OISD STANDARD - 144

FIRST EDITION
APRIL 1994

FOR RESTRICTED
CIRCULATION ONLY

LIQUEFIED PETROLEUM GAS (LPG)

BOTTLING PLANT OPERATIONS

VOLUME-1
DESIGN PHILOSOPHIES

Prepared by

FUNCTIONAL COMMITTEE ON LIQUEFIED PETROLEUM GAS (LPG)

OIL INDUSTRY SAFETY DIRECTORATE

2nd Floor, ‘KAILASH’
26, KASTURBA GANDHI MARG,
NEW DELHI-110001
 LIQUEFIED PETROLEUM GAS (LPG)

BOTTLING PLANT OPERATIONS

CONTENTS

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CHAPTER DESCRIPTION PAGE
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INTRODUCTION

SCOPE

VOLUME 1 : DESIGN PHILOSOPHIES

1. Physical Properties & Characteristics of LPG

2. Statutory Rules and Regulations

3. Plant Layout

4. Plant Design Criteria

5. LPG Cylinders and Valves

VOLUME II : OPERATING PRACTICES

6. Storage and Handling of Bulk LPG

7. Bottling Operations

VOLUME III : INSPECTION & MAINTENANCE PRACTICES

8. Plant Equipment

9. Statutory Testing of Cylinders

VOLUME IV : SAFETY & FIRE PROTECTION

10. Fire Protection Facilities

11. Emergency Management

12. Safety Audit

GLOSSARY OF TERMS

APPENDIX
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CHAPTER 1

PHYSICAL PROPERTIES AND CHARACTERISTICS OF LPG

1.1 LIQUEFIED PETROLEUM GAS (LPG)
LPG is a mixture of commercial butane and
commercial propane having both saturated and
unsaturated hydrocarbons. LPG marketed in
India shall be governed by Indian Stnadard
Code IS-4576 (Refer Table 1.0) and the test
methods by IS-1448.
LPG is inherently dangerous on account of fire,
explosion and other hazards. This calls for
special attention on the manner in which it is
bottled, transported or used. These hazards can
have an impact on both the plants and the
public. As a consequence of this special
emphasis has been placed on the safety
regulations in its handling,system design, etc.
1.2 PHYSICAL PROPERTIES AND
CHARACTERISTICS
1.2.1 DENSITY
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 deg. C.
Since LPG vapour is heavier than air, it would
normally settle down at ground level/ low lying
places, and accumulate in depressions. Under
still conditions the dissipation of accumulated
vapour can be slow. This accumulation of LPG
vapour gives rise to potential fire and explosion
hazard. Some of the areas requiring careful
consideration of this hazard in order to prevent
and control fire and explosion are as given
below :
(a) Terrain and natural drainage must slope
away from process units, buildings or other
plant facilities, storage vessels, property lines
bordering community establishments and
roadways, navigable or inhabited streams, and
towards low incident areas.
(b) There shall be no low spots under or near
the base of the container where spillage could
accumulate and the container can get engulfed
in a fire pot. For the same reasons it is
advisable to compact/ concrete beneath the
storage vessels with a slope to avoid wetting of
soil and to eliminate vegetation. This will also
facilitate evacuation/ channeling, and washing
out the spillage so that it can be trapped or
allowed to burn at a safe location.
(c) The LPG pumping facility is neither to be
provided below ground level nor beneath the
storage vessel in order to avoid the accumulation
of LPG.
1.2.2 VAPOUR PRESSURE
The pressure inside a LPG storage vessel/
cylinder will be 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 which in turn
regulates the lighter ends of hydrocarbons and
this governs the design parameters for storage
vessels.
The vapour pressure is dependent on
temperature as well as on the ratio of mixture of
hydrocarbons. At liquid full condition any
further expansion of the liquid, the cylinder
pressure will rise by approx. 14 to 15 kg./sq.cm.
for each degree centigrade. This clearly explains
the hazardous situation that could arise due to
overfilling of cylinders.
1.2.3 FLAMMABILITY
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.
The auto-ignition temperature of LPG is around
410-580 deg. C and hence it will not ignite on
its own at normal temperature.
Entrapped air in the vapour is hazardous in an
unpurged vessel/ cylinder during pumping/
filling-in operation. In view of this it is not
advisable to use air pressure to unload LPG
cargos or tankers.
1.2.4 COMBUSTION
The combustion reaction of LPG increases the
volume of products in addition to the generation
of heat. LPG requires upto 50 times its own
volume of air for complete combustion and at
the same time yields 3 or 4 times its own volume
of carbon-dioxide yielding approx. 10,900 kcal
heat per kg.
Thus it is essential that adequate ventilation is
provided when LPG is burnt in enclosed spaces
otherwise asphyxiation due to depletion of
oxygen apart from the formation of carbon-
dioxide can occur.
1.2.5 VOLATILITY
The restriction on the evaporation temperature
to 2 degree C for 95% by volume at 760 mm Hg
pressure imposes regulation on the quantity of
hydrocarbons heavier than butane. This ensures
that when the container is nearly empty, the
liquid does not have an unacceptably low vapour
pressure to let in air and to form an explosive
mixture.
When pressure is released, LPG vapourizes
rapidly lowering the surrounding temperature.
This may lead to frost burns by contact of LPG
with the skin. Protective clothing such as gloves
and goggles shall therefore be worn when there
is any possibility of contact with LPG.
Auto refrigeration effect of the vapourisation of
LPG freezes the water vapour in the atmosphere,
which makes the escaping LPG vapour visible as
a whitish cloud. Even if this cloud disappears, it
is not a sign that the inflammable gas/ air
mixture has been dispersed.
Leaking liquid phase LPG will rapidly expand
around 250 times its own volume thereby
creating a greater risk than would occur with a
similar sized vapour leakage. Sufficient ullage
space for the expansion of liquid when the
temperature rises must therefore be left in all
storage/ transport containers.
1.2.6 EFFECT OF WATER IN LPG
Because of a very low solubility of LPG in water
the identification of minor leakage in water is
after and easier.
Water present in LPG may cause rust and
corrosion and freeze-up of valves, drain valves,
excess-flow check valves, cylinder valves and
regulators. Ice-formation may prevent the
closure of drain valves, bleeders in LPG vessels
and lines, self closing valves, etc. and result in
leakage of LPG. Ice crystals formed at the
regulator orifice may lead to plugging of the
orifice and thus stopping the flow of gas. Ice
crystals may also make the linkages in a
regulator inoperable.
1.2.7 FLAME PROPATION
LPG liquid released will form a vapour which
will travel long distance. The vapours of LPG
can give violent concussion in explosion than in
case of hydrogen, due to faster flame
propagation.
1.2.8 CUBICAL EXPANSION
Liquid phase LPG expands considerably when
its temperature increases exceeding most of the
petroleum products. The coefficient of expansion
is around 0.00237 per deg. C. The high rate of
expansion has to be taken into account when
specifying the maximum quantity of LPG
permited to be filled into any pressure vessel.
The maximum permissible liquid volume of any
container is that quantity which will assure that
the container will have a minimum vapour space
of 5% for cylinders and bulk containers, when
the liquid is at the highest anticipated
temperature. These temperatures have been
considered as 55 deg. C for bulk containers and
65 deg. C for cylinders. The safe filling ratio for
cylinders/ storage vessels shall be in accordance
with Gas Cylinders Rules and SMPV Rules
respectively.
Because the filling ratio precautions takenin
storage system cannot be extended to the
connected piping network, relief valves are
provided in all areas where LPG can be trapped
between closed valves in order to protect these
parts of the system.
1.2.9 ODOUR
LPG has only a very faint smell, and
consequently, it is necessary to add some
odorant, so that any escaping gas can easily be
detected.
Ethyl Mercaptan is normally used as stenching
agent for this purpose. The amount to be added
should be sufficient to allow detection in
atmosphere 1/5 of lower limit of flammability or
odour level 2 as per IS : 4576.
1.2.10 COLOUR
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.
1.2.11 VISCOSITY
LPG liquid has low viscosity of around 0.3 CS
@ 45 deg. C and can leak when other petroleum
products normally cannot, thus demanding a
very high integrity in the pressurised system to
avoid leakage. It is also a poor lubricant and
leaks are therefore likely to occur at pump seals
and glands. In view of this a special attention to
the given, for example to the selection of
mechanical seals for pumps and also seals at the
carousel centre column.
1.2.12 PYROFORIC IRON
Pyrophoric Iron sulphide is a highly
inflammable compound formed due to the
reaction of sulphur and its compounds with the
loose iron/ iron oxide on a ferrous surface. Thus
the pyrophoric Iron Sulphide can be controlled
by totally eliminating highly corrosive hydrogen
sulphide, limiting the total volatile sulphur to
0.02% by mass reducing the loose iron oxide by
thoroughly cleaning the storage vessels
internally during the outage.
Pyrophoric Iron Sulphide will not ignite
spontaneously in a sphere/ cylinder containing a
concentration of vapour of gas as long as the
concentration is above the upper flammable
range limit. When these vessels are aired to
(during opening to atmosphere or air entrapped
condition) within or below the range, it will
ignite spontaneously, unless water or steam is
used to cut the sulphur iron reaction. The most
effective extinguishing agent is water spray of
fog. Similar type of precaution is warranted
while opening of LPG pump strainers and any
location where loose iron oxide is expected.
1.2.13 TOXICITY
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.
1.2.14 CAUSTIC RESIDUE
Caustic soda treatment employed for the
removal of hydrogen sulphide could leave traces
of caustic in LPG. This may lead to corrosion on
the storage vessel and other LPG handling
equipment with predominant effect on
TABLE 1.0
LPG SPECIFICATIONS
Salient Features as per IS:4576
aluminium alloys. Hence stipulating absence of
caustic is essential in addition to IS-4576
specification.
1.2.15 PUVCE AND BLEVE'S
PHENOMENA
The hazards associated with the release to
atmosphere of a boiling flammable liquid show
themselves disproportionately where large
quantities are involved - they can give rise to
two phenomena which are highly hazardous ;
(a) Unconfined Vapour Cloud Explosion
(UVCE) and (b) Boiling Liquid Expanding
Vapour Explosion (BLEVE).
Vapour cloud can ignite and burn as
deflagrations or fire balls causing lot of damage
by radiation starting secondary fires at some
distance. Vapour cloud ignites and explodes
causing high over pressures and very heavy
damage. The later is termed as `percussive
unconfined vapour cloud explosion' i.e. PUVCE
in short. Even though large quantities of LPG
emission is necessary, only a fraction of this
contributes to the percussive effect ( more
reactive molecules such as ethylene in much
smaller quantities). Rare though PUVCE may
be, their damage is large and sometimes
enormous.
The boiling liquid expanding vapour explosion
(BLEVE) is due to holding a pressurised
flammable liquid above its boiling point. This
may result from inadequate vapour space for
temperature expansion of the contents or high
temperature due to radiation heat from the
adjacent vessel fires or due to any mechanical
damage. BLEVE even though not as serious as
PUVCE, its potential for spreading fire over a
wide area makes them significant in terms of
both life and property damage.
Ejection of boiling liquid produces reaction
rupturing the vessel causing the rocket
projectioning of dish ends. The released liquid
flashes and atomizes immediately, often
resulting in a large fire ball. Although the fire
ball lasts only a few seconds, its effect can be
devastating due to flame contact and thermal
radiation.
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S.No. Characteristic Requirement for commercial Method of Test Ref. to
Butane-Propane Mixture Page(P) of IS:1448
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1. Vapour pressure at 16.87 Max. P:71

65 deg. C kgf/cm.g.

2. Volatility: evaporation 2 P:72

temperature in deg.C,
for 95 per cent by
volume at 760 mm Hg
pressure, Max.

3. Total volatile sulphur 0.02 P:34

percent by mass, Max.

