Oisd-Std-144 PDF

Sr.
Number:OISD/DOC/2015/393
Page No.I
OISD STANDARD - 144

Second Edition, October 2005
Amended Edition July 2008
FOR RESTRICTED
CIRCULATION ONLY
LIQUEFIED PETROLEUM GAS (LPG)

INSTALLATIONS
Prepared by
FUNCTIONAL COMMITTEE ON
Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2015/393
Page No.II
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is
essential for sovereignty and prosperity of the country. As the industry essentially deals with
inherently inflammable substances throughout its value chain – upstream, midstream and
downstream – Safety is of paramount importance to this industry as only safe performance at all
times can ensure optimum ROI of these national assets and resources including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian
petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of
Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of
constantly updated world-scale standards for design, layout and operation of various equipment,
facility and activities involved in this industry. Moreover, OISD was also given responsibility of
monitoring implementation status of these standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and
participative process of development of standards – starting with research by in-house experts
and iterating through seeking & validating inputs from all stake-holders – operators, designers,
national level knowledge authorities and public at large – with a feedback loop of constant
updation based on ground level experience obtained through audits, incident analysis and
environment scanning.
The participative process followed in standard formulation has resulted in excellent level of
compliance by the industry culminating in a safer environment in the industry. OISD – except in
the Upstream Petroleum Sector – is still a regulatory (and not a statutory) body but that has not
affected implementation of the OISD standards. It also goes to prove the old adage that self-
regulation is the best regulation. The quality and relevance of OISD standards had been further
endorsed by their adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content

requiring its operation to keep pace with the relevant world scale standards & practices. This
matches the OISD philosophy of continuous improvement keeping pace with the global
developments in its target environment. To this end, OISD keeps track of changes through
participation as member in large number of International and national level Knowledge
Organizations – both in the field of standard development and implementation & monitoring in
addition to updation of internal knowledge base through continuous research and application
surveillance, thereby ensuring that this OISD Standard, along with all other extant ones, remains
relevant, updated and effective on a real time basis in the applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides
other issues, calls for total engagement from all levels of the stake holder organizations, which
we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director

Page No.III
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 :

Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Page No.IV
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.
Page No.V
FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)
NAME ORGANISATION
LEADER
Sh. R. Krishnan Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS
Sh. A.N. Biswas Deptt. of Explosives, Nagpur
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
Page No.VI
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
Page No.VII
CONTENTS
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SL. NO. DESCRIPTION PAGE NO
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1 Introduction 1
2 Scope 2
3 Definitions 2
4 Statutory Rules/ Regulations 4
5 Installation Layout 5
6 Design Considerations 11
7 Storage & Handling of Bulk LPG 24
8 Bottling Operations 44
9 Maintenance & Inspection 48
10 Statutory Testing of LPG Cylinders 71
11 Fire Protection Facilities 77
12 Gas Monitoring System 91
13 Emergency Management Plan 94
14 Safety Audit 104
15 References 128
---------------------------------------------------------------------------------
OISD – STD – 144 Page No. 1
INSTALLATIONS

INSTALLATIONS
1.0 INTRODUCTION
Liquefied Petroleum Gas (LPG) is a mixture of light hydrocarbons primarily C3 & C4

derived from petroleum, which is gaseous at ambient temperature and atmospheric
pressure, is liquefied at ambient temperature with application of moderate pressure. LPG
due to its inherent properties is susceptible to fire, explosion and other hazards. Such
hazards can have an impact on the property, equipment, plant personnel and public.
Liquefied Petroleum Gas (LPG) handling, bottling and distribution throw major
challenges due to its inherent properties. Major incidents i.e. fires/explosions in LPG
facilities in world have underlined the need for total in depth review of design,
procedures, maintenance, fire fighting and safety aspects in LPG handling.
The oil and gas industry over the years have learnt lessons from fires and explosions and
have been updating and standardising design, operations, bottling and distribution of
LPG.
Some of the important properties of LPG are as below :
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times
heavier than air. It is readily liquefied under moderate pressures. The density of the
liquid is approximately half that of water and ranges from 0.525 to 0.580 @ 15 oC.
The pressure inside a LPG storage vessel/ cylinder is equal to the vapour pressure
corresponding to the temperature of LPG in the storage vessel. The restriction on
vapour pressure is stipulated by IS-4576.
LPG has an explosive range of 1.8% to 9.5% volume of gas in air. This is
considerably narrower than other common gaseous fuels. This gives an indication of
hazard of LPG vapour accumulated in low lying area in the eventuality of the leakage
or spillage.
Water, being insoluble in LPG, if present in LPG can cause rust and corrosion and
freeze-up of valves, drain valves, excess-flow check valves, cylinder valves and
regulators thereby affecting their functioning and at times can lead to leakage of LPG.
LPG liquid has low viscosity of around 0.3 CS @ 45 oC and can leak when other
petroleum products normally cannot, thus demanding a very high integrity in the
pressurised system to avoid leakage.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”
INSTALLATIONS
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however,
suffocate when in large concentrations due to the fact that it displaces oxygen. In
view of this the vapour posses mild anaesthetic properties.
LPG is colourless both in liquid and vapour phase. During leakage the vapourisation
of liquid cools the atmosphere and condenses the water vapour contained in them to
form a whitish fog which may make it possible to see an escape of LPG.
The coefficient of expansion is around 0.00237 per oC. At liquid full condition any
further expansion of the liquid, the container pressure will rise by approx. 14 to 15
kg./sq.cm. for each degree centigrade.
LPG has only a very faint smell, therefore, ethyl mercaptan is normally used as
stenching agent for identifying the leakage as per IS : 4576.
The auto-ignition temperature of LPG ranges from 410 to 580 oC.
2.0 SCOPE
This standard lays down the minimum safety requirements on design, layout, storage,
loading / unloading, operation, inspection & maintenance, fire protection, emergency
planning and safety audit systems of LPG Installations. This standard does not cover
process plants, the distribution of LPG to domestic & non-domestic consumers and
pipeline operations, road / rail transportation, refrigerated and mounded storage facilities
for LPG.
This standard is not applicable to bottling plants having a bulk LPG inventory not
exceeding 100 MT with minimum two storage vessels and with LPG bottling a total
quantity not exceeding 20 MT per shift of 8 hrs. The safety requirement for such LPG
Bottling plants are covered in OISD-GDN-169.
Safety requirements for mounded Storage facilities are covered in OISD-STD-150. The
requirements for Auto LPG Dispensing Stations are covered in OISD-STD-210.
The green belt /buffer zone beyond the installation boundary is outside the scope of this
standard. Such provisions may be considered based on local environment / security
requirements.
The fire protection and fire fighting requirement for the combined POL and LPG
facilities in the same premised shall be as given in OISD-STD-117 under item 2.4.
3.0 DEFINITIONS
Approved Type : Any equipment which has specific approval for use under specified
conditions by competent authority or authorised person as the case may be.
INSTALLATIONS
Area Classification : It is a method of classifying an area zone wise/ group wise based
on the presence of explosive gas/ vapour - air mixture vis-a-vis the requirement of
precautions for construction and use of electrical apparatus.
Bonding : Bonding is the process by which two electrical conducting bodies are
connected using a conductor to maintain electrical continuity to prevent sparking between
two conducting bodies.
Bulk Vessels : A pressure vessel used for more than 1000 litres water capacity for
storage or transportation of LPG.
Bullet : A horizontal cylindrical pressure vessel used for storage or transportation of LPG
by rail/ road.
Compressed Gas : Any permanent gas, liquefiable gas or gas dissolved in liquid under
pressure or gas mixture which in a closed container exercises a pressure either exceeding
2.5 kg/sq.cm. abs @ 15 oC or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50 oC or both.
Cylinders : A portable LPG container upto 1000 litres water capacity used for both
domestic and industrial purposes.
Explosive mixture : It is a mixture of combustion agent (oxidising product-gas, vapour,

liquid or solid) and a fuel (oxidisable product - gas, liquid or solid) in such proportions
that it could give rise to a very rapid and lively oxidisation reaction liberating more
energy than is dissipated through conduction and convection.
Earthing : Earthing is the provision of a safe path of electrical current to ground, in

order to protect structures, plant and equipment from the effects of stray electrical
current, and electrostatics discharge.
Filling Ratio : It is the ratio of weight of LPG in a container to the weight of water the
same container can hold at 15 oC.
Fire safe : As applied to valves, it is the concept of controlling the leakage to an

acceptable level after damage encountered during and after the fire achieved by dual
seating.
Fire proofing : It is an insulation that provides a degree of fire resistance to protect

substrates like vessels, piping and structures for a predetermined time period against fire.
Flammability : It is the percentage of volume of any flammable vapour in air-vapour

mixtures capable to form an explosive mixture.
Flammable (or Inflammable) : Any substance which when tested in a specified manner
will ignite when mixed with air on contact with a flame and will support combustion.
INSTALLATIONS
Gas-Free : it means the concentration of flammable or toxic gases or both in a pressure

vessel or pipeline is within the safe limits specified for persons to enter and carryout
hotwork in such vessels/ pipelines.
Horton Sphere : A spherical pressure vessel used for storage of LPG.
Hot Work : It is an activity which may produce enough heat to ignite a flammable air-
hydrocarbon mixture or a flammable substance.
Installation : The facilities where LPG is stored or loading/ unloading operations or

bottling operations are carried out.
Kerb Wall : A wall of appropriate height and size constructed of suitable material and
designed to contain the LPG spillage and to direct it to a safe location around the storage
vessel.
Liquefied Petroleum Gas (LPG) : The term applies to a mixture of certain light
hydrocarbon predominately C3 & C4, derived from petroleum & natural gas which are
gaseous at ambient temperature and pressure, may be condensed to a liquid state at
normal ambient temperature by the application of moderate pressure and conforming to
IS : 4576 or IS: 14861.
Purging : It is the act of replacing the atmosphere within a container by an inert

substance in such a manner as to prevent the formation of explosive mixture.
Purging into Service : is the replacement of air in a closed system by an inert substance
and replacement of the later by combustible gas, vapour, or liquid.
Purging out of service : is the replacement of normal combustible content of a closed

system by an inert substance, and replacement of the later by air.
Tare Weight : The weight of the cylinder together with any fitting permanently attached
to it including the weight of valve.
Maximum Working Pressure : It is saturated vapour pressure of LPG at 65 oC for LPG

cylinders and 55 oC for bulk vessels.
Water Capacity : The maximum volume of water in litre that the a container can hold at
15 oC.
4..0 STATUTORY RULES / REGULATIONS
The LPG installation & various facilities are covered under many regulations and require
specific approval / licence from concerned statutory authorities. The various regulations
applicable to LPG installation facilities are as below :
a. Gas Cylinders Rules, 1981 (under Indian Explosives Act,1884)

INSTALLATIONS
b. Static & Mobile Pressure Vessels (unfired) Rules-1981 (Under Indian Explosives Act
1884).
c. The Factories Act, 1948.
d. Indian Electricity Rules
e. The Standards of Weight & Measures Rules - 1987 Under Weight & Measures Act -
1976.
f. The Standards of Weight & Measures (Packaged Commodities Rules-1977)
g. Liquefied Petroleum Gas (Regulation of supply and distribution Order - 1993).
h. The Motor Vehicles Act - 1988.
i. Environmental Regulations :
Water (Prevention & Control of Pollution) Act, 1974.
Air (Prevention & Control of Pollution) Act- 1981
The Environment (Protection) Act – 1986
Manufacture, storage & import of Hazardous chemicals Rules - 1989.
Guidelines for Environmental clearance of new projects - 1981.
In addition to the above Statutory regulations, there are various recommended guidelines
emerging out of the various Committees set up by the Govt. of India from time to time for
streamlining/ improving the safety standards of LPG Bottling/ Distribution:
a. Vasudevan Committee - 1983 Ministry of Energy (Department of Petroleum).
b. Expert Committee Review of Safety and Operating Procedures in LPG facilities -

1986, Ministry of Petroleum & Natural Gas (Department of Petroleum)
c. Sudha Joshi Committee for better services to LPG users - 1987 (Ministry of
Petroleum & Natural Gas).
5.0 INSTALLATION LAYOUT
5. 1 GENERAL
INSTALLATIONS
The layout of the LPG facilities including the arrangement and location of plant roads,
walkways, doors and operating equipment shall be designed to permit personnel and
equipment to reach any area effected by fire rapidly and effectively. The layout shall
permit access from at least two directions.
The general principles of layout of LPG storage, bottling and bulk handling facilities have
been detailed. The various facilities within LPG installation shall be located based on
Table-I and Table-II.
5.2 LOCATION & SEPARATION DISTANCES :
5.2.1 LOCATION
While assessing the suitability of any site for location of LPG installation, the following
aspects shall be considered :
a) The location of residential quarters, other industries, railways, roads, waterways,

overhead power lines, places of public assemblies etc.. This shall be covered in risk
analysis study of the proposed site. The study shall also be used to plan for emergency
measures.
b) Adequate availability of water from a reliable source or alternate arrangements

proposed.
c) The topographical nature of the site with specific reference to its effect on the
accidental release of LPG.
d) The availability of space for future extension of LPG facilities, if any, shall also
comply with the safety norms.
e) The meteorological data of the location including predominant wind direction &
velocity, high flood level, temperatures etc.
5.2.2 SEPARATION DISTANCES
The separation distances as given in Table- I & II are the distances in plane between the
nearest point on a vessel other than the filling/ discharge line and a specified feature, e.g.
adjacent vessel, site boundary etc.
5.3 LAYOUT
The following aspects shall be considered while establishing layout of LPG storage
vessels. Bullets or spheres are used for above ground storage of LPG.
a. The access of mobile fire fighting equipment to the storage vessels shall be at least
from two sides.
INSTALLATIONS
b. Longitudinal axis of static storage vessels (bullets) shall not be pointed towards other
vessels, vital equipments e.g. LPG cylinder sheds, tank lorry/tank wagon gantries,
LPG pump house and buildings wherein control panels for fire and gas detection/
actuation panels are situated.
c. Storage vessels to be located preferably in downwind of potential ignition sources at
lower elevation.
d. No foreign material / combustible substances shall be stored in storage area.
e. Storage vessels shall be laid out in single row in each group.

f. Storage vessels shall not be located one above the other.
5.4 LPG STORAGE FACILITIES:
(a) CONFINEMENT/ GRADING -
Kerb wall shall be provided around all sides of the storage vessel with concrete
flooring of the ground under vessel and extending upto minimum distance of D/2 or
5M whichever is higher and atleast 5 M (min.) from the edge of the storage vessel
with a slope of 1:100 (min.).
Grading of the ground underneath should be levelled and directed to an area

connected with water seal away from the storage vessel.
Kerb wall height shall be minimum 30 cm but shall not exceed 60 cm otherwise
evaporation of spilled LPG may get affected.
Spillage diversion area shall be located at a distance where the flames from fire will
not impinge on the vessel. This distance shall not be less than the diameter of the
nearest vessel or minimum 15 M. No accumulation of LPG should be possible
underneath the storage vessel in any condition.
(b) PIPING - Only piping associated with the storage vessels shall be located within the
storage areas or between the storage area and the manifold system.
(c) SURFACE DRAINAGE - In order to prevent the escape of spillage into the main
drainage system, surface water from the storage area and from the manifold area shall
be directed to the main drainage through a water seal to avoid the spread of LPG.
(d) GROUPING - Vessels shall be arranged into groups, each having a maximum of six
vessels. There shall be minimum spacing as specified in Table-I between adjacent
vessels. Each group shall be separated by roads on all four sides for easy access and
emergency handling.
(e) Spheres and bullets shall be treated as separate groups with minimum 30 M distance
between two groups.
INSTALLATIONS
Top surfaces of all the vessels installed in a group shall be on the same plane. It is
necessary to provide separate manifolds preferably with independent pumping facilities
for bullets and spheres. Alternatively, fail safe interlocks like two way valves shall be
provided so as to avoid any chances of overfilling of adjacent vessels due to gravitation.
5.5 LPG BULK LOADING / UNLOADING FACILITIES
5.5.1 LPG tank lorry loading/ unloading gantry shall be covered and located in a
separate block and shall not be grouped with other petroleum products.
5.5.2 LPG loading/ unloading rail gantries shall have separate rail spur and be grouped
separately at least 50 M from other rail shunting facilities.
5.5.3 Space for turning with minimum radius of 20 M for tank lorries shall be provided
commensurate with the capacities of the tank trucks.
5.5.4 LPG tank wagon loading/ unloading shall be restricted to a maximum of half rake,
not exceeding 600 tonnes. If full rake loading/ unloading is envisaged this shall be
done on two separate rail gantries separated by a minimum distance of 50M.
5.5.5 Maximum number of LPG tank lorry bays shall be restricted to 8 in one group.
Separation distance between the two groups shall not be less than 30 M.
5.5.6 For adequate permanent protection for tank lorry discharge, pipeline island shall
be provided. The minimum width of such pipeline island shall be 1 M.
5.5.7 The layout of the unloading location shall be such that tank truck being unloaded
shall be in drive out position.
5.5.8 The weigh bridge of adequate capacity shall be provided and proper
maneuverability for vehicles.
5.5.9 Tank truck shall be loaded/ unloaded with suitable arrangement for cold flaring of
hose content, if used at the end of the operations.
5.5.10 LPG tank truck parking area (Bulk/ Packed) shall be located in a secured area and
provided with adequate no. of hydrants / monitors to cover the entire parking
area.
5.6 LPG BOTTLING FACILITIES
5.6.1 LPG bottling facilities shall be located at a safe distance from other facilities with
minimum ingress of traffic and upwind direction with respect to bulk storage.
There shall not be any deep ditches in the surrounding areas at least within 15 M
from storage sheds to avoid settling of LPG vapour.
INSTALLATIONS
5.6.2 LPG Bottling section shall be of single storey. Antistatic mastic flooring
conforming to IS-8374 shall be provided in the LPG filling shed/ cylinder storage
including valve changing shed to avoid frictional sparks. The shed shall be
supported by RCC columns alternatively structure steel columns shall be covered
with concrete or fire-proofing material upto full height of columns. Anti static
mastic coating upto 1.5 m (Min.) shall be done of the supporting columns of the
shed.
5.6.3 The bottling operation shall be carried out in the filling shed. Separate sheds for
filled cylinders storage, valve changing, degassing, if any, shall be provided.
Valve changing unit without evacuation can be provided in filling shed itself.
Empty cylinders storage area shall be properly segregated from filling machines
by 5 M (Min.). Cylinders shall always be stacked vertically with maximum stack
height of 1.5 m. For details of cylinders stacking pattern refer Figure - I .
5.6.4 LPG cylinder filling machines and other related testing facilities shall be provided
in sequential order.
5.6.5 A separate shed shall be provided for carrying out degassing of defective
cylinders.
5.6.6 Cylinder storage shall be kept on or above grade and never below grade in cellar
or basement.
5.6.7 Filled cylinders shall not be stored in the vicinity of cylinders containing other
gases or hazardous substances.
5.6.8 Escape routes shall be specified and marked in LPG sheds for evacuation of
employees in emergency.
5.6.9 There shall be sufficient no. of crossovers to avoid trapping of personnel in LPG
sheds by conveyors, cylinders and other facilities. Further, sufficient no. of escape
routes shall be provided.
5.6.10 All steps forming part of the escape routes shall be minimum 1.2 M with treads 30
cms (minimum) and maximum rise of 15 cms.
5.7 PROTECTION OF FACILITIES
5.7.1 Properly laid out roads around various facilities shall be provided within the
installation area for smooth access of fire tenders etc. in case of emergency.
5.7.2 Proper industry type boundary wall atleast 3 M high with 0.6 M barbed wire on
top shall be provided around the installation unless the bottling plant is protected
as a part of refinery complex.
INSTALLATIONS
5.7.3 Emergency exit with proper gate shall be provided in the earmarked zone.
5.7.4 In case provision for green belt is made, the same shall be segregated from
hazardous area by 1 M high wall / chain link fencing. Alternatively, it shall be
treated as a part of hazardous area.
5.8 UTILITIES
Utilities consisting of fire water pumps, admin. building, canteen, motor control centre,
DG room, air compressors, dryers etc. shall be separated from other LPG facilities and
located as per the separation as specified in Table-I.
TABLE - I
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.
INSTALLATIONS
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
6.1 GENERAL
This section describes the design and safety features required in a typical LPG bottling
installation.
6.2 LPG STORAGE VESSELS
The minimum requirements w.r.t. design considerations and various fitting to be provided
LPG storage vessels shall be as under :
6.2.1 MECHANICAL DESIGN
i. The storage vessel shall be designed in accordance with the codes i.e. ASME SEC.
VIII or IS-2825 or PD - 5500 or equivalent duly approved by CCE. Design shall take
into account the Static and Mobile Pressure Vessels (Unfired) Rules 1981 also.
A single code shall be adopted for design, fabrication, inspection and testing i.e.
ASTM and BS shall not be combined.
ii. Material shall be in line with design code. ASTM A516 Gr. 60 shall be used for
refinery service (BS-5500 shall not be used for the same) and for marketing
installation where H2S is not present ASTM A 516 Gr. 70 or A 537 CLASS 1 can be
used. Micro-alloyed steel containing Ni, Mo, Va shall not be considered. Maximum
specified tensile stress shall not be more than 80,000 psi.
iii. Design temperature : (-) 27oC to

