OISD STANDARD - 160

FOR RESTRICTED
CIRCULATION

PROTECTION TO FITTINGS MOUNTED

ON
EXISTING LPG TANK TRUCKS

OISD - STANDARD - 160

First Edition, August, 1993

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
 OISD-STANDARD-160
First Edition
August, 1993.

FOR RESTRICTED
CIRCULATION

PROTECTION TO FITTINGS MOUNTED

ON
EXISTING LPG TANK TRUCKS

Prepared by:
COMMITTEE ON LPG TANK TRUCK MODIFICATIONS, DESIGN & OPERATION

OIL INDUSTRY SAFETY DIRECTORATE

2ND FLOOR, “KAILASH”
26, KASTURBA GANDHI MARG,
NEW DELHI - 110 001
 NOTE

OIL INDUSTRY SAFETY DIRECTORATE (OISD)

publications are prepared for use in the oil and gas industry
under the Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and 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 data contained in these documents,
OISD hereby expressly disclaims any liability or responsibility for
loss or damage resulting from their use.

These documents are intended only to supplement and

not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. Because of various

collaboration agreements, a variety of international codes, standards and
practices have been in vogue. Standardisation in design philosophies and
operating and maintenance practices at a national level was hardly in
existence. This, coupled with feed back from some serious accidents that
occured 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 and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety Directorate
(OISD) staffed from within the industry in formulating and implementing a
series of self regulatory measures aimed at removing
obsolescence,standardising and upgrading the existing standards to ensure
safe operations. Accordingly, OISD constituted a number of functional
committees of experts nominated from the industry to draw up standards
and guidelines on various subjects.

The present document on “Protection to Fittings Mounted on Existing

LPG Tank Trucks’ has been prepared by the Committee on “LPG Tank
Truck Modifications, Design and Operation’. This document was prepared
based on the accumulated knowledge and experience of industry members
and the various national and international codes and practices.

Correspondence from industry members may be addressed to:

The Co-ordinator
Committee on
LPG Tank Truck Modifications, Design and Operation
Oil Industry Safety Directorate,
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg,
NEW DELHI - 110 001.
 COMMITTEE

ON

LPG TANK TRUCK MODIFICATIONS, DESIGN AND OPERATION

LIST OF MEMBERS
--------------------------------------------------------------------------------------------------------------------------------
NAME DESIGNATION/ORGANISATION STATUS
--------------------------------------------------------------------------------------------------------------------------------
S/Shri

R.K. Singh DGM (Distribution), BPCL Leader

V.K. Allawadi Chief LPG Mgr.(OPS), IOCL Member

S.V. Sahni Chief OPS, Mgr., HPCL Member

S.C. Gupta Joint Director (OISD) Member-Co-ordinator

--------------------------------------------------------------------------------------------------------------------------------
In addition to the above several other experts from industry contributed in the
preparation, review and finalisation of this document.
 PROTECTION TO FITTINGS MOUNTED ON
EXISTING LPG TANK TRUCKS

CONTENTS
------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION
------------------------------------------------------------------------------------------------------------------------
1.0 INTRODUCTION