4. Copper strip corrosion Not worse P:15

at 38 deg.C for 1 hour than No.1

5. Hydrogen Sulphide Absent P:73

6. Dryness No free entertained P:74

water

7. Odour Level 2 P:75

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STATUTORY RULES / REGULATIONS
2.1 STATUTORY RULES/ REGULATION &
OTHER RECOMMENDED
GUIDELINES :
Construction and operation of LPG bottling
plants, storage, transportation
distribution of LPG are required to be
carried out in accordance with various
prevailing national statutory rules and
regulations. This section covers the salient
features in brief w.r.t. following regulations
which are in force. For complete details
with regard to the various provisions,
original notifications/ documents may be
referred to.
2.2 STATUTORY RULES/ REGULATIONS
i) Gas Cyliinders Rules, 1981 (under
Indian Explosives Act,1884)
ii) Static & Mobile Pressure Vessels
(unfired) Rules-1981 (Under Indian
Explosives Act 1884).
iii) The Factories Act, 1948 (Amended in
1987).
iv) Electrical Installation under Indian
Electricity Rules - With Latest
Amendments.
v) a) The Standards of Weight &
Measures Rules - 1987 Under Weight &
Measures Act - 1976.
b) The Standards of Weight & Measures
(Packaged Commodities Rules-1977)
Licence to import Gas Cylinders in
Form D issued with latest amendments.
vi) Liquefied Petroleum Gas (Regulation of
supply and distribution Order - 1993).
vii) The Motor Vehicles Act - 1988.
viii) Environmental Regulations :
a) Water (Prevention & Control of
Pollution) Act, 1974 (Amended upto
1988).
CHAPTER 2
b) Air (Prevention & Control of Pollution)
Act- 1981 (Amended upto 1988)
c) The Environment (Protection) Act -
1986
and d) Manufacture, storage & import of
Hazardous chemicals Rules - 1989.
e) Guidelines for Environmental clearance
of new projects - 1981.
2.3 RECOMMENDATION OF
COMMITTEES :
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:
I) Vasudevan Committee - 1983 Ministry
of Energy (Department of Petroleum).
ii) Expert Committee Review of Safety
and Operating Procedures in LPG
facilities - 1986, Ministry of Petroleum
& Natural Gas (Department of
Petroleum).
iii) Sudha Joshi Committee for better
services to LPG users - 1987 (Ministry
of Petroleum & Natural Gas).
N.B. : The summary of the recommendations of
the above committees is covered in this section.
For further details the original documents may
be referred to.
2.4 SALIENT FEATURES OF VARIOUS
RULES/ REGULATIONS :
I) Gas Cylinder Rules - 1981 :
These rules have been framed under the Indian
Explosives Act,1884 to regulate the possession,
delivery, storage, handling and examination/
testing of gas cylinders limited upto capacity of
1000 litres.
Under these rules, prior approval from Chief
Controller of Explosives (CCE) is required to be
taken before constructing any new facility or
altering the existing facility for filling cylinders
and storage area etc. Before commissioning/
operating of LPG bottling plant following
licences are required to be obtained from CCE
after furnishing the details in specified formats :
Licence to import cylinder in Form D:
Application is to be submitted in Form B(under
Rules 57and 61)
Licence to fill/ possess Cylinders in Form E &
F : Application is to be submitted in Form C
under Rules 57,61&62)
Generally licence for import of cylinders (form
D) is valid upto one year (maximum) whereas
other licences in Form E and F granted or
reviewed remain in force till 31st March of the
year subject to validity of maximum 3 years.
Application for renewal must reach CCE,
Nagpur at least 30 days prior to expiry of the
current licence.
Cylinders should conform to specified design,
fittings, markings, identification colour and
should have approved from CCE before use of
the same.
Cylinders in use are required to be inspected and
hydrostatically tested as specified in the BIS
code as per or procedure/ frequency approved by
CCE. Rejected cylinders are to be destroyed by
flattening/ cutting into pieces.
II) STATIC & MOBILE PRESSURE
VESSELS (UNFIRED) RULES -
1981
These rules in conjunction with Gas Cylinders
Rules have been framed under the Indian
Explosives Act to regulate the construction,
fitment, storage, loading/ transport and
inspection of unfired vessels in service of
compressed gas like LPG with capacity
exceeding 1000 litres.
As per these rules it is obligatory to obtain
approval and licences from CCE prior to
construction/ alteration and commissioning/
operation of any LPG storage vessel and allied
facilities. Vessels are required to be designed,
constructed and tested in accordance with BIS -
2825 as amended from time to time or such
code/ standard as approved by CCE.
Application/ licences under these rules are :
Licence to store LPG Application is to
in bulk issued be submitted in
in Form-III : in Form -1
(under rules 49, 54
& 55).
Licence to transport Application is to
LPG in bulk issued be submitted in
in Form -IV : in FORM- II
(under rules
49&54)
1. Approval of initial location or expansion of
existing installation by the site appraisal
committee constituted by the State Govt.
2. Approval of the plan, speficiations/
drawings for construction of the Factory/
Installation by the Chief Factory Inspector
and also registration/ licence for operating
factory. Licence is to be renewed every year
or as specified.
The granted licences which remain in force till
31st March of the year are generally valid for
period of 3 years (max.). Application for renewal
must reach CCE, Nagpur at least 30 days prior
to expiry of the current licence.
Inspection/ hydrotesting of vessels is required to
be carried out once in 5 years or as specified by
a competent agency duly approved by CCE.
Frequency of inspection/ testing of safety valve
is once a year. (Refer OISD-STD No.128 - on
Inspection of Pressure Vessels).
N.B. : The above rules do not apply to transport
compressed gases filled in vessels by Railways
Administration who follow their own RDSO
regulations.
III) FACTORIES ACT - 1948
(AMENDED AS FACTORIES
(AMENDMENT) ACT, 1987)
The act aims at regulating working conditions in
the factories and lays down minimum
requirements for ensuring the safety, health and
welfare of the workmen. It is applicable to all
establishments/ factories employing more than
10 employees.
As per the First Schedule of the amended Act
(1987), installations handling highly flammable
liquids and gases come under Hazardous
process/ operations. Salient provisions to be
complied with rules framed by the State Govts.
under the Factories Act are given below :
- Approval of initial location or expansion of
existing installation by the site appraisal
committee constituted by the State Govt.
- Approval of the plan, specifications/
drawings for construction of the Factory/
Installation by the Chief Factory Inspector
and also registration/ licence for operating
factory. Licence is to be renewed every year
or as specified.
- Disclosure of information by the occupier
regarding hazards/ dangers including health
hazards and measures to overcome such
hazards to workmen and general public
living in the vicinity of the factory.
- Declaration of written safety policy w.r.t.
health and safety of workmen.
- Ensuring proper fencing/ provision of safety
guards on equipment/ machinery. Fire/
accident prevention faciities etc.
- Examination/ testing of machinery/ vessels/
tools/ tackles etc. at specified frequency.
- Maintenance of uptodate Disaster
Management Plan.
- Specific responsibility of the occupier in
relation to -
a) Maintenance of health records of person
likely to be exposed to harmful toxic
substances.
b) Deployment of qualified persons to handle
hazardous substances/ equipment.
c) Appointment of Safety Officer.
IV) STATUTORY REQUIREMENTS OF
LECTRICAL INSTALLATIONS :
(INDIAN ELECTRICITY RULES
MARCH, 1980: AMENDED UPTO
1988)
For supply of power, licence is required from the
designated authority of the State Government
after submitting the application with details of
premises, drawing/ maps of the proposed area of
supply, electrical installation, nature and amount
of supply etc.
The installation must be inspected and approved
by Electrical Inspector of the State Government
before commissioning. Subsequent inspection/
testing shall be required at intervals not
exceeding five years or as specified. Only
licenced contractors/ agencies holding the
certificate of competency should be engaged for
any installation work.
All earthing system in the installation shall
require to be tested for resistance during the dry
season not less than once a year or as specified
by the authorities. Record of every earth test
shall be maintained by the occupier incharge of
the installation and shall be produced as
required before the inspector or authorised
officer. (Refer OISD STD 137 for earthing test
frequencies).
Suitable fire extinguishers for dealing with
electrical fire like Co2, DCP type extinguishers
should be placed in electrical installations.
Note :
i) For appropriate area classification,
guidelines contained in IS:5572 (part 1)
1978 should be followed.
ii) For selection of electrical equipment,
guidelines contained in IS:5571-1979
& IS:9570-1980 as revised from time to
time should be followed.
V) (A) STANDRDS OF WEIGHTS &
MEASURES ACT -1976 :
(WEIGHTS & MEASURES RULES-
1987)
Approval/ certification of Measuring
Appliances: Weighing equipment like
weight scales, weigh bridges etc. before
installation shall have approval and
certification by the Regional Director/
designated authority of Weights &
Measures. in case, the equipment is
imported, the same shall have
certification of appropriate authority of
the country where it is manufactured in
accordance with recommendations of
International Organisation of Legal
Meterology. Such models shall be
tested, if required, and shall be duly
certified by the Indian authorities to
verify the accuracy.
Verification/ stamping : Weighing
equipment shall require re-verification
 by the designated Inspector at
prescribed intervals. Certificates in
prescribed form shall be obtained or
stamping indicating therein the
particulars of verified measures shall be
made. Test weights used for regular
checking the accuracy of weighing
equipment shall also require stamping
of Weights & Measures.
Bulk Meters : Bulk meters used for
measuring Liquid petroleum products
shall be of positive displacement type.
These meters can be fitted with
automatic or manually operated
temperature compensating devices. For
flow accuracy, these shall be correctly
installed as per recommended
procedure and protected by a strainer
filter and air eliminators.
All meters shall be tested under
conditions which duplicate normal
operating conditions in respect of flow
and product involved. The error shall
not exceed +/- 0,1% for any quantity
discharged. Every meters shall be
provided with suitable scaling
arrangement to receive the stamp or
seal of the verification authority.
Site Inspection : Weights & Measure
Authorities within their area of
jurisdiction can visit the premises, for
inspection/ testing of any measuring
equipment in use apart from checking
the relevant records/ documents.
(B) THE STANDARDS OF WEIGHTS &
MEASURES (PACKED
COMMODITIES) RULES AND
AMENDMENT RULES, 1991.
LPG shall be marketed/ sold on weight
basis in packaged form i.e. cylinder of
approved design.
Declaration shall be required on every
cylinder about name/ address of
Manufacturer/ packer, common or generic
name of the commodity, net quantity in
terms of standards weight, size/
dimensional details of the containers etc.
Maximum permissible errors on net
quantities declared by weight or by volume
shall be as below :
Declared Maximum
Quantity permissible error
in excess or in deficiency
gm or ml % gm or ml
1000-10000 1.5 --
1000
1001 10000-15000 -- 150
more than 15000 1.0 --
VI) THE LIQUEFIED PETROLEUM
GAS (REGULATION OF SUPPLY &
DISTRIBUTION ORDER), 1993
AND AMENDMENT ORDER, 1994
This order was brought into force w.e.f.
August 1993 by the Ministry of Petroleum
& Natural Gas, Salient features are outlined
below :
Restriction on possession & consumption
of LPG :
No person shall be granted by an oil
company more than one gas connection and
the same shall not be used for purposes
other than cooking unless specified by a
general or special order for such other
purposes it may specify in that order.
No transporter or delivery person shall
deliver LPG gas either in cylinders or bulk
to any person other than the authorised
consumer.
No person shall fill cylinder with LPG or
transfer from one container to other without
permission of Chief Controller of
Explosives.
Regulation of weight ;
The weight of the LPG contained in a
cylinder shall not vary by a difference of
1.5% of the net weight of the respective
cylinder as indicated on it by the Govt. oil
company.
Restriction on storage & transportation :
No person shall use cylinder, pressure
regulator and gas cylinder valve other than
those specified in schedules "A" and "B".
Storage place should be cool, dry, well
ventilated, easily accessible, place under
 cover being away from open flames/ steam
pipes or other source of heat.
Possession, supply or sale of LPG
equipment :
a) No person shall supply or sell filled or
empty cylinders, gas cylinder valves
and pressure regulators to any person
other than a Govt. oil company or a
parallel marketeer.
b) Unless authorised by a Govt. oil
company or a parallel marketeer,
supply or sell empty cylinder, gas
cylinder valve and pressure regulator to
any person other than a consumer.
c) Possess filed or empty cylinder, gas
cylinder valve or pressure regulator
unless he is a consumer and the same
has been supplied by a distributor, a
Govt. oil company or a parallel
marketeer.
Restriction on Disposal of Discarded
Cylinder/ Equipment
Every manufacturer of cylinder, gas
cylinder valves and pressure regulators
shall dispose off the items which do not
conform to respective BIS
specifications after deshaping/ crushing
such items.
Power of Entry, Search & Seizure :
Notified officers of Central Govt./State
Govt. (Deptt of Food & Civil Supplies)
or Sales Officer of a Govt. oil company
are authorised to inspect Distributor's
premises or transport vehicle to ensure
the compliance with provision of this
order.
VII) THE MOTOR VEHICLE ACT, 1988
Some relevant features w.r.t. safety
provisions in Motor Vehicles Act revised in
1988 are as below
Grant of driving licence for transport