(+) 55 oC.
iv. Design Pressure : 14.5 Kg/ cm2g on top as per IS: 4576 at 55 oC.
INSTALLATIONS
Marketable LPG conforming to IS: 4576 can have a maximum vapour pressure of
16.87 Kg/ Sq.cm.g at 65 o C temperature. LPG with higher vapour pressure are not
expected to be stored in bottling installations.
The recommended design pressure and temperature shall be treated as MINIMUM

requirement and other design consideration and Statutory requirements shall also be
considered.
v. Other Design Considerations
Corrosion Allowance : minimum 1.5 mm
Radiography : Full
Stress Relieving : 100% irrespective of thickness.
Wind pressure : as per IS: 875
Earthquake pressure : as per IS:1893
Hydro test pressure : As per Design Code
Where ever extreme climatic conditions or security reasons warrants, suitable alterations
in design can be made with approval from statutory bodies.
6.2.2 FITTINGS
Spheres/ bullets other than underground shall have a single nozzle at the bottom for
liquid inlet as well as outlet. The nozzle shall be full welded pipe, stress relieved along
with the vessel and shall extend minimum 3 meters from the shadow of the sphere/ bullet.
A remote operated shutdown valve (ROV) shall be provided on this bottom nozzle at a
distance of at least 3 meters from the shadow of sphere/ bullet. The nozzle pipe shall
have a minimum slope of 1.5 o.
There shall not be any other flanges, manhole, instrument tapping on this nozzle upto the
ROV or on sphere/ bullet bottom. In order to avoid stress on the nozzle due to relative
settling of support and storage vessel, suitable supports for the bottom nozzle shall be
provided.
The top vapour zone of the vessel shall be provided with nozzles for vapour outlet,
recirculation wherever applicable. These lines shall be provided with fire safe ROV.
ROVs for vapour / recirculation lines should be provided at the ground level with an
isolation valve at top. In case, ROV is provided at top of the vessel, there is no need to
provide an isolation valve.
INSTALLATIONS
Fire safe ROVs shall also be provided on liquid line at TLD & Tank wagon gantry &
isolation valve (quick closing type) on the entry of liquid lines at LPG filling shed at a
safe location.
Nozzles for two independent level indicators of different type, a high level switch, two
safety relief valves, pressure gauge and a manhole shall be provided on top.
All the fittings shall be suitable for use at the design parameters of the storage vessels and
for the temperatures appropriate to the worst operating conditions. The remote operated
valves on the storage vessel connecting pipelines shall be fire-safe type conforming to
API 607 or equivalent.
The flange joints of these valves shall either have spiral wound metallic gaskets or ring
joints. Plain asbestos sheet / reinforced gaskets shall not be used. Gasket used shall
conform to ASME B16.20 or equivalent. The studs used shall conform to ASTM A 194
Gr 2 H/ ASTM A 193 Gr B7 or equivalent.
Flange connections shall be of minimum of 300 lb rating confirming to ANSI B16.5 class
300 or equivalent. All tapings or openings shall be of minimum 20 mm thickness.
6.2.3 INSTRUMENTS
i) The storage vessel shall have minimum two independent level indicators and one
independent high level switch. High level alarms shall be set at not more than 85% level
of the volumetric capacity of the vessel. Audio visual indication shall be at local panel &
control room. On actuation of high level alarm, the ROVs of the affected vessel shall
close.
ii) Each storage vessel shall have at least two safety relief valves with isolation
arrangement set at different values and at not more than 110% of design pressure of the
vessel and each having 100 % relieving capacity adequate for limiting the pressure build
up in the vessel not more than 120% of design pressure.
The relieving load for the safety valves, shall be based on fire condition and no credit
shall be taken for fire proofing on the vessel, if provided.
The discharge of safety valves shall be connected to flare system, wherever available. In
this case, safety valves shall have lock open (or car seal open) type isolation valves on
both sides of safety valves.
In case of non availability of flare system, the discharge from safety valve shall be
vented vertically upwards to atmosphere at an elevation of 3 meter (minimum) for
effective dispersion of hydrocarbons. In this case, isolation valve on down stream of
safety valve is not required. A weep hole with a nipple at low point shall be provided on
the vent pipe in order to drain the rain water which may get accumulated otherwise.
Weephole nipples shall be so oriented that in case of safety valve lifting and consequent
fire, the flame resulting from LPG coming out from weephole does not impinge on the
INSTALLATIONS
sphere or structure. A loose fitting rain cap with a chain (non sparking) fitted to vent pipe
shall be provided on top of safety valve.
Typical safety fittings on a LPG storage vessel are indicated in Figure-II.
6.3 LPG LOADING/ UNLOADING FACILITIES
Each loading station shall consist of the following :
i. Excess flow check valve & non return valve shall be provided in LPG loading lines.
ii. A vapour return line with an isolation valve connected back to the storage vessel/
suction line with NRV.
iii. Properly designed loading arm or LPG hoses shall be provided at the end of filling
and vapour return lines for connecting to the tank truck vessel. The loading shall be
provided with break away couplings or smart hoses shall be used. Loading arm shall
be of approved type and be tested as per OEM recommendations. In case, LPG hoses
are used, it shall conform to OISD-STD-135.
iv. The hose - coupling / flange joint shall be of Class 300 lb rating with metallic
gasket. The hose coupling shall be provided with a cap or blind flange by which the
nozzle can be closed when not in use.
v. Weigh bridges of suitable capacity for road / rail movements and mass flow meters
for pipeline transfers shall be provided. The mass flow meters shall be certified for its
use with LPG.
vi. A check valve shall be provided in the vapour return line.
Unloading of LPG from tank truck is carried out with vapour compressors using pressure
differential method of liquid transfer. The compressor used for unloading shall be
provided with the following facilities:
(i) Vapour line with isolation valves
(ii) Excess flow check valve & non return valve shall be provided in LPG unloading lines
with isolation valves
(iii) Weigh bridge of suitable capacity
Additionally following shall be ensured.
i. Suitable provision shall be made for evacuation of LPG from bulk storage vessels to
tank truck or another vessel to empty the vessel in case of emergency or for statutory
testing.
INSTALLATIONS
ii. Tank truck shall be loaded/ unloaded with suitable arrangement for flaring of hose
content at the end of the operations.
iii. The unloading arms shall be used for unloading the LPG TT at LPG installation. In
case, LPG hose are used, it shall conform to OISD-STD-135 or equivalent as
approved by CCOE.
iv. The hose - coupling / flange joint shall be of 300 lb rating with metallic gasket.
The hose coupling shall be provided with a cap or blind flange by which the
nozzle can be closed when not in use.
6.4 CYLINDER FILLING FACILITIES
i) The cylinder filling area shall be completely open type and covered from top with
roof designed to ensure good natural ventilation. RCC roofing shall not be used.
The filling area shall not be on upper floors of building or in cellars unless
specifically required on account of extreme weather conditions.
ii) As far as possible, the floor area shall not have any channels or pits. Where these
are necessary for conveyors or other equipment like weigh machine etc., suitable
gas detection system shall be provided. Additionally, proper ventilation system
through ducts fitted with blowers shall be provided to release LPG outside of the
shed at safe location. The whole of the LPG filling shed flooring shall be
provided with mastic flooring.
All carousels & leak detectors including electronic shall be of approved type.
iii) Adequate lighting shall be provided in the cylinder filling area. Emergency
lighting shall also be provided at critical places.
iv) Water drains from the cylinder filling area where they enter an outside drainage
system, shall be provided with vapour seals.
v) Proper access shall be made available for other fire fighting equipment i.e. fire
tender, foam trolley etc.
vi) Cylinder storage area requirement shall be worked out based on the stacking
pattern of filled and empty cylinders as described in Figure-I.
vii) The filling machines shall be provided with auto cut-off system so that LPG
supply is cut off when the desired quantity of product has been filled in the
cylinders. The filling pressure shall not be more than the design pressure of the
cylinders i.e. 16.9 kg/sq.cm.g.
viii) Filling machines in a carousel/ stationary filling machines shall not have a
weighment error of more than + 150 gm of the net quantity of the LPG filled in
INSTALLATIONS
the cylinder, with a capacity of 14.2 kg or as specified in Weights and Measures

Rules.
ix) On-line check weigh scales with a minimum of 50 gms. graduation be installed
so that all the cylinders are check weighed after filling.
x) Compact Valve Tester to check valve and 'O" ring shall be installed on line.
Alternatively electronic leak detectors shall be provided.
xi) Water test bath or electronic leak detectors shall be provided to detect body and
bung leak cylinders.
xii) Vapour extraction system at strategic locations near carousel, cylinder evacuation
unit, valve changing unit, degassing shed and at locations where leaking LPG is
expected to accumulate shall be provided. Further, it shall be interlocked with
filling machine so that filling do not start without vapour extraction unit being
functional.
6.5 UTILITIES
(A) Compressed air
The quality of instrument air shall conform to the requirements as recommended by the
manufacturers of instruments/ equipment:
If one compressor is envisaged to run normally, another standby compressor of 100%

capacity shall be provided. When more than one compressor running is envisaged, 50%
standby capacity shall be provided.
(B) Service Water
Service water is required for the cylinder washing equipment and leak check bath,
compressor cooling and in hose stations for washing etc.
Water may be provided at a pressure of about 3 Kg/sq.cm.g. If one pump is envisaged to

run normally, another pump with 100% capacity shall be provided as a standby. Where
more than one pump running is envisaged, 50% capacity as standby shall be provided.
Water Quality
Water shall be of potable quality conforming to IS : 10500 - Specification for Drinking

Water.
(C) Emergency Power

INSTALLATIONS
The installation shall be provided with battery / diesel generating set for operating the
essential systems such as the instrumentation and safety systems (gas detectors, automatic
fire water sprinkler system) and minimum lighting during the grid power failure.
6.6 LPG PUMPS
i. LPG Pumps shall be designed for handling of LPG and safely withstand the
maximum pressure which could be developed by the product and / or transfer
equipment. Pumps shall conform to API 610 or equivalent.
ii. Check valves shall be installed on the delivery side of all centrifugal pumps.
iii. LPG Pumps shall be provided with suction and discharge pressure gauges, a high
point vent to safe height or flare, and a suction strainer.
iv. Double Mechanical seal with seal failure alarms shall be provided.
v. A pressure switch actuating a low pressure alarm in control room and locally shall
be provided, taken from discharge end.
vi. Pumps shall be designed to build a discharge pressure such that the pressure at the
carousel filling machine is at least 5.0 kg/sq.cm.g. above the vapour pressure at
the operating temperature.
vii. Pumps shall have a by-pass valve and other suitable protection against high
discharge pressure on the delivery side.
viii. The electrical motor drive and switchgear shall conform to area
classification as per OISD Standard-113 / IS -5572. Belt drives shall be of the
anti-static type.
Typical sketch of a bottling pump installation is enclosed as Figure-III.
6.7 LPG VAPOUR COMPRESSOR
i. Compressors shall be suitable for handling LPG and designed to safely withstand
the maximum outlet pressure to which these will be subjected. Compressors shall
conform to API 618 or API 619 or equivalent.
ii. The belts used in shall be of antistatic type & fire resistant.
iii. Compressor shall be provided with the following features as a minimum :
- Pressure gauges in suction and discharge.

- Temperature gauge in discharge
INSTALLATIONS
- Discharge safety valve and a vent valve, their outlets leading to flare/ safe height
outside the shed.
- Low Suction Pressure Trip
- Suction strainer
- High Discharge Pressure Trip
- High Temperature Trip
- Check valve in discharge
- A discharge to suction recycle valve for achieving capacity turndown during
startup.
iv. A suitable size scrubber or liquid knockout drum shall be installed upstream of the
vapour compressor. It shall be equipped with a gauge glass, safety relief valve, a
drain and high liquid level shut down device.
Typical sketch of compressor installation is enclosed as Figure-IV.
6.8 PIPING
Piping shall be designed for handling of LPG. Piping that can be isolated and need
thermal safety valves shall have minimum design pressure of 24 kg/cm2 or the maximum
pressure which could be developed by the transfer equipment or any other source etc,
whichever is higher and comply with the following :
(i) Piping shall conform to the provisions of ANSI B 31.3.
(ii) The material shall conform to API 5L Gr. B / ASTM A106 Gr B or eqv.
(iii) Seamless pipes shall be used. Furnace butt welded or spiral welded pipes shall
not be used.
(iv)Pipe joints should be welded as far as practicable with full penetration weld. Number
of flanged or threaded joints should be kept to a minimum.
(v) Low point drains and high point vents shall be plugged or capped suitably.
(vi)Buried piping shall be protected against physical damage and corrosion with suitable
sleeves, properly sealed at both the ends, at road crossings.
6.9 THERMAL PRESSURE RELIEF SYSTEM
Any equipment or section of pipeline in which liquid LPG may be trapped e.g.
between shut off valves, shall be protected against excessive pressure developed by
thermal expansion of the LPG by providing suitable thermal pressure relief valve(s).
If pressure relieving devices discharge to atmosphere, the discharge shall be done in a
safe manner.
INSTALLATIONS
6.9 VALVES
Steel valves conforming to relevant API standards shall be used. Cast iron valves
should not be used.
6.10 FITTINGS
(i) Steel flanges and flanged fittings conforming to API 105 Class 300 (forged) or eq.
shall be used. Slip on or weld neck flanges should be used. Screwed flanges for
sizes 50 mm or smaller may be used. Steel flanges should conform to the
applicable provisions of ANSI B 16.5.
(ii) Steel screwed fittings and couplings shall conform to ANSI B 16.11 or equivalent.
Steel unions shall have ground metal to metal seats. Gasket type unions shall not
be used.
(iii) Plugs shall be of steel. Cast iron or brass plugs shall not be used.
(iv) All flanges shall be connected for bonding for electrical continuity.
6.10 EVACUATION FACILITY FOR DEFECTIVE CYLINDERS
a. The cylinder evacuation facility shall consist of :
- Cylinder emptying vessel (s)

- Compressor
- Four way valves or equivalent
- Cylinder rack, header to be provided with pressure gauge and a strainer with isolation
valves.
- The LPG line exit cylinder evacuation area to be provided with a non-return valve
before joining the main LPG return header.
- Independent earthing connections.
b. Each of cylinder emptying vessels mentioned above shall be equipped with the
following :
- Pressure gauge
- Level gauge
- high level alarm switch set at 85 % with trip / switchover arrangement.
- Pressure relief valves,
- Vent valves discharging to 1.5 m above the shed.
- Other trims like drain valve, utility connection.
Typical sketch of cylinder evacuation facility is enclosed as Figure-V.
INSTALLATIONS
6.11 PURGING OF NEW CYLINDERS/ TANKERS
(a) The new LPG cylinders containing air shall be evacuated with a vacuum pump.. The
evacuation facility shall consist of :
- Vacuum pump (water/ oil / air cooled type)