2.0 SCOPE

3.0 LPG TANK TRUCK FITTINGS

3.1 OPENINGS/NOZZLES

3.2 SAFETY RELIEF VALVE (SRV)

3.3 EXCESS FLOW CHECK VALVE (EFCV)

3.4 PRESSURE GAUGE

3.5 FIXED LEVEL GAUGE/DRAIN NOZZLES

3.6 ROTO GAUGE

3.7 LIQUID/VAPOUR PIPING

3.8 HEIGHT BARRIER

3.9 MOUNTING

GLOSSARY

ANNEXURES
--------------------------------------------------------------------------------------------------------------------------------
 PROTECTION TO FITTINGS MOUNTED ON
EXISTING LPG TANK TRUCKS
1.0 INTRODUCTION
A large number of road fed bottling
plants have been put up by the Oil Industry
during the last five years. The industry fleet
of tank trucks has also increased
considerably during the last decade.
Prior to 1981, there were no
separate statutory regulations governing
design, fabrication, operation and licensing
of LPG tank trucks. After introduction of
SMPV Rules - 1981, old tank trucks which
were conforming to different codes and
standards have been modified to the extent
possible and new tank trucks have been
fabricated and licensed in line with the
SMPV Rules, 1981 and Petroleum Industry
Standards.
Industry, CCEE and OISD have
been analysing LPG tank truck accidents
from time to time. Based on the experience
gained some modifications have already
been introduced on piece meal basis by the
Industry members individually. Various road
accidents involving LPG tank trucks have
established that their fittings get damaged
due to heavy impact in the event of an
accident resulting in leakage of LPG which,
in turn, poses serious threat to public life
and property. There has hardly been any
damage to the bullets and it is the fittings
which mostly give way.
An OISD committee consisting of
members drawn from Oil Industry therefore
discussed this subject in detail and after
deliberations has identified the problems
and prepared these recommendations for
improvements of the existing LPG tank
truck fleet to prevent leakage of LPG in the
event of LPG tank trucks overturning on the
road.
2.0 SCOPE
SMPV Rules - 1981 lay down
design, fabrication, operating procedure for
carrying compressed gases.
This standard stipulates actions
required for improving some of the
provisions of these rules like fittings,
pressure relief, emergency shut off valves,
liquid level gauging device and pressure
gauge so as to reduce chances of accidental
damage to various fittings mounted on LPG
tank truck.
Some of the recommendations
envisage updating existing Standards and
would require amendment of the exiting
Statutory Rules Viz. Static and Mobile
Pressure Vessels (unfired) Rules 1981.
The provisions which are not in
conformity with SMPV Rules- 1981,
therefore will be made applicable after the
Rules are formally amended.
The standard excludes new tank
trucks which will be fabricated in coming
years as they will be conforming to more
stringent standard which is currently under
development.
3.0 LPG TANK TRUCK FITTINGS
3.1 OPENINGS/NOZZLES
LPG tank truck is provided with the
following openings/nozzles:
I) Safety Relief valves
ii) Excess flow check valves in
the liquid and vapour lines
and pressure gauge nozzle.
iii) Pressure gauge (Provided
in the vapour space of the
vessel)
iv) Temperature gauge
(Provided in the liquid
space)
v) Rotogauge (to measure the
percentage of liquid in the
vessel.

vi) Manhole with cover.
vii) Fixed level gauge
viii) Drain point at the bottom.
ix) Liquid/Vapour manifold.
3.2 SAFETY RELIEF VALVE (SRV)
Each tank truck is provided with two or more
SRVs for providing the relieving capacity
under excess pressure. The SRVs are
mounted on the top surface of the vessel
either in the recessed fittings or at the shell
level with head projecting out. In the event
of an accident causing the tank truck to fall
off the road and topple, there is a possibility
that Safety Relief Valves which projects out
can hit against a hard surface and get
damaged or even come out of the nozzles
as adequate protection as envisaged in the
rules has not been provided. To prevent this
from happening, the following measures
shall be adopted:
I) The SRV of an LPG tank truck
shall be provided in a recessed
cup formation. Alternatively, it
may be adequately protected by
providing a guard allround as
per the CCE approved
procedure for modification
(Ref.Annexures I and II) and
design given in Fig.No.1.
Suitable rain caps shall also be
provided in case of recessed
cup.
ii) SRV shall be replaced by a new
SRV every ten years. If found
defective during any of the
earlier yearly inspections, it
shall be replaced earlier.
iii) Unstamped (Uncertified) SRVs
shall not be used.
iv) At the time of yearly
inspection/each opening, the
threads of the valve and
coupling shall be checked by an
Inspection Agency/Competent
Person using “Go/No Go”
gauges. SRV shall be tightened
to the required torque specified
for its size so as to obtain
minimum engagement of 5-6
threads by hand tightening and
another 1-2 threads by spanner
tightening.
LPG tank trucks shall carry SRV
certificates issued by Inspection
Agency/Competent Persons which apart
from test date and set pressures, shall also
include the following information:
a) The number of threads
engaged in its coupling.
b) The number of threads outside
its coupling.
c) Torque applied for tightening.
d) Identification mark of SRVs.
3.3 EXCESS FLOW CHECK VALVES
(EFCVs.)
Each liquid/vapour pipeline and
pressure gauge nozzle shall be provided for
excess flow check valve. Excess flow
check valve shall be of hinge unit type or
internal flow type.
EFCVs before fitment, shall be
checked using “Go/No Go”, gauges and
shall be tightened to the required torque
specified for the size to obtain minimum
engagement of 5-6 threads through hand
tightening and another 1-2 threads by
spanner tightening. In addition to operation
checks on EFCV at loading/unloading basis,
EFCV shall also be examined for its proper
operation alongwith SRV, once a year by
competent person. Each EFCV shall be
replaced by a new EFCV every ten years. If
found defective during operation or any of
the earlier inspection, it shall be replaced at
that time itself i.e., earlier than ten years.
3.4 PRESSURE GAUGE
The functional parts of EFCV of
pressure gauge shall remain within its
coupling. In addition, the pressure gauge if
not provided in recessed cup shall be
adequately protected with a shroud.
3.5 FIXED LEVEL GAUGE/DRAIN
NOZZLES
With experience these fittings have
been found to be redundant. Therefore, to
minimise the openings in the tanker, these
fittings shall be plugged (After necessary
amendment to the SMPV Rules, 1981).
Plugging shall be approved by Competent
Persons/Inspection Agency.
3.6 ROTO GAUGE
These fittings shall be housed in a
recessed cup formation, when fitted on
longitudinal sides of vessel to avoid any
accidental damage to bleed valve or seal.
The rotogauge shall also be protected with a
provision of hinged cover of 5 mm thick
plate.
3.7 LIQUID/VAPOUR PIPING
The pipes shall conform to the
ASTM A-106B, schedule 80 standards.
Liquid/Vapour piping shall be single piece
and the end flanges shall be of ASA-300
rating. Metal jacketted gasket shall be used
for the piping system.
In addition, sturdy guard shall be
provided between the propeller shaft and
the elbow of the piping. Adequately strong
arrangement shall be provided to fix the
piping rigidly to the bullet/chassis to
minimise the effect of vibrations.
3.8 HEIGHT BARRIER
Whenever cabin height is less than
the height of the vessel and fittings on top of
it, a height barrier shall be provided all
along the width of the cabin in the form of a
cage either 50mm diameter pipe or 50 X 50
X 3 MM angle frame on the top of vessel
and within the height regulation of Road
Transport Authority.
3.9 MOUNTING
U-Bolts used for mounting of the
mounting of the pressure vessel on the
chassis shall conform to ASTM 193 B7 and
the nuts to A194 Gr.2H. The number and
size of bolts should be as per the design
requirements for the particular chassis and
load thereon.
GLOSSARY
1. The term “LPG” i.e., Liquefied
Petroleum Gas as referred in
this standard refers to a
mixture of gaseous
hydrocarbon fractions which
get into liquid phase under
pressure at ambient
temperature with a maximum
RVPof 120 psig at100Deg.
F(8.45 Kg/CM2g at 37.8
Deg.C) conforming to IS-4576.
2. The term “Bullet” refers to
horizontal cylindrical pressure
vessels with dished ends
on LPG service.
3. “Inspection Agency/Competent
Person” means the Agency or
Person recognised by the
Statutory Authority for the
purpose of inspecting the
vessel and its fittings in
accordance with the approved
Design, Specifications or Code
and mandatory requirements.
4. “Statutory Authority” in this
case is normally Chief
Controller of Explosives (CCE)
and/or his representatives only.
 ANNEXURE - I