vehicle used for hazardous goods like LPG
and other petroleum products is restricted.
The person must have some minimum
educational qualification as prescribed by
Central/ State Govt. apart from other
conditions like medical fitness, driving
competence certificate,minimum driving
experience etc.
Registered laden weight/ axle weight as per
notification for particular model should not
exceed the permissible value.
Use of `TREM CARD' or other safety
guidelines issued for particular hazardous
commodity as prescribed by Central/ State
Govt. authorities. This covers specified
arrangement of maintenance/ repairs,
emergency handling procedures in case of
road accidents.
Certificate of fitness/ age limit as specified
in rules of Central/ State Govt.
VIII) ENVIRONMENTAL
REGULATIONS
A) Water (Prevention & Control of
Pollution) Act, 1974 (with latest
amendment) :
Under the main provision of this Act :
Prior consent of State Pollution Control
Board by applying in prescribed format is
required for :
Establishing any industry, operation or
process or any treatment and disposal
system or any extension or addition thereto
which is likely to discharge sewage or
effluent into a stream or on land.
Using any new or altered outlet for
discharge of sewage or effluent.
Application for renewal of consent, which is
generally valid for one year should be made
at least one month in advance. Occupier has
to ensure the compliance of the directions or
stipulations laid down by the Board while
granting the consent. Returns for the
amount of water consumed alongwith
payment of cess must be submitted in
manner as prescribed in the Water
(Prevention & Control of Pollution) Cess
Act, 1977.
b) Air (Prevention & Control of
Pollution) Act-1981 (with latest
amendments)
The objective of this act is to provide for
prevention, control and abatement of air
 pollution" caused by any operation or
process.
Under the main provision of this Act, prior
consent of the State Pollution Control Board
is required regarding discharge or emission
of air pollutants for operation of an industry
as specified in schedule which includes
Petroleum Industry Installation.
Strict compliance with standards/
conditions laid down by the Board or
specified in the consent order must be
ensured.
Application for renewal of consent must be
submitted at least one month prior to expiry
of the current consent order which is
generally valid for one year.
c) The Environment (Protection) Act-
1986 :
The Water Act-1974 and Air Act-1981 deal
specifically with water and air pollution
while this act deals with environment as a
whole including prevention of hazards to
human beings, other living creatures, soil,
plants and property.
This act empowers Central/ State
Government to take all such measures it
may deem fit for protecting and improving
the quality of environment.
*(Air pollution means presence in the
atmosphere, of any solid, liquid or gaseous
substances including noise in such
concentration/ intensity that may be
injurious to human being or other living
creatures or plant or property or
environment.).
Several rules for the specific areas have
been/ are in the process of being notified
under this Act. This also includes issuance
of various standards for effluent water,
atmospheric emissions/ air quality, storage/
handling of hazardous chemicals, solid
waste etc.
d) Manufacture/ Storage and Import of
Hazardous Chemicals Rules-1989
These rules have been framed by the
Ministry of Environment and Forests under
the provision of E.P. Act, 1986 for
prevention/ mitigating pollution of
environment due to hazardous chemicals.
These rules are applicable to all
installations which store/ handle threshold
quantity of 200 MT or more.
Salient provisions to be complied with are -
An occupier who has control of operations
shall identify the major accidents likely to
occur and shall take adequate steps to
prevent such accidents and to limit their
consequences to persons and environment.
State Pollution Control Board/ Factory
Inspectorate shall be informed immediately
in case of any major accident followed by a
report in the prescribed format.
Detailed safety report containing the
information as specified is to be submitted
to the concerned authorities.
An uptodate on-site emergency plan has to
be maintained for dealing with any major
accident or disaster situation likely to affect
the environment. Off-site emergency in
coordination with all industry
establishments.
Occupier shall take appropriate steps to
inform persons outside the installation
either directly or through District
Emergency Authorities, who are likely to be
in area which may be affected by major
accidents about
i) the nature of major accident hazards
ii ) the safety measures required to be
adopted ( Do's & Dont's)
e) Environmental Clearance for New
LPG Bottling Plants :
A. Guidelines for Siting Industry
Ministry of Environment have laid down
certain guidelines for sitting of industries
which includes LPG installation. While
selecting a site, enough care should be taken
to minimise the adverse impact of the
operations in neighbourhood and natural
life sustaining systems.
Letter of intent of the industry can be
converted to the Industrial Licence only
after the following conditions are fulfilled :
The State Director of Industry confirms that
the site of the project has been approved
from the environmental angle by the
concerned state authorities.
The Project Authorities commit to State and
Central Governments to install the
appropriate equipment and implement the
measures prescribed for prevention and
control of environmental pollution.
B. Procedure for obtaining
Environmental Clearance :
Firstly, No Objection Certificate (NOC) has
to be obtained from concerned State
Pollution Control Board by submitting
application in the prescribed form
alongwith detailed project report.
Final clearance from environmental angle is
to be obtained from Department of
Environment Govt. of India. The following
documents will have to be submitted for
obtaining clearance :
- Detailed Project Report (DPR)
- Response to questionaire (Prepared by
DOEn.)
- No objection Certificate (NOC) from
State Pollution Control Board.
- Detailed Environmental Impact
Assessment (EIA)
- Risk Analysis Study Reports
- Disaster Management Plan
- Master Rehabilitation Plan, duly
approved by State Govt. (where
required)
- Green belt Development Plan.
- Safety Manual/Code.
The Department of Environment, after
considering these documents and
presentation by the industry member will
give clearance with/without special
conditions to be complied with. A six
monthly report on the progress of the
facilities being provided for pollution
control is to be submitted to Department of
Environment till the completion of the
report.
Finally, before commissioning of the plant,
consent has to be obtained from the State
Pollution Control Board for the discharge of
liquid effluent and atmospheric emission
under Water Pollution Control Act, 1974
and Air Pollution Act, 1981.
2.5 SUMMARY OF
RECOMMENDATIONS OF VARIOUS
COMMITTEES ON LPG SAFETY :
1) Vasudevan Committee - 1983 (MOP&C)
Ministry of Petroleum & Chemicals had set
up a high level commitee in May, 1983
headed by Shri R. Vasudevan, the then Joint
Secretary, Deptt. of Petroleum to review all
safety and operational procedures adopted
in LPG filling plants, transportation of LPG
by rail/ road, and in the distribution/
delivery of LPG cylinders. Several
recommendations for improvements in
operations/ systems were made by the
committee for adoption/ implementation by
the oil industry. Gist of key points
pertaining to the recommendations are
given below :
1.0 LPG BOTTLING PLANT
i) Location - Should not adjoin
residential areas
ii) Size - Desirable to restrict to 25000
MTPA on 2 shift basis.
iii) Layout - Provision of 80 M wide green
belt beyond perimeter wall, access
roads etc.
iv) Cylinder Filling - 100% cross
schecking of weighments on manual
scale.
v) Cylinder Testing - Use of compact valve
tester, water bath check for leaks.
vi) Cylinder Handling - Conveyor system,
loading/ unloading at 15 M distance
from shed.
vii) Evacuation of leaky cylinders - Use of
proper evacuation system and recovery
of LPG, gas freeing prior to repairs/
replacements of valve.
viii) Cylinder Storage - Vertical stacking in
small lots with min. separation distance
of 1 metre seggregated storage for
empty and filled cylinders, mastic
flooring in the shed.
ix) Other Safety features/ practices - Fail-
safe shut-off valves, extraction of gas/
air mixtures, adequate communication
facilities etc. One designated Safety
Officer for each plant.
x) Manpower & Training - LPG plants to
be headed by Sr. Officers. Structured
training/ refresher courses for staff and
officers on LPG operations, emergency
handling etc. No contract labour on
shop floor for LPG operations.
xi) Fire Prevention/ Fire Fighting - Strict
security check prevention of smoking,
Gas detection/ alarms, automatic Fire
Water deluge/ sprinkler system.
Automatic starting of Fire Water
Pumps, fire drills etc.
1.0 CYLINDERS/ VALVES/ REGULATORS
3. Standardisation and strict quality control in
manufacture of cylinder and fittings,
industry inspection system for quality
assurance etc.
2.0 TRANSPORTATION OF LPG :
i) Bulk by Rail - LPG movement in bulk
rake of 68 wagons, unloading/ loading
in lot of 34 (500 MT) wagons.
Provision of remote operated water
sprinklers at Gantries.
ii) Bulk by Road - Safety training of
Driver/ Attendant, special safety
precautions during loading/ unloading
LPG.
iii) Cylinders by Road - Vertifical stacking,
gradual switchover to palletisation.
3.0 LPG DISTRIBUTION :
i) Distributor's godown - Properly
designed distributor godowns with
mastic covered flooring, fire fighting
equipment etc.
ii) Delivery Equipment - Standardisation
approach with cage design, use of 3
wheeler scooters/ delivery van.
iii) Training of delivery boys/ mechanics -
suitable training programme by oil
companies with certification scheme.
iv) Customer Education - Audio Visual
aids/ films on TV , booklets on LPG
safety emergency complaint cells etc.
v) Control and Supervision - System of
periodic inspection to oversee and
control the working of the distributors
by oil companies.
I) EXPERT COMMITTEE (POST
REVIEW OF VSC) -1986
(MOP&C) :
4. An expert committee was set up in May,
1986 by Ministry of Petroleum & Chemicals
to review the safety and operating
procedures in LPG filling, transportation
and distribution in light of the experience
gained by oil companies and also the safety
practices followed by International
Organisations.
5. Summary of recommendations is given as
below
A) LPG BOTTLING PLANT :
i) Layout - Typical layout showing the
safety distances have been specified for
12500 MTPA bottling plants. Concept
of 80M green belt/ buffer zone around
LPG bottling plant as recommended by
Vasudevan Committee has been
replaced by min. 92 M safety distance
of LPG sphere (600MT) from property
wall.
ii) LPG Storage - No. of storage vessels :
as per OCC norms -
a) 25,000 MTPA Rail - fed plant 4x600 MT
spheres.
b) 25,000 MTPA Road - fed plant 2x600
MT spheres +1x100 MT bullets.
c) 12,500 MTPA- Road fed plant 5x100
MT bullets
iii) Bottling Plant Shed - Single shed for
empty/filled cylinder-cum-filling plus
one cold repair shed.
iv) Cylinder Filling & other equipment - A
Carousel Machine with 12 filling heads
for 12,500 MTPA plant/ 24 filling
heads for 25000 MTPA plant. Other
 facilities should include automatic
check scales, test bath. CVT, on-line
cylinder evacuation and purging
facilities, Off & On screwer, telescopic
conveyor for cylinder loading, cylinder
washing and drying unit etc.
v) Empty & cylinder storage -
a) No. of empty cylinder : one and a half days
& to provide 100% requirement plus one no.
b) No. of filled cylinder : one and a half days.
vi) LPG vapor extraction blower - This
needs to be provided to cater to LPG
accumulation in filling/ cylinder
storage shed particularly in low lying
areas.
vii) Other Safety Features - Remote control
valves on LPG lines, excess flow
valves, safety valves, pop off valves,
Gas detection system etc. as specified
by VSC also.
(B) BULK LOADING/ UNLOADING:
2.0 Nos. & 6 Nos. truck unloading points
for 12,500 MTPA and 25000 MTPA
plant respectively.
6. 2 Rail spurs for unloading of 34 wagons at a
time with use of suitable compressors.
(C) FIRE PROTECTION FACILITIES :
i) Hydrant system around LPG plant/
equipment.
ii) Remote manually operated water spray
for LPG shed dividing area into 13
Mx40 M zones/ segments.
iii) Remote manually operated water
deluge/ sprinkler for LPG vessels/
spheres.
iv) Water turrets for LPG pumps/
compressors, bulk loading/ unloading
area.
v) Pumping requirement shall be based on
the maximum of the following :
a) Deluge/ spray system for total in case of 2
spheres with water density of 10 LPM/ Sq.
M.
OR
Deluge sprinkler system for 2.5 times the
surface area of one sphere where 4 NOs. of
spheres are installed with 10 LPM/ Sq.M.
water denstiy.
b) Spray system for 3 segments at a time with
10 LPM/ Sq.M. water density + 200
Cu.M/hr. for operation of 2 nos. of turrets.
vi) Min. of 2 Nos. of diesel driven water pumps
of electric motor pump (50% requirement as
standby).
vii) Water storage min. 4 hours aggregate
pumping capacity.
(III) SUDHA JOSHI COMMITTEE - 1987 :
Ministry of Petroleum & Natural Gas in 1986
had set up a committee headed by Mrs. Sudha
Joshi, the then M.P. and Marketing Directors of
Oil Companies as members with a view to
provide better services to LPG users with due
regard to safety.
Brief summary of important recommendations
w.r.t. safety aspects are outlined below :
 Streamlining of registration/ release of LPG
connections, issuing booklet like ration card
to each consumer etc.
 Use of auto-driven vehicles to be
encouraged for delivery of refills.
 Consumers to use only BIS marked hot
plates.
 Distributors to check weight of at least 10%
of cylinders before accepting deliveries. Oil
companies to ensure pre-delivery
checks by the Distributors.
 Caging of trucks carrying filled LPG
cylinders.
 - Oil companies to use only
aluminimum/ PVC seals with different
colour code of filling plant embossed.
 Periodic safety inspection of equipment at
consumer premises.
 Regular training of delivery boys by the oil
companies.
 Emergency and complaint cells to be
operated by oil companies in LPG marketed
towns.