- Purging manifold
- Vacuum receiver fitted with vacuum gauge, vent and drain.
- LPG vapour header
- Purging adapters
- Vacuum pump with suction strainer
- Pressure regulator, relief valves
Typical sketch of new cylinder purging system is enclosed as Figure-VI.
(b) Purging of tankers/ vessels shall be done using either Nitrogen or by filling water
and displacing with LPG vapours.
6.12 EQUIPMENT FOR ETHYL MERCAPTAN SERVICE
6.12.1 Material of Construction of Ethyl Mercaptan containers
Stainless steel and copper free steel alloys are the preferred materials of
construction of equipment for mercaptan service. Aluminium of desired pressure
rating can also be used. Use of Iron or carbon steel shall be avoided as there is the
hazard of formation of iron-sulphur complexes which are pyrophoric. Copper or
copper bearing alloys shall not be used for mercaptan service as mercaptan readily
attacks and contaminates them.
6.12.2 Pumps for Mercaptan service
Only hermetically sealed pumps shall be used.
6.12.3 Piping and Fittings
(i) Seamless stainless steel piping shall be used. Threaded fittings can be used
provided they meet the service requirement ratings. A fluoroplastic tape sealant
is recommended.
(ii) Flexible connections shall be seamless stainless steel with pipe nipples welded
to each end.
(iii) Relief valves shall be full nozzle, disc type, closed bonnet carbon steel body
with 304 stainless steel trim and stainless or aluminized steel spring.
(iv) For transfer valves, stainless steel ball valves with fluoroplastic seats and
stainless steel (SS316) trim or their equivalent are recommended.
INSTALLATIONS
(v) Rigid connection should be welded or flanged joint type.
(vi) Fluoroplastics shall be used for gasketing.
(vii) For pressure gauges, stainless steel diaphragm type is recommended with
stainless steel socket and tip.
(viii) Provision for analysis in line with IS:4576 or IS14861 as applicable shall be
made.
6.13 SELECTION OF ELECTRICAL EQUIPMENT
i. Electrical equipment shall be selected, sized and installed so as to ensure

adequacy of performance, safety and reliability. The equipment in general shall
conform to relevant Indian Standards and shall be suitable for installation and
satisfactory operation in the service conditions envisaged.
ii. All electrical equipment shall be selected considering the system neutral earthing.
iii. Electrical equipment including for lighting system shall conform to hazardous
area classification and be selected in accordance with IS:5571. These shall be
tested by agencies such as CMRI, ERTL, CPRI or independent test laboratory of
country of origin for such equipment. Indigenous Flameproof equipment shall
comply with relevant BIS standard as per requirements of statutory authorities.
All equipment used in hazardous area shall be approved by Chief Controller of
Explosives.
iv. For details on hazardous area classification, enclosure protection etc., OISD-
STD–113, OISD-RP-149, NEC – 1985, IS:2148, IS:5571, 5572, IS: 13408,
Petroleum Rules, 2002 shall be referred.
6.14 Installation Lighting
i) Sufficient lighting shall be provided so as to enable plant operators to move safely

within the accessible areas of installation and to perform routine operations. In the
event of normal power failure, emergency lighting shall be provided.
ii) Normal lighting system shall be on 415/ 240V AC supply, whereas emergency
lighting will be either on 220V or 110V DC.
iii) Lighting requirements provided during the failure of power supply for Normal
lighting are intended broadly,
a. to facilitate carrying out of specified operations, for safe shutdown of the

installation.
INSTALLATIONS
b. to gain access and permit ready identification of fire fighting facilities such as
fire water pumps, fire alarm stations etc.
c. Escape route for safe evacuation of operating personnel.
iv) Under normal operation, both emergency and normal lighting shall be fed by
normal power source. On failure of normal supply, emergency lighting shall be
transferred to emergency source until the start of D.G. set within 15 seconds.
Critical lighting (D.C. supply based) shall be normally kept ‘ON’. During power
failure, battery bank shall be used to provide power.
v. Low pressure sodium vapour lamps shall not be installed in hazardous areas.
vi. The illumination levels in different areas shall be as per good engineering
practice. Depending on the nature of job activities to be carried out the suggested
minimum illumination levels for various areas are covered in OISD-STD-149.
vii. The lighting fixtures on various circuits shall be suitably interlaced so that failure
of any one circuit do not result in complete darkness.
viii. Switches controlling the lighting fixtures and exhaust fan shall be installed
outside the battery room.
ix. Switches of lighting panels installed in hazardous area, shall have a pole to break
the neutral in addition to the poles for phases.
When the means of isolation is located in a non-hazardous area, the switch shall break
all poles including neutral or alternatively may break only live poles, the neutral being
isolated by a removable link.
For details on inspection practices OISD standard 147 to be referred..
6.15 Installation Earthing
i. All electrical equipment shall be suitably earthed. Earthing system shall cover the
following:
Equipment earthing for personnel safety.
System neutral earthing, and
Protection against Static and Lightning discharges.
The earthing system shall have an earthing network with required number of earth
electrodes connected to it. The following shall be earthed:
System neutral
INSTALLATIONS
Metallic non-current carrying parts of all electrical apparatus such as

transformers, switchgears, motors, lighting / power panels, terminal boxes,
control stations, lighting fixtures, receptacles etc.
Steel structures, loading platform etc.
Cable trays and racks, lighting mast and poles.
Spheres, Bullets etc.
Electrical equipment fencing (e.g. transformer, yard etc.)
Cable shields and armour.
Flexible earth provision for wagon, truck.
ii. Installation earthing design shall be carried out in accordance with the requirements
of Indian Electricity Rules and IS : 3043. All earth connections should be visible for
inspection to the extent possible.
iii. Where installed, lightning protection shall be provided as per the requirements of
IS:2309.
iv. The resistance values of an earthing system to the general mass of earth should be as
below:
For the electrical system and equipment a value that ensures the operation of the
protective device in the electrical circuit but not in excess of 4 Ohms.
10 Ohms in the case of all non-current carrying metallic parts of major electric
apparatus or any metallic object.
v. The earth conductor shall be adequately sized to carry the applicable maximum earth
fault current without undue temperature rise. All joints shall be protected against
corrosion.
v. All the electrical equipment operating above 250 volts shall have two separate and
distinct connections to earth grid.
vi. The main earthing network shall be used for earthing of equipment to protect it
against static electricity.
An independent earthing network shall be provided for lightning protection and

this shall be bonded with the main earthing network below ground, minimum at
two points.
INSTALLATIONS
vii. Every Sphere/ bullet shall be electrically connected with the earth in an efficient
manner by not less than two separate and distinct connections. The connections
and the contacts required shall have as few joints as possible. All joints shall be
riveted, welded or bolted and also soldered to ensure both mechanical and
electrical soundness. The resistance to earth shall not exceed 7 Ohms and the
resistance to any part of the fitting to the earth plate or to any other part of fitting
shall not exceed 2 Ohms.
viii. All joints in pipelines, valves in installations, and associated facilities and
equipment for LPG shall be made electrically continuous by bonding or
otherwise; the resistance value between each joint shall not exceed 1 Ohm.
7.0 STORAGE AND HANDLING OF BULK LPG
7.0 GENERAL
This section deals with the safe practices and provisions applying to unloading of
bulk LPG and storage of bulk LPG at installations. There should be strict compliance
w.r.t selection, deployment of proper skilled manpower for effective operation and
maintenance.
7.1 BULK HANDLING FOR MOVEMENT BY ROAD
The tank truck for road movement shall be designed, constructed and tested in
accordance with the Static and Mobile Pressure Vessels (Unfired) Rules, 1981 and
OISD-STD-159.
7.1.1 SAFETY PRECAUTIONS
Following precaution should be taken due to associated hazards during transfer of

LPG to or from a tank truck.
1. No source of ignition must be allowed in the area where product transfer

operations are carried out.
2. Fire extinguishers shall be placed near the tank trucks during transfer
operations.
3. The first operation after positioning the truck should be to provide proper
earthing. Earthing shall be disconnected just before the release of the truck.
4. Before removing plugs or caps, always crack open to allow for release of
trapped LPG and further to ensure that the valves are effectively sealing.
INSTALLATIONS
5. Hoses shall be handled with care and inspected periodically as per OISD-STD-
135.
6. While disconnecting hoses/arm, connections shall be loosened only slightly at

first to allow release of trapped pressure, if any.
7. Do not expose hands, face or clothing to liquid LPG. Always use personal
protective equipment while making or breaking the connections to avoid cold
burns.
8. The master switch shall be put off immediately after parking the truck in
position. No electrical switch on the truck shall be turned " on" or " off" during
the transfer operation.
9. No repairs shall be made on the truck while it is in the loading area.
10. Availability of wheel chokes.
11. New tank trucks vessels or vessels received after repair shall be purged as per
laid down procedure.
12. In case, the receiving vessel is having a pressure of less than 1 Kg/sq.cm.g, it
shall not be filled. Such vessel shall be taken for filling only after detailed
safety checks.
13. Venting and purging of LPG during transfer operation shall not be carried out
in open atmosphere. It shall be piped to a suitable flare system. Where such
facility does not exist, vent pipes shall be provided to carry the vented product
to a safe distance and released at a height not less than 1.5 m above the eves of
the structure.
14. Filling/transfer operations should be stopped immediately in the event of -
(i) Uncontrolled leakage occurring

(ii) A fire occurring in the vicinity
(iii) Lightning and thunder storm
7.1.2 PROCEDURES FOR OPERATION
(a) LOADING OPERATIONS
1. Check for following in a tank truck as per statutory regulations before

accepting it for filling:
Provision of two safety valves, level gauge, Excess flow check and control
valve on liquid and vapour lines, pressure gauge, temperature gauge on the
vessel / bullet.
INSTALLATIONS
Fire screen between cabin and vessel is provided. For this purpose, cabins
with metallic back cover without any opening will be considered as fire
screen.
Provision of 2 nos. of 10 Kgs. DCP Fire Extinguishers.
Fitment of Spark arrestors of approved quality.
No leakage in exhaust silencer pipe exists.
Manufacturer's name plate with date of testing is fitted on the vessel.
Valid Explosive Licence and RTO certificate is available.
Approved drawings of vessel are available.
Blind flanges/caps are provided on vessel.
Availability of Earthing cable.
Bonding between vessel and chassis and between flanges is satisfactory.
Earthing / bonding point is available.
Third party inspection/test certificates for vessel/fittings are available.
Liquid / vapour line valves are in good condition.
2. Move truck to the loading bay/weigh bridge and record the weight of the empty tank
truck.
3. Place the truck on loading bay and place choke blocks at front and rear wheels. Keep
the truck in neutral mode with hand brakes "ON".
4. Stop the engine and switch off all electrical equipment.
5. All persons should leave the driver's cabin.
6. Make earthing connections of the vehicle at specified point to the fixed grounding
system.
7. Connect liquid and vapour lines suitably with the loading point. Crack open valves
on loading & vapour return lines and inspect hoses & connections for leakage.
Loading should start only when the system is leak free.
8. Start the loading pump.

INSTALLATIONS
9. The quantity loaded into the truck can be determined by -
(i) Liquid level
(ii) Weighment
(iii) Positive displacement meter
(iv) Mass flow meter
The quantity of LPG filled shall not exceed the RLW of the tank truck.
10. Liquid level may be determined by roto-gauge or fixed liquid level gauge. Percentage
volume to be filled shall not exceed 85 % at 55OC i.e. the allowable filling limit as per
CMV Rules.
11. Where weigh bridge is used, it is necessary to determine the density of the product
being loaded to avoid excess filling in terms of volume. The weigh bridge shall be
periodically calibrated and stamped by Weights & Measures Authorities.
12. When the filling operation is in progress, the pressure within the tank truck vessel
shall be observed to ensure that it does not approach the start-to-discharge pressure
of the relief valve. Filling rate may be regulated as required.
13. The couplings may then be removed and plugs/caps replaced on the tank truck valves.
Re-check tightness with soap solution.
(b) Unloading Operations
1. Operations described under Item 1 through 6 in para 7.1.2(a) should be carried

out.
2. Liquid line and vapour line of the tank truck shall be connected to the respective
hoses fixed to the unloading point.
3. Test the connections for leaks by slightly opening the valves for pressurising.
When satisfied, valves on the tank truck and the receiving vessel shall be opened.
4. Start the LPG compressor. Vapours will be sucked from the receiving vessel and
will be discharged into the vapour space of the tank truck vessel creating pressure
differential thereby pushing the liquid from the tank truck vessel to the receiving
vessel.
5. Care should be exercised to see that the pressure created within the delivering
vessel does not reach or exceed the set pressure of the relief valve.
INSTALLATIONS
6. An authorised person of the company shall supervise the transfer operation and
respond immediately in the event of an emergency.
7. After the liquid has been expelled, the vapour recovery operation may be started.
Care should be taken not to bring down the pressure of the delivering vessel
below 1.5 Kg/cm2g.
Checklist for bulk LPG tank Trucks at unloading locations is given at Annexure 7 –I.
7.2 BULK HANDLING FOR MOVEMENT BY RAIL
LPG is moved in Tank Wagons by the Railways. These wagons are designed by
RDSO and are fitted with various devices as shown in Figure-VII.
The loading facilities are similar as for tank truck loading while unloading of LPG
from tank wagons shall be done with the help of compressor. The compressor is used
to create a differential pressure between the receiving and discharging vessels by
withdrawing vapors from the receiving vessel and forcing it at high pressure into the
discharging vessel thereby establishing a smooth flow. The content of tank wagons
can be ascertained by weighment on weigh bridge before and after emptying or,
alternatively, mass flow meters can be used.
Checklist for bulk LPG tank wagons at unloading locations is given at Annexure 7 –
II.
7.2.1 SAFETY PRECAUTIONS
1. Do not allow the locomotive to come on the weigh bridge unless its capacity is
designed to take the locomotive load.
2. Sufficient number of dummy wagons may be used to avoid electric loco coming
closer to the gantry. Maintain the distance of 15 m from first fill point.
3. The first operation after positioning the wagon shall be to provide for proper
earthing. Earthing shall be disconnected just before the release of the wagon.
4. For connecting and disconnecting hoses, only non-sparking tools shall be used.
5. After the wagons are placed on weigh bridge and before the loco is detached, the
hand brakes on each and every wagon shall be applied.
6. Like-wise, before the wagons are moved from the weigh bridge, release brakes on
all the wagons.
7. Do not use footwear with protruding nails.
INSTALLATIONS
8. Ensure that the lower portion of flapper bridge at wagon side is fitted with rubber
or wooden padding.
9. Ensure that electrical continuity of the system is intact.
10. Ensure that all fittings on the wagons are checked physically.
11. Hoses shall be tested as per OISD-STD-135 and records maintained.

12. The loading/unloading operation shall be carried out under close supervision of
authorised person.
13. During unloading operation, after the liquid transfer is over, the wagon pressure
shall not be reduced below 1.5 Kg/sq.cm.(g).
7.2.2 OPERATING PROCEDURES
(a) LOADING OPERATION
1. Place the wagon on weigh bridge taking care to see that all the four wheels are
properly accommodated on the platform. Engage hand brakes.
2. Ask loco to move away and exhibit caution sign at suitable distance away
from the wagons on both ends.
3. Switch off loco engine, if parked nearby.
4. Apply brakes on all wagons
5. Ensure fire system, safety interlocks, communication system are OK
6. Take loading advice.
7. Connect earthing lugs to the wagons.
8. Lower the flapper bridge slowly on the wagon.
9. Open the lid of the wagon.
10. Take the tare weight reading and set the pointer of the scale to zero. Compare
this with the marked tare weight on the wagon. Alternatively, use mass flow
meter to fill the wagons.
11. Connect the filling hose or loading arm and vapour return line hose or arm to
the wagon. Ensure that the flare connection valves are closed.
12. Ensure that the header is charged with LPG and the bulk loading pump is
running.
INSTALLATIONS
13. Open the tanker filling line valve and vapour return line valve.
14. Check the system for leaks.
15. Open the valve on the vapour return line. Now slowly open the valve on the
filling line. Increase the valve opening and gradually open the valve fully.
Ensure filling is upto safe filling level keeping in view temperature factors.
Take mass flow meter readings if used.
16. Once the filling is over, close the wagon filling and vapour return lines valves
and also valves on filling and vapour return lines at the loading point.
17. Open the valve on flare line connection to both feed line and vapour return
line slowly to avoid ice formation. Thus, the hoses are depressurised. Then,
close the flare line connection valves.
18. Disconnect the filling and vapour return line hose connections from the
wagon. Replace and tighten the plugs on filling and vapour return lines.
19. Close the top cover of the wagon and seal it properly. Remove earthing
connections.
20. Release the hand brake of the wagon.
21. Release all the wagons on the loading points in the lot.
22. Check the gross and net weight at the weigh bridge.
Use loading arms for loading / unloading operations.
(b) Unloading Operations
1. Ascertain that the liquid discharge valve and the vapour valve within the tank
wagon cover are in the closed position.
2. Open the port covers in the side of the dome shell, if exist. Unscrew the plugs
in the outlets of the vapour valve and the liquid valves using a box wrench.
This must be done slowly.
3. If there is any sound of escaping vapour or if there seems to be pressure

behind the plugs, the pressure must be allowed to relieve itself past the threads
before the plugs are entirely disengaged.
4. If the vapour discharge continues or if there is evidence of a liquid discharge,

the valves should be re-tightened.
INSTALLATIONS
5. With the plugs removed, screw pipe nipples into the outlets of the valves after
first having applied a modest quantity of sealant to the male threads, keeping
the sealant away from the end of the thread. Tighten nipples with a pipe
wrench.
6. Connect the two liquid transfer unloading swing arms or hoses to the nipples
attached to the liquid discharge valves. Connect the vapour or equalizing
swing arm or hose to the nipple attached to the vapour valve. In most of the
cases, these connections will be made by means of either a ground joint union
or a hose coupling.
7. In the event, a ground joint union is used, no gasket will be required. If a hose
coupling is employed, ensure that the appropriate gasket is in place. Make sure
that they are secured tightly by appropriate means.
8. After the vapour and liquid hoses have been connected and before any valve is
opened, the valves on the tank wagon are crack opened in order to apply
pressure to the hoses / loading arms as a test for leaks.
9. If any leak appears, the valve should be immediately closed and corrective
measures applied.
10. Recheck the lines and connections to make sure that they are connected
correctly.
11. After the liquid and vapour lines have been secured and tested, both liquid
education valves should be opened slowly and completely. Then, open all
other valves in the liquid line working from the tank wagon to the storage
tank.
12. If the tank wagon pressure is higher than that in the storage tank, do not open
the valves in vapour line or operate the compressor. When the rate of liquid
flow drops to an unsatisfactory level with the storage tank filling valve wide
open, open the vapour valves between the tank wagon and the storage tank.
13. At this point, make sure that the control valves at the compressor are in a
position which allow the compressor to draw vapours from the storage tank
and force it into the tank wagon, then start the compressor.
14. When the tank wagon is held at a pressure of 2.0 to 2.5 Kg/sq.cm. above the
storage tank pressure, the tank wagon should be emptied into the storage
vessel.
15. A flow of gas instead of liquid through the sight-flow glass in the unloading
line indicates that the wagon is empty of liquid. Recheck this by opening the
sample valve in the tank wagon dome.
INSTALLATIONS
16. When the tank wagon is emptied of all liquid, stop the compressor and close
the liquid valves beginning at the storage tank and progressing to the tank
wagon.
17. If the facilities are so arranged that vapours may be removed from the tank
wagon, the pipeline at the compressor should be arranged so that the
compressor will draw vapour from the tank wagon and force it into the storage
tank.
18. In this operation, the vapour should be discharged below the surface of the
liquid in the storage tank to hasten the liquefaction and, in turn, help prevent
excessive pressure in the storage tank.
19. Restart the compressor and when the tank wagon pressure is reduced to about
1.5 - 2.0 Kg/ sq.cm., stop the compressor and close all the valves in the vapour
line.
20. After bleeding off the pressure in the hoses, disconnect both the liquid and
vapour lines. Replace all the plugs in the tank wagon valves and the unloading
fittings.
21. Recheck sample valve, gauging device and thermometer well to determine that
they have been returned to their original condition and are closed tight. Lower
the dome cover carefully and lock it in place with the locking pin or secure by
appropriate means.
22. Remove bonding connections.
23. Reverse or remove and replace the "Flammable" placard with "Dangerous -
Empty" placard.
24. Remove the "Stop - Tank Wagon Connected" sign and wheel blocks.
25. Any defect observed in the tank wagon should be noted on the appropriate
forms and routed in accordance with acceptable procedure.
26. Notify the railways in writing about release of wagon and ensure that it is
removed from the siding promptly.
27. Gauge the storage tanks, within the installation, which have received the LPG
to determine that the liquid level is appropriate.
28. In the event of LPG received on weight basis, the tank wagon may require
weighing following the completion of the unloading operation.
INSTALLATIONS
7.2.3 DEGASSING OF SICK/LEAKY TANK WAGONS
(a) Recommended Procedure

In the degassing system recommended for LPG wagons, vacuum cycle purging
technique should be followed as outlined below :
-Vessel should be evacuated repeatedly by a vacuum pump.
-Vapour should be discharged through high rise vent, keeping the steam on.
-Maximum possible vapours should be sucked out in first step depending on

the capacity of vacuum pump/compressor. As per RDSO, vessel can sustain the
full vacuum also.
-Between the two vacuum cycles, nitrogen/inert gas should be used for breaking
the vacuum.
- Cycle should be repeated till the LPG concentration is found below the
end point of LPG (for butane, it is 4% by volume when purging is done by
nitrogen). Periodically, samples should be drawn from suitable location and
analysed for LPG concentration.
-Finally the vessel should be flushed with air to displace the nitrogen. Barrel
should be tested finally with explosive meter to ensure that hydrocarbon
concentration is below 10% of LEL.
(b) Alternate Procedure
Alternately, wagons may be degassed by steaming or filling with water.

