices" shall be
followed. 9.5.8 INSTRUMENTATION

9.5.6 ROTARY EQUIPMENT : a) TEMPERATURE INDICATING

DEVICES
a) COMPRESSORS : OISD
Standard No. OISD-120 on Temperature indicating devices shall
"Inspection of Compressors" shall be checked daily for its proper
be followed. In addition, periodic functioning and shall be calibrated
maintenance checks, as detailed in once in 6 months.
Annexure-I to be followed.
b) LEVEL GUAGING DEVICES
b) PUMPS : OISD Standard No.
OISD-110 on "Inspection of The gauging devices shall be
Pumps" shall be followed. In checked daily for proper
addition, periodic checks as detailed functioning. Zero level check and
in Annexure-II to be followed. calibration shall be carried out
monthly and annually as applicable.
c) DIESEL ENGINES: OISD
Standard No. OISD-123 on c) PRESSURE GAUGES
"Inspection and Maintenance of Pressure gauges shall be checked
Rotating Equipment components daily for its proper functioning and
shall be followed. shall be calibrated once in 6 months.

9.5.7 FILLING EQUIPMENT d) FLOW MEASURING DEVICES

It shall be ensured that the All flow measuring devices shall be

equipment is in good working checked daily for proper functioning
condition to ensure quality output and calibration shall be carried out
and also safe operation. monthly and quarterly as applicable.
Inspection checks are given at
Annexure 9-III for the following 9.5.9 FIRE FIGHTING EQUIPMENT
equipment:
Fire fighting equipment shall be
a) CAROUSEL inspected and tested as per. OISD-
STD-142 - "Inspection of Fire
i) Drive units Fighting Equipment".
ii) Centre column
iii) Running Rail
iv) Introduction and Ejection 9.5.10 ELECTRICAL EQUIPMENT
devices
v) Filling machines Proper functioning of electrical
equipment can only be ensured by
b) Check Weigh Scales means of periodic preventive and
c) Chain/ Roller conveyor predictive maintenance of the
d) Drive Units for Conveyors equipment. This enhances
e) CVT-leak detector equipment life and also ensures
f) Cylinder Test Bath safety of the equipment,
g) General
 installation and operating purposes of effecting repairs and
personnel. testing and alterations, provided
that the area in which such
Maintenance shall be daily, apparatus or wiring has been
weekly, quarterly or annual installed, has first been made safe
depending upon the type of and certified by a competent
equipment. Adequate logs shall person after testing with an
be maintained to ensure that approved gas – testing apparatus
maintenance is carried out as per to be safe and free from
approved checklists. Preventive inflammable vapours, gases or
maintenance should be carried out liquids and is maintained in such
as per schedules laid down in conditions, so long as the work is
OISD-STD-137. in progress.

Special emphasis shall be laid on iii. No alteration that might

the maintenance of equipment invalidate the certificate or other
installed in hazardous areas. document relating to the safety of
the apparatus, shall be made to
All electric apparatus and wiring in any apparatus.
a hazardous area shall at all times
be so maintained as to retain the Replacement fasteners, nuts,
characteristic on which their studs and bolts shall be of the
approval has been granted” type specified by the
manufacturer for the particular
Precautions to be taken for apparatus. No attempt shall be
repairs and testing of flameproof made to replace or repair a glass
equipment shall be as below: in a flameproof enclosure e.g. in
a luminaire or other enclosures,
i. No Flame proof or intrinsically except by replacement with the
safe apparatus shall be opened complete assembly or part
and no work likely to impair the obtainable from the
safety characteristics of such manufacturer, complying with
apparatus or electric wiring the approval certificate.
connected thereto shall be
carried out until all voltage has If replacement components such
been cut off from said apparatus as cable glands, conduit or
or wiring. The voltage shall not conduit accessories, are available
be restored thereto until the work only with thread forms which
has been completed and the differ from those provided on the
safety characteristics provided in apparatus, suitable adaptors
connection with the apparatus having necessary certification
and wiring have been fully and approval shall be employed.
restored.
iv. Equipment enclosures and
ii. Use of soldering apparatus or fittings shall be examined to see
other means involving flame, fire that all stopping plugs and bolts
or heat or use of industrial type are in position and properly
of apparatus in a zone “1” area tightened. Locking and sealing
shall be permitted for the devices shall be checked to
 ensure that they are secured in check shall be made to ensure
prescribed manner. that the equipment selection
corresponds to the revised area
v. If at any time, there is a change classification.
in the area classification or in the
characteristics of the flammable vi. A system shall be established to
material handled in the area or if record the results of all
the equipment is relocated in the inspections and the action taken
area, the area classification to correct defects.
drawing should be
correspondingly revised and a
 ANNEXURE 9-I
MAINTENANCE SCHEDULE

COMPRESSORS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
1. Check Lub. Oil Level of plunger *
pump unit & top up if necessary.

2. Check the oil level in the crank *

case & top up if necessary.

3. Before start check flow of cylinder *

cylinder jacket cooling water.

4. Check oil flow from plunger pump to *

gland packing assembly.& compressor
cylinder.

5. Check for flow rate from plunger pump *

6. Drain water from receiver/ liquid trap. *

7. Check belt tension and adjust *

if necessary. *

8. Ensure tightness of foundation bolts. *

9. Flush out lube oil system : *

a) Crank case
b) Pump chamber and fill fresh oil.

10. Flush jacket water cooling system. *

11. Check alignment of compressor & motor pullies. *

12. Change lube oil filter and clean LPG Suction filter. *

13. Clean oil strainer *

14. Clean Breather *

15. Open and inspect suction and discharge valves. *

16. Check instrumentation calibrate if necessary. *

--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------

17. Check safety release valve. *

18. Suction & discharge valves of compressor cylinder *

19. Interlock with High level alarm *

20. All Trips . *

21. Pressure & Temperature Gauges *

22. Control Panel *

23. Complete over-haul. *

--------------------------------------------------------------------------------------------------------------------------------
 ANNEXURE 9-II

MAINTENANCE SCHEDULE

CENTRIFUGAL PUMP

--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Annually
Yrly
(1) (2) (3) (4) (5) (6) (7)
--------------------------------------------------------------------------------------------------------------------------------

1. Check lub oil & top up level *

if necessary.

2. Check cooling water flow *

(where provided).

3. Check mechanical seal/ gland leakage. *

4. Check the "AMPS" are within limits. *

5. Change lube oil every 800 running *

hours.

6. Check coupling and coupling bolts *

and replace worn out parts.

7. Check tightness of foundation bolts. *

8. Clean suction strainer of : *

a) Product pumps
b) Other pumps

9. Check alignment of pump and motor. *

10. Overhaul. *

11. Greasing of Bearings. *

12. High Level Alarm *

13. Relief Valve *

--------------------------------------------------------------------------------------------------------------------------------
 ANNEXURE 9-III

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 :

1. Check oil level & top up if required. *

2. Check oil pressure. *

3. Put oil drop in orifice of cut-off valve. *

4. Grease guide rollers. *

5. Check & adjust drive belt. *

6. Unscrew magnetic plug and clean. *

7. Change hydraulic oil &clean filter. *

8. Clean hydraulic oil tank. *

9. Inspect gears for wear and tear. *

10. Check electric motor & grease motor bearing. *

11. Complete overhaul of the drive unit. *

(B) CENTRAL COLUMN

1. Check air & gas joints for leakage. *

2 Grease bearing. *

(C) RUNNING RAIL :

1. Clean & apply graphite. *

2. Lubricate rail wheels. *

3. Check rail levels. *

--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------

(D) INTRODUCTION AND EJECTION DEVICES:

1. Blow the air filter free of water & dirt. *

2. Check & top up oil in air lubricator. *

3. Oil the introduction arms. *

4. Check functioning & adjust if required. *

5. Greasing all grease points. *

6. Tighten guide rollers. *

7. Check & repair leaks. *

8. Inspect for wear and tear. *

9. Overhaul the unit. *

(E) FILLING MACHINES:

1. Thoroughly cleaning by using *

dry air.
2. Checking & adjustment of auto *
cut off device.

3. Check operation of filling head *

by supplying air.

4. Check leakage of LPG and repair. *

5. Check condition of LPG filling hoses. *

6. Check oil level in air lubricators. *

7. Lubricate pullies holding filling guns. *

8. Carry out calibration and adjustment. *

9. Suspension system bearings & knife *

edges to be thoroughly cleaned.

10. Inspect knife edges for wear & tear *

and repair where required.

11. Complete overhauling. *

--------------------------------------------------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
(F) CHECK SCALE :

1. Thorough cleaning by using dry air. *

2. Air Filter :
a) Blow-out dirt & condensate. *
b) Clean. *

3. Check oil level in lubricator *

and its functioning.

4. Calibrate with standard weights. *

5. Greasing of cylinder stop unit. *

6. Clean suspension system bearings *

knife edges etc.

7. Check for wear & tear of knife edges *

& replace if necessary.

8. Complete overhauling. *

II. CHAIN CONVEYOR :

1. Top up soap solution trays. *

2. Check position of tension roller *

of chain and adjust if required.

3. Lubricate tension rollers & wheels. *

4. Clean soap solution tray. *

5. Grease the bearing *

6. Check foundation bolts of conveyor *

frame for tight- ness.

III. DRIVE UNIT OF CONVEYORS :

1. Check & top up oil level. *

2. Check coupling bolts & rubber *

bushings. Replace the cracked
or worn out bushings.

3. Check alignment of gear box & *

correct if necessary.

--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
4. Clean & lubricate chain. *

5. Tighten foundation bolts. *

6. Drain & change oil. *

7. Inspect for wear & tear. *

IV. CVT/ DCVT LEAK DETECTOR :

1. Check for proper functioning. *

2. Top up kerosene Every shift

chamber.

3. Check leakage rate thru verifier. *

4. Dismantle/ clean the interiors & *

apply silicon grease to "O" ring.

V. CYLINDER TEST BATH:

1. Fill with clean water. *

2. Lubricate moving parts. *

3. Clean tank walls from inside. *

4. Check & lubricate pneumatic *

circuitry of all equipments.

5. Check all fasteners and tighten. *

6. Paint tank walls from inside. *

--------------------------------------------------------------------------------------------------------------------------------
 ANNEXURE 9-IV

DIESEL ENGINES

MAINTENANCE STEPS

1. KEEP THE DIRT OUT OF THE ENGINE.

2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.

3. REGULATE THE ENGINE'S FUEL.

4. CONTROL OPERATING TEMPERATURES.

5. GUARD AGAINST CORROSION.

6. LET THE ENGINE BREATHE.

7. PREVENT OVERSPEEDING.

8. KNOW YOUR ENGINE'S CONDITION.

9. CORRECT TROUBLES WHILE THEY ARE SIMPLE.

10. SCHEDULE AND CONTROL YOUR MAINTENANCE.

 DIESEL ENGINES

"A" CHECK EVERY DAY

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

1. CHECK PREVIOUS DAY'S 1A CORRECT AS REQUIRED

ENGINE LOG BOOK.

2. DRAIN WATER AND SEDIMENT 2A BEFORE STARTING ENGINE.

FROM FUEL TANK AND FUEL
FILTER THROUGH DRAIN COCK.

3. CHECK ENGINE OIL LEVEL 3A MUST BE SLIGHTLY LESS THAN

AND TOP UP IF NECESSARY OR EQUAL TO "H" MARK ON DIP
STICK WHEN ENGINE IS STOPPED
AND HAS STOOD FOR 20 MINUTES
OR MORE (MUST BE MEASURED
AFTER ALL OIL IS DRAINED
BACK INTO OIL PAN).

4. CHECK FOR FUEL,OIL,WATER 4A CORRECT IF LEAKING.

5. FILL RADIATOR/SURGE TANK 5A RADIATOR CAP MUST BE FIRMLY

WITH TREATED WATER TIGHTENED BACK INTO THE
(CHROMATE CONCENTRATION RADIATOR/SURGE TANK NECK,
3500 PPM). ENGINE MUST NOT BE OPERATED
WITHOUT THE RADIATOR CAP
SINCE THIS WILL CAUSE
AERATION AND OVERHEATING
OF THE COOLANT.

6. CHECK AIR CLEANER OIL 6A USE CLEAN ENGINE OIL.

LEVEL AND CHANGE OIL, IF
REQUIRED (IF OIL BATH
TYPE) CLEAN DUST PAN AND
PRECLEANER OF DAY TYPE
AIR CLEANER.

7. CHECK AIR LINE CONNECTIONS 7A CORRECT AS REQUIRED

FOR LEAKS.

8. REMOVE AND CLEAN AIR COM- 8A FILL WITH CLEAN OIL, UPTO
PRESSOR BREATHER, IF MARK.
EQUIPPED.

9. DRAIN AIR RECEIVER TANK

AT THE BEGINNING OF EACH
SHIFT AND THEN CLOSE THE
DRAIN COCK.
 DIESEL ENGINES

"A" CHECK EVERY DAY

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

10. CLEAN CRANKCASE BREATHER 10A DISCARD PAPER TYPE ELEMENT,

IF CLOGGED.

11. CHECK OIL LEVEL IN 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.
--------------------------------------------------------------------------------------------------------------------------

"B" CHECK EVERY 250 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

1. REPEAT ALL MAINTENANCE 1B

STEPS OF CHECK "A" 1 TO 14.