 Consumer education in LPG SAFETY

THROUGH TV media and curriculam to
high school.

 - Oil companies to strengthen the

inspection system of LPG bottling plants
and working of the Distributors.

 Establishment of more bottling plants near

the consuming centre to the extent possible.
 CHAPTER 3
PLANT LAYOUT
3.1 GENERAL
The general layout principles of LPG storage,
bottling and bulk handling facilities have been
detailed in the chapter, which also conform to
OISD Standard-118 on layout. The various
facilities within LPG storage and bottling
premises shall be located based on Table-I and
Table-II.
3.2 LOCATION & SAFETY DISTANCES :
3.2.1 LOCATION :
While assessing the suitability of any site for
location of LPG storage facilities, the following
aspects shall be considered :
(a) In addition to the requirements for safety
distances as given in Table I & II, the
location of residential quarters, other
industries, public railways, public roads,
public waterways, overhead power lines,
working areas etc. based on risk analysis
study of the proposed site should be taken
into account as required by the
Statutory/State Govt. regulations.
(b) Adequate availability of water from a nearby
reliable source of water should be ensured.
(c) The topographical nature of the site with
special reference to its effect on the disposal
of escaping LPG shall be considered.
(d) The access of mobile fire fighting equipment
to the storage vessels under all foreseen
circumstances, preferably from two sides
and upwind (prevailing wind) is an
important parameter.
(e) The availability of space for future extension
of LPG facilities which will still comply
with the safety standards shall be taken into
account.
(f) Predominant direction of wind and velocity
shall be considered.
(g) Longitudinal axis of horizontal vessels
(bullets) shall not be pointed towards other
vessels, vital process equipment and control
room.
(h) Storage vessels shall be located downwind
of process units, important buildings and
facilities.
(i) Storage vessels shall not be located within
the same dykes where other flammable
liquid hydrocarbons are stored.
(j) Storage vessels shall be laid out in single
row both in case of the spheres and bullets
within a group. Spheres and bullets shall
not be grouped together and will be
provided with separate piping manifold.
(k) Storage vessels shall not be located one
above the other.
3.2.2 SAFETY DISTANCES :
The safety 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.
3.3 TYPE OF STORAGE VESSELS :
3.3.1 HORIZONTAL CYLINDRICAL
VESSELS:
Horizontal bullets with volumetric capacity up to
400 Cu.M each shall be used for storing LPG.
3.3.2 SPHERICAL VESSELS :
Spheres are the most economical form of storage
for capacities of more than 400 Cu.M of each
vessel.
3.4 LAYOUT:
The following aspects shall be considered while
establishing layout of LPG storage vessels. A
typical layout of LPG storage vessels is shown in
Annexure-I.
3.4.1 LPG STORAGE FACILITIES:
(a) CONFINEMENT/ GRADING - Kerb wall
shall be provided around sites 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 Horton
Spheres with a slope of 1:100 (min.). Grading of
the ground underneath should be levelled so as
to direct spillage from the fourth side to a
shallow sump away from the storage vessel and
kerb wall height shall be minimum 30 cm but
shall not exceed 60 cm otherwise evaporation of
spilled LPG may get affected.
(b) SPILLS AND LEAKS - Spillage
collection shallow sump shall be located at a
distance where the flames from sump fire will
not impinge on the vessel. This distance shall
not be less than the diameter of the nearest
vessel or 15M whichever is higher. The
capacity of the collection sump shall be based as
per drawing enclosed (Annexure-I). This
drawing is valid for 2 spheres or more. In case
of one sphere, the sump size shall be equal to
layout of 2 spheres.
(c) PIPING - Only piping associated with the
storage vessels shall be located within the
storage areas or between the storage area and the
manifold system.
(d) 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 hydrocarbon.
(e) GROUPING - Vessels shall be arranged
into groups, each having a maximum of six
vessels. Capacity of each group shall be limited
to 15000 Cu.M. There shall be minimum
spacing as specified in Table-I between adjacent
vessels.
(f) Spheres and bullets shall be treated as
separate groups with minimum 30 M safety
distance between two groups.
Top surfaces of all the vessels installed in a
group shall be on the same plane so that the
safety blowout from them do not affect each
other.
It is preferable to provide separate manifolds
with independent pumping facilities for bullets
and spheres so as to avoid any chances of
overfilling of adjacent vessels due to gravitation.
A typical layout plan of LPG sphere area with
major safety requirement of distances, drawing
sump, pump location etc. is enclosed at
Annexure-I for general guidance.
3.5 LPG BULK HANDLING FACILITIES :
3.5.1 LPG tank lorry loading/ unloading
gantry shall be covered and located in a
separate block and shall not be grouped
with other petroleum products.
3.5.2 LPG loading/ unloading rail gantries
shall have separate rail spur and be
grouped separately from other rail
shunting facilities by minimum
distance of 50M.
3.5.3 Space for turning with minimum radius
of 20M for tank lorries shall be
provided commensurate with the
capacities of the tank trucks.
3.5.4 LPG tank wagon loading/ unloading
shall be restricted to a maximum of half
rake, present capacity of which is 500
tonnes. If full rake loading/ unloading
is envisaged this shall be done on two
separate rail gantries separated by a
minimum distance of 50M. In case of
8-wheeler wagons half rake unloading
capacity shall be 600 tonnes.
3.5.5 Maximum number of LPG tank lorry
bays shall be restricted to 8 in one
group. The bays should be designed in
such a way that the drivers cabin will
be facing the exit direction, and shall
have no other obstructions. Safety
distance between the two groups shall
not be less than 50 M.
3.5.6 Adequate permanent protection for tank
lorry discharge pipeline island shall be
provided. The minimum width of such
pipeline island shall be 1 M.
3.6 LPG BOTTLING FACILITIES ;

3.6.1 LPG bottling facilities should be
located at a safe distance from other
facilities with minimum ingress of
trucking traffic and upwind direction
with respect to bulk storage.
There shall not be any deep distances in
the surrounding areas to avoid LPG
vapour settling.
3.6.2 Bottling section shall be of single storey
having asbestos roofing and open from
all sides for adequate ventilation so that
leaked gas can drift away from the
shed. RCC roofing shall not be used.
Antistatic mastic flooring conforming
to IS-8374 shall be provided in the LPG
filling shed/ cylinder storage including
cold repair shed to avoid frictional
sparks. Fire-proofing upto full height
of structural columns and Antistatic
mastic coating upto 1.5 (Min.) shall be
done of the supporting columns of the
shed.
3.6.3 3 Sheds, 1 for storage of empty
cylinders and filling, 1 for filled
cylinders storage and 1 for cold repairs
of defective cylinders shall be provided
(Annexure-II). Empty cylinders
storage area shall be properly
segregated from filling machines by 5
M (Min.). Cylinders shall always be
stacked vertically in two lines. For
details of cylinder stacking pattern refer
Annexure-I of chapter 7.
3.6.4 LPG cylinder filling machines and
other related testing facilities shall be
organised in sequential manner as
shown in line diagram (Annexure-II of
Chapter 7).
3.6.5 A separate shed shall be provided for
carrying out cold repairs/ degassing of
defective cylinders.
3.6.6 Cylinder storage shall be kept on or
above grade and never below grade in
cellar or basement.
3.6.7 Filled cylinders shall not be stored in
the vicinity of cylinders containing
other gases or hazardous substances.
3.6.8 Escape routes shall be specified in LPG
sheds for evacuation of employees in
emergency.
3.6.9 There shall not be any trapping of
personnel in LPG sheds by conveyors,
cylinders and other facilities. If such
trapping cannot be eliminated, it should
be kept to the minimum. In such places
sufficient arrangements for escape
routes to be provided.
3.6.10 All steps forming part of the escape
routes shall be minimum 1.2 M with
treads 30 cms (Min.) and maximum
rise of 15 cms.
3.7 PROTECTION OF FACILITIES :
3.7.1 There shall be road all around the
various facilities within the bottling
plant area for accessibility of fire
fighting operations.
3.7.2 There shall be proper industry type
boundary wall atleast 3 M high with
0.6M barbed wire overhand all around
bottling plant including buffer zone
(green belt) unless the bottling plant is
otherwise protected as a part of refinery
complex.
3.7.3 Emergency escape exit with proper gate
shall be provided in the earmarked
zone.
3.7.4 Provision for green belt development of
minimum 30M width within the
boundary wall shall be made and
segregated from hazardous/ licensed
area by 1.0M high brick masonary wall
with 0.6M high barbed wire fencing as
shown in the typical layout (Annexure-
II).
3.7.5 LPG lorry parking area (Bulk/Packed)
shall be located in a secured area with
proper hydrant coverage.
3.8 UTILITIES :
Utilities consisting of fire water pumps, admin.
building, canteen, motor control centre, DG
room, air compressors, driers etc. shall be
separated from other LPG facilities and located
as per the area classification as specified in
Table-I (Annexure-III).
 ANNEXURE III
TABLE - I
INTERDISTANCES FOR LPG FACILITEIS
---------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7
---------------------------------------------------------------------------------------------------------------------------

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

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

group of bldgs. not associated
with LPG plant

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

4. Tank wagon/Tank truck 30 30 30 50 50 30 60

gantry-LPG

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

6. Pump house/Comp.house 15 30 15 30 30 - 60
(LPG)

7. Fire Pump House 60 ** 60 60 60 60 -

---------------------------------------------------------------------------------------------------------------------------
Notes :
1. All distances are in Metres.
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. Provisions of 30M green belt is over and above the safety distances from property line as given in
Table-I and II.
TABLE - II

DISTANCE BETWEEN LPG STORAGE VESSELS AND BOUNDARY/ PROPERTY

LINE/GROUP OF BUILDINGS NOT ASSCIATED WITH LPG PLANT
---------------------------------------------------------------------------------------------------------------------------
Capacity of each Distance
vessel (Cu.Mt. of water)
---------------------------------------------------------------------------------------------------------------------------
10-20 15
21-40 20
41-350 30
351-450 40
451-750 60
751-3000 90
--------------------------------------------------------------------------------------------------------------------
Note : All distances are in Metres

CHAPTER 4

DESIGN CRITERIA FOR LPG BOTTLING PLANTS

 b) Bullets are recommended for Micro and
4.1 GENERAL Mini plants. For Major and Mega plants,
spheres are recommended.
This section describes the broad process design
and safety features required in a typical LPG c) Recommended maximum water capacity of
bottling plant. For design details about the plant a sphere (based on 18 meters diameter
layout reference should be made to Chapter 3 of maximum) is approx 3,000 cubic meters.
this standard. For bullets the maximum recommended
water capacity is 400 cubic meters.
4.2 DESIGN BASIS
4.2.3 LPG LOADING/ UNLOADING
4.2.1 PLANT CATEGORIES FACILITIES

Based on operation, maintenance and safety For Micro and Mini plants only truck loading/
considerations, the plants are classified into the unloading facilities are recommended. For Mega
following four categories depending upon their and Major plants both rail and road tanker
capacities. loading/ unloading facilities are recommended.

Category Capacity Remarks To reduce the risk of accidental LPG release

(MTPA) during product transfer, excess flow check
valves shall be provided in LPG loading/
Micro Below 6000 Single shift/ unloading lines.
(small) stationary machine
4.2.4 CYLINDER FILLING FACILITIES
Mini 6000 and below Double shift/
22,000 stationary machines A. FILLING MACHINES AND WEIGHING

Major 22,000 and Double shift/single I) The filling machines shall be provided with
below 68,000 carousel auto cut-off system so that the liquid and
gas supply is cut off when the desired
Mega 68,000 and Double shift/ multi quantity of product has been filled in the
above carousel cylinders. The filling pressure shall not be
more than the design pressure of the
The filling capacities, per carousel on a two shift cylinders i.e. 16.9 kg/sq.cm. gauge.
basis are given below :
ii) Filling machines in a carousel/stationary
No. of filling Capacity Facilities filling machines shall not have a weighment
machines per (MTPA) error of more than +1% of the net quantity
carousel of the LPG filled in the cylinder, with a
capacity of 14.2/19 kg.
12 22,000 1CS 1 DCVT 1 in-line bath
18 34,000 2 CS 2DCVT " iii) It is recommended that in-line check weigh
24 44,000 2 CS 2DCVT " scales with a minimum of 50 gms.
36 68,000 3 CS 3DCVT 2 in-line baths graduation be installed so that all the
cylinders can be check weighed after filling.
CS - Check Scale
DCVT - Double Compact Valve Tester B. LAYOUT AND SAFETY