However, it should be ensured that wagon is made water free after degassing.
7.3 BULK HANDLING FOR MOVEMENT BY SEA
Transportation of LPG in bulk by tankers may be carried out under fully-

pressurised, semi-pressurised (semi-refrigerated) or fully refrigerated at atmospheric
pressure conditions.
7.3.1 CARGO CARRIER DESIGN & CONSTRUCTION
The design and construction of cargo carrier is in line with International Maritime
Organisation (IMO) Gas code.
7.3.2 TANKER FACILITIES
The cargo handling equipment in a tanker usually comprise of Cargo pumps

(submersible and booster), Compressors, Condensers, Heat Exchangers,
Vapourisers, Cargo heaters etc.
INSTALLATIONS
The deep well pump supplies liquid to the booster pump to send the product ashore.
In pressurised ship, liquid is withdrawn by pressurising the tank through vapour
compression from other tanks. All semi and fully-refrigerated tankers are provided
with cargo heaters to enable the vessels to discharge into pressure storage ashore
and a booster pump if the discharge pressure is significantly above 9 bars. Each
cargo tank is provided with the following equipment:
a) Two cargo pumps, one each on either side of the longitudinal bulk head.
b) Liquid discharge line from the tank dome, connected to the main liquid line.
c) All emergency pump trunk way.
d) A liquid loading line connected to the main liquid line.
e) Two liquid level indicating devices one on each side. These usually consist of a
float attached to a self winding tape which moves up and down, either on guide
wires or inside a guide tube. The liquid level is read off the tape through a gas-
tight window at the top of and outside the tank.
f) Two sets of purge lines at the top and bottom of the tank. These are used to
distribute inert gas or vapour for gas-freeing or gassing-up of the cargo tanks.
g) A vapour line for withdrawal of vapour to the compressor.
h) Sample tubes.
Safety Devices
(a) Atleast two safety valves in each cargo tank
(b) High and Low level alarms
(c) Overfill alarm. When actuated, this will shuttle main loading valve and sound
an alarm.
However, the design of the tankers with regard to provision of facilities, equipment,
accessories and safety features must be in accordance with the IMO requirements.
7.3.3 TRANSFER PIPING
The following facilities on transfer piping between Terminal and Shore tanks should
be provided:
(a) ROVs at both the ends of transfer line.(Additional ROV at critical locations in
the pipe line route.)
INSTALLATIONS
(b) Relief valves on liquid line to surge vessel with an audible alarm system
connected to high safe venting system
(c) Physical protection against impact to vent/drain pipes
(d) Protection of pipeline against corrosion, particularly when the pipeline passes
under public road way, which is likely to be water-logged
(e) Pipe work passing public road way be designed to acceptable public highway
authority standard in terms of roadway axle weights
7.3.4 TERMINAL FACILITIES
Transfer of LPG from ship to terminal and vice versa is accomplished using
loading arms of approved type as per OCIMF guidelines. Provision of vapour return
facility shall be made.
In case of pressurised gas transfer, it is observed that the pumping rate falls off
gradually due to back pressure of the shore tank. A suitable vapour recovery system
or re-liquefaction of the gas from the receiving tank shall be provided.
7.3.5 UNLOADING OPERATIONS
It is essential that the ship and terminal operators are familiar with the basic
characteristics of each other's facilities, are aware of the precise division of
responsibilities and are able to communicate effectively during the time they are
together involved in the joint operation of cargo handling.
7.3.6 COMMUNICATION
Reliable and effective communications, irrespective of whether these are directly

between the tanker and the terminal or indirectly via third party, are pre- requisites
of safe and efficient cargo operations before the tanker comes alongside and during
the period of cargo operations and until the tanker departs. Terminal communication
shall be compatible with tanker's system.
7.3.7 PRE-CARGO TRANSFER DISCUSSIONS
Before any cargo transfer operation, it is imperative that the intended procedures are
thoroughly discussed between the responsible personnel from the tanker and the
terminal with a view to make both sides fully conversant with the characteristics of
the tanker and shore cargo handling systems, the envisaged operational and safety
procedures and requirements and the parameters to be adhered to during the
transfer.
The broad outlines for the discussions are as under :
INSTALLATIONS
(a) The names and roles of terminal and ship personnel who will be responsible for
cargo transfer operations may be noted.
(b) The terminal representatives shall check that pre-arrival instructions to the ship
on cargo, cargo disposition and cargo conditioning have been carried out. They
also shall check that all necessary tanker equipment inspection and tests have
been performed.
(c) Similarly, the tanker's officers shall satisfy themselves that the relevant
terminal equipment and inspection checks have been carried out satisfactorily.
(d) Terminal representatives and customs and/or independent surveyors, where

necessary, will be informed of the cargo tank data e.g. temperature, pressure,
whether free of cargo, liquid heel or arrival dip, composition of tank vapour
and quantity of cargo on board.
7.3.8 SHIP / SHORE SAFETY CHECKLIST
Checklist for Ship/Shore safety is given in Annexure 7-III.
7.3.9 DISCONNECTION OF HOSE/ UNLOADING ARM
On completion of unloading operation the tanker discharge pipeline need to be

purged to push liquid LPG to the receiving tank. Purging may be done by LPG
vapour, inert gas or water as per the design of the system. However, before
disconnecting hoses or unloading arm, it is to be ensured that there is no liquid LPG
left between the tanker main valve and shore isolation valve. Product from this
length of pipeline is to be safely vented.
7.4 STORAGE OF BULK LPG
Precautions for storage of LPG in bulk :
a) Liquid level in the vessel shall not exceed the permissible limits. Filling shall not
exceed safe permissible filling ratio.
b) Vessel shall be inspected daily for any LPG leakage and corrective action taken.
c) All gauges, viz. High level alarm, measuring gauges, pressure gauges, temperature
gauges should be kept in operating condition at all times and be checked daily.
7.5 SAMPLING AND DRAINING

7.5.1 SAMPLING
Sampling is primarily required at supply locations i.e. Refineries, Gas Processing

Plants, Import Terminals, etc. Sampling of LPG for different analytical tests shall be
INSTALLATIONS
carried out in accordance with IS:1448. During handling of LPG samples, the
following safety precautions shall be followed :
(i) Special sampling bombs shall be used for LPG sampling. Arrangement of rupture disc
or any other suitable safety relief device shall be incorporated in the sampling bomb.
(ii) Sampling bombs shall be inspected periodically and tested hydrostatically at regular
intervals. Record of such inspection/test shall be maintained.
(iii) Sample bombs shall be earthed effectively before and during discharge of sample.
(iv)LPG samples shall be collected only in open/ventilated areas and the person taking
the sample shall stand on the windward side.
(v) The sampler shall wear protective goggles, hand gloves, shoes etc. while taking
samples.
(vi)Samples, after collection, shall be properly labeled and kept at designated place.
(vii) Sampling of LPG should preferably be done in bombs with provision of pre-
charge at one end. This will not only eliminate the possibility of undesirable presence
of air in the bomb, which may become a safety hazard, but also minimises flashing of
sample during collection, thereby providing a truly representative sample.
7.5.2 DRAINING
Storage vessel should be drained regularly for its water content, sediments, caustic
contents etc. Draining operation should be carried out under the supervision of an
authorised person.
For draining of water from LPG vessels , following procedure shall be followed :
(i) The valve nearer to the vessel shall be opened first and closed. Then, draining shall
be carried out by gradually opening the valve farther from the vessel. The operation
shall be repeated till LPG release starts.
(ii) It shall be ensured that the drain outlet is at a safe distance from the vessel so that
accidental ignition of any escaping vapour would not expose the vessel to flame
impingement.
It is important not to attempt removal of the entire quantity of water as considerable

liquid LPG may escape in the process. At the first sign of appearance of LPG, the
operation shall be stopped. Escape of LPG may lead to formation of ice block at the valve
seat, preventing closure of valve. This will result in escape of uncontrolled vapour to the
atmosphere causing a very serious hazard.
The valve shall be operated slowly to avoid ice formation.
INSTALLATIONS
ANNEXURE - 7 - I
CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION
1. CHECKS REQUIRED TO BE CARRIED OUT BEFORE ALLOWING ENTRY OF TT

INSIDE LICENCED AREA
ON THE TANK TRUCK :
- Properly fitted spark arrestor of make and design approved by CCE, Nagpur.
- Proper Fittings i.e. SRV, EFCV, temperature & pressure gauges etc. as SMPV Rules & OISD-STD-
159.
- 2 nos. 10 kg. DCP extinguishers in easily accessible and removable position with Truck No. date of
checking and charging painted on it.
- Provision of quick closing manifold valve with lever indicating close and open status.
- No visible dent on the bullet.
ELECTRICALS :
- All junction boxes are properly sealed
- Any loose electrical wiring/ terminal
- Electrical wiring is insulated and provided with suitable over current protection.
- Truck is self starting
- Readily accessible master switch for switching off the engine is provided inside the cabin.
- Dipole wiring. (Note 1)
TANK FITTINGS :
- Leakage from any fittings or joints.
2. CHECKS REQUIRED TO BE CARRIED OUT BEFORE ISSUING LOADING MEMO

(DURING THE COURSE OF UNLOADING OPERTIONS)
TANK TRUCK
- Height barrier provided as per specifications
- Fuel tank is protected by means of stout guard and fuel tank cap is locked.
- Paint of bullet is not peeling off.
GENERAL
INSTALLATIONS
- First aid kit is available.
3. CHECKS REQUIRED TO BE CARRIED OUT ON RANDOM BASIS - MINIMUM ONE DAY,

ONCE IN A MONTH :
TANK TRUCK :
- Internals of fire extinguishers in good condition
- Carries TREM CARD, instructions booklet detailing instructions on handling emergencies en route.
- Carries route map
- Has valid CCE licence and authenticated copy of drawing
- Carries RTO permits
- RLW-ULW> Licenced capacity
- HAZCHEM sign, name of contractor with address and telephone No. displayed prominently.
- Bullet has no sign of external corrosion.
TANK FITTINGS :
- Excess flow check valves are functioning.
- Liquid / vapour lines are adequately anchored and are well protected by means of stout steel guard.
- Liquid/ vapour pipe lines are in single piece from excess flow check valve to discharge valves - Safety
fittings viz., safety valve, roto-gauge, pressure gauge and temperature gauge are adequately protected.
- Operative fittings like roto gauge, pressure gauge and temperature gauge are operational.
GENERAL :
- Flanges and bend pipe on liquid / vapour lines

should be of rating of 300.
Following are available in Tank Truck :
- Tools for all fittings
- 4 Nos. caution sign board with luminous paint for stopping traffic in case of any emergency.
Based on the nature of defects either all the deficiencies should be got corrected at the unloading location
itself or the tanker should be allowed to get the repairs done en route and submit the details at loading
location.
INSTALLATIONS
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
INSTALLATIONS
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....
INSTALLATIONS
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...
INSTALLATIONS
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

INSTALLATIONS
8.1 GENERAL
This section covers the operations in the LPG bottling plants,
Safe work practices shall be established to ensure safe operation, maintenance, and
modification activities while carrying out various jobs. These practices shall be
documented and approved. The manuals shall be updated at least once in a year by
authorised personnel.
Activity on bottling line including valve change, shall be carried out by trained
personnel.
8.2 BOTTLING OPERATIONS
The Bottling Operations can be classified under following heads :
i) Receipt of LPG cylinders
ii) Filling & despatch of LPG Cylinders
iii) Handling & storage of LPG cylinders
iv) Auxiliary Operations
8.2.1 Receipt of LPG cylinders
Cylinders shall be received in capped condition. Cylinder shall conform to IS:3196.
8.2.2 Filling of LPG cylinders
(a) Pre-filling operation : Cylinder before filling shall be checked for following :
- Visually inspected as per IS:5845/ IS : 13258

- Ò' Ring (joint packing) is present and there is no apparent damage to valve.
- Tare weight is legible.
(b) Filling operation - All cylinders shall be filled on gross weight basis on filling
machine.
Maximum permissible errors on net quantity declared by weight shall be in

accordance with the Standards of Weights & Measures (Packaged Commodities)
Rules 1977 and Amendment Rules, 1992. The filling pressure should not exceed
maximum working pressure of cylinder i.e. 16.9 kg/cm2 at 65 deg.C.
(c) Post Filling Operation - Cylinder shall be counter weighed with check scale for
accuracy of weight. Variation of net weight. Variation of net weight shall not exceed
INSTALLATIONS
permissible limits. All under-filled/ over-filled cylinders should be corrected on

correction scale.
Cylinder shall be checked for Ò" ring condition and for valve leak by means of
Compact valve Tester (CVT) or electronic leak detector.
CVT or electronic leak detector shall be calibrated to detect leakage beyond 0.5
gm/hr. For cylinders found with Ò' ring defect, the Ò' ring shall be replaced with a
new one. Further all "O" ring or valve change cylinders shall be rechecked for leakage
with CVT or electronic leak detectors.
The on line valve removal machines is used shall be checked for integrity of the
system with regard to proper sealing. The machine shall be further checked for leak
tightness, torque settings before being put in use every day. The maintenance shall be
carried out as OEM recommendation.
Cylinder shall be checked for body leak and bung leak by dipping in water test bath or
by an established electronic leak detection system. Cylinder shall be capped prior to
dipping in test bath water.
Only those cylinders found passing all above checks shall be processed further for
sealing.
Cylinders shall be sealed with PVC seal or Aluminium seal. Seal shall have
identification mark of oil company, preferably name of plant and period of filling.
No bypassing of safety interlocks, fire water system, gas detection system, vapour
extraction system and heat detection system shall be permitted unless authorised by
plant manager in writing.
8.2.3 Handling & Storage of LPG
Handling and storage of LPG cylinders shall be governed by Gas Cylinders Rules, 1981.
Following safe practices shall be observed :
a) Handling of LPG Cylinders - LPG cylinders shall not be dropped, rolled on body
and shall not be subjected to any violent contact with any other cylinder or object
cylinder shall be moved by rolling on its foot ring or on conveyors or hand trolleys.
b) Defective filled cylinders - Any cylinder having body leak, bung leak, bulge, fire
ravaged or spurious shall be evacuated immediately.
Any cylinder with valve leak shall be immediately capped and thereafter evacuated
immediately.
Cylinders requiring repairs other than valve leak shall be degassed for repairs.
INSTALLATIONS
All above cylinders shall be clearly identified, with markers, to their nature of defects
and shall be kept capped during storage.
c) LPG cylinder storage - All cylinders shall be stacked vertically (with valve in
upright position) in not more than 1.5 m.
Cylinders of different capacity and type shall be stacked separately.
All cylinders shall be capped during storage.
The cylinders shall be stacked in small lots of 4 rows and 25 cylinders length. A
minimum access path of 1 mtrs. must be maintained on both sides of 4 rows and 2
metres after every 5 such lots. After each length of 25 cylinders, there must be a
passage of 2 metres. The cylinder storage space shall be properly marked/ painted on
the flooring.
Typical stacking arrangement for 14.2 kg cylinder is given in Figure-I.
Empty and filled cylinders shall be demarcated clearly.
Minimum distance of 15 metres from cylinder loading area and minimum distance of
10 metres from filling point shall be observed for all filled cylinders stack.
8.2.4 Auxiliary Operations
a) Cylinder requiring valve removal and valve fixing
Cylinder having defective valve and with bung leak shall have to undergo valve
removal and valve refixing operation.
Following safe procedures shall be observed for the operation :
- Cylinder shall be evacuated of its product upto pressure, 1.5 kg/cm2 or less, thereafter
depressurised to near atmospheric pressure through cold flare before opening the
defective valve.
- The valve of cylinders with bung / valve leak shall be replaced.
- Cylinder bung shall be cleaned with 3/4" NGT tap and cylinder bung threads checked
with L1 and L9 gauge.
- Only cylinders passing above tests shall be taken up for valve change operation.
- Good valve shall be fixed using a torque wrench. The torque shall not exceed 20 +/-
2kg.m. Before fixing the valve suitable jointing compound shall be used. Jointing
compound shall be compatible with LPG, water and metallurgy of cylinders and
INSTALLATIONS
valves. Teflon tape/ paste of suitable valve joining material are recommended as
jointing material.
b) Purging of cylinders
- New cylinders and cylinders degassed for repairs shall be purged of air prior to be
taken up for refilling with LPG. Following safe procedure shall be observed for
purging of LPG cylinders :
- Connect the cylinder valve to vacuum pump and evacuate air so that the pressure in
cylinder is brought down to maximum 0.35 kg/cm2 absolute. Inject LPG vapour in
the cylinder so that pressure is minimum 1 kg/cm2 and not above working pressure of
cylinder i.e. 16.9 kgf/cm2 at 65 degree C.
c) Degassing of Cylinders :
Cylinders shall be evacuated and depressurised to near atmospheric pressure. The residual
LPG in the cylinder should be cold flared in the atmosphere at a vent outside the shed at
1.5 m height above the eves of the shed.
Valve shall be removed with suitable torque wrench or by using online valve changing
machines. Cylinders shall be filled with water fully and water should be allowed to over
flow. Thereafter, cylinders shall be emptied out of water and checked with explosimeter
for degassing. Not more than 6 cylinders shall be degassed at a time.
8.3 DISPOSAL OF ETHYL MERCATAN CONTAINERS
It shall be ensured that the drums are emptied of mercaptan to the extent possible. The
empty drums then can be washed with water and detergent, followed by wash with a
5% bleach solution. After again washing with copious amount of water, the drums
will be ready for disposal.
(ii) Treatment of Leaks and Spills
Leaks and spills of mercaptan can be treated with commercially available masking
agents (e.g.Aldor and Neutroleum Alpha etc.) to make them odourless. Large
mercaptan spills shall be covered with sand or activated carbon or any other
absorbing material, which are then buried or incinerated. The area over the spill
should then be washed with ordinary household bleach solution and then thoroughly
with water. Dry bleaching powder should never be used in treating mercaptan spills.
A violent reaction could occur.
INSTALLATIONS
9.0 MAINTENANCE & INSPECTION OF EQUIPMENT
9.1 GENERAL :
This section covers the maintenance and inspection practices to be followed to ensure
safe and trouble free operation of various equipment.
9.2 MAINTENANCE SCHEDULES :
To facilitate the maintenance service to be rendered in a planned manner, a preventive