2. CHANGE ENGINE OIL 2B WHEN LUB. OIL IS EXAMINED

THROUGH LUB. OIL ANALYSIS IN
LABORATORY. OIL CHANGE PERIOD
MAY BE EXTENDED IN SUCH CASES
(REFER TO YOUR SERVICE REP.)
 DIESEL ENGINES

"B" CHECK EVERY 250 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

3. FIT NEW LUBRICATING OIL 3B INSPECT THE CHANGED FILTER

FULL FLOW FILTER ELEMENT ELEMENTS AND CHECK FOR METAL
PARTICLES AND OIL SLUGING/
OXIDATION.

4. REMOVE CLEAN AND INSPECT 4B BLOW OUT DUST WITH COMPRESSED

DRY TYPE AIR CLEANER AIR IN THE OPPOSITE DIRECTION
ELEMENT, REMOVE AND CLEAN OF THE NORMAL AIR FLOW, IF
DUST PAN. INSPECT FOR HOLES VERY DIRTY WITH OIL AND
AND TEARS, CHECK GASKETS CARBON WASH IN SOLUTION OF
AND "O" RINGS FOR DAMAGE WARM WATER (120-140 DEG F)
AND NON-SLUDGING DETERGENT
ALLOW IT TO DRY FIRST, THEN
USE COMPRESSED AIR. REPLACE
IF WASHED TWO TIMES. CAUTION
EXCESS AIR PRESSURE WILL
DAMAGE PAPER. AIR NOZZLE
MUST BE KEPT AT LEAST 20 cm
FROM THE ELEMENT. MUST NOT
BE USED IF EVEN ONE PIN HOLE
EXISTS. DISCARD ELEMENT IF
PUNCTURED AND ALSO CHANGE
GASKET ALONG WITH
ELEMENT.

5. CLEAN OIL BATH AIR CLEANER 5B

TRAY SCREEN

6. CHANGE LUBRICATING OIL 6B RECORD OIL PRESSURE.

BY-PASS FILTER ELEMENT
AND GASKET, IF PROVIDED.

7. CLEAN FLOAT TANK AND/OR 7B

MAIN FUEL TANK BREATHER.

8. CHECK COOLANT PH VALUE- 8B CHANGE CORROSION PRESISTER

CONCENTRATION OF DCA/ ELEMENT IF PH VALUE IS BELOW
CHROMATE CONCENTRATION NORMAL RANGE 8.5-10.5. CHECK
(3500 PPM). CHROMATE CONCENTRATION AT
3500 PPM. FOR DCA REFER O&M
MANUAL.

9. CHECK MAGNESIUM PLATE 9B CHECK MAGNESIUM PLATE FOR

IN ASSEMBLY CORROSION PITTING OR BEING EATEN AWAY
REGISTER CHANGE WATER CHANGE IF MORE THAN 50% OF

DIESEL ENGINES
 "B" CHECK EVERY 250 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

FILTER ELEMENT. OF AREA IS LOST. USE DCA

SERVICE ELEMENT OR CHROMATE
ELEMENT OR CHROMATE ELEMENT
BAGS (AR95679) IF CONCEN-
TRATION IS LOW.

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.

13. TIGHTEN FOUNCTION BOLTS AND

FLEXIBLE COUPLING BOLTS OF
ENGINE AND ALTERNATOR.

14. CHECK ALL AIR CLEANER CON- 13B CORRECT AS REQUIRED.

NECTIONS FOR CRACKS.
CHAFING ETC. TIGHTEN ALL
AIR INTAKE CONNECTIONS.

15. CHECK FAN HUB AND DRIVE. 14B USE SPECIAL TOOL FOR
TIGHTENING THE FAN HUB NUT.

16. CLEAN/CHANGE AIR COMPRE- 15B CHANGE ELEMENT FOR NATURALLY

SSOR BREATHER ELEMENT. ASPIRATED ENGINE CLEAN SCREEN
FOR TURBO ENGINE.

17. CHECK THROTTLE LINKAGE.

 DIESEL ENGINES

"C" CHECK EVERY 1500 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

1. REPEAT ALL MAINTENANCE

STEPS OF CHECKS "A" & "B".

2. CHECK THERMOSTATE OPERATION 2C IT SHOULD START OPENING AND

OPEN FULLY WITHIN RANGE 165
DEG. F. OR 170 DEG. F. DISCARD
AND FIT NEW THERMOSTATE
IF OPERATION IS NOT
SATISFACTORY.

3. CHECK FAN HUB AND DRIVE 3C CHECK MOUNTING BOLTS AND

BEARING END PLAY.

4. CHECK IMPLELLER WATER PUMP 4C CORRECT IF NECESSARY.

FOR PLAY.

5. CHECK FOR TURBOCHARGER 5C CORRECT AS REQUIRED.

OIL LEAKS.

6. TIGHTEN TURBOCHARGER 6C TIGHTEN TO THE SPECIFIED TORQUE

MOUNTING NUTS. DO NOT TIGHTEN WHEN ENGINE IS
HOT.

7. CHECK INLET AIR RESTRICTION 7C CHECK AFTER CLEANING DRY TYPE

AIR CLEANER ELEMENT. IF
RESTRICTION IN EXCESS OF 1000 MM
WATER A NEW ELEMENT MUST BE
FITTED.

8. CLEAN OIL BATH AIR CLEANER 8C REMOVE COMPLETE ASSEMBLY AND

CLEAN INCLUSIVE OF FIXED
SCREENS.

9. CLEAN AND TIGHTEN ALL ELEC- 9C

TRICAL CONNECTIONS.

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
----------------------------------------------------------------------------------------------------------------------------

TAKING CARE OF PROTECTING

ELECTRICAL SYSTEM.

12. TIGHTEN ALL MOUNTING BOLTS 12C TIGHTEN AS REQUIRED. OVER TIGHTEN-
AND NUTS. NING MAY RESULT IN DISTORTION OR
DAMAGE.

13. CLEAN ANEROID AIR BREATHER. 13C REPLACE BREATHER IF NECESSARY.

14. CHECK SEA WATER PUMP 14C CHECK FOR LEAKS/ OPERATION/
(MARINE APPLICATION ONLY) PERFORMANCE.

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

ZINC PLUG (MARINE APPLICATION) PLUGS.

16. CHECK EXHAUST AND INLET MANI- 16C

FOLD NUTS AND CAPSCREWS.

17. CHECK ENGINE BLOWER. 17C READINGS IN EXCESS OF RECOMMENDED

LIMITS. CORRECTIVE ACTION MUST BE
TAKEN. THOROUGH ANALYSIS WITH THE
HELP OF TROUBLE SHOOTING CHART.

18. CLEAN RADIATOR 18C BLOW AIR THROUGH THE RADIATOR CORE
IN OPPOSITE DIRECTION TO THE NORMAL
FLOW OF AIR, IF WORKING UNDER
DUSTRY/ DIRTY CONDITIONS.
(REVERSE FLUSHING OPERATION)

19. CHECK AIR COMPRESSOR 19C CHECK SHAFT END CLEARANCE.

20. ADJUST INJECTORS AND VALVES. 20C FINAL ADJUSTMENTS MUST BE CARRIED
OUT WITH ENGINE HOT AND WITH
CORRECT TORQUE AS SPECIFIED
(REFR O&M MANUAL).

21. CLEAN FUEL INLET CONNECTIONS. 21C

22. CHANGE HYDRAULIC GOVERNOR 22C USE ENGINE LUBRICATING OIL.

OIL/ ANEROID OIL.

23. CHECK VIBRATION DAMPER. 23C CHECK WOBBLE AND ECCENTRICITY

ALIGNMENT MARKS ON RUBBER TYPE.
DISCARD DAMPER IF MISALIGNMENT
IF MORE THAN 1/16 IN.
 DIESEL ENGINES

"D" CHECK EVERY 4500 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------

1. REPEAT ALL MAINTENANCE STEPS 1D

OF CHECKS "A", "B" & "C".

2. CHECK EXHAUST AND INLET 2D

MANIFOLD NUTS AND CAPSCREWS.

3. TIGHTEN ALL MOUNTING BOLTS 3D

AND NUTS.

4. CLEAN TURBOCHARGER DIFFUSER 4D

AND IMPELLER AND CHECK END
FLOAT.

5. CHECK TURBOCHARGER REARING 5D ONLY END FLOT ON SEMI FLOATING

CLEARANCES BEARINGS IF IN EXCESS OF LIMITS,
REPLACE.

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

CORRECTIVE ACTION IS INDICATED.

7. CLEAN INJECTOR INLET SCREENS.

8. CLEAN AND CALIBRATE ALL MUST BE DONE ONLY IF A PERFORMANCE

INJECTORS. DETERIORATION IS EVIDENT.
SOME OF THE INDICATIONS FOR
PERFORMANCE DETERIORATION ARE:

9. CHECK FUEL PUMP CALIBRATION 1 BLACK SMOKE.

2 CHANGE IN FUEL MANIFOLD PRESSURE
10. REPLACE ANEROID BELLOWS AND 3 LOSS OF POWER
CALIBRATE ANEROID. 4 MALFUNCTION OF ANEROID.

11. REPLACE FUEL PUMP FILTER

SCREEN AND MAGNET.

12. STEAM CLEAN ENGINE 12D IF STEAM IS NOT AVAILABLE, THEN

USE CLEAN SOAP WATER SOLUTION
AS OUTLINED IN "C" CHECK ITEM-11C.
 `E' CHECK EVERY 8000 HOURS

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.

THE `E' MAINTENANCE CHECK IS A METHODOLOGY FOR INSPECTION OF WEAR OR

ASSEMBLY DETRIORATION OF PARTS AND ASSEMBLIES, AND SHOULD BE
RESORTED TO ONLY WHEN TROUBLE SHOOTING IN ADDITION TO PERFORMING
A,B,C AND D MAINTENANCE CHECKS, WHICH MAY ELIMINATE THE ENGINE
PERFORMANCE PROBLEM AND BRING THE ENGINE BACK TO NORMAL OPERATING
CONDITIONS. IT IS ANTICIPATED THAT GOOD OPERATING AND MAINTENANCE
PRACTICES AS PRESCRIBED THROUGH A,B, C & D CHECKS WILL ENSURE THAT THE
ENGINE WILL PERFORM BEYOND 25000 HOURS BEFORE THAT THE ENGINE MUST BE
DISMANTLED FOR INSPECTION PRELUDE TO A MAJOR OVERHAUL. THE TIME
INTERNAL OF 8000 HOURS IS A PERIOD AT WHICH THE ENGINE MAY DEVELOP
SYMPTOMS ASCRIBED ABOVE 1-5 AND ARE INDICATIVE OF PERFORMANCE
DETERIORATION DUE TO INADEQUATE A,B,C & D CHECKS AND FAILURE TO
IDENTITY PERFORMANCE DETERIORATION. THIS FIGURE HAS BEEN ARRIVED AT
ON THE BASIS OF CURRENT MAINTENANCE PRACTICES AND SHOULD NOT BE
TREATED AS AN ABSOLUTE FOR MAKING AN `E' CHECK. HOWEVER, IT IS ESSENTIAL
THAT THE ABOVE ROUTINE ANALYSING ENGINE PERFORMANCE BE STRICTLY
FOLLOWED IN ORDER TO PREVENT DISMANTLING OF ENGINE WHOSE
PERFORMANCE CAN BE SIMPLY CORRECTED BY TROUBLE SHOOTING AND ROUTINE
MAINTENANCE CHECKS.

3. THE `E' MAINTENANCE CHECK IS OFTEN REFERRED TO AS "IN FRAME INSPECTION"

WHERE SOME KEY PARTS, SUCH AS BEARINGS, ARE CHECKED FOR WEAR TO
DETERMINE IF THE ENGINE MAY BE OPERATED FOR ANOTHER SERVICE PERIOD.
LIKEWISE, OIL CONSUMPTION, OIL PRESSURE AND OTHER SIGNS OF WEAR SHOULD
BE ANALYSED DURING THE CHECK WEAR LIMITS AND OTHER INFORMATIONIS
AVAILABLE FROM DISTRIBUTOR AND DEALERS. (IT MUST BE CLEARLY
UNDERSTOOD THAT THE DECISION TO INSPECT KEY PARTS MUST BE ARRIVED
THROUGH ROUTINE OUTLINED IN POINT TWO ABOVE).
 10.0 STATUTORY TESTING OF LPG CYLINDERS

10.0 STATUTORY TESTING OF cleaning by immersing the cylinder

LPG CYLINDERS in the caustic soda bath and soap
water and the same is then rinsed
All cylinders used for filling LPG with water.
are required to be tested periodically
to ensure fitness of the cylinders for 10.1.3 CHECKING TARE WEIGHT
further service. First re-testing is :
required to be done after 7 years and
subsequent re-testing after every 5 All the LPG cylinders shall be
years interval. Such tests are to be weighed and if the loss in tare
conducted by the CCE approved weight is more than 5% of
parties only. original weight such cylinders
shall be segregated and scrapped.
10.1 TESTING PROCEDURE At the time of weighing the
weight of valve is also
10.1.1 DEGASSING OF LPG accounted.
CYLINDERS
10.1.4 VISUAL INSPECTION :
All the LPG cylinders are
depressurised in the approved a) The detailed visual inspection of the
premises by opening valves by cylinder body shall be carried out as
means of suitable adapters to ensure per IS:5845/ IS : 13258.
that the internal cylinder pressure is
reduced to atmospheric pressure. b) Depending upon the visual
Only after depressurising the inspection, cylinders are segregated
cylinder, cylinder valve is removed for scrapping, for cold repairs and for
and LPG cylinder is taken up for hot repairs in case required.
water filling and water is overflown
and retained in the cylinder for not c) The interior of the cylinder shall be
less than one hour to remove any examined by means of infra low
traces of LPG. Degassing can also voltage FLP lamp. The internal
be achieved by stripping, Nitrogen examination shall be carried out as
purging, etc. per IS:5845 / IS : 13258.