4.2.2 STORAGE CAPACITY i) The cylinder filling area shall be completely

a) The designed storage capacity in bottling
plants shall be as per the OCC guidelines.
It is preferable to divide the storage to
minimum number of vessels. However for
convenience of operation, maintenance and
inspection, 3 vessels are required as
minimum.
open type and covered from top with
asbestos roof designed to ensure good
natural ventilation, RCC roofing shall not
be used.
The filling area will not be on upper floors
of building or in cellars.
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 they shall be ventilated
through ducts fitted with blowers to outside
of the shed at safe location. The whole of
the LPG filling shed flooring shall be
provided with bitumenistic mastic flooring.
iii) Adequate lighting shall be provided in the
cylinder filling area. Additionally
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) Fixed water spray system shall be installed
for fire fighting inside the cylinder filling
area as described in section 4.4. Besides
this, access shall be made available for other
fire fighting systems.
4.2.5 CYLINDER STORAGE
Maximum cylinder storage of empty and filled
cylinders combined shall be restricted to a total
of 3 days bottling capacity of the plant. Storage
area requirement shall be based on the stacking
pattern of filled and empty cylinders described
in section 7.2.
4.2.6 UTILITIES
(A) Compressed air
The quality of instrument air shall conform to
the following specifications :
Pressure 7 kg/sq.cm.g
Moisture Dew Point, -15 deg.C at
7 kg/sq.cm.g
Quality Oil free
For the plant air/ service air, the specifications
are given below :
Pressure 7 kg/ sq.cm.g
Moisture No free moisture
Quality Oil free
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 shall 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
shallbe provided as a standby. Where more than
one pump running is envisaged, 50% capacity as
standby shall be provided.
i) Water Quality
Water shall be of potable quality conforming to
IS-10500-1983 (Indian Standard Specification
for Drinking Water). Suitable treatment facility
(Softener or demineraliser) shall be provided
whenever required to meet the above
specifications, depending upon the quality of
available water.
ii) Water Cooling Systems
These can be either closed circuit or once
through to drain type. Control of water quality
is better, in closed circuit system. This in turn
leads to much less downtime for cleaning.
Closed circuit water circulation system
circulating inhibited potable water can be
provided. Following shall be the concentration
of inhibitors.
Zinc as Zn 5 ppm
PH 7-8
The circulating water heat to be dissipated
through exchangers (not by evaporation).
Alternately, if the once through to drain system
is provided, it requires to be periodically cleaned
by chemical cleaning. Accordingly the design
should have provisions to hook up some portable
type of chemical cleaning kit which may contain
tank, pump etc. for circulation. During this
operation the equipment is taken out of service
and put back into service after the heat transfer
surfaces are cleaned. Normally the cleaning
consists of degreasing, followed by circulation of
inhinbited hydrochloric acid solution and finally
passivation using trisodium phosphate.
(C) Emergency Power
The plant shall be provided with 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.
4.3 LPG STORAGE VESSELS
Following are recommended :
4.3.1 MECHANICAL DESIGN
The mechanical design of storage vessel shall be
based on following considerations :
a) Design Code : ASME SEC. VIII or IS-2825
or BS - 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.
b) Material: Micro-alloyed steel containing Ni,
Mb, Va shall not be considered.
Since H2S presence cannot be completely ruled
out in the Refinery LPG storages, high stress
material shall not be used as it is prone to
Hydrogen induced stress corrosion cracking.
c) Recommended maximum tensile stress shall
be below 80,000 PSI.
d) Recommended material of construction for
sphere/ bullet :
i) For Refinery service : ASTM A516 Gr.
60 (BS-5500 shall not be used for the above).
Code and Material used should be the same.
ii) For marketing installation : Where H2S is
not present ASTM A 516 Gr. 70 or A 537
CLASS 1.
iii) Design temperture : -27 o C to +55 Deg C.
iv) Design Pressure : 14 Kg/ Sq.cm.g Vapour
pressure of LPG (as per IS: 4576) at 55 Deg C.
Marketable LPG conforming to IS: 4576 can
have a maximum vapour pressure of 16.87
Kg/Sq.cm.g at 65 Deg C temperature. LPGs
with higher vapour pressure are not expected to
be stored in bottling installations.
This (IS:4576) LPG will have a vapour pressure
(depending on composition) of around 13-14
(max.) Kg/Sq.cm.g at 55 Deg C.
This forms the basis of 14 Kg/sq.cm.g as design
pressure for IS:4576 LPG storage at bottling
installations.
The recommended design pressure and
temperature shall be treated as MINIMUM
requirement and other design consideration and
Statutory requirements may call for something
additional.
e) Other Considerations
Corrossion Allowance : 1.5 mm (minimum)
Radiography : Full
Stress Relieving : 100% irrespective of
thickness.
Wind pressure : as per IS: 875
Earthquake pressure : as per IS:1893
Hydrotest pressure : As per Design Code
4.3.2 FITTINGS
Spheres/ bullets shall have a single nozzle at the
bottom for inlet as well as outlet. The nozzle
shall be full welded pipe, stress relieved along
with th vessel and shall extend minimum 3
meters from the shadow of the sphere/ bullet. A
remote operated shutdown value (ROV) shall be
provided on this bottom nozzle at a distance of
atleast 3 meters from the shadow of sphere/
bullet. The nozzle pipe shall have a slope of 1.5
Deg.
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 sphere, supporting the bottom
nozzle from the vessel support legs should be
considered.
The top vapour zone of the vessel shall be
provided with nozzles for vapour outlet and
recirculation, which shall also be provided with
fire-safe ROVs.
Two independent level indicators, a high level
switch, pressure gauge and a manhole shall be
provided on top.
Each vessel shall have atleast two safety relief
valves, each set at not more than 110% of design
pressure of the vessel and having the relieving
capacity adequate for limiting the pressure build
up in the vessel not more than 120% of design
pressure.
All the fittings shall be suitable for use at not
less than the design pressure of the sphere/
bullet and for the temperatures appropriate to
the worst operating conditions. The remote
operated valves on the sphere/ bullet connected
lines shall be fire-safe type. The flange joints of
these valves shall either have spiral wound
metallic gaskets or ring joints. Plain asbestos
sheet gaskets shall not be used.
Flange connections shall be a minimum of
ANSI-300 lb flange class. All fittings shall be a
minimum of 20 MM.
4.3.3 INSTRUMENTS
i) The storage vessel shall have minimum
two different type of level indicators and one
independent high level switch. One level
indicator shall be float type and the other may be
differential pressure type in case of spheres. DP
type level transmitter shall either be sealant
filled type or LP side tubing heat traced.
Magnetic float type gauge is recommended for
bullets in place of differential pressure type.
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.
ii) The relieving load for the safety valves,
(minimum 2 nos. installed, each having 100%
relieving capapcity) shall be based on fire
condition and no credit shal lbe takne for fire
proofing on the vessel.
For safety reasons, the discharge of safety valves
shall be connected to flare system wherever
available. In this case PSVs shall have lock open
(or car seal open) type isolation valves on both
sides of Pressure Safety Valves (PSVs).
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) from the top of the
highest platform in a radius of 50 metre for
effective dispersion of hydrocarbons. In this
case, isolation valves on down stream of PSVs
are not required. A weephole 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 sphere or structure. A loose
fitting rain cap with a chain (non sparking)
fitted to vent pipe shall be provided on top of
PSV.
4.4 SAFETY/ SECURITY SYSTEM
The features of safety/ security system for the
different areas in the LPG bottling plants shall
be as follows :
4.4.1 AUTOMATIC FIRE PROTECTION
SYSTEM
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 described
below :
(A) LPG STORAGE AREA
In storage area these detectors shall be provided
encircling each vessel, equispaced 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.
The thermal fuses shall be designed to blow at
79 deg C temperature (max). Instrument air
will start leaking as a result of thermal fuse
blowing. The capacity of the restriction orifice
is such that the discharge of air through even
one thermal fuse will depressurise the
downstream side of the restriction orifice to
below set point of the pressure switch.
The actuation of pressure switch on any one of
the vessels shall initiate the following :

- an audio visual alarm at the local/ main
control panel and fire water station,
indicating the vessel on fire.
- the Remove Operated Valve (ROV) on liquid
inlet/ outlet line to the affected vessel will
close.
- the ROVs on vapour balance line and liquid
return line of the affected vessel will close.
- LPG pumps and compressors in LPG storage
area will trip.
- the deluge valves on fire water supply lines to
that vessel will open.
Additionally push buttons for initiating all the
above actions shall be provided on remote
operating panel and also in field at safe location
for enabling manual actuation of a trip by
operator. In the field, manual bypass valves of
fire water deluge valves shall also be provided.
Arrangement to routinely test the security
system shall also be provided.
(B) OTHER AREAS
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. Opon actuation there shall be alarm
in central panel, LPG pumps and compressors
would trip, ROVs (wherever provided) on LPG
supply and return lines would trip and the
deluge valves on fire water sprinkler system will
get actuated.
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.
4.4.2 GAS DETECTION SYSTEM
Suitable gas detectors shall be placed at
identified critical locations in the LPG storage,
compressor house, pump house, filling shed,
cylinder storage area, evacuation/ testing area,
LPG loading/ unloading area.
This shall include the area described in 4.2.4B
and shall also include places where water,
draining/ sampling are done on a routine basis.
Audio visual alarms showing the location of gas
leakage shall be provided on the control panel.
First level alarm can be set at 20% LEL and
second level alarm at 60^ LEL.
4.4.3 GAS EXTRACTION SYSTEM
A gas extraction system having suction points at
critical places where gas concentration is high
like carousel, evacuation, valve change shed etc.
shall be provided.
4.5 OTHER EQUIPMENT/ SYSTEM
4.5.1 BOTTLING PUMPS
There shall be a minimum of two pumps,
including one standby. Pumps shall be provided
with suction and discharge pressure gauges, a
high point vent to safe height or flare, and a
suction strainer. Mechanical seal shall be
provided (double mechanical seal with seal
failure alarms is preferred). A pressure switch
actuating a low pressure alarm in control room
shall be provided, taken from pump discharge.
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.
Typical sketch of a bottling pump installation is
enclosed as Annexure-1.
4.5.2 LPG COMPRESSOR
Gear driven compressor shall preferably by used.
However belt driven compressors can also be
used provided the belts used are antistatic type &
fire resistant.
There shall be a minimum of two compressors
including one as a standby.
The operating parameters shall be decided on a
case to case basis. However, typical operating
conditions may be as follows:
Suction pressure 10.0 kg/sq.cm.g abs
(max.)during unloading
2-11.8 kg/sq.cm.g abs
during vapour recovery.
Discharge pressure 13.0 kg/sq.cm.g. abs
during unloading.
 11.5 kg/sq.cm.g. abs
during vapour recovery.
Compressor shall be provided with the following
features as a minimum :
- Pressure gauges in suction and
discharge.
- Temperature gauge in discharge
- Discharge safety valve and a vent valve,
their outlets leading to flare/ safe height
outside the shed.
- Suction and discharge block valves
(lock open type)
- Suction strainer
- Check valve in discharge
- A discharge to suction recycle valve for
achieving capacity turndown during
startup.
Besides these, other indications/ protections can
also be provided along with those recommended
by compressor vendor. Typical sketch of
compressor installation is enclosed as Annexure-
II.
4.5.3 EVACUATION FACILITY FOR
SICK/ LEAKY CYLINDERS
The cylinder evacuation facility shall consist of :
- Cylinder emptying vessels (2 nos. with
attachments given below)
- Compressor (1 no.) as per 4.5.2.
- Four way valves
- 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 shall
be provided.
Each of cylinder emptying vessels mentioned
above shall be equipped with the following :
- Pressure gauges
- Level gauges and high level alarm
switches
- Pressure relief valves and vent valves
discharging to safe height.
- Other trims like drain valve, utility
connection.
Typical sketch of cylinder evacuation facility is
enclosed as Annexure-III .
4.5.4 PURGING OF NEW CYLINDERS/
TANKERS
(a) The new LPG cylinders containing air shall
be evacuated with a vacuum pump. The vacuum
pump shall be water/ oil cooled type. The
evacuation facility shall consist of :
- Purging manifold
- Vacuum receiver fitted with vacuum
gauge, vent and drain.
- LPG vapour heaader
- Purging adaptors
- Portable oxygen analyser
- Nitrogen cylinder manifold
- Vacuum pump with suction strainer
- Pressure regulator, relief valves etc.
Typical sketch of new cylinder purging/
evacuation system is enclosed as
Annexure-IV.
(b) Purging of tankers/ vessels shall be done
using either Nitrogen or by filling water and
displacing with LPG vapours.
4.5.5 ELECTRICAL AREA
CLASSIFICATION
All electrical fittings/ equipments to be of
Flame-proof type in vulnerable areas.
For electrical area classification refer to IS-
5571, IS-5572 (Part-1) and OISD Standard
No.113.
4.6 DESIGN DEVELOPMENTS
Some recent developments in equipment designs
and safety systems have taken place. These may
be considered in future installations:
a) Systems are now available for on-line
evacuation of leaky cylinders. These
would reduce the risk involved in
handling leaky cylinders.
b) In the event of leakage of LPG from
any of the sphere bottom area
connections, a nozzle can be provided
on the common liquid inlet/ outlet line
outside the ROV, or a line to the top of
storage, to supply water and flood the
bottom portion inside the sphere with
water. Repairing of small leakages
would be easier under conditions of
water leakage than in the case of LPG
leakage.
 CHAPTER 5

DESIGN OF CYLINDERS AND VALVES

5.1 CYLINDERS : IS:6240-1976 or IS:10787-1984 as amended

from time to time.
5.1.1 Since the cylinders and valves remain
in customer's premises for a longer time than in b) Bungs or Valve Pad - The bund shall
any other location, the quality of the cylinders conform to IS:3196 (Part-1):1992. It shall be
must receive utmost attention and importance. hot forged from rolled steel conforming to class
1-A of IS:1875-1978 OR IS:226-1975. The
5.1.2 The various capacities of cylinders used bung machined from such forgings shall be free
in our country for marketing LPG and the from surface defects such as fissures, surface
applicable IS code is given in the table below. cracks, porosity, lamination and pin holes etc.
The cylinders are designed, manufactured and
tested as per applicable IS codes and in c) Backing Strips; The material used for
accordance with Indian Gas Cylinders Rules, Backing Strips shall conform to IS:226-1975 Or
1981. IS:2062-1969 or steel of equivalent or superior
quality.
S.No. Water Capacity Net Weight IS Code
(in litres) (in kg.) d) Foot Rings: The foot Rings, where fitted as
a fixture to the bottom end of the cylinder, shall
1. 10.0 4.2 3196 be at least 20mm away from the circumferential
weld. The thickness of sheet from which the foot
2. 26.4 11.2 3196 ring is made shall not be less than 2.4 mm. The
foot ring may be intermittently welded and its
3. 33.3 14.2 3196 bottom edge shall be curled inwards to facilities
safe handling. It shall be provided with holes
4. 44.5 19.0 3196 for ventilation, as well as draining holes to avoid
corrosion. The maximum permissible deviation
5. 110.0 50.0 3196 from the vertical shall not exceed 1 degree. The
foot ring shall be sufficiently strong and made
NOTE : out of steel compatible with that of the steel
prescribed in IS:1079-1973 or of other steel
Bureau of Indian Standards specifications as per having equivalent properties. The bottom of the
IS:3196-(part 1) 1992 covers the design, foot ring shall not be less than 8 mm below the
fabrication and testing of welded low carbon outside bottom of the cylinder shell for cylinders
steel cylinders intended for storage and upto 34 litres water capacity. For cylinders of
transportation of low pressure liquefiable gases, more than 34 litres water capacity this value
other than toxic gases, of nominal water shall be minimum 25 mm.
capacity above 5 litres and upto and including
250 litres water capacity. The cylinders below 5
litres water capacity are covered by IS:7142- 5.1.4 CONSTRUCTION :
1974.
a) The minimum wall thickness of
Since maximum number of cylinders used in the cylinder body is to be calculated taking
country for domestic purpose are of nominal into account the test pressure, outer
water capacity of 33.3 litres, most of the details diameter and the minimum specified
are for this type of cylinders. For details on yields strength. The minimum agreed
other type of cylinders, relevant code and thickness, however, shall not be less
drawing may be referred to. than 2.4 mm and also calculated as per
Section 5.2.1 of IS:3196 (Part-1):1982
5.1.3 MATERIAL OF CONSTRUCTION : which ever is higher.