maintenance schedule covering the necessary work to be done, mentioning the periodicity
i.e. daily, weekly, monthly, half yearly and yearly schedules, must be worked out. While
basic recommendations given by the manufacturers should be considered and modified
bearing in mind the local conditions (refer Annexure 9- I-IV).
9.3 PERSONAL PROTECTIVE EQUIPMENT :
Necessary personal protection equipments such as Hand gloves, Safety shoes, Helmets,
Safety belts, Safety goggles etc. shall be used ( for details refer OISD- STD-155).
9.4 WORK PERMIT SYSTEM :
Any maintenance, inspection, disassembly or removal of fittings while any part of the
system is under pressure shall not be carried out without a proper work permit and
approved procedure.
1. All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard ;
OISD-STD-105 on "Work Permit System".
2. Electrical maintenance / inspection, provisions of OISD-STD-137 shall be adhered

to.
9.5 INSPECTION & MAINTENANCE OF VARIOUS FACILITIES IN LPG

INSTALLATIONS :
9.5.1 STATIC EQUIPMENT :
a) PRESSURE VESSELS & STORAGE FACILITIES :
OISD Standard OISD-STD-128 on "Inspection of Pressure Vessels shall be

followed.
Weld cracking has been experienced in the lower half portions of LPG vessels.
Small amounts of wet H2S present in LPG is supposed to be responsible for this
in service stress corrosion cracking of welds. LPG vessels made from micro-
alloyed high tensile steels have shown greater susceptibility to such cracking.
INSTALLATIONS
Wet Fluoroscent Magnetic Particle Testing (WFMPT) is considered the most

reliable test method for detecting these micro-cracks. WFMPT should be carried
out prior to hydraulic test wherever cracks are found, their depths should be
assessed by ultrasonic testing. All cracks having depths less than corrosion
allowance may be removed by grinding, edges smoothened and areas left as such
after final WFMPT check. Weld build up of grooves so formed is essential
wherever depths of groove is more than corrosion allowance.
b) SHUT-OFF VALVES, CONTROL VALVES, NON-RETURN VALVES,

EXCESS CHECK VALVES, PIPELINES, VALVES AND FITTINGS :
All new valves shall be inspected and tested to ensure conformation to required
specifications and for leak tightness. All new valves shall be inspected and tested
as per requirements of API-598. The closure torque during testing for hand wheel
and gear operated valves shall not be greater than that obtainable by hand
tightening. Further fire safe valves shall comply with following :
Low pressure seat test shall be conducted with the ball and seat dry and free of oil,
grease or any lubricant.
The high pressure seat test is not required except for threaded and valves.
No leakage shall be permitted.
Fire-safe test shall be carried out as per API : 607.
Valves shall be dismantled at the time of specified comprehensive inspection or during

the shutdown of the line to permit examination of all internal parts. Body thickness
measurements shall be made at locations inaccessible before, dismantling, particularly at
locations showing evidence of erosion. Bodies of valves operating in severe cyclic
temperature service shall be checked internally for cracks.
Gate valves, which have been used for throttling, shall be measured for thickness at the
bottom between the seats, as serious deterioration may have occurred because of
turbulence. This is particularly weak point because of the wedging action of the disc
when the valve is closed. The seating surface shall be inspected visually for defects
which might cause leakage. The wedging guides shall be inspected for corrosion and
erosion. The stem and threads on the stem and in the bonnet of valves shall be examined
for corrosion which might cause failure., The connection between stem and disc shall be
inspected to assure that the disc will not detach from the stem during operating.
Swing check valves shall be inspected by removing the cover or cap. The clapper or disc
shall be checked for freedom of rotation and the nut holding it to the arm shall be checked
for security and presence of a locking pin, lock washer, or tack weld. The arm should be
free to swing and the anchor pin shall be inspected for wear. Also the seating surface on
both the disc and valve body shall be checked for deterioration by feeling them with the
fingers. After the valve has been reassembled, it shall be hydrostatically and/or
INSTALLATIONS
pneumatically tested for tightness. If tested pneumatically, a soap solution shall be

applied to the edges of the seating surface and observed for any evidence of leakage.
9.5.2 Flanges, Gaskets and Bolts
The gasket faces of flanged joints, which have been opened, shall be inspected visually
for corrosion and for defects such as scratches, cuts and gouges which might cause
leakage. The gasket faces shall be checked for true flatness or warping by placing a
straight edge across the diameter of the face of the flange and rotating it about an axis
through the center line of the flange. Grooves and rings of ring joints shall be checked
for defects.
Flanges bolts should be inspected for stretching. Where excessive bolt loading is
indicated or where flanges are deformed, nuts may be rotated along the entire
length of the stud. If studs are stretched, thread pitch will be changed and nuts
will not turn freely. Inspection involve checking to determine whether bolts of the
proper specification have been used and may involves chemical analyse or
physical tests to determine the yield point and the ultimate strength of the
material. If flanges are bolted too tightly, they may bends until the outer edges of
the flanges are in contact. When this occurs, there may be insufficient pressure on
the gasket to assure a tight joint. Visual inspection of the gasket will reveal this
condition. Permanently deformed flanges must be replaced.
9.5.3 PIPELINES
(i) Inspection data as well as thickness data of newly constructed pipelines shall be
collected at the earliest and with in two years of their commissioning to function
as base for establishment of corrosion rates.
(ii) External inspection of LPG pipelines within the installation shall be carried out
once in three years which shall include both visual inspection and ultrasonic
thickness readings taken externally.
The details of thickness survey shall be maintained on an isometric sketch.
(iii) Comprehensive inspection of LPG pipelines shall be carried out once in 6 years
which shall cover the following :
i) Visual inspection
ii) Hammer test
iii) Ultrasonic thickness measurement
iv) Dye penetration test or Magnetic particle test
v) Hydrotest
(iv) Piping in coastal installations and in corrosive environment shall be visually

inspected once a year. Years of inspection experience have revealed that failures
INSTALLATIONS
of most of the Offsite pipelines are due to external corrosion and that internal
corrosion failures are minimum.
(v) The underground lines having wrapping and coating as well as cathodic protection
shall be inspected whenever current leaks are observed and/or any damage to the
coating is suspected. Parameters of cathodic protection like pipe-to-soil voltage or
pipe-to-water voltage shall be monitored once a month.
(vi) All underground lines having only wrapping and coating shall be inspected once
in three years using Pearson Survey for locating coating damage, if any.
Additionally, all these lines shall be visually inspected at random once in ten years
by digging at a few locations. Pipelines crossing the roads and dykes shall be
inspected once in ten years by digging and exposing the line completely.
Provisions of OISD Standard ; OISD-STD-130 on "Inspection of Pipes and Valves and

Fittings" shall be followed.
9.5.4 HOSE AND FLEXIBLE CONNECTION :
LPG hoses shall be inspected & tested at maximum interval of 4 months as detailed in
OISD Standard ;. OISD-STD-135 on "Inspection of Loading and Unloading Hoses for
petroleum products" and records maintained thereof.
LPG hoses shall be discarded after 3 years of service or earlier in case the permanent
elongation exceeds 5%.
9.5.5 STRAINERS AND FILTERS :
Strainers & filters shall be inspected and cleaned as per following frequency, unless
sluggish operation warrants earlier inspection :
TYPE / LOCATION FREQUENCY
Air filters Weekly

Strainers on evacuation Weekly
line
Pump Suction Quarterly
Up stream of filling Quarterly
carousel
up stream of PD-Meter Quarterly
e) SAFETY RELIEF VALVES
Safety Relief valves shall be tested once in a year. Further an on stream visual inspection
should be carried out at least once in every 6 months to check the following:
a) Gags, blinds do not exist.

INSTALLATIONS
b) Upstream and down stream isolation valves, if any, are opened and sealed.
c) Seals protecting the spring setting have not been broken.
d) Relief device is not leaking. This may be checked visually and by thermography,
contact thermometers or by hand touch at outlet nozzle wherever practicable.
e) The continuous operation of heat tracing provision, if any, provided for low
temperature application on valve and discharge piping.
f) Condition of insulation and cladding on the heat traced piping and valves.
a) Inspection and test of the valve shall be done in as received condition. This is
important and helps in establishing the frequency of inspection.
Provisions of OISD Standard ; OISD-STD-132 on "Inspection of Pressure Relieving
Devices" shall be followed.
9.5.6 ROTARY EQUIPMENT :
a) COMPRESSORS : OISD Standard No. OISD-120 on "Inspection of Compressors"

shall be followed. In addition, periodic maintenance checks, as detailed in
Annexure-I to be followed.
b) PUMPS : OISD Standard No. OISD-110 on "Inspection of Pumps" shall be

followed. In addition, periodic checks as detailed in Annexure-II to be followed.
c) DIESEL ENGINES: OISD Standard No. OISD-123 on "Inspection and Maintenance

of Rotating Equipment components shall be followed.
9.5.7 FILLING EQUIPMENT
It shall be ensured that the equipment is in good working condition to ensure

quality output and also safe operation. Inspection checks are given at Annexure 9-
III for the following equipment:
a) CAROUSEL
i) Drive units
ii) Centre column
iii) Running Rail
iv) Introduction and Ejection devices
v) Filling machines
b) Check Weigh Scales

c) Chain/ Roller conveyor
d) Drive Units for Conveyors
e) CVT-leak detector
f) Cylinder Test Bath
g) General
9.5.8 INSTRUMENTATION
INSTALLATIONS
a) TEMPERATURE INDICATING
DEVICES
Temperature indicating devices shall be checked daily for its proper functioning and
shall be calibrated once in 6 months.
b) LEVEL GUAGING DEVICES
The gauging devices shall be checked daily for proper functioning. Zero level check
and calibration shall be carried out monthly and annually as applicable.
c) PRESSURE GAUGES
Pressure gauges shall be checked daily for its proper functioning and shall be
calibrated once in 6 months.
d) FLOW MEASURING DEVICES
All flow measuring devices shall be checked daily for proper functioning and
calibration shall be carried out monthly and quarterly as applicable.
9.5.9 FIRE FIGHTING EQUIPMENT
Fire fighting equipment shall be inspected and tested as per. OISD-STD-142 -

"Inspection of Fire Fighting Equipment".
9.5.10 ELECTRICAL EQUIPMENT
Proper functioning of electrical equipment can only be ensured by means of

periodic preventive and predictive maintenance of the equipment. This enhances
equipment life and also ensures safety of the equipment, installation and operating
personnel.
Maintenance shall be daily, weekly, quarterly or annual depending upon the type of
equipment. Adequate logs shall be maintained to ensure that maintenance is
carried out as per approved checklists. Preventive maintenance should be carried
out as per schedules laid down in OISD-STD-137.
Special emphasis shall be laid on the maintenance of equipment installed in

hazardous areas.
All electric apparatus and wiring in a hazardous area shall at all times be so
maintained as to retain the characteristic on which their approval has been granted”
Precautions to be taken for repairs and testing of flameproof equipment shall be

as below:
INSTALLATIONS
i. No Flame proof or intrinsically safe apparatus shall be opened and no work likely
to impair the safety characteristics of such apparatus or electric wiring connected
thereto shall be carried out until all voltage has been cut off from said apparatus
or wiring. The voltage shall not be restored thereto until the work has been
completed and the safety characteristics provided in connection with the apparatus
and wiring have been fully restored.
ii. Use of soldering apparatus or other means involving flame, fire or heat or use of
industrial type of apparatus in a zone “1” area shall be permitted for the purposes
of effecting repairs and testing and alterations, provided that the area in which
such apparatus or wiring has been installed, has first been made safe and certified
by a competent person after testing with an approved gas – testing apparatus to be
safe and free from inflammable vapours, gases or liquids and is maintained in
such conditions, so long as the work is in progress.
iii. No alteration that might invalidate the certificate or other document relating to the
safety of the apparatus, shall be made to any apparatus.
Replacement fasteners, nuts, studs and bolts shall be of the type specified by the
manufacturer for the particular apparatus. No attempt shall be made to replace or
repair a glass in a flameproof enclosure e.g. in a luminaire or other enclosures,
except by replacement with the complete assembly or part obtainable from the
manufacturer, complying with the approval certificate.
If replacement components such as cable glands, conduit or conduit accessories,

are available only with thread forms which differ from those provided on the
apparatus, suitable adaptors having necessary certification and approval shall be
employed.
iv. Equipment enclosures and fittings shall be examined to see that all stopping plugs
and bolts are in position and properly tightened. Locking and sealing devices
shall be checked to ensure that they are secured in prescribed manner.
v. If at any time, there is a change in the area classification or in the characteristics

of the flammable material handled in the area or if the equipment is relocated in
the area, the area classification drawing should be correspondingly revised and a
check shall be made to ensure that the equipment selection corresponds to the
revised area classification.
vi. A system shall be established to record the results of all inspections and the action
taken to correct defects.
INSTALLATIONS
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. *

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--------------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS

--------------------------------------------------------------------------------------------------------------------------------
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. *

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INSTALLATIONS
ANNEXURE 9-II
CENTRIFUGAL PUMP
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
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 *
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INSTALLATIONS
ANNEXURE 9-III
FILLING EQUIPMENTS
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
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. *
--------------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS
(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)
--------------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS
(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 tightness.
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)
--------------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS
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. *

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ANNEXURE 9-IV
DIESEL ENGINES
INSTALLATIONS
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.
INSTALLATIONS
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.
INSTALLATIONS
DIESEL ENGINES
"A" CHECK EVERY DAY
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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.
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"B" CHECK EVERY 250 HOURS
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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

INSTALLATIONS
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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
----------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS

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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.
INSTALLATIONS
DIESEL ENGINES
"C" CHECK EVERY 1500 HOURS
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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
INSTALLATIONS
"C" CHECK EVERY 1500 HOURS
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
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
INSTALLATIONS
"D" CHECK EVERY 4500 HOURS
----------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
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.
È' CHECK EVERY 8000 HOURS
INSTALLATIONS
1. REPEAT ALL MAINTENANCE STEPS OF CHECK À', `B', `C' & `D'.
2. THE È' 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 È' 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 È' 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 È' 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).
INSTALLATIONS
10.0 STATUTORY TESTING OF LPG CYLINDERS
All cylinders used for filling LPG are required to be tested periodically to ensure
fitness of the cylinders for further service. First re-testing is required to be done after
7 years and subsequent re-testing after every 5 years interval. Such tests are to be
conducted by the CCE approved parties only.
10.1 TESTING PROCEDURE
10.1.1 DEGASSING OF LPG CYLINDERS
All the LPG cylinders are depressurised in the approved premises by opening valves
by means of suitable adapters to ensure that the internal cylinder pressure is reduced
to atmospheric pressure. Only after depressurising the cylinder, cylinder valve is
removed and LPG cylinder is taken up for water filling and water is overflown and
retained in the cylinder for not less than one hour to remove any traces of LPG.
Degassing can also be achieved by stripping, Nitrogen purging, etc.
10.1.2 SURFACE CLEANING
a) After depressurising the cylinder and emptying out the water, the same is kept in
inverted position and stroked gently with a non-sparking hammer such as wooden
mallet to remove any dust, rust or any loose remnants in the cylinders.
b) The depressurized cylinder bung is plugged and is taken up for surface cleaning by
immersing the cylinder in the caustic soda bath and soap water and the same is then
rinsed with water.
10.1.3 CHECKING TARE WEIGHT :
All the LPG cylinders shall be weighed and if the loss in tare weight is more than
5% of original weight such cylinders shall be segregated and scrapped. At the
time of weighing the weight of valve is also accounted.
10.1.4 VISUAL INSPECTION :
a) The detailed visual inspection of the cylinder body shall be carried out as per IS:5845/
IS : 13258.
b) Depending upon the visual inspection, cylinders are segregated for scrapping, for cold
repairs and for hot repairs in case required.
c) The interior of the cylinder shall be examined by means of infra low voltage FLP
lamp. The internal examination shall be carried out as per IS:5845 / IS : 13258.
d) LPG cylinders selected at random may be cut into two holes for assessing internal
corrosion.
INSTALLATIONS
e) In case of dented/ buckled cylinders, visual inspection of welds needs to be done more
carefully since the welds are more susceptible to cracking. Denting or buckling by
more than nominal plate thickness may be attended by repairs/ replacement.
10.1.5 HYDROSTATIC TESTING :
a) All the LPG cylinders shall be taken up for hydrostatic test at an interval of 7 years
for first testing and subsequent testing after every 5 years in accordance with IS:8868.
Only water should be used as a medium for hydrostatic testing and the pressure to be
applied should be the test pressure marked on the cylinder body (25.35 kg/sq.cm) and
the same should be retained for a minimum period of 30 seconds. Any reduction in
pressure noticed during the test, any leakage, visible bulge or deformation should be
treated as a case of failure. Such cylinders should be properly marked, observation
recorded and segregated for scrapping and disposal.
b) Pressure Gauges shall be calibrated at least once a week and the Pressure Gauges used
for verification should be tested once in every three months.
10.1.6 VALVE FIXING :
a) Before commencing the fitting of valve operation, all the water inside the cylinder
should be drained and the cylinder should be made dry with the use of hot air jet.
Before refitting the valve, internal threads of the cylinder bung should be cleaned with
3/4" NGT thread tap and checked against thread damage. In case old valves are being
refitted the same should be tested by compressed air at 7 kg/sq.cm for leakage from
seat.
b) Teflon paste/ suitable sealing compound should be used as a sealing material for
tightening the valve and the torque of 20+/-2 kg. m. should be applied. In no case
spanners and ordinary wrenches be used for tightening the valves.
10.1.7 PNEUMATIC TEST :
a) The Pneumatic test should be applied to the cylinder at a pressure of 7 kg/sq.cm. for a
minimum of 60 seconds as per IS:3196. This is basically to check the tightness of the
valve cylinder joints.
b) With the cylinder under pressure, a soap solution should be applied to the cylinder
valve bung joint to ensure that there is no leak. The same can be checked by dipping
the cylinders in water bath. Depressurise the cylinders. All the Pressure Gauges used
for Pneumatic test shall be calibrated at least once in 3 weeks and the Pressure Gauge
used for verification should be tested once in every three months.
10.1.8 PAINTING OPERATIONS :