10.1.2 SURFACE CLEANING d) LPG cylinders selected at random

may be cut into two holes for
a) After depressurising the cylinder assessing internal corrosion.
and emptying out the water, the
same is kept in inverted position and e) In case of dented/ buckled cylinders,
stroked gently with a non-sparking visual inspection of welds needs to
hammer such as wooden mallet to be done more carefully since the
remove any dust, rust or any loose welds are more susceptible to
remnants in the cylinders. cracking. Denting or buckling by
more than nominal plate thickness
b) The depressurized cylinder bung is may be attended by repairs/
plugged and is taken up for surface replacement.
 valve and the torque of 20+/-2 kg. m.
10.1.5 HYDROSTATIC TESTING : should be applied. In no case
spanners and ordinary wrenches be
a) All the LPG cylinders shall be taken used for tightening the valves.
up for hydrostatic test at an interval
of 7 years for first testing and 10.1.7 PNEUMATIC TEST :
subsequent testing after every 5 years
in accordance with IS:8868. Only a) The Pneumatic test should be applied
water should be used as a medium to the cylinder at a pressure of 7
for hydrostatic testing and the kg/sq.cm. for a minimum of 60
pressure to be applied should be the seconds as per IS:3196. This is
test pressure marked on the cylinder basically to check the tightness of the
body (25.35 kg/sq.cm) and the same valve cylinder joints.
should be retained for a minimum
period of 30 seconds. Any reduction b) With the cylinder under pressure, a
in pressure noticed during the test, soap solution should be applied to
any leakage, visible bulge or the cylinder valve bung joint to
deformation should be treated as a ensure that there is no leak. The
case of failure. Such cylinders same can be checked by dipping the
should be properly marked, cylinders in water bath.
observation recorded and segregated Depressurise the cylinders. All the
for scrapping and disposal. Pressure Gauges used for Pneumatic
test shall be calibrated at least once
b) Pressure Gauges shall be calibrated in 3 weeks and the Pressure Gauge
at least once a week and the Pressure used for verification should be tested
Gauges used for verification should once in every three months.
be tested once in every three months.
10.1.8 PAINTING OPERATIONS :

a) To enhance the life of the cylinder

and to project a better image to the
10.1.6 VALVE FIXING : customers, maintaining a well
painted surface of cylinder is most
a) Before commencing the fitting of desirable.
valve operation, all the water inside
the cylinder should be drained and b) All LPG cylinders are painted with
the cylinder should be made dry with one coat of zinc chromate primer and
the use of hot air jet. Before refitting a coat of super synthetic enamel
the valve, internal threads of the paint of signal red colour (IS:2932
cylinder bung should be cleaned with shade 575). Special care should be
3/4" NGT thread tap and checked taken to paint the cylinders in
against thread damage. In case old vulnerable areas like underneath the
valves are being refitted the same foot ring.
should be tested by compressed air at
7 kg/sq.cm for leakage from seat. c) The valve should be protected while
painting the cylinder.
b) Teflon paste/ suitable sealing
compound should be used as a 10.1.9 CHECKING MARKING THE
sealing material for tightening the TARE WEIGHTS
 body as close to the previous
a) Tare Weight of the cylinder should markings as practicable :
be ascertained and if in variance with
the original tare weight (this could be a) Date of retest
as a result of change of cylinder
valves ) the observed tare - weight b) Code marking for the Test Plant/
should be punched as close to the Repairer.
original tare weight marking as
recorded in the register maintained. c) Tare weight of the cylinder
should be stencilled with black
b) The observe tare weight should be paint within the V.P. Ring circle
stencilled with paint on the shoulder diameter at 3 places for easy
and as well as on inside of one of the identification by filling operators.
vertical stay. The recommended lettering size
is 25 mm and the thickness of the
c) Gross weight punched/ stencilled on numerals is 6-7 mm.
the cylinder should be changed in
case of change of tare weight. d) It is also recommended that the
net weight of LPG to be filled
- Weighing machines used for should be stencilled on the body
checking the tare weight should of the cylinders outside the V.P.
be duly certified by Weights & Ring diameter. The size of the
Measures Authority. The lettering recommended is 18 mm
machine should be tested daily and the thickness of the numerals
with the standard weights to is 4-5 mm.
verify accuracy. The test used
for checking should be tested Sequence of operations for
against standard weights and the statutory pressure testing of LPG
same must be stamped Cylinders is given at Annexure
periodically by Weights and 10-I.
Measures Authority. The
minimum graduations of 50 gms. 10.1.11 COLOUR CODING OF
must be available. CYLINDER

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
-------------------------------------------------------------------------------------------------------------------------------

1997 1999 2004 Dove grey 694 Black

1998 2000 2005 Aircraft Blue 108 White

1999 2001 2006 Salmon Pink 443 Black

2000 2002 2007 Black 521 White

2001 2003 2008 Yellow 355 Black

2002 2004 2009 White 127 Black

2003 2005 2010 Sea Green 217 Black

--------------------------------------------------------------------------------------------------------------------------------

10.1.12 CERTIFICATION :
k) External
A detailed record of each cylinder tested
at the installation or at the repairer's 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

e) Weight of cylinder - Quarter/ year of retest punched on

the cylinder
f) Punched on cylinder
- Stencilling/ colour coding for age
profile
g) Observed weight
- Relevant test certificate number
h) Whether satisfactory/ rejected
REMARKS :
i) Visual defects

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

SEQUENCE OF OPERATIONS FOR STATUTORY

PRESSURE TESTING OF LPG CYLINDERS

1. Receipt of Cylinders

2. Depressurising

3. Recording details
(like Sr.No., Test Dates, Tare weight, Manufacturer's name)

4. Valve Removal

5. Degassing

6. External surface cleaning

7. Internal cleaning and internal inspections

8. Visual Inspections of external surface and bung threads

by L-1 and L-9 plug gauges

9. Tare weight checking

10. Hydrostatic testing

11. Internal cleaning and checking

12. Primer coating

13. Signal red painting

14. Punching of new test date and repairer's identification mark

15. Tare weighing

16. Colour code painting to indicate ownership of cylinders,

stencilling new tare weight, new weight and next test date

17. Tapping the bung thread, cleaning the same by brass wire
brush and checking the bung threads by L-1 & L-9 plug gauges.

18. Valve fixing

19. Pneumatic test

20. Certification and despatches.

 CHAPTER 11

FIRE PROTECTION FACILITIES

11.1 GENERAL The main components of the fire

water system are :
LPG Installations shall have well
defined in-built fire prevention and - Fire Water Storage
protection system to mitigate any
exigency. The requirements of fire - Fire Water Pumps
prevention and protection system shall
be as under : - Fire Hydrant/ Monitor
distribution piping network.
11.2 DESIGN CRITERIA
- Water Sprinkler/ Deluge system.
i) The single largest fire risk shall be
considered. 11.4 FLOW RATE DESIGN

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. e) Tank Wagon Gantry

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.

The entire pump /compressor house 11.5 FIRE WATER SYSTEM

shall be considered as single risk area : DESIGN
alternatively it can be divided into
suitable number of zones with minimum i) The Fire Water pressure system shall
10 meter width. be designed for a minimum residual
pressure of 7.0 kg/ cm2 g at the
d) Tank Lorry Gantry remotest place of application in the
plant.
In case of Tank Lorry Gantry, automatic
detection of heat for automatic actuation ii) A fire water ring main shall be
of MV sprinkler system having remote/ provided all around perimeter of the
local operated deluge valve with spray LPG Plant facilities with hydrants/
density 10.2 LPM/Sq.M of surface area monitors spaced at intervals not
shall be provided. A maximum of 8 exceeding 30 M when measured
bays shall be considered as single risk aerially. Fire hydrants and monitors
area. In addition to the tank lorry shall not be installed within 15
surface, MV spray system shall Meters from the facilities/ equipment
effectively cover the tyres, manifold to be protected.
and dish ends of various size of tank
lorries. There shall be atleast 3 tiers of iii) Fire hydrant network shall be in
MV sprinkler system and heat detectors closed loops to ensure
uniformly cool the top , middle and the multidirectional flow in the system.
bottom of the tank lorry. Isolation valves shall be provided to
 enable isolation of any section of the farthest end of the hydrant system
network without affecting the flow in with the help of Jockey Pump
the rest. The isolation valves shall be operating automatically.
located normally near the loop
junction. Additional isolation valves The Jockey Pump shall start-stop
shall be provided in the segments automatically actuated by pressure
where, the length of the segment switches.
exceeds 300 Mts.
A standby jockey pump shall be
provided if the number of hydrant
11.6 FIRE WATER STORAGE points is more than 100. One
monitor shall be considered as
i) Water for the hydrant service shall equivalent to 4 hydrant points.
be stored in any easily accessible
surface or underground lined iii) The fire water pump(s) including the
reservoir or above ground tanks of stand by pump(s) shall be diesel
steel, concrete or masonary. The engine driven . The pumps shall be
effective capacity of the reservoir capable of discharging 150% of its
above the level of suction point shall rated discharge at a minimum of 65%
be minimum 4 hours aggregate of the rated head. Each engine shall
working capacity of pumps. Where have an independent fuel tank of
make up water supply system is 50% suitable size for 6 Hrs. continuous
or more this storage capacity may be running.
reduced to 3 hours aggregate rated
capacity of pumps. In refineries / gas processing plants,
where reliable source of electric
Large natural reservoirs having power is available electrical driven
water capacity exceeding 10 times centrifugal pumps can be used upto a
the aggregate water requirement of maximum of 50 % of total pumping
fire pumps may be left unlined. capacity. Power supply to the pump
motors should be from two separate
ii) Storage tank/ reservoir shall be in feeders.
two inter connected compartments to
facilitate cleaning and repairs. In iv) At least one standby fire water pump
case of steel tanks there shall be a shall be provided upto 2 nos of main
minimum of two tanks. pumps For main pumps 3 and more,
minimum two standby pumps of the
11.7 FIRE WATER PUMPS same capacity as the main pumps
shall be provided.
i) Centrifugal type fire water pumps
shall be installed to meet the iv) Fire water pumps shall be
designed fire water flow rate and used exclusively for Fire
head. These pumps shall have a protection and prevention
flooded suction, alternatively purpose only.
suitable arrangement for auto v) Suction and discharge valves
priming shall be provided. of fire water pump shall be
kept open all the time.
ii) The system pressure has to be
maintained at 7 kg/cm2g at the
The fire water pumps shall be provided ground pipelines, water circulation to
with automatic starting facilities which be carried out.
shall function with specified logic even
if initial pump does not start or having iii) For Fire water ring main laid
started , fails to build up the required underground the following shall be
pressure in the fire water ring main ensured :
system within 20 seconds.
a) The Ring main shall have at least
11.8 FIRE HYDRANT NETWORK one meter earth cushion in open
ground, 1.2 meters cushion under the
i) Fire hydrant ring main shall be laid road crossings and in case of rail
above ground ensuring that : crossing, provisions stipulated by
Indian Railways shall be complied.
a) Pipe line shall be laid at a height
of 300 mm to 400mm above b) The Ring main shall be suitably
finished ground level. protected against soil corrosion.

b) The mains shall be supported at c) In case of poor soil conditions it may

regular intervals not exceeding 6 be necessary to provide concrete/
meters or as per design approved. masonry supports under the pipe
line.
c) The system for above ground
portion shall be analysed for iv) Fire water ring main shall be sized
flexibility against thermal for 120% of the design water flow
expansion and necessary rate. The velocity of water shall not
expansion loops where called for exceed 5 meter per second in fire
shall be provided. water ring main. Design flow rates
shall be distributed at nodal points to
ii) However the ring main may be laid give the most realistic way of water
underground at the following places : requirements in an emergency.
In case of sea water service, the fire
a) Road crossings. water main pipes shall be concrete
mortar lined internally or other
b) Places where above ground piping is suitable coating material shall be
likely to cause obstruction to used.
operation and vehicle movement.
v) Hydrants/ monitors shall be located
c) Places where above ground piping is considering various fire scenario at
likely to get damaged mechanically, different sections of the premises to
particularly in the LPG storage area be protected and to give most
where water supply lines are laid for effective service. At least one
feeding sprinkler deluge system.
hydrant post shall be provided at a
d) Where Frost conditions warrant and every 30 mtrs of external wall
ambient temperature is likely to fall measurement or perimeter of battery
below zero deg. centigrade limit in case of high hazard areas.
underground piping at least 1 meter For non-hazardous area, they shall be
below the ground level should be spaced at 45 mtrs. intervals. The
provided. Alternatively, for above horizontal range & coverage of
 hydrants with hose connections shall 30 mtrs. on both sides of the gantry.
not be considered beyond 45 mtrs. The hydrants & monitors shall be
located at a minimum distance of 15
vii) Hydrants shall be located at a mtrs. from the Tank Wagon/Tank
minimum distance of 15 mtrs. from Trucks measured from edge of the
the periphery of storage tank or facilities.
equipment under protection. In case
of buildings this distance shall not be xii) Fire water monitors shall be
less than 2 mtrs. and not more than provided with independent isolation
15 mtrs. from the face of building. valves.
Provision of hydrants within the
building shall be provided in xii) Hose box with 2 nos. hoses and a
accordance with IS : 3844. nozzle shall be provided at each
Hydrant/Monitors shall be located hydrant points.
along road side berms for easy
accessibility. xiii) The deluge valves shall be
located out side the kerb wall at a
safe distance in case of LPG spheres/
viii) Double headed hydrants with two
bullets and 15 meters away from the
separate landing valves on 3"/ 4" limits of LPG cylinder sheds. A fire
standpost shall be used. All hydrant wall shall be provided for the
outlets shall be 1.2 mtrs. above protection of deluge valve and for
ground level. operating personnel.