a) BODY: The cylinder should be fabricated b) The cylinder shall be welded by any
out of steel sheets manufactured conforming to suitable fusion welding method and
 shall conform, as for welding procedure
and welder's performance
qualifications, to the requirements of
IS:2825-1969, when cylinder welding
is required to be rediographed and to
the requirements of IS:817-1966, when
the cylinder welding is not to be
radiographed.
c) Before welding, the plates to be joined
shall be inspected and should be free
from grease, oil and dirt or any other
surface defects.
d) The circumferential seam shall consist
of butt joint in conjunction with
permanent backing material, or
alternatively a toggle joint may be used,
ensuring that the external surface of the
container is smooth. A longitudinal
seam in case of LPG cylinders is not
permitted.
e) Surfaces of the plates at the seam shall
not be out of alignment with each other
at any point by more than 10% of the
plant thickness.
f) Welds shall not be dressed without
approval of the inspecting authority.
The weld surfaces shall have a smooth
contour and there shall be no
undercutting.
g) All welding of the shell and
attachments shall be completed before the final
heat treatment.
h) Welds shall have an even finish and
shall merge into the parent material
without undercutting or abrupt
irregularity.
i) Welding electrodes used shall be such
that the desired properties of the weld
are obtained and the physical values of
the welded metal are not lower than
specified values of the parent metal, as
certified by BIS.
j) The chemical composition of the weld
material shall be compatible with that of the
parent metal.
k) All welded joints shall be double
welded butt joints. In case where
second side welding is not possible,
single welded butt joint may be used,
provided sufficient care is taken to
ensure complete fusion and penetration.
5.1.5 MARKINGS ON THE CYLINDERS :
The details of markings are standardised on the
industry basis :
a) MARKING ON FOOT RING :
Foot ring is stamped and embossed
with Oil Company's name on one side
and product trade name on other side.
The foot rings are provided with
adequate no. of openings for
Ventilation.
b) MARKINGS ON VERTICAL STAYS :
Following markings are provided on
the vertical stays supporting valve protection
ring :
Ist STAY PLATE
I) Manufacturers' identification mark/
logo
ii) S.No. followed by source of steel (S-
SAIL, T-TISCO, I-IMPORTED).
iii) Tare weight
iv) Maximum gross weight.
2nd STAY PLATE
I) IS-No. and BIS logo
ii) Water Capacity
iii) Maximum working pressure
iv) Test pressure
3rd STAY PLATE
i) Test dates
In addition test date due with appropriate colour
code to be provided on the inside portion of the
stay plat by stencilling.
c) MARKINGS ON BUNG :
i) Serial number of the cylinder
ii) Manufacturer's identification mark
iii) Tare weight
iv) Month and year of manufacture.
5.1.6 CYLINDER TESTING/ INSPECTION
DURING MANUFACTURE :
A) BEFORE CLOSING-IN OPERATIONS :
Each cylinder shall be examined for
wall thickness before the closing-in
operation, circularity of the cylindrical
shell and skirt portion of the ends,
external and internal surface defects,
profile regularity of the ends, offset at
the joints and straightness. The
manufacturers shall assure themselves
that the wall thickness is not less than
the agreed finished thickness at any
point.
b) ROUNDNESS :
The out-of roundness of the cylindrical
shell shall be limited to such a value tht
the difference between the max. and the
min. outside diameter in same cross
section is not more than 1% of the
mean of these diameters.
c) SURFACE DEFECTS :
The internal and external surfaces of
the cylinder shall be free from defects
which will adversely affect the safe
working of the cylinders.
d) PROFILE REGULARITY :
The inner surface of the end shall not
deviate from the prescribed shape by
more than 1.25% of the nominal
diameter of the head skit. Such
deviations shall not have abrupt
changes.
e) OFFSET AT THE JOINT :
The misalignment measure at the
surface at the plates shall not exceed
10% of the nominal plate thickness.
Where the thickness of the ends
exceeds the shell thickness by more
than 25%, the abutting edges shall be
reduced by smooth taper extending for
a distance of 4 times the offset between
the abutting edges.
f) STRAIGHTNESS :
The maximum deviation of the shell
from a straight line shall not exceed
0.3% of the cylindrical length.
g) VALVE CONNECTIONS :
The valve connection shall consist of a
welded pad or bung and shall be
threaded to suit the type of valve
specified as per IS:8737 (Part II) -
1978.
h) VALVE PROTECTION RING (VP RING)
The cylinder shall have the valve
protected against damage by the
provision of a stout V.P. Ring welded
with the help of 3 stay plates on the
body of the cylinder. The height of the
V.P. Ring from the body of the cylinder
shall be 122+/-3mm. The diameter of
the V.P. Ring tube shall be 21 mm and
should be provided with a vent hole.
I) HEAT TREATMENT :
All cylinders shall be efficiently
normalised or stress, relieved in
accordance with the steel maker's
recommendations, after manufacture
and completion of all welding and
before subjecting to hydrostatic test. A
complete record of heat treatment cycle
shall be maintained.
5.1.7 RADIOGRAPHIC EXAMINATION :
Radiographic examination when
required shall conform to the
techniques and acceptability criteria set
forth in the relevant Indian Standards.
A reference may be made to IS:1182-
1967, IS:2595-1978, IS:3657-1978,
IS:4853-1968 and 8.7 of IS:2825-1969.
The Radiographic techniques used shall
be sufficiently sensitive to reveal the
defect having thickness equal to 2% of
the combined thickness of the weld and
backing strip.
One out of each batch of 50 cylinders,
or less shall be taken for spot
radiography of the seam weld i.e. the
sample taken for Acceptance Tests as
per IS:3196 (Part-1) should also be
radiographed before destructive testing.
5.1.8 INSPECTION OF FNISHED
CYLINDERS :
a) CHECK OF WATER CAPACITY :
The water capacity of each cylinder
shall be checked. This shall be done by
weighing, by filling the cylinder with a
calibrated volume of liquid or by other
means approved by the inspecting
authority in order to ensure compliance
with the required specified water
capacity. The tolerance for water
capacity shall be +3-0%.
b) HYDROSTATIC TEST :
Each heat treated cylinder shall be
subjected to hydrostatic test. During the
hydrostatic test, the pressure shall be
increased gradually till the required test
pressure is reached i.e. 25.35
kgf/sq.cm. After the test pressure is
reached, it shall be retained for a period
of not less than 30 seconds. Any
reduction in pressure noticed during
this retention period or any leakage or
visible bulge or deformation shall be
treated as the case of failure in the test.
c) PNEUMATIC LEAKAGE TEST :
Subsequent to the Hydrostatic test, each
cylinder after it has been dried shall be
tested for leakage by subjecting to air
pressure of not less than 10 kgf/sq.cm
for a period of one minute while
immersed in water and shall show no
leakage.
d) BURSTING TEST :
One cylinder taken at random from
each batch of 403 cylinders or less shall
be subjected to an internal hydrostatic
pressure till it bursts, as stipulated in
IS:3196-1982.
The normal hoop stress corresponding
to the pressure at which destruction
occurs shall be calculated as per
Section 16.1.1 of IS:3196-1982. The
cylinder shall burst without
fragmentation. The fracture should not
occur in the weld in the direction of
seam nor parallel to the weld within 10
mm of the weld in the direction parallel
to the weld.
e) ACCEPTANCE TEST :
One cylinder at random shall be taken
out from each batch of 202 or less and
the acceptance test for the parent metal
and weld joint shall be carried out in
accordance with section 17 of IS:3196
(Part -1)-1982 for tensile strengths
yield strength and root bend test.
f) PAINTING AND FINISHING :
As per BIS code, each cylinder shall be
shot blasted for cleaning the scales, rust
etc. and should be subjected to
metalising with zinc to prevent against
corrosion. The thickness of the metal
film should be minimum 37 microns.
After metalising the cylinder shall be
applied with one coat of zinc chromate
primer and one coat of enamel paint.
The total dry film thickness of the paint
and metal spray thickness of the paint
and metal spray should not be less than
67 microns.
g) OVERALL DIMENSIONS OF
CYLINDER
The following are the important
dimensions of a 33.3 Lts. Water capacity
cylinder :
I) Overall height - 625 +/-5mm
ii) Height of shroud - 143 +/-3mm
iii) Internal diameter - 314.4+1%,-0%
iv) Height of foot ring - 44 mm
v) Outer dia of foot - 265 +/-3mm
ring
5.2 VALVES :
The LPG cylinder valve shall be
manufactured conforming to IS:8737
(Part II)-1978 and as per Kosan
Technova (Denmark) Technology.
5.2.1 MATERIAL :
All components used in valve
construction shall be made out of
material compatible with LPG and with
 material of cylinder. The material of the
valve body shall have properties as
described here under :
The valve body shall be forged from
wrought or extruded sections.
5.2.2. MARKINGS ON THE VALVES :
a) The specification of the valve
& name of product.
b) Quarter/ Year of manufacture
c) ISI Monogram
d) Maximum working pressure
(WP)
e) Batch No.
f) Manufacturer's symbol
5.2.3 PHYSICAL PROPERTIES :
a) The tensile strength and
elongation of the material of
valve body determined
according to IS:1608-1972,
IS;1816-1961 and IS:2654-
1977 shall be respectively
atleast 40 kgf/sq.mm and 18%
measured on a gauge length of
5.65/50 mm, 50 being the
original area of cross section
in mm.
b) IMPACT STRENGTH
The Izod impact strength of
the material of valve body
determined according to
IS:1598-1977 shall not be less
than 2.2 kgf/sq.m for brass.
Test samples of tensile and
Izod impact test shall, where
practicable, be taken from
valve body bland, where this is
not practicable, the test sample
shall be made from the same
raw material giving the same
outside shape as to valve body
blanks it represents. The scale
of sampling and criteria for
conformity shall be in
accordance with Section 2.5 of
IS:8737 (Part II)-1978.
All the dimensions,
threadings, material
specifications, etc. shall be in
accordance with the
Implementation Report on
Import of Technology for self-
closing type LPG cylinder
valves of March, 1985.
5.2.4 TESTS :
a) Representative samples of
machined valve bodies shall be
subjected to a hydrostatic test
at 1.5 times the maximum
working pressure i.e. 25.35
kgf/sq.cm as per IS:8737 (Part
II)-1978.
b) Each assembled valve shall be
subjected to a pneumatic
pressure of 17 kgf/sq.cm. in
both, open and closed position.
c) The valve shall perform
satisfactorily at not less than
5000 cycles of opening and
closing operations. After the
tests, the valve shall be
subjected to a pneumatic test at
17 kgf/sq.cm. pressure.
d) For carrying out all other tests,
the scheme of testing and
inspection as prescribed by
IS:8737 (Part II)-1978 shall be
referred to.
5.2.5 SAFETY CAPS :
The safety caps for the valves have been
standardised. This being an important
component for valve protection as well
as stopping leakage in case of
emergency, should be tested for
material and also operation at 17
kgf/sq.cm. The tests and the inspection
scheme adopted should be as per
inspection scheme prescribed below.
The material of the caps shall be acetal
homopolymer/ co-polymer.
5.2.6 JOINT PACKING :
The joint packing or the`O' Ring of the
valve is highly critical component of
 the valve, as it is the main component design and dimensions of the `O' Ring
which prevents leakage between valve must be strictly adhered to.
and Regulator assembly. Therefore, the
quality control checks on the material,
ANNEXURE

INSPECTION FORMAT FOR SAFETY CAPTS

TEST CRITERIA : f) 1.4 + 0.2
- 0.0
1. Fitment on SC valves g) 37.5 + 0.1
2. Pneumatic test - 0.2
a) 5 kgf/sq.cm h) 18.8 + 0.3
b) 17 kgf/sq.cm 4. Spring wire dia 1.35 mm

3. Dimensions : 5. Strap length 275 +/-5mm

(All dimensions in mm)
6. Performance with AL Seal
a) 26 + 0.2 O.K./NOT O.K.
- 0.2
7. Marking a) Marketing Co. symbol
b) 11.5 + 0.1 b) Arrow
- 0.05 c) Patent No.
d) Cavity No.
c) 6.5 + 0.2
- 0.2 8. Weight of caps 7.5 gms.