INSTALLATIONS
a) To enhance the life of the cylinder and to project a better image to the customers,
maintaining a well painted surface of cylinder is most desirable.
b) All LPG cylinders are painted with one coat of zinc chromate primer and a coat of
super synthetic enamel paint of signal red colour (IS:2932 shade 575). Special care
should be taken to paint the cylinders in vulnerable areas like underneath the foot
ring.
c) The valve should be protected while painting the cylinder.
10.1.9 CHECKING MARKING THE TARE WEIGHTS
a) Tare Weight of the cylinder should be ascertained and if in variance with the original
tare weight (this could be as a result of change of cylinder valves ) the observed tare -
weight should be punched as close to the original tare weight marking as recorded in
the register maintained.
b) The observe tare weight should be stencilled with paint on the shoulder and as well as
on inside of one of the vertical stay.
c) Gross weight punched/ stencilled on the cylinder should be changed in case of change
of tare weight.
- Weighing machines used for checking the tare weight should be duly certified by
Weights & Measures Authority. The machine should be tested daily with the
standard weights to verify accuracy. The test used for checking should be tested
against standard weights and the same must be stamped periodically by Weights
and Measures Authority. The minimum graduations of 50 gms. must be available.
e) Weighing scale error should not be greater than 1.0%.
f) The tare weight should be recorded with an accuracy of +/-50 gms. and rounded off as
per IS:2.
10.1.10 PUNCHING OF MARKS :
In addition to punching of revised tare weight/ gross weight wherever applicable,

following details should also be punched on the cylinder body as close to the
previous markings as practicable :
a) Date of retest
b) Code marking for the Test Plant/ Repairer.
c) Tare weight of the cylinder should be stencilled with black paint within the V.P.
Ring circle diameter at 3 places for easy identification by filling operators. The
INSTALLATIONS
recommended lettering size is 25 mm and the thickness of the numerals is 6-7

mm.
d) It is also recommended that the net weight of LPG to be filled should be stencilled
on the body of the cylinders outside the V.P. Ring diameter. The size of the
lettering recommended is 18 mm and the thickness of the numerals is 4-5 mm.
Sequence of operations for statutory pressure testing of LPG Cylinders is given at

Annexure 10-I.
10.1.11 COLOUR CODING OF CYLINDER
This is done primarily to facilitate easy segregation of cylinders for repairs at installations
without going through the test date of manufacturing dates punched on each and every
cylinder. Currently, the following colour codes have been selected for easy identification
of cylinders and the same shall be repeated after every five/ seven years cycle. Colour
coding is done on the inside of one of the Stay Plates and the same is given below:
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 :
A detailed record of each cylinder tested at the installation or at the repairer's premises
should be maintained. The record should include the minimum following details :
a) Running serial number
b) Date of testing
INSTALLATIONS
c) Serial number of cylinder & name of manufacturer
d) Month and year of test
e) Weight of cylinder
f) Punched on cylinder
g) Observed weight
h) Whether satisfactory/ rejected
i) Visual defects
j) Internal
k) External
l) Whether passed/ rejected
10.1.13 HYDROSTATIC TEST/ HYDROSTATIC STRETCH TEST :
- Whether passed/ rejected

- Condition of bung threads (internal)
- Whether satisfactory/ rejected Pneumatic Test
- Whether passed/ rejected
- Quarter/ year of retest punched on the cylinder

- Stencilling/ colour coding for age profile
- Relevant test certificate number
REMARKS :
(The Remarks columns should indicate whether the cylinder has been finally passed or
rejected besides any other relevant details not covered above).
The test certificate issued by the Plant or by the Repairers should include :
- Running Serial Number of cylinder

- Cylinder Serial Number
- Date of testing
INSTALLATIONS
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
INSTALLATIONS
FIRE PROTECTION FACILITIES
11.1 GENERAL
LPG Installations shall have well defined in-built fire prevention and protection system
to mitigate any exigency. The requirements of fire prevention and protection system shall
be as under :
11.2 DESIGN CRITERIA
i) The single largest fire risk shall be considered.
ii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump /
compressor Houses, remote operating valves /motor operating valves on LPG lines
Bulk Lorry and Tank Wagon Gantries shall be fully covered by medium velocity
water spray system.
iii) Fire Protection Facilities shall have fire fighting access, means of escape in case of
fire and also segregation of facilities so that the adjacent facilities are not endangered
during the fire.
iv) Heat Detectors for detection of fire for automatic actuation of medium velocity water
sprinkler system shall be provided. The QB/EP detectors shall be placed directly
overhead or inside the hazard. In areas without specific hazard, detectors shall be
placed evenly across the ceiling or with maximum spacing of 3 meter inside the
shed. Any other detectors if provided shall comply with the design requirements.
11.3 FIRE WATER SYSTEM
The main components of the fire water system are :
- Fire Water Storage
- Fire Water Pumps
- Fire Hydrant/ Monitor distribution piping network.
- Water Sprinkler/ Deluge system.
11.4 FLOW RATE DESIGN
The Fire Water pumping requirement for medium velocity spray system shall be
calculated based on minimum spray density as 10.2 LPM/Sq.M of the exposed surface or
area to be cooled, in case of LPG Pump/ compressor it shall be 20.4 LPM/Sq.M .
a. Storage Vessels
INSTALLATIONS
MV sprinkler system with automatic heat detection having remote/ local operated Deluge
valve with spray density of Minimum 10.2 LPM/ Sq.M shall be provided on all above
ground storage vessels.
For water flow calculations aggregate surface area of all vessels within distance of 30
Mts. from the periphery of the affected LPG vessel shall also be considered as single
risk .
b) Sheds
valve with spray density of minimum 10.2 LPM/Sq.M shall be provided in the entire shed
including the loading / unloading fingers.
For spray water calculations, the shed can be divided into suitable number of zones, each
served by independent deluge system. The adjacent zones shall be operative around the
zone under fire and the same shall be considered as a single risk. The width of a zone
shall not be less than 10 meter except of the zone on either end of the shed. As there is
no storage of cylinders in the loading / unloading fingers, spray system can be taken as
separate zone with independent deluge valve to optimise the fire water requirement .
c) LPG Pump / Compressor House
valve with spray density of Minimum 20.4 LPM/Sq.M shall be provided.
The entire pump /compressor house shall be considered as single risk area : alternatively
it can be divided into suitable number of zones with minimum 10 meter width.
d) Tank Lorry Gantry
In case of Tank Lorry Gantry, automatic detection of heat for automatic actuation of MV
sprinkler system having remote/ local operated deluge valve with spray density 10.2
LPM/Sq.M of surface area shall be provided. A maximum of 8 bays shall be considered
as single risk area. In addition to the tank lorry surface, MV spray system shall
effectively cover the tyres, manifold and dish ends of various size of tank lorries. There
shall be atleast 3 tiers of MV sprinkler system and heat detectors uniformly cool the top
, middle and the bottom of the tank lorry.
e) Tank Wagon Gantry
MV sprinkler system with automatic heat detection having remote/ local operated deluge
valve with effective spray density of 10.2 LPM/Sq.M shall be provided. The gantry can
be divided into suitable number of zones with minimum zone length of 30 meters and
adjacent zones shall operate around zone under fire and same shall be considered as
INSTALLATIONS
single risk. The spray system shall cover tank wagons surface on either side of tank
wagon gantry atleast in two tiers as well as the associated LPG pipelines in the gantry.
The fire water system in the plant shall be designed to meet the highest fire water flow
requirement of a single largest risk of any of the above cases at a time plus 288 Cu.M/Hr.
for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
11.5 FIRE WATER SYSTEM DESIGN
i) The Fire Water pressure system shall be designed for a minimum residual pressure of
7.0 kg/ cm2 g at the remotest place of application in the plant.
ii) A fire water ring main shall be provided all around perimeter of the LPG Plant
facilities with hydrants/ monitors spaced at intervals not exceeding 30 M when
measured aerially. Fire hydrants and monitors shall not be installed within 15 Meters
from the facilities/ equipment to be protected.
iii) Fire hydrant network shall be in closed loops to ensure multidirectional flow in the
system. Isolation valves shall be provided to enable isolation of any section of the
network without affecting the flow in the rest. The isolation valves shall be located
normally near the loop junction. Additional isolation valves shall be provided in the
segments where, the length of the segment exceeds 300 Mts.
11.6 FIRE WATER STORAGE
i) Water for the hydrant service shall be stored in any easily accessible surface or
underground lined reservoir or above ground tanks of steel, concrete or masonary.
The effective capacity of the reservoir above the level of suction point shall be
minimum 4 hours aggregate working capacity of pumps. Where make up water
supply system is 50% or more this storage capacity may be reduced to 3 hours
aggregate rated capacity of pumps.
Large natural reservoirs having water capacity exceeding 10 times the aggregate
water requirement of fire pumps may be left unlined.
ii) Storage tank/ reservoir shall be in two inter connected compartments to facilitate
cleaning and repairs. In case of steel tanks there shall be a minimum of two tanks.
11.7 FIRE WATER PUMPS
i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head. These pumps shall have a flooded suction, alternatively suitable
arrangement for auto priming shall be provided.
ii) The system pressure has to be maintained at 7 kg/cm2g at the farthest end of the
hydrant system with the help of Jockey Pump operating automatically.
INSTALLATIONS
The Jockey Pump shall start-stop automatically actuated by pressure switches.
A standby jockey pump shall be provided if the number of hydrant points is more than
100. One monitor shall be considered as equivalent to 4 hydrant points.
iii) The fire water pump(s) including the stand by pump(s) shall be diesel engine driven .
The pumps shall be capable of discharging 150% of its rated discharge at a minimum
of 65% of the rated head. Each engine shall have an independent fuel tank of suitable
size for 6 Hrs. continuous running.
In refineries / gas processing plants, where reliable source of electric power is

available electrical driven centrifugal pumps can be used upto a maximum of 50 % of
total pumping capacity. Power supply to the pump motors should be from two
separate feeders.
iv) At least one standby fire water pump shall be provided upto 2 nos of main pumps For
main pumps 3 and more, minimum two standby pumps of the same capacity as the
main pumps shall be provided.
iv) Fire water pumps shall be used exclusively for Fire protection and prevention
purpose only.
v) Suction and discharge valves of fire water pump shall be kept open all the
time.
The fire water pumps shall be provided with automatic starting facilities which shall
function with specified logic even if initial pump does not start or having started , fails to
build up the required pressure in the fire water ring main system within 20 seconds.
11.8 FIRE HYDRANT NETWORK
i) Fire hydrant ring main shall be laid above ground ensuring that :
a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground
level.
b) The mains shall be supported at regular intervals not exceeding 6 meters or as per
design approved.
c) The system for above ground portion shall be analysed for flexibility against
thermal expansion and necessary expansion loops where called for shall be
provided.
ii) However the ring main may be laid underground at the following places :
a) Road crossings.
INSTALLATIONS
b) Places where above ground piping is likely to cause obstruction to operation and
vehicle movement.
c) Places where above ground piping is likely to get damaged mechanically, particularly
in the LPG storage area where water supply lines are laid for feeding sprinkler deluge
system.
d) Where Frost conditions warrant and ambient temperature is likely to fall below zero
deg. centigrade underground piping at least 1 meter below the ground level should be
provided. Alternatively, for above ground pipelines, water circulation to be carried
out.
iii) For Fire water ring main laid underground the following shall be ensured :
a) The Ring main shall have at least one meter earth cushion in open ground, 1.2 meters
cushion under the road crossings and in case of rail crossing, provisions stipulated
by Indian Railways shall be complied.
b) The Ring main shall be suitably protected against soil corrosion.
c) In case of poor soil conditions it may be necessary to provide concrete/ masonry

supports under the pipe line.
iv) Fire water ring main shall be sized for 120% of the design water flow rate. The
velocity of water shall not exceed 5 meter per second in fire water ring main. Design
flow rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.
In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally or other suitable coating material shall be used.
v) Hydrants/ monitors shall be located considering various fire scenario at different

sections of the premises to be protected and to give most effective service. At least
one hydrant post shall be provided at a every 30 mtrs of external wall measurement
or perimeter of battery limit in case of high hazard areas. For non-hazardous area,
they shall be spaced at 45 mtrs. intervals. The horizontal range & coverage of
hydrants with hose connections shall not be considered beyond 45 mtrs.
vii) Hydrants shall be located at a minimum distance of 15 mtrs. from the periphery of
storage tank or equipment under protection. In case of buildings this distance shall not
be less than 2 mtrs. and not more than 15 mtrs. from the face of building. Provision of
hydrants within the building shall be provided in accordance with IS : 3844.
Hydrant/Monitors shall be located along road side berms for easy accessibility.
viii) Double headed hydrants with two separate landing valves on 3"/ 4" standpost shall
be used. All hydrant outlets shall be 1.2 mtrs. above ground level.
INSTALLATIONS
ix) Monitors shall be located to direct water on the object as well as to provide water
shield to firemen approaching a fire.
The requirement of monitors shall be established based on hazards involved and

layout considerations.
The location of the monitors shall not exceed 45 mtrs from the hazard to be protected.
x) Hydrants and monitors shall not be installed inside the dyked areas.
xi) LPG tank wagon Loading/ unloading facility and Tank Truck gantry area should be
provided hydrants having multipurpose combination nozzles for jet spray & fog
arrangement and fire hydrants located at a spacing of 30 mtrs. on both sides of the
gantry. The hydrants & monitors shall be located at a minimum distance of 15 mtrs.
from the Tank Wagon/Tank Trucks measured from edge of the facilities.
xii) Fire water monitors shall be provided with independent isolation valves.
xii) Hose box with 2 nos. hoses and a nozzle shall be provided at each hydrant points.
xiii) The deluge valves shall be located out side the kerb wall at a safe distance in case
of LPG spheres/ bullets and 15 meters away from the limits of LPG cylinder sheds. A
fire wall shall be provided for the protection of deluge valve and for operating
personnel.
xiv) The fire water deluge valves shall be kept outside the kerb wall at a safe distance
in case of sphere/ bullet, and located 15 M away from limits of other sheds or
shadows of spheres. A fire wall shall be provided for the protection of the deluge
valve and for personal protection of the operator.
11.9 MATERIAL SPECIFICATIONS
All the materials used in fire water system using fresh water shall be of type as indicated
below.
i) Pipes : Carbon Steel (CS)

per IS:3589/IS:1239
ii) Isolation Valves Carbon Steel
iii) Deluge valve Carbon Steel
iv) Hydrant
Standpost CS
Outlet valves Gunmetal/ Aluminium
v) Monitors CS
Equivalent or superior materials meeting the design requirements can also be used .
INSTALLATIONS
vi) In case of underground mains the isolation valves shall be located in RCC/ brick
masonary chamber.
vii) The above ground fire water main and the fire hydrant standpost shall be painted with
corrosion resistant "Fire Red" paint as per IS : 5.
viii)Water monitor, hydrant point and hose box shall be painted "Luminous Yellow' IS :
5.
11.10 MEDIUM VELOCITY SPRINKLER SYSTEM
The medium velocity spray system shall be provided in all critical areas like LPG
Storage Area, Sheds, LPG Pump/Compressor House, Tank truck/ wagon loading /
unloading areas, valve manifolds etc.
i) Spray nozzles shall be directed radially to the vessel at a distance not exceeding 0.6 m
from the equipment surface. Only one type and size of spray nozzle shall be used in
a particular facility. The horizontal extremities of water flow from spray nozzles
shall at least meet.
Where projections (manhole flanges, pipe flanges, staircase, supports brackets)

obstruct the water spray coverage, including rundown or slippages on vertical surface,
additional nozzles shall be installed around the projections to maintain the wetting
pattern. First valve of the vessel shall be adequately covered with sprinklers.
Horizontal dry piping down stream of the block valve and after deluge valve shall
have adequate drain facilities at selected locations.
11.11 AUTOMATIC FIRE PROTECTION SYSTEM
i. Automatic fire protection (Fixed) system based on heat detection through thermal
fuses/ quartz bulbs/ EP detectors shall be employed. Sensors shall be installed at all
critical places wherever medium velocity spray system has been installed as described
below :
a. In LPG storage area, such detectors shall be provided encircling each vessel, equi-
spaced with a maximum spacing of 1 meter at an elevation of about 1.5 to 2.0
meter from bottom of vessel. Also minimum 2 nos. detectors shall be provided at
the top of the vessel and atleast one near the liquid line ROV to take care of
failure of flanges. In case of an automatic thermal fuse based fire protection
system the instrument air supply pressure to thermal fuses shall be maintained
through a pressure control valve and a restriction orifice.
b. Detectors shall be placed at critical locations in LPG sheds (filling, cylinder

storage, testing, evacuation, etc.) loading/ unloading gantries, LPG compressor
house, piping manifold, repair sheds etc. Upon actuation there shall be alarm in
control panel, LPG pumps and compressors would trip, ROVs (wherever
INSTALLATIONS
provided) on LPG supply and return lines would trip and the deluge valves on fire
water sprinkler system will get actuated.
ii) In case, Quartzoid Bulbs are used for detection, the same shall be designed to blow at
79 deg. centigrade (max.) and Quartzoid Bulb network shall be maintained with plant
air at a pressure not more than 3.5 kgs/sq.cm.g and shall be such that the discharge of
air through one Quartzoid Bulb will depressurise the system to actuate the deluge
valves.
iii) In case of Electro pneumatic (E.P) heat detectors, it shall actuate the deluge valve in
any of the following conditions :
a) Rate of rise - 10 oC/min of temp.
b) At 79 deg. C (max.)
The EP detectors shall be divided in groups and alternate detectors shall be connected
in one circuit. Two detectors from two different groups shall function/ operate for
actuation of sprinkler system.
iv) Water spray nozzles and heat detection system shall be of approved type and duly
certified for the performance.
iv) The actuation of detectors shall initiate the following :
0i) Opening of deluge valve of the affected zone as well as adjacent zones.
ii) Audio-visual alarm indicating the affected zone at the fire pump house and
manned control panel. The control panel shall also have status indications for
deluge valves with facility for actuation.
iii) Fire siren of l km range
iv) Closure of all Remote Operated Valves in affected facility.
v) Tripping of main power supply barring the emergency power
vi) The water spray from all nozzles within 30 seconds.
vii) The fire water pump(s) shall start based on their set pressure to supplement/ to
maintain the fire water pressure in the ring main.
Additionally suitable systems like push buttons etc. for initiating all the above actions
shall be provided on remote operating panel. Further similar system like push buttons, air
release valves etc shall also be provided in the field at safe location for enabling manual
actuation by an operator. In case, the zoning concept is used for MV sprinkler system, the
INSTALLATIONS
operations of sprinklers in various zones shall be clearly earmarked on the push buttons.
In the field, manual bypass valves of fire water deluge valves shall also be provided.
The performance test certificates after installation in respect of spray density, flow rate,
response time for each facility to be protected provided by manufacturer shall be
maintained at the LPG Installations and verified once in 6 months and records
maintained thereof. Further, all spray nozzles shall be inspected for proper positioning,
corrosion and cleaned if necessary at intervals of not more than 12 months or earlier
based on actual experience.
Care shall be taken in positioning nozzles so that water spray does not miss the
targeted surface and reduce the efficiency or calculated discharge rate.
11.12 FIRST AID FIRE FIGHTING EQUIPMENT
11.12.1 PORTABLE FIRE EXTINGUISHERS
i) Portable fire extinguishers shall be located at convenient locations and shall at all
times be readily accessible and clearly visible.
ii) The maximum running distance to locate an extinguisher in working areas shall not
exceed 15 meters.
iii) The top surface of the extinguisher shall not be more than 1.5 meter high.
iv) The fire extinguishers shall be provided at various locations as under :
Area Portable Fire Extinguisher
LPG Storage 2 Nos. 10 kg DCP extinguisher.