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.

The location of the monitors shall 11.9 MATERIAL SPECIFICATIONS

not exceed 45 mtrs from the hazard
to be protected. All the materials used in fire water
system using fresh water shall be of
x) Hydrants and monitors shall not be type as indicated below.
installed inside the dyked areas.
i) Pipes : Carbon Steel (CS)
per IS:3589/IS:1239
xi) LPG tank wagon Loading/ unloading ii) Isolation Valves Carbon Steel
facility and Tank Truck gantry area iii) Deluge valve Carbon Steel
should be provided hydrants having iv) Hydrant
multipurpose combination nozzles Standpost CS
for jet spray & fog arrangement and Outlet valves Gunmetal/ Aluminium
fire hydrants located at a spacing of v) Monitors CS
 Horizontal dry piping down stream
Equivalent or superior materials of the block valve and after deluge
meeting the design requirements can valve shall have adequate drain
also be used . facilities at selected locations.

vi) In case of underground mains the 11.11 AUTOMATIC FIRE

isolation valves shall be located in PROTECTION SYSTEM
RCC/ brick masonary chamber.
i. Automatic fire protection (Fixed)
vii) The above ground fire water main system based on heat detection
and the fire hydrant standpost shall through thermal fuses/ quartz bulbs/
be painted with corrosion resistant EP detectors shall be employed.
"Fire Red" paint as per IS : 5. Sensors shall be installed at all
critical places wherever medium
viii) Water monitor, hydrant point and velocity spray system has been
hose box shall be painted installed as described below :
"Luminous Yellow' IS : 5.
a. In LPG storage area, such
11.10 MEDIUM VELOCITY detectors shall be provided
SPRINKLER SYSTEM encircling each vessel, equi-
spaced with a maximum spacing
The medium velocity spray system of 1 meter at an elevation of
shall be provided in all critical areas about 1.5 to 2.0 meter from
like LPG Storage Area, Sheds, LPG bottom of vessel. Also minimum
Pump/Compressor House, Tank 2 nos. detectors shall be provided
truck/ wagon loading / unloading at the top of the vessel and atleast
areas, valve manifolds etc. one near the liquid line ROV to
take care of failure of flanges. In
i) Spray nozzles shall be directed case of an automatic thermal fuse
radially to the vessel at a distance not based fire protection system the
exceeding 0.6 m from the equipment instrument air supply pressure to
surface. Only one type and size of thermal fuses shall be maintained
spray nozzle shall be used in a through a pressure control valve
particular facility. The horizontal and a restriction orifice.
extremities of water flow from spray
nozzles shall at least meet. b. Detectors shall be placed at
critical locations in LPG sheds
Where projections (manhole flanges, (filling, cylinder storage, testing,
pipe flanges, staircase, supports evacuation, etc.) loading/
brackets) obstruct the water spray unloading gantries, LPG
coverage, including rundown or compressor house, piping
slippages on vertical surface, manifold, repair sheds etc. Upon
additional nozzles shall be installed actuation there shall be alarm in
around the projections to maintain control panel, LPG pumps and
the wetting pattern. First valve of the compressors would trip, ROVs
vessel shall be adequately covered (wherever provided) on LPG
with sprinklers. supply and return lines would trip
and the deluge valves on fire
 water sprinkler system will get indications for deluge valves
actuated. with facility for actuation.

ii) In case, Quartzoid Bulbs are used for iii) Fire siren of l km range
detection, the same shall be designed
to blow at 79 deg. centigrade (max.) iv) Closure of all Remote
and Quartzoid Bulb network shall be Operated Valves in affected
maintained with plant air at a facility.
pressure not more than 3.5
kgs/sq.cm.g and shall be such that v) Tripping of main power
the discharge of air through one supply barring the emergency
Quartzoid Bulb will depressurise the power
system to actuate the deluge valves.
vi) The water spray from all
iii) In case of Electro pneumatic (E.P) nozzles within 30 seconds.
heat detectors, it shall actuate the
deluge valve in any of the following vii) The fire water pump(s) shall start
conditions : based on their set pressure to
supplement/ to maintain the fire
a) Rate of rise - 10 oC/min water pressure in the ring main.
of temp.
Additionally suitable systems like push
b) At 79 deg. C (max.) buttons etc. for initiating all the above
actions shall be provided on remote
The EP detectors shall be divided in operating panel. Further similar system
groups and alternate detectors shall like push buttons, air release valves etc
be connected in one circuit. Two shall also be provided in the field at safe
detectors from two different groups location for enabling manual actuation
shall function/ operate for actuation by an operator. In case, the zoning
of sprinkler system. concept is used for MV sprinkler system,
the operations of sprinklers in various
iv) Water spray nozzles and heat zones shall be clearly earmarked on the
detection system shall be of push buttons. In the field, manual bypass
approved type and duly certified for valves of fire water deluge valves shall
the performance. also be provided.

iv) The actuation of detectors shall The performance test certificates after
initiate the following : installation in respect of spray density,
flow rate, response time for each facility
i) Opening of deluge valve of the to be protected provided by
affected zone as well as adjacent manufacturer shall be maintained at the
zones. LPG Installations and verified once in 6
months and records maintained thereof.
ii) Audio-visual alarm indicating Further, all spray nozzles shall be
the affected zone at the fire inspected for proper positioning,
pump house and manned corrosion and cleaned if necessary at
control panel. The control intervals of not more than 12 months or
panel shall also have status earlier based on actual experience.
 Care shall be taken in positioning Tank Wagon loading/ 1 No. 10kg
nozzles so that water spray does not unloading gantries DCP Extinguisher
miss the targeted surface and reduce for every 15/20
the efficiency or calculated discharge meters of gantry.
rate.
Other Pump Houses 2 Nos. 10 kg
11.12 FIRST AID FIRE FIGHTING DCP
EQUIPMENT extinguisher

11.12.1 PORTABLE FIRE Office/Canteen/ 2 X 10 kg DCP

EXTINGUISHERS Stores extinguishers in
each building
i) Portable fire extinguishers shall be
located at convenient locations and MCC/ At 2 x. 4.5 kg
shall at all times be readily DG Room/ CO2 extinguisher
accessible and clearly visible. HT Room in each room or
for floor Area of
ii) The maximum running distance to about 100 Sq.m.&
locate an extinguisher in working 4 sand buckets &
areas shall not exceed 15 meters. a stand shall be
provided in MCC/
iii) The top surface of the extinguisher DG Room.
shall not be more than 1.5 meter
high. v) 100% spare CO2 cartridges and 50%
(Min) spare DCP bags (as per Fire
iv) The fire extinguishers shall be Extinguisher Capacities) shall be
provided at various locations as stored in the LPG plant.
under :
11.12.2 WHEELED/ MOBILE
Area Portable Fire FIRE FIGHTING
Extinguisher EQUIPMENT

LPG Storage 2 Nos. 10 i) One No. Mobile 75 Kg DCP fire

Vessel(Each) kg DCP extinguisher shall be provided in
extinguisher. filling shed, LPG storage vessels/
LPG Pump House area, Tank truck
LPG cylinder 2 Nos. 10 kg DCP loading/ unloading gantry area &
sheds extinguisher per tank wagon loading/ unloading
200 Sq.M.Area. gantry area.

LPG Pump 2 Nos.10 kg. DCP ii) The Dry chemical powder used in the
houses extinguisher per extinguishers shall be Potassium/
50 Sq.m. Area. Urea based or Sodium Bicarbonate
as per OISD-GDN-115. Nitrogen/
Tank Truck loading/ 1 No. 10 kg. Carbon Dioxide shall be used as
loading gantries DCP Extinguisher expelling gas.
in each bay. iii) A trolley containing first aid fire
protective accessories shall be
readily available in the LPG plant.
 rubber hand gloves
11.12.3 HOSES, NOZZLES for LPG emergency
AND ACCESSOREIS as per OISD-GDN-115

i) Reinforced rubber lined hoses 8. Low tem. protective Min. 2 sets

(63mm) conforming to IS : 636 (type clothing for LPG
A or B) shall be provided. emergency.

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

iii) Minimum of two or 25% spare 13. Self contained

Hoses shall be stored in the LPG Min. 1 No.
plant. breathing apparatus
with one spare cyl.
iv) In addition to the nozzles provided (Cap. 30 minutes)
in the hose boxes there shall be at
least 2 Nos. spare nozzles in each 14. Water jel blankets Min. 2 nos.
category viz. Jet Nozzles with branch
pipes, Fog Nozzles, universal 15. Portable Gas detectors min. 2.
Nozzles, water curtain Nozzles, / Explosimeter
Spray Nozzles and Tripple purpose
nozzles in the plant. The above are guidelines and
minimum requirements of each item
v) The following accessories/ first aid and can be increased depending upon
items shall be provided in the plant : the scale of operations, statutory/
mandatory requirement of local
1. Fire hoses Two nos. for each bodies/ State Governments or any
Hose Box other expert body.

2. Safety helmets 1 no. for each 11.13 EMERGENCY CONTROL /

person. ALARM SYSTEM
(min. 10 nos.)
11.13.1 FIRE ALARM SYSTEM
3. Hose Box At each hydrant
point. i) Manual call points near to filling
shed, storage area, tank truck/ wagon
4. Stretcher with Min. 2 Nos. gantry, pump house, etc. shall be
blankets. provided and clearly marked in the
installation. Operation of these points
5. First aid Box Min. 2 nos. shall raise audio visual alarm in
6. Rubber hand gloves Min. 2 pairs control room.
for electrical (BIS approved)
purpose. ii) Electricity operated Fire Siren shall
be audible to the farthest distance in
7. Low temperature 4 pairs
 the plant (1 K.M. from the periphery passive measure like fire proofing/
of the plant). insulation or fire retardant coating will
provide protection in the initial period of
iii) Manually operated fire sirens shall be fire which is very crucial. This will give
provided at strategic places. some breathing time for activating other
fire fighting measures like starting of
iv) For fire condition the siren shall be pumps, organising people, opening of
wailing sound for minimum `2 valves etc. This will also take care of
minutes and for all clear signal it automation failure wherever it is
shall be straight run siren for 2 provided.
minutes.
The fireproofing of LPG storage vessel
v) For Disaster condition the wailing should be decided based on the risk
sound given shall be repeated thrice analysis keeping in view local
with a minimum 10 seconds gap. considerations, availability of water and
societal risk.
11.13.2 COMMUNICATION
SYSTEM The fireproofing of LPG storage vessel
shall be decided based on the fire safety
i) Communication system like analysis keeping in view local
telephone/ PA or paging or walkie- considerations, population density,
talkie shall be provided. availability of water, societal risk and
fire protection measures provided.
ii) In the hazardous areas, flame-proof /
intrinsically safe telephones shall be Fire proofing provided on the vessel and
provided. supporting legs shall be adequate to
protect the shell material from
iii) Wherever possible Hot line overheating and consequent failure. The
connection between City Fire minimum rating for fire proofing shall be
Brigade/ near by major Industries as under :
shall be provided.
LPG storage vessel & connected 1 hr.
iv) Plant shall have a ` Mutual Aid' lines upto the fire safe ROVs
arrangement with near by industries.
Supporting legs of all above 2 hr.
11.14 SPECIAL FIRE
PROTECTION Fire proofing is not required for diagonal
bracing, including tie rods, or redundant
The most hazardous situation in LPG members that are not necessary for
vessel is the possibility of BLEEVE. supporting the static loads.
This usually takes place when the vessel
is subjected to external fire. Before fire-proofing application,
protected metal surfaces shall be
The unwetted (vapour space) portion of prepared through such means as sand-
the shell gets overheated and fails even blasting and corrosion-protective
at the operating pressure. As such, it is primers. Particular attention shall be
important that metal temperature in the given to the top junction of the fire-
vapour space is protected from proofing with the protected metal to
overheating by some measures. A prevent water ingress. OISD-STD-164
on "Fire proofing" shall be referred for 11.15.2 FIRE WATER RING
details on fire proofing. MAIN
Fire water line to each sphere should be i) The ring main shall be kept
so routed that it is not exposed to direct pressurised at 7 kg/sq.cm.g with the
fire. This is to protect it from failure in help of one or more jockey pumps.
the initial period when water flow has
not commenced. It is recommended that ii) The ring main shall be inspected for
riser should be located away from any visual leaks, detects, damage and
bottom ROV. The horizontal run of the corrosion at least once in week and
Fire Water line may be buried if fire records maintained thereof.
engulfment cannot be avoided otherwise.
Fire proofing shall include connected iii) All valves on the ring main/ hydrant/
LPG lines and pipe supports within 15 M monitor valves shall be checked for
of a storage vessel or in the drainage leaks/ operation and lubricated once
paths. in a month.