PROCEDURE * FOR MODIFICATION TO

EXISTING LPG ROAD TANKERS

I) Degas the storage vessel (Bullet ) taking standard safety precautions.

ii) Remove the fittings.

iii) Fabricate the pad plates/protection shroud plates/gussets plates as shown in draining B-
1382 (Rev-A). All gas out edges to be ground smoothly. Check for laminations, if any in
the plates.

iv) Weld the pad plates over the Bullet and then the shroud plates/gussets to the pad plate
strictly as shown in drg.: B-1382 (Rev-A) using low hydrogen 7018 Electrodes. Check for
thickness of weld with standard welding gauge.

v) Locally stress relieve the area around the safety fittings.

vi) Carry out pneumatic test of the bullet at 6 Kg/Cm2 after fixing all the fittings.

vii) Test all fillet welds with magnetic particle test.

viii) Hydrotest the Bullet up to test pressure.

ix) The entire work to be supervised and certified by CCOE approved third party Inspection
Agency.

* (Approved by CCE)
 ANNEUXRE -II

CALCULATIONS FOR SUITABILITY OF SHROUD AROUND SAFETY VALVES

REF. DRAWING OF SHROUD ARRANGEMENT (B 1382 REV. - 0)

DESIGN DATA : MAX.SIZE & DIA. ROAD TANKER AT 40 KMPH TOPPLING

OVER ASSUME MAX. LOADING DUE TO
MOTION=3G

TANK : 2350 mm I/D X 9254 mm Overall Length, mounted on Double

Axle Trailor

: Total Payload = 18000 Kgs (39672 lbs)

: Permissible

GLW. = 35000 Kgs (77140 lbs)

EFFECTIVE WEIGHT : GLW-(Wt.of Cabin + Prime Mover + Vth Wheel)

= 35000 Kgs.
(-) 6000 Kgs.
= 29000 Kgs. = (63916) lbs)

SHROUD - MOC : CS A 515 Gr.70, Shear Stress 1/3 of UTS

: i.e, 1/3 of 70,000 psi

: Stress Value “S”
: Length “L” 1000mm = 40”
: Width ‘B’ 600 mm = 24”

:’E’ = Joint efficiency for butt weld (CI UW - 12)

= 0.6

: R = Height of shroud above C.G. of Tank

= 50”

THICKNESS ‘’t’’ UNDER : 3XW

t= ------------------------ (3G effect)
2(L + B) X S X E
 : = 3 X 63916
----------------------------------- = 0.107”=2.7mm.....(1)
2(40+20) X 23333 X 0.6
‘‘t” DUE TO THE BENDING
MOMENT : WxR 63916 x 50
-------------------- = ---------------------------
(L x B)XSXE 960 X 23333 X 0.6

= 2237 = 6.04 mm ......(2)

TOTAL THICKNESS REQUIRED =2.7+6.04 = 8.74mm
Provided 10mm (Safe)

CALCULATIONS FOR SUITABILITY OF SHROUD AROUND SAFETY VALVES

REV
DATE: 21-3-92 A-1504
0