Vessel(Each)
LPG cylinder 2 Nos. 10 kg DCP extinguisher per 200 Sq.M.Area.

Sheds
LPG Pump 2 Nos.10 kg. DCP extinguisher per 50 Sq.m. Area.

Houses
Tank Truck loading/ 1 No. 10 kg. loading gantries DCP Extinguisher

in each bay.
Tank Wagon loading/ 1 No. 10kg unloading gantries DCP Extinguisher

for every 15/20 meters of gantry.
Other Pump Houses 2 Nos. 10 kg DCP extinguisher
Office/Canteen/ 2 X 10 kg DCP
INSTALLATIONS
Stores extinguishers in each building
MCC/ At 2 x. 4.5 kg CO2 extinguisher in each room or

DG Room for floor Area of about 100 Sq.m.& 4 sand buckets
/ HT Room & a stand shall be provided in MCC/ DG Room.
v) 100% spare CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher
Capacities) shall be stored in the LPG plant.
11.12.2 WHEELED/ MOBILE FIRE FIGHTING EQUIPMENT
i) One No. Mobile 75 Kg DCP fire extinguisher shall be provided in filling shed, LPG
storage vessels/ LPG Pump House area, Tank truck loading/ unloading gantry area &
tank wagon loading/ unloading gantry area.
ii) The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based or
Sodium Bicarbonate as per OISD-GDN-115. Nitrogen/ Carbon Dioxide shall be used
as expelling gas.
iii) A trolley containing first aid fire protective accessories shall be readily available in
the LPG plant.
11.12.3 HOSES, NOZZLES AND ACCESSOREIS
i) Reinforced rubber lined hoses (63mm) conforming to IS : 636 (type A or B) shall be

provided.
ii) The hoses shall be of 15 Meters standard length and shall be provided with Gun
metal/ Aluminium alloy male & female couplings of instantaneous pattern.
iii) Minimum of two or 25% spare Hoses shall be stored in the LPG plant.
iv) In addition to the nozzles provided in the hose boxes there shall be at least 2 Nos.
spare nozzles in each category viz. Jet Nozzles with branch pipes, Fog Nozzles,
universal Nozzles, water curtain Nozzles, Spray Nozzles and Tripple purpose nozzles
in the plant.
v) The following accessories/ first aid items shall be provided in the plant :
1. Fire hoses Two nos. for each

Hose Box
2. Safety helmets 1 no. for each person.

(min. 10 nos.)
3. Hose Box At each hydrant point.
4. Stretcher with Min. 2 Nos. blankets.

INSTALLATIONS
5. First aid Box Min. 2 nos.

6. Rubber hand gloves Min. 2 pairs
for electrical (BIS approved)
purpose.
7. Low temperature 4 pairs

rubber hand gloves
for LPG emergency
as per OISD-GDN-115
8. Low tem. protective Min. 2 sets

clothing for LPG
emergency.
10. Fire proximity suit Min. 1 No.
11. Resuscitator Min. 2 No.
12. Red/Green Flags As reqd
13. Self contained Min. 1 No.

breathing apparatus
with one spare cyl.
(Cap. 30 minutes)
14. Water jel blankets Min. 2 nos.
15. Portable Gas detectors Min. 2.

/ Explosimeter
The above are guidelines and minimum requirements of each item and can be
increased depending upon the scale of operations, statutory/ mandatory requirement
of local bodies/ State Governments or any other expert body.
11.13 EMERGENCY CONTROL / ALARM SYSTEM
11.13.1 FIRE ALARM SYSTEM
i) Manual call points near to filling shed, storage area, tank truck/ wagon gantry, pump
house, etc. shall be provided and clearly marked in the installation. Operation of these
points shall raise audio visual alarm in control room.
ii) Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1
K.M. from the periphery of the plant).
iii) Manually operated fire sirens shall be provided at strategic places.

INSTALLATIONS
iv) For fire condition the siren shall be wailing sound for minimum `2 minutes and for all
clear signal it shall be straight run siren for 2 minutes.
v) For Disaster condition the wailing sound given shall be repeated thrice with a
minimum 10 seconds gap.
11.13.2 COMMUNICATION SYSTEM
i) Communication system like telephone/ PA or paging or walkie-talkie shall be

provided.
ii) In the hazardous areas, flame-proof / intrinsically safe telephones shall be provided.
iii) Wherever possible Hot line connection between City Fire Brigade/ near by major
Industries shall be provided.
iv) Plant shall have a ` Mutual Aid' arrangement with near by industries.
11.14 SPECIAL FIRE PROTECTION
The most hazardous situation in LPG vessel is the possibility of BLEEVE. This usually
takes place when the vessel is subjected to external fire.
The unwetted (vapour space) portion of the shell gets overheated and fails even at the
operating pressure. As such, it is important that metal temperature in the vapour space is
protected from overheating by some measures. A passive measure like fire proofing/
insulation or fire retardant coating will provide protection in the initial period of fire
which is very crucial. This will give some breathing time for activating other fire fighting
measures like starting of pumps, organising people, opening of valves etc. This will also
take care of automation failure wherever it is provided.
The fireproofing of LPG storage vessel should be decided based on the risk analysis
keeping in view local considerations, availability of water and societal risk.
The fireproofing of LPG storage vessel shall be decided based on the fire safety analysis
keeping in view local considerations, population density, availability of water, societal
risk and fire protection measures provided.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect the
shell material from overheating and consequent failure. The minimum rating for fire
proofing shall be as under :
LPG storage vessel & connected 1 hr.

lines upto the fire safe ROVs
Supporting legs of all above 2 hr.
INSTALLATIONS
Fire proofing is not required for diagonal bracing, including tie rods, or redundant
members that are not necessary for supporting the static loads.
Before fire-proofing application, protected metal surfaces shall be prepared through such
means as sand-blasting and corrosion-protective primers. Particular attention shall be
given to the top junction of the fire-proofing with the protected metal to prevent water
ingress. OISD-STD-164 on "Fire proofing" shall be referred for details on fire proofing.
Fire water line to each sphere should be so routed that it is not exposed to direct fire.
This is to protect it from failure in the initial period when water flow has not commenced.
It is recommended that riser should be located away from bottom ROV. The horizontal
run of the Fire Water line may be buried if fire engulfment cannot be avoided otherwise.
Fire proofing shall include connected LPG lines and pipe supports within 15 M of a
storage vessel or in the drainage paths.
11.15 INSPECTION AND TESTING
The fire protection equipment shall be kept in good operating condition all the time.
The fire fighting system shall be periodically tested for proper functioning and logged for
record and corrective actions. In addition to routine daily checks/ maintenance the
following periodic inspection/ testing shall be ensured.
11.15.1 FIRE WATER PUMPS
i) Every Pump shall be in test run for atleast 10 minimum twice in a week at the rated
conditions.
ii) Once in a month each pump shall be checked and tested and the shut-off pressure
observed and logged. Also the pump performance shall be ascertained.
iii) The Jockey pump operation shall be checked periodically. Frequent start/ stop
condition of Jockey pump indicates that there are water leaks in the system.
11.15.2 FIRE WATER RING MAIN

i) The ring main shall be kept pressurised at 7 kg/sq.cm.g with the help of one or more
jockey pumps.
ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion at
least once in week and records maintained thereof.
iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/
operation and lubricated once in a month.
INSTALLATIONS
11.15.3 FIRE WATER SPRINKLER SYSTEM
i) All deluge valves and sprinkler system shall be operated and checked once in a
quarter for correct remote operation performance of each nozzle and effectiveness of
system in total.
ii) Testing of sprinkler system in the sheds shall be carried out by closing the outlet of
the deluge valve for correct remote operation once in a quarter.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.
11.15.4 FIRE WATER RESERVOIR
In case of a Reservoir the same shall be cleaned once in 6 months or earlier as and when
needed so that there shall not be any foreign particles/ fungus/ vegetation in the reservoir.
11.16 MAKE UP WATER
Facilities to make up water during fire fighting shall be provided.
INSTALLATIONS
CHAPTER 12
GAS MONITORING SYSTEM
12.0 GENERAL
The best method of prevention of explosion is to avoid basic build up of gas

concentration immediately on occurrence of leakage. This would require basically a
reliable and continuous detection system with warning annunciation to alert the plant
personnel to take corrective action.
The Gas Monitoring system shall provide early warning on build up of dispersed gas
concentration below the LFL limits.
The system shall be designed considering small leaks (leaks which have secondary
closures) such as mechanical seals failure, sampling point left open, gasket leaks, hose
pinholes, valves gland leakage, drain point left partially open, TSV’s relief discharge
in manifold area, filling/ evacuation hoses leakage.
12.1 APPLICATION
i) The detectors for the gas monitoring system shall be strategically located in LPG
Bottling Plant at all facilities close to the potential source of leakage.
ii) The detection control equipment should be provided in the control room for
continuous monitoring even during power failure.
12.2 DETECTORS
Amongst the various methods of detection available, the following proven systems
for LPG can be considered.
i) Catalytic detectors
ii) Infra-red detectors
12.3 CONTROL SYSTEMS
i) This is a critical equipment for plant’s safety. Hence, the system should have
independent control equipment, power supply, UPS to ensure that the system remains
in operation even if the plant DCS or other common process controls are not
functioning. In case of bottling plant in Refineries, dropping of the signals on the
DCS is acceptable wherever hot standby DCS control system is available.
ii) In case of failure or during maintenance when the system is not in operation, the plant
safety officer should keep the plant personnel on alert to be more vigilant during
operations and night security patrolling.
INSTALLATIONS
iii) The control equipment should have data logging facilities to provide print outs of the
history of the events with date and time of leakages.
iv) The control equipment should be able to generate at least two alarms at different
levels of LEL concentration of gas.
v) The control equipment is not required to have automatic corrective action capabilities
on sensing leakages as this is basically a warning device. However, in case of any
specific recommendations made in the risk analysis / HAZOP studies, the same
should be implemented.
12.4 ANNUNCIATION SYSTEMS
Appropriate annunciation system shall be available to ensure that all the alarms
generated, both, audio and visual are reported to the plant personnel, who are authorized
to take corrective action. Depending on the manning practice of the plant, the alarms
both, audio and visual can be repeated at additional location to ensure corrective action is
taken.
12.5 LOCATION OF DETECTORS
i) The behaviour of the gas leakage governs the positioning of the gas detector. As LPG
is heavier than air, the height of the detector should not be more than 0.3 M from the
mounting level.
ii) The pre-dominant wind direction should be considered with respect to the potential
source of leakage to ensure positioning of the detector on the down stream side of the
wind direction.
iii) The detectors especially the catalytic type should not be positioned very close to the
potential source of leakage to avoid poisoning of the detectors(temporary
malfunctioning). The detectors should be located at least 0.3 mtrs. away from the
potential source of leakage.
iv) In case of infra-red detectors, the same shall be installed on the down wind side
ensuring the path is free from obstructions. In case any additional expansion/
construction if undertaken, the detectors will have to be pre-positioned.
v) The minimum detectors facilities-wise are as given below:
Storage vessels (above ground) – 1 No. top and 1 No. near bottom ROV.
LPG pump house 1 No. in pump house and 1 No. in manifold.
Filled cylinder shed - 2 No.
Valve change shed – 1 No.

INSTALLATIONS
Empty-cum-filling shed – 2 Nos. near carousel, 1 No. near evacuation unit tank, 1 No.
weight correction unit.
TLD – one at each manifold and at ends.
Tank wagon gantry – 1 no. for every two bays or 30 m whichever is less at bottom.
Additionally, some detectors at selected locations shall be provided at the top of
platform.
The number and location of the detectors required over and above the minimum
requirements specified above shall be as per the specific requirements identified in the
risk analysis / HAZOP study report.
The location can be decided by assessing the behaviour of gas drift and consequential
safety risk.
vi) Inspection and testing
The gas monitoring system shall be kept in good operating condition all the time.
The inspection of the system shall be done at an interval of 1 month in which the gas
shall be released at all the detectors and the performance of the systems shall be
established.
The calibration of the equipment shall coincide with the monthly inspection schedule
every three months for calibration of the gas detectors the calibrated gas with known
and certified level of concentration shall be used.
The drift in the sensitivity of the individual detectors shall be recorded in maintenance
history log book during calibration and the detectors with abnormal or wide drift in
sensitivity.
The plants should have at least 2 Nos. spare detectors for each system maintained at
all times to facilitate immediate replacement of defective detectors.
INSTALLATIONS
CHAPTER 13
EMERGENCY MANAGEMENT PLAN
13.0 GENERAL
13.1 The best way to manage any emergency is to prevent it. Following guidelines for
emergency prevention shall be followed :
a) Sound engineering practice in the design, fabrication, installation and

maintenance of facilities.
b) Careful selection and correct use of equipment.
c) Observance of safety and security regulations.
d) Proper and constant training and guidance to all personnel working in the Plant,
with particular reference to product knowledge and maintenance practices.
e) Good House-keeping.
f) Constant supervision and alertness.
13.1.2 EMERGENCY PLANS :
Plant Manager shall ensure that suitable instructions are issued to both Corporation's and
contractor's personnel identifying the action to be taken by each one in an emergency.
This should be achieved by display of organisation chart/ posters not only for fire-
fighting but also for other likely emergencies. Likewise, for emergencies of large
magnitude Emergency Response Plan (or Disaster Management Plan) to be drawn out in
coordination with related outside agencies, such as local administration, Police
authorities, Fire Brigade, hospital authorities, home guards, neighbouring industries etc.
Periodic mock drills for all such plans to be conducted, and plans to be updated/ modified
based on experience gained during such drills.
13.1.3 CHECK FOR LPG LEAKAGE AT FOLLOWING LOCATIONS
a) Through water drain valve while draining.
b) Leaking sample valve.
c) Breakage of glass on Sight Flow Indicator on the pipeline.
d) Opening of pop-off valve, gland/ packing etc.
e) Leakage through LPG compressor/ pump.

INSTALLATIONS
f) Leakage due to bursting/ rupture of hose or through sviwel joints of body arms.
g) Leakage from the filling guns.
h) Escape of liquid/ vapour LPG during maintenance/ repairs.
13.1.4 SOME OF THE COMMON CAUSES OF FIRE :
(a) ELECTRICAL :
i) Short circuiting due to loose wiring including that of automobile moving in the
area.
ii) Use of non-flame proof fittings such as lights, torch, motors, fan, telephone,
temporary lighting etc. (Note : Flameproof fittings become non-flame proof due
to poor maintenance e.g. increase in gap in junction boxes, due to missing nuts
and bolts or improper glands used for connection to junction box, or sealing
compound not used in junction boxes etc.)
iii) Static electricity as result of improper bonding/ grounding to tanks, conveyor

system, tank truck, tank wagon etc.
(b) VEHICLE :
i) Exhaust of vehicle, if effective spark arrestors are not provided.
ii) Operation of non-FLP electrical switches such as vehicle ignition.
iii) Spark from the loose contact on vehicle batteries.
iv) Spark from exhaust of railway engine.
v) Cinders from the steam locomotives.
(c) OTHERS
i) Landing of crackers (flying type ) in hazardous areas.
ii) Chiselling/ hammering.
iii) Spark from studed shoes, with steel button by friction against ground/ metal.
iv) Lighted agarbatti in a truck.
v) Excessive release of vapour beyond safe limit and fire due to outside source of
ignition.
INSTALLATIONS
vi) Lighting
vii) Smoking.
13.2 ACTION DURING EMERGENCY
13.2.1 Immediate action is the most important factor in emergency control because the
first few seconds count, as LPG fires develop and spread very quickly unless
prompt and efficient action is taken. In the event of fire/ gas leak within LPG Plant
the following action shall be taken as quickly as possible:
a) Take immediate steps to stop LPG leakage/ fire and raise alarm simultaneously.
b) Initiate action as per Fire Organisation Plan or Disaster Management Plan, based on
gravity of the emergency.
c) Stop all operations and ensure closure of all ROVs and isolation valves.
d) All out effort should be made to contain the spread of leakage/ fire.
e) Saving of human life shall get priority in comparison to stocks/ assets.
f) Plant personnel without specific duties should assemble at the nominated place.
g) All vehicles except those required for emergency use should be moved away from
the operating area, in an orderly manner at pre-nominated route.
h) Electrical system except for control supplies, utilities, lighting and fire fighting
system, should be isolated.
i) If the feed to the fire cannot be cut off, the fire must be controlled and not
extinguished.
j) Start water spray system at areas involved in or exposed to fire risks.
k) In case of leakage of LPG without fire and inability to stop the flow, take all
precautions to avoid source of ignition.
l) Block all roads in the adjacent area and enlist Police support for the purpose if
warranted.
13.2.2 Fire Fighting Operations :
a) Enlist support of local fire brigade and neighbouring industries.
INSTALLATIONS
b) If escaping vapour cannot be stopped, jets of water should be directed at the point of
leakage to assist controlled release of vapour and in between water fog should be
used for dilution and rapid dispersion of vapour cloud.
c) Fire Fighting personnel working in or close to un-ignited vapour clouds or close to

fire must wear protective clothing and equipment including safety harness and
manned life line. They must be protected continuously by water sprays. Water
protection for fire fighters should never be shut off even though the flames appear to
have been extinguished until all personnel are safely out of the danger area.
d) Exercise care to ensure that static charge is not generated in LPG vapour cloud. For
this purpose solid jets of water must be avoided, instead fog nozzles should be used.
e) Fire fighters should advance towards a fire down wind if possible.
f) Cylinder fire should be approached using proper barricades/ protection to avoid