11.15 INSPECTION AND TESTING 11.15.3 FIRE WATER SPRINKLER

SYSTEM
The fire protection equipment shall be
kept in good operating condition all the i) All deluge valves and sprinkler
time. system shall be operated and checked
once in a quarter for correct remote
The fire fighting system shall be operation performance of each
periodically tested for proper functioning nozzle and effectiveness of system in
and logged for record and corrective total.
actions. In addition to routine daily
checks/ maintenance the following ii) Testing of sprinkler system in the
periodic inspection/ testing shall be sheds shall be carried out by closing
ensured. the outlet of the deluge valve for
correct remote operation once in a
11.15.1 FIRE WATER PUMPS quarter.

i) Every Pump shall be in test run for iii) The strainers provided in the Fire
atleast 10 minimum twice in a week water sprinkler system shall be
at the rated conditions. cleaned once in a quarter and records
maintained.
ii) Once in a month each pump shall be
checked and tested and the shut-off 11.15.4 FIRE WATER RESERVOIR
pressure observed and logged. Also
the pump performance shall be In case of a Reservoir the same shall be
ascertained. cleaned once in 6 months or earlier as
and when needed so that there shall not
iii) The Jockey pump operation shall be be any foreign particles/ fungus/
checked periodically. Frequent start/ vegetation in the reservoir.
stop condition of Jockey pump
indicates that there are water leaks in 11.16 MAKE UP WATER
the system.
Facilities to make up water during fire
fighting shall be provided.
 CHAPTER 12

GAS MONITORING SYSTEM

12.0 GENERAL Amongst the various methods of

detection available, the following
The best method of prevention of proven systems for LPG can be
explosion is to avoid basic build up considered.
of gas concentration immediately on
occurrence of leakage. This would i) Catalytic detectors
require basically a reliable and ii) Infra-red detectors
continuous detection system with
warning annunciation to alert the 12.3 CONTROL SYSTEMS
plant personnel to take corrective
action. i) This is a critical equipment for
plant’s safety. Hence, the system
The Gas Monitoring system shall should have independent control
provide early warning on build up of equipment, power supply, UPS to
dispersed gas concentration below ensure that the system remains in
the LFL limits. operation even if the plant DCS or
other common process controls are
The system shall be designed not functioning. In case of bottling
considering small leaks (leaks which plant in Refineries, dropping of the
have secondary closures) such as signals on the DCS is acceptable
mechanical seals failure, sampling wherever hot standby DCS control
point left open, gasket leaks, hose system is available.
pinholes, valves gland leakage, drain
point left partially open, TSV’s relief ii) In case of failure or during
discharge in manifold area, filling/ maintenance when the system is not
evacuation hoses leakage. in operation, the plant safety officer
should keep the plant personnel on
12.1 APPLICATION alert to be more vigilant during
operations and night security
i) The detectors for the gas monitoring patrolling.
system shall be strategically located
in LPG Bottling Plant at all iii) The control equipment should have
facilities close to the potential data logging facilities to provide
source of leakage. print outs of the history of the events
with date and time of leakages.
ii) The detection control equipment
should be provided in the control iv) The control equipment should be
room for continuous monitoring able to generate at least two alarms at
even during power failure. different levels of LEL concentration
of gas.
12.2 DETECTORS
v) The control equipment is not wind side ensuring the path is free
required to have automatic corrective from obstructions. In case any
action capabilities on sensing additional expansion/ construction if
leakages as this is basically a undertaken, the detectors will have to
warning device. However, in case of be pre-positioned.
any specific recommendations made
in the risk analysis / HAZOP studies, v) The minimum detectors facilities-
the same should be implemented. wise are as given below:

12.4 ANNUNCIATION SYSTEMS Storage vessels (above ground) – 1

No. top and 1 No. near bottom ROV.
Appropriate annunciation system shall
be available to ensure that all the alarms LPG pump house 1 No. in pump
generated, both, audio and visual are house and 1 No. in manifold.
reported to the plant personnel, who are
authorized to take corrective action. Filled cylinder shed - 2 No.
Depending on the manning practice of
the plant, the alarms both, audio and Valve change shed – 1 No.
visual can be repeated at additional
location to ensure corrective action is Empty-cum-filling shed – 2 Nos.
taken. near carousel, 1 No. near evacuation
unit tank, 1 No. weight correction
12.5 LOCATION OF DETECTORS unit.

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.
The inspection of the system shall be The drift in the sensitivity of the
done at an interval of 1 month in individual detectors shall be recorded
which the gas shall be released at all in maintenance history log book
the detectors and the performance of during calibration and the detectors
the systems shall be established. with abnormal or wide drift in
sensitivity.
The calibration of the equipment
shall coincide with the monthly The plants should have at least 2
inspection schedule every three Nos. spare detectors for each system
months for calibration of the gas maintained at all times to facilitate
detectors the calibrated gas with immediate replacement of defective
known and certified level of detectors.
concentration shall be used.
 CHAPTER 13

EMERGENCY MANAGEMENT PLAN

13.0 GENERAL agencies, such as local administration,

Police authorities, Fire Brigade, hospital
13.1 The best way to manage any authorities, home guards, neighbouring
emergency is to prevent it. industries etc. Periodic mock drills for
Following guidelines for emergency all such plans to be conducted, and plans
prevention shall be followed : to be updated/ modified based on
experience gained during such drills.
a) Sound engineering practice in
the design, fabrication, 13.1.3 CHECK FOR LPG
installation and maintenance of LEAKAGE AT FOLLOWING
facilities. LOCATIONS

b) Careful selection and correct a) Through water drain valve while

use of equipment. draining.

c) Observance of safety and b) Leaking sample valve.

security regulations.
c) Breakage of glass on Sight Flow
d) Proper and constant training Indicator on the pipeline.
and guidance to all personnel
working in the Plant, with d) Opening of pop-off valve, gland/
particular reference to product packing etc.
knowledge and maintenance
practices. e) Leakage through LPG compressor/
pump.
e) Good House-keeping.
f) Leakage due to bursting/ rupture of
f) Constant supervision and hose or through sviwel joints of
alertness. body arms.

g) Leakage from the filling guns.

13.1.2 EMERGENCY PLANS :
h) Escape of liquid/ vapour LPG
Plant Manager shall ensure that suitable during maintenance/ repairs.
instructions are issued to both
Corporation's and contractor's personnel 13.1.4 SOME OF THE COMMON
identifying the action to be taken by each CAUSES OF FIRE :
one in an emergency. This should be
achieved by display of organisation (a) ELECTRICAL :
chart/ posters not only for fire-fighting
but also for other likely emergencies. i) Short circuiting due to loose
Likewise, for emergencies of large wiring including that of
magnitude Emergency Response Plan (or automobile moving in the area.
Disaster Management Plan) to be drawn
out in coordination with related outside
 ii) Use of non-flame proof fittings v) Excessive release of vapour
such as lights, torch, motors, beyond safe limit and fire due to
fan, telephone, temporary outside source of ignition.
lighting etc. (Note : Flameproof
fittings become non-flame vi) Lighting
proof due to poor maintenance
e.g. increase in gap in junction vii) Smoking.
boxes, due to missing nuts and
bolts or improper glands used 13.2 ACTION DURING
for connection to junction box, EMERGENCY
or sealing compound not used
in junction boxes etc.) 13.2.1 Immediate action is the most
important factor in emergency
iii) Static electricity as result of control because the first few
improper bonding/ grounding seconds count, as LPG fires
to tanks, conveyor system, tank develop and spread very quickly
truck, tank wagon etc. unless prompt and efficient action
is taken. In the event of fire/ gas
(b) VEHICLE : leak within LPG Plant the
following action shall be taken as
i) Exhaust of vehicle, if effective quickly as possible:
spark arrestors are not provided.
a) Take immediate steps to stop LPG
ii) Operation of non-FLP electrical leakage/ fire and raise alarm
switches such as vehicle ignition. simultaneously.

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.

(c) OTHERS d) All out effort should be made to

contain the spread of leakage/ fire.
i) Landing of crackers (flying type )
in hazardous areas. e) Saving of human life shall get
priority in comparison to stocks/
ii) Chiselling/ hammering. assets.

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.

iv) Lighted agarbatti in a truck. 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. d) Exercise care to ensure that static
charge is not generated in LPG
h) Electrical system except for control vapour cloud. For this purpose
supplies, utilities, lighting and fire solid jets of water must be avoided,
fighting system, should be isolated. instead fog nozzles should be used.

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.

j) Start water spray system at areas f) Cylinder fire should be approached

involved in or exposed to fire risks. using proper barricades/ protection
to avoid direct hit from flying
k) In case of leakage of LPG without cylinders.
fire and inability to stop the flow,
take all precautions to avoid source g) If the only valve that can be used to
of ignition. stop the leakage is surrounded by
fire, it may be possible to close it
l) Block all roads in the adjacent area manually. The attempt should be
and enlist Police support for the directed by trained persons only.
purpose if warranted. The person attempting the closure
should be continuously protected
13.2.2 Fire Fighting Operations : by means of water spraying
(through fog nozzles), fire entry
a) Enlist support of local fire brigade suit, water jel blanket or any other
and neighbouring industries. approved equipment. The person
must be equipped with a safety
b) If escaping vapour cannot be harness and manned life line.
stopped, jets of water should be
directed at the point of leakage to h) Any rapid increase in pressure or
assist controlled release of vapour noise level of product discharged
and in between water fog should be through safety relief valve of the
used for dilution and rapid vessel/ pipeline should be treated
dispersion of vapour cloud. as a warning of over pressurisation.
In such cases all personnel should
c) Fire Fighting personnel working in be evacuated immediately.
or close to un-ignited vapour
clouds or close to fire must wear i) As in case of any emergency
protective clothing and equipment situation, it is of paramount
including safety harness and importance to avoid endangering
manned life line. They must be human life in the event of fire
protected continuously by water involving or seriously exposing
sprays. Water protection for fire LPG equipment or serious leakage
fighters should never be shut off of LPG without the fire.
even though the flames appear to
have been extinguished until all 13.2.3 Action in the event of LPG
personnel are safely out of the leakage without fire :
danger area.
a) Take basic action as detailed in depending upon various factors
13.2.1 above. such as nature, sources, size,
location, etc. of fire. Basic fire
b) If escaping LPG is not on fire, fighting techniques have been
close any valve which will stop the explained earlier in section 13.2.2.
flow. However, for the purpose of
guidelines, fire fighting techniques
c) In some cases like the leakage from for few common cases are as
a pressure vessel without a fire follows :
(such as leak from tank truck bullet
or overturning) it may be desirable (i) Cylinder Fire : If a filled cylinder
to move the vessel to some remote is involved in fire, internal pressure
area such as block of isolated may start rising and if not relieved
roadway or open field where it can the built up pressure could rise
be allowed to leak safely without a above 70 kgf/cm2g and ultimately
source of ignition nearby. rupture the container. Ignition of
However, if this is to be done, the the escaping gas would aggravate
vessel must be moved in an upright the fire but the release of pressure
position. Never drag the vessel in a would reduce the possibility of
manner which might damage valve rupture of the container. No
or pipeline. Any attempt to turn a attempt should be made to
vessel back upright to move it to extinguish the burning gas. Bus
some remote location should be the container and other containers
done carefully to avoid damage to in the vicinity should be kept cool
valve and pipelines. by water sprays until the contents
of the container have burnt away.
Take necessary actions as detailed If the gas leakage does not ignite,
in 13.2.2. the container should be approached
from upwind (if in the open air)
13.2.4 Action in the event of LPG fire and be removed to a place of safety
remote from sources of ignition.
a) Take basic action as detailed in Cylinders not directly involved in
13.2.1 above. the fire should be moved away
from heat exposure, while applying
b) Extinguishing Fires - A small fire cooling water sprays on cylinders
at the point of leakage should be directly involved.
extinguished by enveloping with a
water spray or a suitable (ii) Fire on storage vessel : If a
smoothening agent such as carbon pressure vessel is exposed to
dioxide or dry chemical powder. radiant heat from external fire, it
However, it is again stressed that should be kept cool by water
LPG fire should not; except in sprays to prevent excessive
special circumstances explained pressure rise in the vessel. Cooling
earlier; be extinguished until the water sprays must be applied
escape of product has been without delay to the heat affected
stopped. area using fixed water sprinkler
system or equivalent spray water
c) Fire fighting procedure - Fire coverage, through fixed monitors
fighting procedures would vary or other equipment. Cooling the
 vessel with water sprays reduces Water pressure in LPG vessels.
the heat input to the vessel and
thereby reduces the pressure, thus, If LPG vessel's SRVs have started
reducing the rate of discharge from blowing vapour, take no further
the relief valves. action (apart from cooling) unless
vessel pressure continues to rise.
(iii) Leakage of LPG burning at the
outlet of a cylinder valve: If fire enters LPG storage area,
Extinguish the fire by means of a concentrate available cooling water
portable fire extinguisher, or on LPG vessels, most affected.
smoothening with a thick non-
synthetic cloth (preferably wet) or Do not try to empty LPG vessels
sand/ earth etc. exposed to fire. They become
more vulnerable to overheating as
Fix safety cap on the valve to their liquid content decreases.
prevent further leakage.