d) 29.5 + 0.1 9. General Workmanship

- 0.2 O.K/ NOT O.K.
e) 3.5 + 0.0
- 0.2
GLOSSARY OF TERMS

1. Area Classification
It is 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.
2. Bulk Vessels
A pressure vessel used for more than 1000 litres
water capacity for storage or transportation.
3. Bullet
A horizontal pressure vessel used for storage or
transportation by rail/ road.
4. 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 Deg C
or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50
Deg C or both.
5. Cylinders
A portable container upto 1000 litres water
capacity used for both domestic and industrial
purposes.
6. 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.
7. Earthing & Bonding
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 electrostatis
discharge.
Bonding is the process of connecting the
equipment/ system to be earthed to the ground
by the bond wire to prevent sparking between
two conducting bodies.
8. 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 deg. C.
9. 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.
10. Fire proofed
It is a passive concept of exposure protection of
structures, vessel surface or cables that could be
exposed to direct flame impingement, free
burning plus pressure torching conditions, and/
or prolonged periods of high intensity radiant
heat fluxes by the application of coating with a
specified rating.
11. Flammability
It is the percentage of volume of any flammable
vapour in air-vapour mixtures capable to form
an explosive mixture.
12. 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.
13. 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 hot work in such vessels/
pipelines.
14. Hot Work
It is an activity which may produce enough heat
to ignite a flammable air-hydrocarbon mixture
or a flammable substance.
15. 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.
16. Liquefied Petroleum Gas (LPG)
The term applies to a mixture of certain light
hydrocarbon C2 to C5, derived from petroleum
which are gaseous at ambient temperature and
pressure test may be condensed to a liquid state
at normal ambient temperature by the
application of moderate pressure.
17. 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.
(A) 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.
(B) 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.
18. Reid Vapour Pressure
Reid Vapour Pressure is the vapour pressure in
pounds per square inch (psi) at 100 Deg F as
determined by Reid apparatus.
19. Spheres
A spherical pressure vessel used for storage.
20. Tare Weight
It is the weight of the cylinder together with any
fitting permanently attached to them and
includes the weight of valve.
21. Working Pressure
It is saturated vapour pressure at 65 Deg. C.
22. Water Capacity
The volume of water in litres that the container
can hold at 15 Deg. C.
 CHAPTER 6
STORAGE AND HANDLING OF BULK LPG
6.1 GENERAL
This section is recommended as a guide to safe
practices and provisions applying to unloading
of bulk LPG and storage of bulk LPG at plants.
This section cover -
- Unloading of bulk Tank Truck and Tank
Wagon
- Storage of bulk LPG
6.2 UNLOADING OF BULK LPG TANK
TRUCK & TANK WAGONS
Bulk LPG is transported through Rail Tank
wagon, Road Tank Trucks. Currently various
capacities of Tank wagons and Tank-trucks are
in use.
Rail tank wagons - 5,10,12,13,15,37 MT
Road tank trucks - 6-18 MT
Unloading of bulk T/Ts and T/Ws shall be
carried out only at location as approved by
CCOE and under the supervision of a
responsible person. All safety precautions shall
be observed :
- All electrical equipment/ lighting are of
flameproof type
- Vapour vent line should be for individual
bay at 1.5 M height above the eaves of the
shed fitted with flame cap. ( applicable
where flare system are not available or not
used for venting).
- Extinguishers as referred in Chapter 10,
shall be positioned as an immediate aid to
fight fire.
- No hot work/ cold work is carried out in the
vicinity of unloading operation.
- decanting all liquid LPG, close the valve
- Checks shall be carried out for each T/T and
T/W prior to unloading of LPG as per check
list given in Annexure I and II respectively.
6.3 PROCEDURE FOR UNLOADING
TANK TRUCKS
6.3.1 Checks essential for plant safety shall be
carried out for each Tank Truck before its
entry to the licensed area as per
Annuexre-I.
6.3.2 Tank pressure, temperature and weight of
filled tank truck shall be recorded.
6.3.3 Tank shall be placed in drive out position
with entire tank truck consisting of bullet
and engine covered by sprinklers.
6.3.4 After placement, engine as well as master
control switch shall be switched off and
minimum two wooden chokes shall be
placed under wheels.
6.3.5 Following shall be connected -
- Chassis and bullets both are to be earthed
independently for which bare metal cleats to
be provided.
- Liquid and vapour hoses to tank trucks after
examining the integrity of gaskets and using
proper studs. Bolts and nuts are not be
used.
- Earthing lines to tank bare metal or
earthing point to tank.
- Liquid and vapour hoses to tank trucks.
6.3.6 The tank truck valves shall be crack
opened and ensured there are no leaks.
6.3.7 After the above, unloading should be
done preferably with LPG compressor by
differential pressure method.
6.3.8 Pressure and level in the tank truck shall
be monitored at regular intervals so that it
does not exceed safe limits. After
of liquid line of the bay. Thereafter, LPG
vapour should be recovered such that
vapour pressure in the tank truck is
brought down to 1.5 kg/cm2 minimum
but not below atmospheric pressure.
6.3.9 On completion of unloading, following
operations shall be done in sequence :
a) Isolate rigid liquid and vapour lines of
bay by closing the valves and stop LPG
compressor.
b) Close the valves of liquid/ vapour lines of
the tank truck. Depressurise the hose
through high vent - close vent valve.
c) Remove hose connections, electrical
bonding wires.
d) Cap the vapour/ liquid outlet lines of tank
trucks.
e) Remove chokes placed under wheels.
6.3.10 Record the weight of empty tank truck
along with rotogauge, pressure gauge and
temperature gauge readings.
6.4 PROCEDURE FOR UNLOADING OF
TANKWAGONS
6.4.9 Clear the track for movement of wagons.
6.5 STORAGE OF BULK LPG
LPG is stored in liquid and vapour form under
pressure in specially designed tanks known as
Pressure Vessels (Unfired). For details of design,
facilities etc. refer to Chapter 3 on Plant Layout
& Chapter 4 on Design criteria.
The bulk storage of LPG shall be governed by
SMPV (U) Rules, 1981.
Precautions for storage of LPG in bulk :
a) Filling shall not exceed safe permissible
filling ration.
b) Vessel shall be inspected daily for any LPG
leakages and corrective action taken.
Storage vessel should be drained regularly for its
water content, sediments, caustic contents etc.
Draining operation should be carried out under
the supervision of a responsible person.

6.4.1 Checks shall be carried out as given in
Annexure-II.
6.4.2 The tank shall be placed in position and
secured against any movement. The hand
brakes must be put on and hand brake
lever secured in "ON" position.
Following precaution should be observed :
The valve closest to the Pressure vessel must be
fully opened first. The draw off rate as required,
to be adjusted by operating the lower valve. This
is to ensure that valve near to the Pressure vessel
remain free from freezing, blockage.

6.4.3 After placement, the points leading to the c) All gauges, viz. High level alarm,
track/ lines on which the tank to be measuring gauges, pressure gauges,
unloaded shall be set and pad locked so as temperature gauges should be kept in
to isolate it from other track/ lines. operating condition at all times and be
checked daily.
6.4.4 The siding site shall be properly protected
to prevent any Wagons dashing against
the tank wagons. Caution sign be
exhibited at suitable distance away from
tanks on both ends as applicable.
6.4.5 Tank pressure, temperature and dips of
filled wagons shall be recorded. Record
weighments wherever weighbridge is
provided.

6.4.6 Procedure enumerated from 6.3.5 to 6.3.8

& 6.3.9 (a,b,c,d) shall be followed.

6.4.7 Release hand brakes, remove caution sign

and pad locks.

6.4.8 Weight the empty wagon, wherever

weighbridge is provided.
 ANNEXURE - 1

CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION

1. CHECKS REQUIRED TO BE - Fuel tank is protected by means of stout

CARRIED OUT BEFORE ALLOWING guard and fuel tank cap is locked.
ENTRY OF TT INSIDE LICENCED
AREA - Paint of bullet is not peeling off.

TANK TRUCK : GENERAL

- has suitable spark arrestor of make and - First aid kit is available.
design approved by CCE, Nagpur properly
fixed to exahust.
3. CHECKS REQUIRED TO BE
- carries 2 nos. 10 kg. DCP extinguishers in CARRIED OUT ON RANDOM BASIS -
easily accessible and removable position MINIMUM ONE DAY, ONCE IN A
with Truck No. date of checking and MONTH :
charging painted on it.
TANK TRUCK :
- quick closing manifold valve with lever
indicating close and open status. - Internals of fire extinguishers in good
condition
- No visible dent on the bullet.
- Carries TREM CARD, instructions booklet
ELECTRICALS : detailing instructions on handling
emergencies en route.
- All junction boxes are properly sealed
- Carries route map
- Any loose electrical wiring/ terminal
- Carries TREM card
- Electrical wiring is insulated and provided
with suitable over current protection. - Has valid CCE licence and authenticated
copy of drawing
- Truck is self starting
- Carries RTO permits
- Readily accessible master switch for
switching off the engine is provided inside - RLW-ULW> Licenced capacity
the cabin.
- HAZCHEM sign, name of contractor with
address and telephone No. displayed
TANK FITTINGS : prominently.

- Leakage from any fittings or joints. - Bullet has no sign of extern corrosion.

2. CHECKS REQUIRED TO BE
CARRIED OUT BEFORE ISSUING TANK FITTINGS :
LOADING MEMO (DURING THE
COURSE OF UNLOADING - Excess flow check valves are functioning.
OPERTIONS)
- Liquid / vapour lines are adequately
TANK TRUCK anchored and are well protected by means
of stout steel guard.
- Height barrier provided as per specifications
- 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 :
- 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.

Following are available in Tank Truck :

ANNEXUR -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.
 CHAPTER 7
BOTTLING OPERATIONS
7.1 GENERAL
This section covers the safe practice of LPG
filling plants dealing with cylinders fit for
filling, having cylinder capacities as referred in
Chapter 5.
Activity on bottling line including valve change,
shall be carried out by trained company's
personnel and shall be carried out in an area
approved by CCE and filling shall be governed
as per -
- Gas Cylinder Rules, 1981 (under Indian
Explosives Act,1884)
- The Standards of Weights and Measure
Rules, 1987 (under Weights & Measures
Act, 1976)
- The LPG Regulation of Supply &
Distribution Order, 1993.
7.2 BOTTLING OPERATIONS
The Bottling Operations can be classified under
following heads :
I) Receipt of LPG cylinders
ii) Filling of LPG Cylinders
iii) Handling & storage of LPG cylinders
iv) Auxilliary Operations
I) Receipt of LPG cylinders
Cylinders shall be received in capped condition.
Cylinder shall conform to IS:3196.
II) Filling of LPG cylinders
(a) Pre-filling operation Cylinder before filling
shall be checked for following :
- Visually inspected as per IS:5845
- Cylinder surface is clean
- Cylinder is free of air.
- `O' 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 working
pressure of cylinder i.e. 16.9 kgf/sq.cm 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
1.5%. All under-filled/ over-filled cylinders
should be corrected on adjustment scale.
Cylinder shall be checked for `O" ring
condition and for valve leak by means of
Compact valve Tester (CVT).
CVT should be calibrated so as to detect
leakage beyond 0.5 gm/hr. For cylinders
found with `O' ring defect, the `O' ring shall
be replaced with a new one and the same
should be rechecked for `O' ring condition
with CVT.
Cylinder shall be checked for body leak and
bung leak by dipping in water test bath.
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.
For typical layout of filling shed with
carousel refer to Annexure-I.
III) Handling & Storage of LPG Cylinders in
cylinder filling and cylinder storage shed :
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
sides 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/ Bung leak shall be degassed for
repairs.
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 2 stack high.
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.
For typical stacking arrangement refer
Annexure-II.
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.
IV) Auxilliary 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.
- Cylinder having bung leak, same valve be
used. Cylinder having defect in valve shall
be replaced with good valve.
- 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 used. Jointing
compound shall be compatible with LPG,
water and metallurgy of cylinders and
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 :
Degassing shall be carried out as follows :
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 1.0M
height above the roof of the shed.
Valve shall be removed with suitable torque
wrench. 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.
 CHAPTER 8
PLANT EQUIPMENT
8.1 GENERAL :
8.1.1 SERVICEABILITY OF PLANT :
The serviceability and safety of LPG plant
equipments, especially in the long term, are
affected by the standard of maintenance and
inspection carried-out.
8.1.2 MAINTENANCE SCHEDLES :
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 (See Annexure I-III).
8.1.PERSONALPROTECTION
EQUIPMENT :
Necessary personal protection equipments such
as Hand gloves, Safety shoes, Helmets, Safety
belts, Safety goggles etc. shall be used (Ref.
OISD STD-155).
8.2 WORK PERMIT SYSTEM :
No Maintenance/ Inspection work shall be
carried out without following the OISD
Standard OISD-105 on "Work Permit System"
and Section 4 of OISD-137 for electrical
maintenance purpose.
8.3 INSPECTION & MAINTENANCE OF
VARIOUS FACILITIES IN LPG BOTTLING
PLANTS :
8.3.1 STATIC EQUIPMENTS :
a) PRESSURE VESSELS & STORAGE
FACILITIES :
OISD Standard Nos. OISD-128 on "Inspection
of Pressure Vessels and OISD-129 on
"Inspection of Tankages" 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
microalloyed high tensile steels have shown
greater susceptibility to such cracking. Wet
Fluoroscent Magnetic Particle Testing
(WFMPT) is considered the most reliable test
method for detecting these microcracks.
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
smoothered 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 :
OISD Standard No. OISD-130 on "Inspection of
Pipes and Valves and Fittings" shall be followed.
c) HOSE AND FLEXIBLE CONNECTION :
OISD Standard No. OISD-135 on "Inspection of
Loading and Unloading Hoses for petroleum
products" shall be followed.
d) STRAINERS AND 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 :
e) Cylinder Test Bath
OISD Standard No. OISD-132 on
"Inspection of Pressure Relieving f) General
Devices" shall be followed.
8.3.4 INSTRUMENTATION :
8.3.2 ROTARY EQUIPMENT :
a) TEMPERATURE INDICATING
a) COMPRESSORS : OISD Standard No. DEVICES
OISD-120 on "Inspection of
Compressors" shall be followed. In Shall be checked daily for its proper
addition, periodic maintenance checks, as functioning and shall be calibrated once in
detailed in Annexure-I to be followed. 6 months.

b) PUMPS : OISD Standard No. OISD-110 b) LEVEL GUAGING DEVICES :

on "Inspection of Pumps" shall be
followed. In addition, periodic checks as The gauging devices shall be checked daily for
detailed in Annexure-II to be followed. proper functioning. Zero level check and
calibration shall be carried out monthly
c) DIESEL ENGINES: OISD Standard No. and quarter as applicable.
OISD-123 on "Inspection and
Maintenance of Rotating Equipment c) PRESSURE GAUGES :
components shall be followed.
Shall be checked daily for its proper functioning
8.3.3 FILLING EQUIPMENT : and shall be calibrated once in 6 months.