direct hit from flying cylinders.
g) If the only valve that can be used to stop the leakage is surrounded by fire, it may be
possible to close it manually. The attempt should be directed by trained persons
only. The person attempting the closure should be continuously protected by means
of water spraying (through fog nozzles), fire entry suit, water jel blanket or any
other approved equipment. The person must be equipped with a safety harness and
manned life line.
h) Any rapid increase in pressure or noise level of product discharged through safety
relief valve of the vessel/ pipeline should be treated as a warning of over
pressurisation. In such cases all personnel should be evacuated immediately.
i) As in case of any emergency situation, it is of paramount importance to avoid

endangering human life in the event of fire involving or seriously exposing LPG
equipment or serious leakage of LPG without the fire.
13.2.3 Action in the event of LPG leakage without fire :
a) Take basic action as detailed in 13.2.1 above.
b) If escaping LPG is not on fire, close any valve which will stop the flow.
c) In some cases like the leakage from a pressure vessel without a fire (such as leak
from tank truck bullet or overturning) it may be desirable to move the vessel to
some remote area such as block of isolated roadway or open field where it can be
allowed to leak safely without a source of ignition nearby. However, if this is to be
done, the vessel must be moved in an upright position. Never drag the vessel in a
manner which might damage valve or pipeline. Any attempt to turn a vessel back
upright to move it to some remote location should be done carefully to avoid
damage to valve and pipelines.
INSTALLATIONS
Take necessary actions as detailed in 13.2.2.
13.2.4 Action in the event of LPG fire
a) Take basic action as detailed in 13.2.1 above.
b) Extinguishing Fires - A small fire at the point of leakage should be extinguished by

enveloping with a water spray or a suitable smoothening agent such as carbon
dioxide or dry chemical powder. However, it is again stressed that LPG fire should
not; except in special circumstances explained earlier; be extinguished until the
escape of product has been stopped.
c) Fire fighting procedure - Fire fighting procedures would vary depending upon
various factors such as nature, sources, size, location, etc. of fire. Basic fire fighting
techniques have been explained earlier in section 13.2.2. However, for the purpose
of guidelines, fire fighting techniques for few common cases are as follows :
(i) Cylinder Fire : If a filled cylinder is involved in fire, internal pressure may start
rising and if not relieved the built up pressure could rise above 70 kgf/cm2g and
ultimately rupture the container. Ignition of the escaping gas would aggravate the
fire but the release of pressure would reduce the possibility of rupture of the
container. No attempt should be made to extinguish the burning gas. Bus the
container and other containers in the vicinity should be kept cool by water sprays
until the contents of the container have burnt away. If the gas leakage does not
ignite, the container should be approached from upwind (if in the open air) and be
removed to a place of safety remote from sources of ignition. Cylinders not directly
involved in the fire should be moved away from heat exposure, while applying
cooling water sprays on cylinders directly involved.
(ii) Fire on storage vessel : If a pressure vessel is exposed to radiant heat from
external fire, it should be kept cool by water sprays to prevent excessive pressure
rise in the vessel. Cooling water sprays must be applied without delay to the heat
affected area using fixed water sprinkler system or equivalent spray water coverage,
through fixed monitors or other equipment. Cooling the vessel with water sprays
reduces the heat input to the vessel and thereby reduces the pressure, thus, reducing
the rate of discharge from the relief valves.
(iii) Leakage of LPG burning at the outlet of a cylinder valve: Extinguish the fire by
means of a portable fire extinguisher, or smoothening with a thick non-synthetic
cloth (preferably wet) or sand/ earth etc.
Fix safety cap on the valve to prevent further leakage.
After the fire is extinguished, if the leakage cannot be stopped the cylinder should
be moved carefully to a safe location to vent out the contents under controlled
conditions.
INSTALLATIONS
(iv) Fire of LPG vapour escaping from a damaged vessel fitting (flame not playing
on vessel)
Allow fire to continue till exhaustion.
Spray vessel with water to cool it, if vessel is being heated by radiation from the flame or
if flame is endangering other plant equipment.
Cool adjacent vessels and structures.
(v) Fire at Safety Relief Valves of vessels exposed to adjacent fire.
(vi) Fire in Oil storage area adjacent to LPG storage :

Start water sprays only on those LPG vessels exposed to fire/ heat.
Isolate affected vessels and run out fire water hoses in case hose stream cooling
becomes necessary.
Water pressure in LPG vessels.
If LPG vessel's SRVs have started blowing vapour, take no further action (apart
from cooling) unless vessel pressure continues to rise.
If fire enters LPG storage area, concentrate available cooling water on LPG vessels,
most affected.
Do not try to empty LPG vessels exposed to fire. They become more vulnerable to
overheating as their liquid content decreases.
13.2.5 Fire Fighting Organisation Plan
(a) A plan of action for use in the event of a major LPG product leakage with a fire or
risk of fire is essential. Such a plan must be carefully prepared for each plant. It
should be fully understood by all LPG plant supervisory personnel and other
personnel responsible for action as per plan. It shall be based on the following :
(i) Plant personnel shall be fully trained for the specialized techniques necessary for
combating LPG leakages and LPG fires.
(ii) If leakage and/ or fire occurs, all personnel should use the equipment provided and
to carry out their allotted tasks as detailed in the fire fighting organisation plan.
(iii) All personnel should be conversant with fire control equipment and also its location.
(iv) LPG plant personnel should know the position and method of operation of all
Remove Operation valves (ROVs) in the plant.
INSTALLATIONS
(v) Plant personnel should be familiar with the standard recognition markings of fire
control, first aid and all safety equipment, must know the location of emergency
exits, and they should know the location of water hydrant points/ monitors and must
be familiar with the sound of the emergency (fire) alarm.
(b) The Fire Fighting Organisation Plan together with layout of fire fighting and safety
devices shall be displayed at prominent places and explained to all personnel. It
shall include the following functions, expanded to suit the location facilities/
requirement:-
(i) Sounding the emergency (fire) alarm.
(ii) Shutting off the LPG supply to any leakage point/ fire.
(iii) Summoning the fire brigade/ police.
(iv) Fire control, with first aid, fire fighting equipment.
(v) LPG vapour dispersal.
(vi) Operation of LPG vessel's fixed water sprinkler system, starting of fire pump (s) and
application of water hose jets/ sprays for containing/ extinguishing fires.
(vii) Cooling of vessels/ cylinders and other equipment/ facilities.
(viii) Closing down all operations in the plant including closure of valves and stopping of
pumps.
(ix) Preventing all sources of ignition in case of LPG leakage.
(x) Evacuation of vehicles.
(xi) Evacuation and mustering of personnel.
(xii) Establishing an emergency fire-control centre.
(xiii) Traffic control.
(xiv) Stations and duties of all personnel.
(xv) Policing of affected areas.
(xvi) Any other specialised duties.
(xvii) Display of fire brigade, ambulance, Police telephone numbers etc.
(xviii) All clear signal by competent person.

INSTALLATIONS
(c) Liaison with local fire brigade :
Close co-operation with the local fire authorities is essential and shall take the following
form :
(i) The fire brigade should be made familiar with the layout of the plant and the location
of important equipment/ facilities provided, and their method of use. Mock fire
drills/ exercise jointly by plant personnel and local fire brigades shall be planned.
(ii) Fire fighting equipment at the plant shall be compatible with the fire brigade
equipment, otherwise adapters shall be kept ready for hoses, hydrants etc.
(iii) The fire brigade shall be aware of the plant's fire fighting organisation plan and the
views held at the plan regarding the most effective LPG fire control methods.
(iv) In the event of an emergency/ fire, the plant manager and/ or his representative shall
advise the Fire Officer about particular or potential hazards that may be present e.g.
stocks of filled cylinders at that particular point of time.
(d) Fire Drills & Training :
a) Drills for all Plant personnel, making use of the "Fire fighting Organisation Plan"
and practicing the specialised techniques required for fighting LPG fires or
dispensing/ diluting LPG vapour clouds shall be held minimum once in a month.
b) The drills should cover various types of incidents, e.g. major spillage, LPG bulk
lorry fire, cylinder fire etc.
c) Extinguishers due for recharging/ due for hydrotesting shall be discharged during
drills and replenished subsequently 50% (Min.) stock of refills as replenishment for
FEs should be maintained.
d) The fire pump should be run, sprinkler system activated, emergency systems tested,
water hoses run out and spray/ set techniques practiced during drills.
e) Fire alarms shall be sounded/ tested (neighbouring plants/ factories and the fire
brigade shall be warned in advance of this test).
f) Protective clothing, breathing apparatus and any other specialised safety equipment
available shall be tried out during drills to train all concerned in their application.
g) The local fire brigade should be encouraged to participate in fire drills periodically.
h) Any shortcoming, noticed during the drill shall be rectified.
INSTALLATIONS
13.2.6 Disaster Management Plan :
ON- SITE
a) It is basically a pre-plan to handle any emergency situation of a higher magnitude

arising out of factors listed below:
(i) Major fire/ explosions
(ii) Uncontrollable leakage of LPG
(iii) Lightning
(iv) Heavy floods
(v) Earthquakes/ land slides
(vi) Sabotage/ terrorist outrage
(vii) War situation
The objective of the plan shall be to reduce the probability of serious loss/ damage to
general stock, plant and machinery, documents etc. utilizing combined resources of the
location itself and the outside agencies. In order to have an effective organisation,
preliminary meeting shall be conducted with the representatives from local fire services,
police authorities, voluntary organisations like ambulance service/ Govt. medical service/
contractors and even Home Guards and defence personnel. In the course of the meeting,
there should be exchange of knowledge, training and plans for development of expertise
and skills to gain knowledge about the plant layout/ facilities, potential of likely hazards/
risks, likely emergencies that may arise. This group should draw out modalities of the
exercises in the given situation and arrive at an agreed action plan which should be
updated from time to time and put to test in the form of periodical mock drills.
(b) Due to varying risk potentials and also varying hazards at/ around each location
`Disaster Management Plan' for each location shall be drawn up individually based
on the outline given below:
(i) Identify Disaster scenario i.e. the situation under which the plan would become
operational. Plan for the worst possible scenario.
(ii) Identify resources required from each of the outside agencies.
(iii) Establish outside agencies, role of each agency and obtain their commitment for
rendering the assistance in crisis situation as per the agreed plan.
INSTALLATIONS
(iv) Establish organogram for Disaster Management based on available manpower in

various groups and identify the leader and alternative leader for each for the groups
and the role to be played by each team in various likely crisis situations.
(v) Identify Disaster control room/ group.
(vi) Furnish detailed data and drawings relevant for the crisis management.
(vii) Establish channel of communication at the local level to Statutory Authorities and
higher authorities within the organisation.
(vii) Mock drills to be conducted minimum once a year.
(ix) Modify the plan based on the experience gained through mock drills and try out the
modified plan through subsequent mock drills.
(x) The plan shall be updated as and when the changes recorded in the plan occur and
communication sent to all concerned.
(c) Communication organogram :
As a part of Disaster Management Plan, communication organogram shall be drawn up

giving flow of communication from the originating location to various local agencies and
also to Statutory Authorities and upwards within the organisation to mobilise support and
to consider alternatives for maintaining essential supplies.
INSTALLATIONS
CHAPTER 14 : SAFETY AUDIT
14.1 GENERAL:
Safety audit is a well recognised tool to improve the effectiveness of safety programme
and loss prevention measures by carrying out systematic and critical appraisal of potential
safety hazards involving personnel, plants and equipments.
For a structured and systematic safety audit of any plant/ facility, check lists are the most
important prerequisite. Check lists should cover all the operational areas, major
equipments, operating/ maintenance procedures, safety practices, fire prevention/
protection systems etc. Observations/ recommendations of safety audit team should be
presented in the form of a formal report and action plan for corrective measures should be
prepared and subsequently monitored for implementation.
General guidelines on safety audit methodologies and techniques are also given in OISD
- GDN- 145.
14.2 TYPE OF SAFETY AUDIT AND PERIODICITY :
In view of the high hazard potential of LPG, safety audits at frequent intervals by the
teams/ personnel of various levels are advocated, Broad check lists for different
recommended safety audits are given in the Annexure 10-I, II, III, IV. These check lists
can be further supplemented and modified suitably to meet the specific requirements of
individual plant. Recommended minimum safety audits at different levels, their
frequencies and broad check lists to be used are indicated below :-
Daily audit essentially shall cover the compliance of recommended operating procedures/
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken on priority wherever required.
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S.No. Type of Safety By Frequency Checklist
Audit (Annexure)
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1 2 3 4 5
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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
--------------------------------------------------------------------------------------------------------------------------------
INSTALLATIONS
Daily audit essentially shall cover the compliance of recommended operating procedures/
safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis
and corrective action be undertaken alongwith the target dates shall be done immediately.
The compliance to other audit recommendations along with target schedules shall be
monitored on monthly basis. Alternate, safety measures shall be taken till the
recommendations are complied in totality.
In case of external safety audit, following areas besides the points given in check list of
Annexure 14- III shall be covered.
1. Safety Organisation
2. Security System
3. Fire prevention/ protection system
4. Preparedness to handle any emergency --Disaster control plan and mock drills.
5. Skill level and training needs for HRD.
6. Operating manual/ instructions, display of Do's/ Don'ts etc.
INSTALLATIONS
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)
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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).
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INSTALLATIONS

1 2 3 4 5 6
(status)
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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 -----------
INSTALLATIONS
C. TANK WAGON UNLOADING
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1 2 3 4 5 6
(status)
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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 -----------
INSTALLATIONS
D. BULK TRUCK UNLOADING

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1 2 3 4 5 6
(status)
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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 -----------
INSTALLATIONS
E. PUMP HOUSE/ COMPRESSOR ROOM
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1 2 3 4 5 6
(status)
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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 -----------
INSTALLATIONS
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.
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1 2 3 4 5 6
(status)
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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
INSTALLATIONS
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.
INSTALLATIONS
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.
INSTALLATIONS
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1 2 3
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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.
INSTALLATIONS
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
INSTALLATIONS
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1 2 3
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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.
INSTALLATIONS
ANNEXURE 14- III
DETAILED SAFETY AUDIT OF LPG BOTTLING PLANTS
LOCATION _____________ Dated ____________
AUDIT/ INSPECTION BY ______________________
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1 2 3
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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.
INSTALLATIONS
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1 2 3
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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 -
INSTALLATIONS
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 Ò' 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
(Ò' 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.
INSTALLATIONS
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1 2 3
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- PTFE tape/ paste or other suitable sealing compound used.
C-20 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys.
C-21 Mastic flooring provided on the floor storage area to avoid accidental sparks.
C-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.
INSTALLATIONS
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1 2 3
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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
INSTALLATIONS
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1 2 3
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- 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.
INSTALLATIONS
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1 2 3
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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.
INSTALLATIONS
--------------------------------------------------------------------------------------------------------------------------------
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.
INSTALLATIONS
ANNEXURE 14- IV
INSPECTION & MAINTENANCE SYSTEM AUDIT

LOCAL _______________ DATED: _________
AUDIT/ INSPECTION BY ________________
--------------------------------------------------------------------------------------------------------------------------------
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.
INSTALLATIONS
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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.
INSTALLATIONS
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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.
INSTALLATIONS
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
INSTALLATIONS
--------------------------------------------------------------------------------------------------------------------------------
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

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
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
INSTALLATIONS
-------------------------------------------------------------------------------------------------------------------------------
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
INSTALLATIONS
-------------------------------------------------------------------------------------------------------------------------------
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

LPG
IS:9902-1982 - RECOMMENDED PRACTICE FOR LEAK

TESTING
IS:9975 - Ò' 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
INSTALLATIONS
--------------------------------------------------------------------------------------------------------------------------------
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
INSTALLATIONS
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
INSTALLATIONS
Figure I
INSTALLATIONS
Figure
Figure II
INSTALLATIONS
Figure III
INSTALLATIONS
Figure IV
INSTALLATIONS
Figure V
INSTALLATIONS
Figure VI
INSTALLATIONS

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OISD STANDARD - 144

LIQUEFIED PETROLEUM GAS (LPG)

Oil Industry Safety Directorate

Petroleum industry in India is significantly globalized at present in terms of technology content

Oil Industry Safety Directorate

This document will be reviewed periodically for improvements based on the

Oil Industry Safety Directorate

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

FUNCTIONAL COMMITTEE MEMBERS

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

LIQUEFIED PETROLEUM GAS (LPG)

Liquefied Petroleum Gas (LPG) is a mixture of light hydrocarbons primarily C3 & C4

Some of the important properties of LPG are as below :

The auto-ignition temperature of LPG ranges from 410 to 580 oC.

Explosive mixture : It is a mixture of combustion agent (oxidising product-gas, vapour,

Earthing : Earthing is the provision of a safe path of electrical current to ground, in

Fire safe : As applied to valves, it is the concept of controlling the leakage to an

Fire proofing : It is an insulation that provides a degree of fire resistance to protect

Flammability : It is the percentage of volume of any flammable vapour in air-vapour

Gas-Free : it means the concentration of flammable or toxic gases or both in a pressure

Horton Sphere : A spherical pressure vessel used for storage of LPG.

Installation : The facilities where LPG is stored or loading/ unloading operations or

Purging : It is the act of replacing the atmosphere within a container by an inert

Purging out of service : is the replacement of normal combustible content of a closed

Maximum Working Pressure : It is saturated vapour pressure of LPG at 65 oC for LPG

4..0 STATUTORY RULES / REGULATIONS

a. Gas Cylinders Rules, 1981 (under Indian Explosives Act,1884)

c. The Factories Act, 1948.

d. Indian Electricity Rules

f. The Standards of Weight & Measures (Packaged Commodities Rules-1977)

g. Liquefied Petroleum Gas (Regulation of supply and distribution Order - 1993).

h. The Motor Vehicles Act - 1988.

Water (Prevention & Control of Pollution) Act, 1974.

Air (Prevention & Control of Pollution) Act- 1981

The Environment (Protection) Act – 1986

Manufacture, storage & import of Hazardous chemicals Rules - 1989.

Guidelines for Environmental clearance of new projects - 1981.

a. Vasudevan Committee - 1983 Ministry of Energy (Department of Petroleum).

b. Expert Committee Review of Safety and Operating Procedures in LPG facilities -

5.0 INSTALLATION LAYOUT

5.2 LOCATION & SEPARATION DISTANCES :

a) The location of residential quarters, other industries, railways, roads, waterways,

b) Adequate availability of water from a reliable source or alternate arrangements

5.2.2 SEPARATION DISTANCES

d. No foreign material / combustible substances shall be stored in storage area.

e. Storage vessels shall be laid out in single row in each group.

5.4 LPG STORAGE FACILITIES:

(a) CONFINEMENT/ GRADING -

Grading of the ground underneath should be levelled and directed to an area

5.5 LPG BULK LOADING / UNLOADING FACILITIES

5.6 LPG BOTTLING FACILITIES

5.7 PROTECTION OF FACILITIES