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

c) Extinguishers due for recharging/ (v) Earthquakes/ land slides

due for hydrotesting shall be
discharged during drills and (vi) Sabotage/ terrorist outrage
replenished subsequently 50%
(Min.) stock of refills as (vii) War situation
replenishment for FEs should be
maintained. The objective of the plan shall be to
reduce the probability of serious loss/
d) The fire pump should be run, damage to general stock, plant and
sprinkler system activated, machinery, documents etc. utilizing
emergency systems tested, water combined resources of the location itself
hoses run out and spray/ set and the outside agencies. In order to
techniques practiced during drills. have an effective organisation,
preliminary meeting shall be conducted
e) Fire alarms shall be sounded/ with the representatives from local fire
tested (neighbouring plants/ services, police authorities, voluntary
factories and the fire brigade shall organisations like ambulance service/
be warned in advance of this test). Govt. medical service/ contractors and
even Home Guards and defence
personnel. In the course of the meeting, leader for each for the groups and
there should be exchange of knowledge, the role to be played by each team
training and plans for development of in various likely crisis situations.
expertise and skills to gain knowledge
about the plant layout/ facilities, (v) Identify Disaster control room/
potential of likely hazards/ risks, likely group.
emergencies that may arise. This group
should draw out modalities of the (vi) Furnish detailed data and drawings
exercises in the given situation and relevant for the crisis management.
arrive at an agreed action plan which
should be updated from time to time and (vii) Establish channel of
put to test in the form of periodical mock communication at the local level to
drills. Statutory Authorities and higher
authorities within the organisation.
(b) Due to varying risk potentials and
also varying hazards at/ around (vii) Mock drills to be conducted
each location `Disaster minimum once a year.
Management Plan' for each
location shall be drawn up (ix) Modify the plan based on the
individually based on the outline experience gained through mock
given below: drills and try out the modified plan
through subsequent mock drills.
(i) Identify Disaster scenario i.e. the
situation under which the plan (x) The plan shall be updated as and
would become operational. Plan for when the changes recorded in the
the worst possible scenario. plan occur and communication sent
to all concerned.
(ii) Identify resources required from
each of the outside agencies. (c) Communication organogram :

(iii) Establish outside agencies, role of As a part of Disaster Management Plan,

each agency and obtain their communication organogram shall be
commitment for rendering the drawn up giving flow of communication
assistance in crisis situation as per from the originating location to various
the agreed plan. local agencies and also to Statutory
Authorities and upwards within the
(iv) Establish organogram for Disaster organisation to mobilise support and to
Management based on available consider alternatives for maintaining
manpower in various groups and essential supplies.
identify the leader and alternative
 CHAPTER 14 : SAFETY AUDIT

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.

In case of external safety audit, 6. Operating manual/ instructions,

following areas besides the points given display of Do's/ Don'ts etc.
in check list of Annexure 14- III shall be
covered.
 ANNEXURE 14- I

DAILY SAFETY AUDIT - CHECKLIST

FOR LPG BOTTLING PLANTS

LOCATION ______________

Audit/ Inspection by _________________

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------

A. SAFETY/ FIRE PROTECTION SYSTEM

A-01 Water level in static Yes/No

water tank is satisfactory.

A-02 Hydrant pressure Yes/No

maintained with jockey pump.
Record Pressure.

A-03 Fire water pumps/engines Yes/No

a) Are the batteries in good condition.

b) Are the diesel tanks full

c) Start one pump, record pressure developed.

d) Whether auto start system working.

A-04 Fire alarm/ Yes/No

communication system in working order.

A-05 Automatic Gas Detection Yes/No

system operating.

A-06 Vapour Extraction Unit operating Yes/No

A-07 Any unsafe condition of Yes/No

S&FP system observed
(specify in brief under remarks column).

A-09 Regular surprise checks/ testing Yes/No

being done at gate/ at the plant.

A-10 Direction of wind Yes/No

(specify in remarks column by
observing wind sock).
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------

A-11 Caution signs displayed Yes/No

at appropriate places.

A-12 Last fire drill in this area done on -----------

B. BULK STORAGE AREA

B-01 Whether water draining Yes/No
sampling done under constant
supervision.

B-02 Earthing connection Yes/No

apparently sound.

a) Whether level instruments are working.

b) High level alarm in working condition (test check).

B-04 Portable fire Yes/No

extinguishers in position.

B-05 Water spray/ sprinkler Yes/No

system apparently O.K.

B-06 Housekeeping is in order Yes/No

B-07 Gas detection system working Yes/No

B-08 Any sign of LPG leakage Yes / No

B-09 Any settlement of vessel observed Yes / no

B-10 Condition of Water seal Yes / no

B-11 ROVs on remote mode Yes / no

B-12 Pressure and temperature gauge Yes/ no

Functional

B- 13 Bonding across flanges visible Yes / no

B-14 Last fire drill in this area done on -----------

 C. TANK WAGON UNLOADING

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------

C-01 Any visible sign of LPG leakage Yes/No

C-02 Earthing connection apparently sound Yes/No

C-03 a) Whether hose condition/ Yes/No

connections are proper

b) Are these properly Yes/No

plugged if not in use.

C-04 House keeping in order. Yes/No

C-05 Portable fire Yes/No

extinguishers in position.

C-06 Water spray/ sprinkler Yes/No

system apparently O.K.

C-07 Housekeeping is in order Yes/No

C-08 Condition of Water seal Yes / no

C-09 Gas detectors functional Yes/ no

C-10 ROVs on remote mode Yes / no

C-11 Pressure and temperature gauge Yes/ no

Functional

C- 12 Bonding across flanges visible Yes / no

C-13 Last fire drill in this area done on -----------

 D. BULK TRUCK UNLOADING
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------

D-01 Are all vehicles allowed in licensed Yes/No

area permanently fitted with CCE
approved spark arrestors on exhaust
pipe (Random check)

D-02 Is the vehicle engine and master Yes/No

switch being shut off during
unloading bulk LPG (site check)

D-03 Are the earthing connection Yes/No

properly made before connecting
hoses to tank trucks.

D-04 Rotogauge, Fixed level instrument Yes/No

in working order (Random check.
Record TT No)

D-05 Any visible sign of LPG leakage Yes/No

D-06 Random safety check of Yes/No

tank truck No.

a) CCE licence available/ valid Yes/No

b) Fittings as per CCE Yes/No

c) 2 Nos. of fire extinguishers Yes/No

available in good condition/
easily accessible.
(physical check)

d) Safety instruction booklet Yes/No

TREMCARD available. Record
any abnormality/discrepancies observed.

e) Wheel choke used Yes/No

D-07 a) Portable extinguisher Yes/No

available in nominated places.

b) Sprinkler system in Yes/No

working condition.

D-08 House keeping in order Yes/No

D-09 Bonding of flange connection given Yes/No

D-10 Hose test date Yes /No

D-11 Last fire drill in this area done on -----------

 E. PUMP HOUSE/ COMPRESSOR ROOM

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------

E-01 Electrical connections apparently sound Yes/No

E-02 Earthing apparently proper Yes/No

E-03 Gauges on pumps/compressor Yes/No

in working condition, record pressure.

E-04 Drain/ vent connection cap in position. Yes/No

E-05 Safety guards in position Yes/No

E-06 Abnormal vibration/ excessive noise. Yes/No

E-07 Portable fire extinguisher in position Yes/No

E-08 Any visible sign of LPG leak or any Yes/No

unsafe conditions observed (record
under remarks column).

E-09 Housekeeping in order. Yes/No

E-10 Gas detection system working. Yes/No

E-11 Last fire drill in this area done on -----------

 F. FILLING SHED
F-01 No ignition sources visible in operating Yes/No
areas or area in vicinity.

F-02 Are the LPG cylinders empty or empty Yes/No

or filled, properly loaded/ unloaded and
handled to avoid impact, falling, horizontal
rolling etc.

F-3 Are earthing connection on filling Yes/No

carousel properly made.

F-04 Are the cylinder chain conveyors adequately Yes/No

lubricated to avoid metallic rubbing and friction.

F-05 Water in test bath is clean and maintained Yes/No

upto the required level.

F-06 Any sign of leakage of unsafe condition Yes/No

None of the filling guns or adapters used
for cylinder filling/emptying are leaking.
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
F-07 Are all the fire extinguishers available Yes/No
in accessible location.

F-08 All electrical connection apparently Yes/No

intact & safe.

F-09 Is the concentration level of gas checked Yes/No

with explosimeter twice a day in the filling
area in filled and empty cylinder area, pump/
compressor room. Record reading for sample
check.

F-10 Sprinkler system in working condition Yes/No

F-11 Housekeeping is in order. Yes/No

F-12 Rotary equipment/ coupling etc Yes/No

F-13 Gas detection system working. Yes/No

F-14 CVT is functional Yes/ No

F-15 Last fire drill in the area -----------

F-16 Vapour extraction system functional Yes / no

F-17 Emergency trip at Carousel functional Yes/ No

 G. CYLINDER STORAGE/ HANDLING
G-01 Are cylinders stacked properly in Yes/No
demarcated areas.

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

the end of the day. Record No. if any,
of the leaky unevacuated cylinder.

G-03 Safety cap fixed on cylinders in stock. Yes/No

G-04 Sprinklers functional

G-05 Cylinders loaded in to trucks through Yes/No

conveyors.

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

empty cylinders from tank trucks and
are in good condition.

G-07 Last fire drill in the area -----------

* Put specific observation wherever the conditions are not in line with specified
requirement levels.
 ANNEXURE 14 - II.

ELECTRICAL AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________ Dated ____________

AUDIT/ INSPECTION BY ______________________

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

A. ELECTRICAL SUBSTATION/ SWITCH ROOM

A-01 Is painted line diagram of power/ lighting distribution provided.

A-02 Is the equipment easily accessible for operation, inspection & maintenance.

A-03 MCC Panel condition :

a) Doors okay and closed

b) Dust/soot/ cobwebs not existed

c) Lugs existing at each cable, termination not loose.

d) Visual condition of switch contact fuse etc. O.K.

e) Control wiring condition satisfactory.

f) Jumper condition between bus and distribution okay.

g) Grounding OK

h) Alarm/ trip circuit working.

A-04 Live parts of equipment made inaccessible by barriers/ shrouds.

A-05 No temporary electrical connection existing.

A-06 Condition of cable duct

a) Cables are on rack

b) Cable deck clear

c) Sealing of duct

d) Cable identification tags.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

A-07 Rubber mats (with ISI mark) existing are enough in number.

A-08 Protective relays set at recommended values.

A-09 All fuses are of proper type and rating as specified in single line diagram.

A-10 Fire extinguishers are of proper type and are in working condition.

A-11 Lighting condition OK (fixtures/ tubes/ wtiches etc.)

A-12 Emergency lighting system in order.

A-13 All energised equipment provided with caution boards.

A-14 Condition of transformer :

a) Grounding OK

b) No oil leak

c) Silica gel OK

d) Oil level OK

e) Terminal box earthing OK

f) Oil/winding temp. OK

g) Periodic oil quality test conducted.

A-15 Whether location/type of transformer in conformity with area classification drawings.

A-16 Housekeeping is good.

B. MOTORS IN PUMP HOUSE/ COMPRESSOR

ROOM/ FILLING & STORAGE SHED ETC.

B-01 Is double independent earthing connection for all motors provided.

B-02 Is grounding wire OK (not loose).

B-03 a) Is terminal box and gland OK

Flame-proofness maintained and not tampered.

b) Existing cable termination are proper

B-04 a) Is push button earthed properly and flame proof condition not tampered.
b) General condition of push button good.

B-05 Ground resistance at motor/ push button measured and found okay.
B-06 No motor abnormality

- Vibration/ bearing condition, faulty guard, fan condition,

excessive noise, high body temperature.

B-07 Existing preventive maintenance schedule OK.

B-08 a) Earthing resistance test schedules/ records satisfactory.

b) Earthing pit condition OK

B-09 i) Carousel machine frame to filling gun earthing continuity maintained.

ii) Carousel machine frame to central column earthing continuity OK.

B-10 Conveyor system bonding and earthing maintained.

B-11 First-aid chart for treating electrical shocks displayed prominently in MCC room.

C. UNIT LIGHTING

C-01 All lighting fixture flame proof as per area classification.

C-02 Whether flame proof condition of fixtures ensured ?

C-03 Whether proper earthing of fixture provided ?

C-04 Condition of wiring good.

C-05 Does water enter and accumulate in fixture distribution boxes etc ?

C-06 Whether lighting DB, switches, MCB well maintained ?

C-07 Any other unsafe point observed.

D. MAST LIGHTS (AREA LIGHTING)

D-01 Whether grounding of mast OK ?

D-02 Condition of junction boxes, switch board, fuses etc. OK

D-03 Approach to electrical installation and ladder good and safe.

D-04 Condition of flood lights :

a) Is gasket present ?

b) Is glass cover in good condition ?

c) Is control gear condition OK

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

D-05 Is earthing electrode of mast OK and its

connection with mast proper ?

E. TANKAGE AREA, PIPELINES, LOADING/

UNLOADING GANTRY

E-01 Are LPG pipelines provided with flange earth jumper connection
for electrical continuity?

E-02 Are earthing provision on LPG storage vessel well maintained ?

E-03 Condition of grounding electrode OK

E-04 Continuity of location, hoses maintained.

E-05 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.)

E-06 Connection of earth-bonding of railway track OK.

F. GENERAL

F-01 a) Area classification drawings duly approved by CCE, Nagpur?

b) Conditions if any, specified by CCE for electrical substation, switch

room etc. and their compliance.

F-02 Certificate in respect of FLP for each electrical equipment- records maintained.

F-03 Earthing network diagram available and site checks done from time to time.

F-04 Records for electrical testing/ checks maintained upto date.

F-05 Work permit system is effective and records are maintained.

Note : For developing a detailed check list refer OISD-GDN-145-09 document on safety audit check list for
electrical system.
 ANNEXURE 14- III

DETAILED SAFETY AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________ Dated ____________

AUDIT/ INSPECTION BY ______________________

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

A. BULK STORAGE AREA

A-01 Area under the sphere is having concrete pavement with proper
slope leading to shallow sumps.

A-02 a) Water drain chamber provided away from shadow of sphere.

b) Double valves on water drain line provided: the first one

(near to chamber) of quick shut off type and the other are
throttle type (Globe valve).

c) Safety instructions for draining operations displayed prominently

and water draining is done under supervision.

A-03 a) Relief valves provided with isolation valves.

b) Isolation valves in locked open condition.

A-04 Last safety valve test done as per statutory requirement and record maintained.

A-05 Remote operated valves provided on liquid inlet/outlet lines with push
buttons/ indication control and located at safe distance.

A-06 Two independent level instruments and high level alarm provided in
storage vessels and are in working condition.

A-07 All leg supports of Horton spheres/ vessels encased in concrete with
fire proof coating/ motor.

A-08 a) Sprinkler system provided on all vessels and are in working condition.

b) Deluge valve is remote operated and is located at safe distance from storage vessels.

A-09 Gas detection system provided and in good working condition (To be checked).

A-10 a) All flame-proof electrical fittings provided.

b) Earthing connections properly maintained.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

A-11 Statutory inspection/ hydro test records maintained.

B. PUMPS/ COMPRESSORS AREA

B-01 a) All electrical motors/ push buttons properly earthed and flame proofness maintained.

b) Flame proof light fittings provided.

c) Earthing resistance test conducted periodically and record maintained.

B-02 Venting through high rise vents or flare systems only.

B-03 a) No leakage from mechanical seals.

b) Double seal provided to minimise chances of leakage.

c) No abnormal sound and vibration from motor and bearings condition OK.

d) Coupling guards in position.

B-04 Drain points/ vent points/ sample points capped when not in use.

B-05 Operating instructions Do's and Don'ts displayed.

B-06 Long range monitors/ fixed water spray with proper throw/ sprinkler system
installed and in good condition.

C. CYLINDER FILLING/ STORAGE AREA

C-01 LPG bottling facilities located at safe distance from other facilities with
minimum ingress to trucking traffic.

C-02 Facilities provided for positioning of trucks 15 m away from storage shed
for receipt/ loading of cylinders.

C-03 Transfer of cylinders from truck to conveyor.

- Telescopic conveyor

- Trolley use

C-04 Proper purging facilities provided for new/ retested/ reconditioned cylinders

C-05 a) Inspection/ visual checks followed for spurious/ defective cylinders and
record maintained.

b) Segregated storage marked for -

i) Spurious
 ii) Hot repairs

iii) 5/7 years testing due cylinders

iv) Other defects

C-06 Gross weight filling :

- Auto cut off after completion of filling

C-07 Hoses are of approved quality and periodically tested.

C-08 Vapour extraction system provided for carousel and system is working satisfactorily.

C-09 100% weight checking facilities provided and in use.

C-10 Accuracy of check scales being checked daily and records maintained.

C-11 CVT checks done for `O' ring defects.

C-12 Check facilities provided for valve seat leakage and working satisfactorily.

- CVT with verifier

- Electronic

C-13 Proper facilities/ correction conveyor loops are provided for defective cylinders
(`O' ring & weight correction).

C-14 Bung leak/ body leak check are done through in-line water bath with caps in position.

C-15 Capping/ Pilfer proof sealing facilities provided.

- Aluminium foil

- PVC sealing

C-16 Neck label being put

- Plastic

- Paper

C-17 Quality control checks (SQC) carried out/ records maintained.

C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily.

C-19 Cold repairs facilities evacuation for evacuated depressurized cylinders.

- Valve removal/ replacement by use of torque wrench with proper settings.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
- PTFE tape/ paste or other suitable sealing compound used.

C-20 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys.

C-21 Mastic flooring provided on the floor storage area to avoid accidental sparks.

C-22 a) Cylinders stacked in vertical position

b) Stacking discipline with small lots of 4 rows and 25 cylinder lengths

followed, a minimum access path of 1M maintenance on both sides of 4 rows.

C-23 Cylinders are inspected for leakage with explosimeter or portable leak detector.

C-24 Sprinkler system provided in the storage shed and in working condition.

D. BULK LPG UNLOADING FACILITIES

D-01 Whether the location and layout of the facilities meet statutory distances/ design guidelines.

D-02 Effective earthing system provided and working satisfactorily.

D-03 a) Hoses used are of approved quality standard.

b) They are periodically tested and replaced after prolonged use.

D-04 Hose contents after unloading are released to high vent located at safe distance.

D-05 Blocked hoses/ pipelines provided with TSVs.

D-06 a) Sprinkler system provided on the railway siding/ tank truck loading/
unloading area are and working satisfactorily.

b) Fire hydrant/ long range monitors provided.

D-07 Remote operated valves provided on liquid loading headers.

D-08 a) Weigh bridge provided on liquid loading headers.

b) Calibration certificate obtained from Weights & Measures Authorities available.

D-09 a) Vehicles are properly checked for any sign of leak, proper fittings and
other valid documents.

b) 2 Nos. of fire extinguishers (DCP type).

c) Explosive licence, safety certificate, fitness certificate.

d) Proper earthing cable with clamps.

D-10 Loading/ unloading procedures along with safety precautions prominently displayed.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

E. SAFETY/ FIRE PROTECTION SYSTEM

E-01 Fire organisation chart prepared, updated and displayed.

E-02 Contingency plan updated for tackling major emergencies.

E-03 Important telephone Nos. of State Fire Services, Police, District Admn./
other offices etc. displayed.

E-04 Are fire emergency mock drills conducted periodically and records maintained.

E-05 Work permit system for repairs/ hot jobs etc. followed and records maintained.

E-06 a) Fire water network (layout displayed)

- above ground/ under ground

- corrosion protection

- material of construction

b) Pressure at farthest end and flow

c) Condition of hydrants, long range monitors. Maintenance and inspection schedules

followed and records maintained.

d) Provision of sprinkler system and testing schedules for checking :

- Adequate water distribution : spray nozzle are clean.

- Defective nozzles to be identified for replacement.

- Deluge valve operation satisfactory.

e) Strainers provided at inlet of deluge/ sprinkler water supply main piping. Strainers are
cleaned periodically and records maintained.

E-07 Fire Water Pumps :

- Adequacy of capacity, nos. discharge pressure etc.

- Auto starting (system security logic) provided.

- Working jockey pump operating parameters maintained.

E-08 Static water storage tank -

- capacity and adequacy

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

- Source of water supply and rate of replenishment.

E-09 a) Fire vehicles well maintained.

b) Mutual aid scheme with neighbouring industries/ district

authorities existing.

E-10 a) Fire extinguishers - type, make, capacity, location, provision of

tamper seals on retainer clips.

b) Maintenance procedures/ records of fire extinguishers.

E-11 a) Fire alarm and communication system working satisfactorily.

b) Testing schedule/ maintenance.

E-12 Protective clothing :

- Availability of special fire fighting suits (Aluminised suits)

- Breathing apparatus & its upkeep

- Water jel blankets.

- Use of nylon clothes prohibited.

E-13 Automatic Gas Detection System :

- Working satisfactorily

- Regularly tested.

E-14 No smoking cautions/ signs in Hindi/ English local languages displayed at prominent places.

E-15 First aid facilities maintained.

E-16 a) Emergency lighting system provided in strategic locations and system working satisfactorily.

b) Flame-proof torches available

F. MANPOWER AND TRAINING

F-01 Supervisory/ managerial cadre staff fully trained in all aspects of LPG plant
operations, Disaster control/ emergency handling.

F-02 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

F-03 Training programmes are organised periodically in LPG operations;

fire fighting/ emergency handling etc. for

a) Regular staff

b) Contractor workmen

c) Security staff

d) Tank truck operators/ drivers

F-04 All activities are effectively supervised with available manpower.

F-05 a) Operating manuals and standing instructions provided to working personnel.

b) Small handy safety booklets distributed to all including contractor employees

in English/ Hindi/ Local language.

F-06 Important Do's and Don'ts displayed prominently in operation areas.

G. GENERAL

G-01 a) Plant approach/ access roads well maintained and at least two emergency
exits are there.

b) Fencing/ wall around the plant is in proper condition.

c) Segregated parking area for LPG trucks outside the plant.

d) Adequate escape route available for operational facilities.

G-02 a) Strict security checks employed for compliance to safety regulations.

b) Spot checks being done.

G-03 a) Valid CCE licences available for :

- Storage of LPG

- Storage of LPG cylinders

- Filling of LPG cylinders

- Storage of HSD in tanks for running DG sets/ fire water engines.

- Layout plan approved by CCE(layout plan updated and approved by CCE).

G-04 Accident records maintained and updated.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
G-06 Hot work permit/ clearance issued - proper procedures followed and
documents maintained.

G-07 Following manual/ documents available:

a) LPG operating manual.

b) Safety and Fire Prevention manual

c) Emergency/ disaster control plan

d) Operation/ Inspection manual of equipment supplied by vendors.

e) Gas Cylinders Rules, 1981, SMPV Rules 1981 and other relevant
BIS Standards with latest amendments.

G-08 a) Records of periodic testing of hoses/ replacement.

b) Testing records of Pn relief valves/ pop action valves.

c) Inspection records of underground pipelines etc.

d) Weights & Measures certificates.

G-09 Updated P&I Diagrams, drawing of layout and other facilities available.

G-10 Records of "Daily Safety Audits" reviewed. Corrective action taken.

G-11 General housekeeping standards : area/ facility wise.

G-12 Pipeline colour code system maintained.

 ANNEXURE 14- IV

INSPECTION & MAINTENANCE SYSTEM AUDIT

LOCAL _______________ DATED: _________

AUDIT/ INSPECTION BY ________________

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

A. GENERAL

A-01 Whether standard system of inspection/ maintenance schedule

developed and followed and records maintained.

A-02 Whether equipment documents supplied by vendors are readily

available and recommended maintenance procedures are strictly
adhered to.

A-03 Whether spare parts for different equipment/ machinery are maintained.

A-04 Whether data card/ history records of static and rotary equipment are
maintained (as per OISD Std.127/28).

A-05 Whether proper work permit system is followed for maintenance jobs and
records maintained.

A-06 Whether personnel protective equipment such as hand gloves, safety shoes,
safety helmet etc. provided to the concerned workmen and their use is ensured
(OISD Std.-155).

A-07 Fire fighting equipment and portable fire extinguishers periodically checked /
tested as per maintenance schedules & records maintained (OISD Std.-142).

A-08 Fire alarm/ communication system scheduled testing & maintenance ensured.

A-09 Whether Explosimeters are periodically checked and calibrated.

A-10 Whether continuous monitoring devices are periodically checked and calibrated.

A-11 Whether exhaust fans and other ventilation devices are properly maintained and
regularly used.

A-12 Whether inspection/ testing of pressure vessels carried out periodically as per statutory
requirements and records maintained.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

B. BULK STORAGE HANDLING FACILITIES

B-01 Whether design of pressure storage vessels conform to relevant
BIS/BS/ASME code with standard engineering practices. All
required fittings/ instruments/ safety valves have been provided.

B-02 Whether inspection/ test certificate at the time of original fabrication

available and subsequent inspection/ hydraulic test carried out as per
SMPV Rules 1981 of CCE and records maintained. Guidelines of
OISD Standard-128 followed for detailed inspection of pressure vessels.

B-03 Annual inspection and testing of safety valves carried out at proper set
pressure and records maintained.

B-04 All instruments, level indicators, pressure and temperature gauges, ROVs
are maintained in working condition following daily scheduled checks,
periodic calibration and preventing maintenance schedule.

B-05 Regular operation checks are carried out on pumps/ compressors

(condition of bearings/ mechanical seal/ abnormal sound etc. as
per OISD STD-119, 120).

B-06 Preventive maintenance and servicing schedules for pumps and

compressors for daily/ weekly/ monthly/ yearly are checked and
records maintained.

B-07 Gas detection system is checked and calibrated periodically. Audio

visual alarm/ security logic system maintained in working condition.

B-08 Fire water system & sprinkler spray system checked/ tested periodically
and maintenance jobs carried out and records maintained.

B-09 LPG bullets/ spheres having fire proofing are periodically checked for cracks,
spalling/ bulging and suspected area are further inspected for presence of corrosion
etc. and corrective steps taken.

B-10 Earthing connections are periodically checked and good electrical contact is maintained.
Records of resistance testing as outlined in OISD Std-137 maintained.

B-11 Foundation/ Anchor bolts, ladders, stairways, platforms/ structurals checked periodically
for any corrosion/damage etc.

B-12 Annual testing of chain pulley blocks and other tool tackles is carried out by certified agency.

B-13 Weigh bridges calibration and certification done once in a year.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------

C. CYLINDER FILLING

C-01 LPG filling carousel - Drive unit, central column, running rails, etc.
are daily checked, scheduled maintenance (weekly, monthly, quarterly,
annual) are carried out and records maintained.

C-02 Introduction/ Ejection devices and filling machines are checked daily and
scheduled maintenance/ overhaul work carried out.

C-03 Checking of pin travel done regularly and records maintained.

C-04 Check scales are well maintained and calibrations carried out on daily basis
with standard weights.

C-05 Calibration of CVT/DCVT detectors being done regularly and maintenance

schedule followed.
15.0 REFERENCES

15.1 BIS CODES PERTAINING TO LPG OPERATIONS

--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------

IS:2-1960 - RULES FOR ROUNDING OFF NUMERICAL VALUES

IS:5-1978 - COLOURS FOR READY MIXED PAINTS & ENAMELS

IS:1196-1978 - CODE OF PRACTICE FOR LAYING BITUMEN MASTIC

FLOORING

IS:1432-1959 - GENERAL REQUIREMENTS FOR WEIGHING

INSTRUMENTS

IS:1435-1991 - PLATFORM WEIGHING MACHINE

IS:1436-1991 - WEIGHBRIDGES

IS:1437-1967 - AUTOMATIC WEIGHING MACHINES

IS:1448(P:70-1968) - RESIDUE IN LPG

IS:1448(P:71-1979) - VAPOUR PRESSURE OF LPG

IS:1448(P:72-1968) - VOLATILITY OF LPG

IS:1448(P:73-1968) - HYDROGEN SULPHIDE IN LPG

IS:1448(P:74-1968) - DRYNESS OF LPG

IS:1448(P:75-1968) - ODOUR OF LPG

IS:1448(P:76-1968) - DENSITY OF LPG

IS:1448(P:111-1983) - ANALYSIS OF LPG AND PROPYLENE

CONCENTRATES BY GAS CHROMATOGRAPHY

IS:2148-1981 - FLAMEPROOF ENCLOSURES FOR ELECTRICAL

APPRATUS

IS:2206 - FLAME PROOF ELECTRIC LIGHT FITTINGS

IS:2206(PART 1)-1984 - WELL GLASS AND BULKHEAD TYPES

IS:2206(PART 2)-1976 - FITTINGS USING GLASS TUBES

IS:2808-1964 - METHOD FOR COMPUTATION OF CAPACITY TABLES

FOR PRESSURIZED STORAGE TANKS
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------

IS:2825-1969 - CODE FOR UNFIRED PRESSURE VESSELS

IS:2827-1976 - METHODS FOR CALIBRATION OF PRESSURIZED

STORAGE TANKS

IS:3196(PART 1)-1992 - WELDED LOW CARBON STEEL GAS CYLINDER

EXCEEDING 5 LITRE WATER CAPACITY FOR LOW
PRESSURE LIQUEFIABLE GASES CYLINDERS FOR
LPG.

IS:3465-1966 - JOINTING COMPOUND FOR USE IN LPG APPLIANCES

AND INSTALLATIONS

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

GAS.

IS:4093-1981 - NON-REFILLABLE LPG CONTAINERS

IS:4246-1984 - SPECIFICATION FOR DOMESTIC GAS STOVES FOR

USE WITH LIQUEFIED PETROLEUM GASES

IS:4379-1981 - IDENTIFICATION OF CONTENTS OF INDUSTRIAL GAS

CYLINDERS

IS:4576-1978 - SPECIFICATION FOR LIQUEFIED PETROLEUM GASES

IS:4784-1968 - LOW PRESSURE REGULATORS FOR USE WITH

BUTANE GASES

IS:4785-1968 - LOW PRESSURE REGULATORS FOR USE WITH

PROPANE GAS

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

WITH LPG

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

STRUCTURES FOR EXPLOSIONS ABOVE
GROUND

IS:5116-1985 - GENERAL REQUIREMENT FOR DOMESTIC AND

COMMERCIAL EQUIPMENT FOR USE WITH LPG

IS:5571-1979 - GUIDE FOR SELECTION OF ELECTRICAL EQUIPMENT

FOR HAZARDOUS AREAS

IS:5572 - CLASSIFICATION OF HAZARDOUS AREAS (OTHER

THAN MINES) FOR ELECTRICAL INSTALLATIONS
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------

IS:5572(PART 1)-1978 - AREAS HAVING FLAMMABLE GASES AND VAPOURS

IS:5844-1970 - RECOMMENDATIONS FOR HYDROSTATIC STRETCH

TESTING OF COMPRESSED GAS CYLINDERS

IS:5845-1984 - CODE OF PRACTICE FOR VISUAL INSPECTION OF

LOW PRESSURE WELDED STEEL GAS CYLINDERS IN
USE

IS:5903-1970 - RECOMMENDATIONS FOR SAFETY DEVICES FOR

GAS CYLINDERS

IS:6044 - CODE OF PRACTICE FOR LPG TORAGE

INSTALLATIONS

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

INSTALLATIONS

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

STORAGE INSTALLATIONS

IS:6539-1972 - INSTRINSICALLY SAFE MAGNETO TELEPHONES FOR

USE IN HAZARDOUS ATMOSPHERES

IS:6665-1972 - CODE OF PRACTICE FOR INDUSTRIAL LIGHTING

IS:7142-1974 - WELDED LOW CARBON STEEL GAS CYLINDER FOR

LOW PRESSURE LIQUEFIABLE GASES, NOT
EXCEEDING 5 LT WATER CAPACITY

IS:7145-1973 - TECHNICAL SUPPLY CONDITION FOR TORQUE

WRENCHES

IS:7241-1981 - GLOSSARY OF TERMS USED IN GAS CYLINDER

TECHNOLOGY

IS:8198(PART 5)-1984 - CODE OF PRACTICE FOR STEEL CYLINDERS FOR

COMPRESSED GASES ; LIQUEFIED PETROLEUM GAS
(LPG)

IS:8374-1977 - SPECIFICATION FOR BITUMEN MASTIC, ANTI STATIC

ELECTRICALLY CONDUCTING GRADE

IS:8451-1984 - CODE OF PRACTICE FOR VISUAL INSPECTION OF

HIGH PRESSURE GAS CYLINDERS
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS:8737 - VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF
MORE THAN 5 LIT. WATER CAPACITY

IS:8737(PART 1)-1979 - VALVE FITTINGS FOR REPLACEMENT PURPOSES

IS:8737(PART 2)-1978 - VALVE FITTINGS FOR NEWLY MANUFACTURED LPG

CYLINDERS

IS:8776-1988 - VALVE FITTINGS FOR USE WITH LIQUEFIED

PETROLEUM GAS (LPG) CYL. UPTO AND INCLUDING
5 LIT WATER CAPACITY

IS:8790 - GENERAL REQUIREMENTS OF POWERED

INDUSTRIAL TRUCKS WORKING IN HAZARDOUS
AREAS

IS:8790(PART 1)-1978 - INTERNAL COMBUSTION ENGINES POWERED

TRUCKS

IS:8790(PART 2)-1979 - ELECTRIC BATTERY POWERED INDL. TRUCKS

IS:8867-1987 - SATURATED VAPOUR PRESSURE AND TEST

PRESSURE FOR LOW PRESSURE LIQUEFIABLE GASES
CONTAINED IN GAS CYLINDERS

IS:8868-1988 - PERIODICAL INSPECTION INTERVAL OF GAS

CYLINDERS IN USE

IS:9121-1979 - INSPECTION GAUGES FOR CHECKING TYPE 1 (SIZE 2)

TAPER THREADS OF GAS CYLINDER VALVES, TAPER
1 IN 16

IS:9122-1979 - INSPECTION GAUGES FOR CHECKING TYPE 2 TAPER

THREADS OF GAS CYLINDER VALVES, TAPER 3 IN 25

IS:9199-1979 - INSPECTION GAUGES FOR CHECKING TAPER

THREADS OF GAS CYL. VALVES, TAPER 60 DEGREE
INCLUDED ANGEL

IS:9200-1979 - METHOD OF DISPOSALS OF UNSERVICEABLE

COMPRESSED GAS CYLINDERS

IS:9281 - ELECTRONIC WEIGHING SYSTEMS

IS:9281(PART 1)-1979 - TERMS AND DEFINITIONS

IS:9281(PART 2)-1979 - METHODS OF MEASUREMENTS

--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------

IS:9281(PART 3)-1981 - REQUIREMENTS

IS:9281(PART 4)-1983 - CODE OF PRACTICE FOR USE &

INSTALLATION

IS:9583-1981 - EMERGENCY LIGHTING UNITS

IS:9639-1980 - CODE OF PRACTICE FOR VISUAL INSPECTION

OF LOW PRESSURE WELDED STEEL GAS
CYLINDERS IN USE

IS:9777-1981 - DATA SHEET FOR SELECTION OF

WEIGHBRIDGES FOR BULK HANDLING
EQUIPMENT

IS:9798-1981 - LOW PRESSURE REGULATORS FOR USE WITH

LPG

IS:9902-1982 - RECOMMENDED PRACTICE FOR LEAK

TESTING

IS:9975 - `O' RINGS

IS:9975(PART 1)-1981 - DIMENSIONS

IS:9975(PART 2)-1984 - MATERIAL SELECTION & QUALITY

ACCEPTANCE CRITERIA

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

TOLERENCES

IS:9975(PART 4)-1984 - TERMINOLOGY AND DEFINITIONS OF TERMS

IS:10733-1983 - ELECTRICALLY BONDED ROAD AND RAIL

TANKER HOSE OF RUBBER, RESISTANT TO
PETROLEUM PRODUCTS

IS:10908-1991 - FLEXIBLE RUBBER TUBING FOR LPG

IS:11498-1985 - LEVER TYPE DIA GAUGES

IS:12936-1990 - CODE FOR BASIC REQUIREMENTS FOR

DELIVERY PERSONS ENGAGED IN THE
DELIVERY OF LPG CYLINDERS
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS:13258-1991 - WELDED LOW CARBON STEEL CYLINDERS
EXCEEDING 5 LT WATER CAPACITY FOR
LOW PRESSURE LIQUEFIED PETROLEUM GAS
CODE OF PRACTICE FOR INSPECTION AND
RECONDITIONING OF USED LPG CYLINDERS

IS:13432(PART 1)-1992 - GAS LEAK DETECTOR FOR USE WITH LOW

PRESSURE LIQUEFIED PETROLEUM GAS
BURNING APPLIANCES SPECIFICATION

PART I – MECHANICAL TYPE

--------------------------------------------------------------------------------------------------------------------------------

ii. The Static and Mobile Pressure Vessels (Unfired) Rules-1981

iii. LPG (Regulation of use in Motor Vehicles) Order 2001

iv. Gas Cylinder Rules, 2003

v. API Standard 25 – Design and Construction of LP Gas Installations

vi. ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American
Society of Mech.Engrs., New York

vii. NFPA 58 : Storage and Handling of Liquefied Petroleum Gases

viii. NEPA 59 : LP Gases at Utility Gas Plants

ix. OISD-STD-105 : Work Permit System.

x. OISD-STD-113 : Classification of Areas for Electrical Installations at

Hydrocarbon processing and handling facilities

xi. OISD-STD-135 : Inspection of Loading/Unloading hoses for

Petroleum Products.

xii. OISD-STD-144 : Liquefied Petroleum Gas (LPG) Bottling Plant

Operations

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

Mounded Storage Vessels

xiv. OISD-STD-158 : Recommended Practices on Storage and Handling

of Bulk Liquefied Petroleum Gas (LPG)
xv. OISD-STD-159 : LPG Tank Trucks Requirements of Safety on
Design/ Fabrication & Fittings
xvi. OISD-STD-179 : Requirement of Safety for Compression, Storage,
Handling & Refueling of Natural Gas for Use in
Automotive Sector.

xvii. ASME B - 31.3 : Chemical Plant and Petroleum Refinery Piping

xviii. ASME B - 31.4 : Liquid Transportation Systems for Hydrocarbons,

Liquid Petroleum Gas, Anhydrous Ammonia and
Alcohols

xix. PD-5500 : Specification for unfired fusion welded pressure

vessels
Figure - I
Figure - II
Figure - III
Figure - IV
Figure - V
Figure - VI
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