It shall be ensured that the equipment is d) FLOW MEASURING DEVICES :

in good working condition to ensure quality
output and also safe operation. Specimen Shall be checked daily for proper functioning
inspection checks are serving schedule given and calibration shall be carried out
at Annexure --- for ready reference for the monthly and quarterly as applicable.
following equipments:
8.3.5 FIRE FIGHTING EQUIPMENT :
a) CAROUSEL
OISD Standard No. OISD-142 on "Inspection of
i) Drive units Fire Fighting Equipments" shall be
ii) Centre column followed.
iii) Running Rail
iv) Introduction and Ejection devices 8.3.6 ELECTRICAL EQUIPMENT
v) Filling machines
vi) Check Weigh Scales OISD Standard No. OISD-137 on
"Inspection of Electrical Equipment"
b) Chain/ Roller conveyor shall be followed.
c) Drive Units for Conveyors

d) CVT-leak detector

ANNEXURE -I
MAINTENANCE SCHEDULE

COMPRESSORS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half Annually
Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
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. *

17. Check safety release valve. *

18. Complete over-haul. *

 ANNEXURE -II

MAINTENANCE SCHEDULE

CENTTRIFUGAL PUMP

--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half Annually
Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------

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. *

--------------------------------------------------------------------------------------------------------------------------------
 ANNEXURE-III

MAINTENANCE SCHEDULE

FILLING EQUIPMENTS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half Annually
Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------

I. CAROUSEL :
(A) DRIVE UNIT :

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

2. Check oil pressure. *

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

4. Grease guide rollers. *

5. Check & adjust drive belt. *

6. Unscrew magnetic plug and clean. *

7. Change hydraulic oil &clean filter. *

8. Clean hydraulic oil tank. *

9. Inspect gears for wear and tear. *

10. Check electric motor & grease motor bearing. *

11. Complete overhaul of the drive unit. *

(B) CENTRAL COLUMN

1. Check air & gas joints for leakage. *

2 Grease bearing. *

(C) RUNNING RAIL :

1. Clean & apply graphite. *

2. Lubricate rail wheels. *

3. Check rail levels. *

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

(D) INTRODUCTION AND EJECTION DEVICES:

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

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

3. Oil the introduction arms. *

4. Check functioning & adjust if required. *

5. Greasing all grease points. *

6. Tighten guide rollers. *

7. Check & repair leaks. *

8. Inspect for wear and tear. *

9. Overhaul the unit. *

(E) FILLING MACHINES:

1. Thoroughly cleaning by using *

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

3. Check operation of filling head *

by supplying air.

4. Check leakage of LPG and repair. *

5. Check condition of LPG filling hoses. *

6. Check oil level in air lubricators. *

7. Lubricate pullies holding filling guns. *

8. Carry out calibration and adjust- ment. *

9. Suspension system bearings & knife *

edges to be thoroughly cleaned.

10. Inspect knife edges for wear & tear *

and repair where required.

11. Complete overhauling. *

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

(F) CHECK SCALE :

1. Thorough cleaning by using dry air. *

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

3. Check oil level in lubricator *

and its functioning.

4. Calibrate with standard weights. *

5. Greasing of cylinder stop unit. *

6. Clean suspension system bearings *

knife edges etc.

7. Check for wear & tear of knife edges *

& replace if necessary.

8. Complete overhauling. *

II. CHAIN CONVEYOR :

1. Top up soap solution trays. *

2. Check position of tension roller *

of chain and adjust if required.

3. Lubricate tension rollers & wheels. *

4. Clean soap solution tray. *

5. Grease the bearing *

6. Check foundation bolts of conveyor *

frame for tight- ness.

III. DRIVE UNIT OF CONVEYORS :

1. Check & top up oil level. *

2. Check coupling bolts & rubber *

bushings. Replace the cracked
or worn out bushings.

3. Check alignment of gear box & *

orrect if necessary.
--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------

4. Clean & lubricate chain. *

5. Tighten foundation bolts. *

6. Drain & change oil. *

7. Inspect for wear & tear. *

IV. CVT/ DCVT LEAK DETECTOR :

1. Check for proper functioning. *

2. Top up kerosene Every shift

chamber.

3. Check leakage rate thru verifier. *

4. Dismantle/ clean the interiors & *

apply silicon grease to "O" ring.

V. CYLINDER TEST BATH:

1. Fill with clean water. *

2. Lubricate moving parts. *

3. Clean tank walls from inside. *

4. Check & lubricate pneumatic *

circuitory of all equipments.

5. Check all fasteners and tighten. *

6. Paint tank walls from inside. *

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

DIESEL ENGINES

MAINTENANCE STEPS

1. KEEP THE DIRT OUT OF THE ENGINE.

2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.

3. REGULATE THE ENGINE'S FUEL.

4. CONTROL OPERATING TEMPERATURES.

5. GUARD AGAINST CORROSION.

6. LET THE ENGINE BREATHE.

7. PREVENT OVERSPEEDING.

8. KNOW YOUR ENGINE'S CONDITION.

9. CORRECT TROUBLES WHILE THEY ARE SIMPLE.

10. SCHEDULE AND CONTROL YOUR MAINTENANCE.

 DIESEL ENGINES

"A" CHECK EVERY DAY

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

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

ENGINE LOG BOOK.

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

FROM FUEL TANK AND FUEL
FILTER THROUGH DRAIN COCK.

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

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

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

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

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

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

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

7. CHECK AIR LINE CONNECTIONS 7A CORRECT AS REQUIRED

FOR LEAKS.

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

9. DRAIN AIR RECEIVER TANK 9A

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

"A" CHECK EVERY DAY

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

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

IF CLOGGED.

11. CHECK OIL LEVEL IN 11A CHECK FOR LEAKS, USE SPECI-
HYDRAULIC GOVERNOR,IF FIED ENGINE OIL FOR TOPPING
PROVIDED. UP.

12. START THE ENGINE AND NOTE 12A IF THERE IS A CHANGE IN OIL
THE OIL PRESSURE BOTH AT PRESSURE FROM THAT RECORDED
IDLING AND MAXIMUM SPEED. IN THE LONG BOOK ON EARLIER
OCCASION THEN STOP ENGINE
AND CHECK THROUGH TROUBLE
SHOOTING TECHNIQUE THE CAUSE
FOR OIL PRESSURE CHANGE AND
CORRECT IF NECESSARY (FOR
ASSISTANCE IN DIAGNOSING THE
CHANGE IN OIL PRESSURE
CALL YOUR SERVICE
REPRESENTATIVE IF NECESSARY.

13. RECORD OIL PRESSURE 13A REFER O&M MANUAL FOR LUB.
OIL PRESSURE LIMITS.

14. FILL FUEL TANK AT THE 14A USE CLEAN FUEL AND A STRAI-
END OF THE SHIFT. NER. ALSO CLEAN THE CAP AND
SURROUNDING AREA BEFORE
OPENING THE FILLER CAP.
--------------------------------------------------------------------------------------------------------------------------

"B" CHECK EVERY 250 HOURS

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

1. REPEAT ALL MAINTENANCE 1B

STEPS OF CHECK "A" 1 TO 14.

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

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

DIESEL ENGINES

"B" CHECK EVERY 250 HOURS

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

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

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

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

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

5. CLEAN OIL BATH AIR CLEANER 5B

TRAY SCREEN

6. CHANGE LUBRICATING OIL 6B RECORD OIL PRESSURE.

BY-PASS FILTER ELEMENT
AND GASKET, IF PROVIDED.

7. CLEAN FLOAT TANK AND/OR 7B

MAIN FUEL TANK BREATHER.

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

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

9. CHECK MAGNESIUM PLATE 9B CHECK MAGNESIUM PLATE FOR

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

DIESEL ENGINES

"B" CHECK EVERY 250 HOURS

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

FILTER ELEMENT. OF AREA IS LOST. USE DCA

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

10. CHANGE FUEL FILTER ELE 10B CLEAN SHELL FUEL FILTER
MENT WASHER AND "O" RING CHANGE ELEMENT WHEN RESTRI-
ON MOUNTING BOLT. CTION EXCEEDS VACUUM 200MM
OR MERCURY.

11. CHECK OIL IN ANEROID 11B USE SAME OIL AS USED IN OIL
CONTROL, IF REQUIRED. PAN.

12. CHECK & ADJUST BELTS.NEW 12B TIGHTEN BELT TENSION REFER
BELTS WILL STRETCH WITHIN MAINTENANCE MANUAL.
ONE HOUR OR USE THEY MUST
BE READJUSTED.

13. TIGHTEN FOUNCTION BOLTS AND 13B

FLEXIBLE COUPLING BOLTS OF
ENGINE AND ALTERNATOR.

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

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

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

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

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

17. CHECK THROTTLE LINKAGE. 17B

 DIESEL ENGINES

"C" CHECK EVERY 1500 HOURS

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

1. REPEAT ALL MAINTENANCE

STEPS OF CHECKS "A" & "B".

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

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

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

BEARING END PLAY.

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

FOR PLAY.

5. CHECK FOR TURBOCHARGER 5C CORRECT AS REQUIRED.

OIL LEAKS.

6. TIGHTEN TURBOCHARGER 6C TIGHTEN TO THE SPECIFIED TORQUE

MOUNTING NUTS. DO NOT TIGHTEN WHEN ENGINE IS
HOT.

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

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

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

CLEAN INCLUSIVE OF FIXED
SCREENS.

9. CLEAN AND TIGHTEN ALL ELEC- 9C

TRICAL CONNECTIONS.

10. CHECK GENERATOR BRUSHES AND 10C REPLACE AND CLEAN AS REQUIRED.
COMMUTATOR.

11. CLEAN ENTIRE ENGINE 11C HIGH PRESSURE AND SOAP WATER
MIXTURE PREFERRED AFTER
SPRAYING ENGINE WITH
CLEANSER

DIESEL ENGINES

"C" CHECK EVERY 1500 HOURS

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

TAKING CARE OF PROTECTING

ELECTRICAL SYSTEM.

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

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

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

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

ZINC PLUG (MARINE APPLICATION) PLUGS.

16. CHECK EXHAUST AND INLET MANI- 16C

FOLD NUTS AND CAPSCREWS.

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

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

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

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

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

21. CLEAN FUEL INLET CONNECTIONS. 21C

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

OIL/ ANEROID OIL.

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

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

"D" CHECK EVERY 4500 HOURS

----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
1. REPEAT ALL MAINTENANCE STEPS 1D
OF CHECKS "A", "B" & "C".

2. CHECK EXHAUST AND INLET 2D

MANIFOLD NUTS AND CAPSCREWS.

3. TIGHTEN ALL MOUNTING BOLTS 3D

AND NUTS.

4. CLEAN TURBOCHARGER DIFFUSER 4D

AND IMPELLER AND CHECK END
FLOAT.

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

CLEARANCES BEARINGS IF IN EXCESS OF LIMITS,
REPLACE.

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

CORRECTIVE ACTION IS INDICATED.

7. CLEAN INJECTOR INLET SCREENS.

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

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

9. CHECK FUEL PUMP CALIBRATION 1 BLACK SMOKE.

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

11. REPLACE FUEL PUMP FILTER

SCREEN AND MAGNET.

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

USE CLEAN SOAP WATER SOLUTION
AS OUTLINED IN "C" CHECK ITEM-11C.

`E' CHECK EVERY 8000 HOURS

1. REPEAT ALL MAINTENANCE STEPS OF CHECK `A', `B', `C' & `D'.

2. THE `E' MAINTENANCE CHECK IS NECESSARY ONLY WHEN THE ENGINE OPERATING
CONDITIONS SIGNIFY DETERIORATION IN PERFORMANCE AS CAN BE ASCERTAINED
BY THE SYMPTOMS :

(1) HEAVY SMOKE (2) LOSS OF POWER (3) HIGH OIL TEMPERATURE HIGH WATER
TEMPERATURE (4) LOSS OF LUB. OIL PRESSURE (5) UNUSUAL NOISE & VIBRATIONS.
 THE `E' MAINTENANCE CHECK IS A METHODOLOGY FOR INSPECTION OF WEAR OR
ASSEMBLY DETRIORATION OF PARTS AND ASSEMBLIES, AND SHOULD BE RESORTED
TO ONLY WHEN TROUBLE SHOOTING IN ADDITION TO PERFORMING A,B,C AND D
MAINTENANCE CHECKS, WHICH MAY ELIMINATE THE ENGINE PERFORMANCE
PROBLEM AND BRING THE ENGINE BACK TO NORMAL OPERATING CONDITIONS. IT
IS ANTICIPATED THAT GOOD OPERATING AND MAINTENANCE PRACTICES AS
PRESCRIBED THROUGH A,B, C & D CHECKS WILL ENSURE THAT THE ENGINE WILL
PERFORM BEYOND 25000 HOURS BEFORE THAT THE ENGINE MUST BE DISMANTLED
FOR INSPECTION PRELUDE TO A MAJOR OVERHAUL. THE TIME INTERNAL OF 8000
HOURS IS A PERIOD AT WHICH THE ENGINE MAY DEVELOP SYMPTOMS ASCRIBED
ABOVE 1-5 AND ARE INDICATIVE OF PERFORMANCE DETERIORATION DUE TO
INADEQUATE A,B,C & D CHECKS AND FAILURE TO IDENTITY PERFORMANCE
DETERIORATION. THIS FIGURE HAS BEEN ARRIVED AT ON THE BASIS OF CURRENT
MAINTENANCE PRACTICES AND SHOULD NOT BE TREATED AS AN ABSOLUTE FOR
MAKING AN `E' CHECK. HOWEVER, IT IS ESSENTIAL THAT THE ABOVE ROUTINE
ANALYSING ENGINE PERFORMANCE BE STRICTLY FOLLOWED IN ORDER TO
PREVENT DISMANTLING OF ENGINE WHOSE PERFORMANCE CAN BE SIMPLY
CORRECTED BY TROUBLE SHOOTING AND ROUTINE MAINTENANCE CHECKS.

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

WHERE SOME KEY PARTS, SUCH AS BEARINGS, ARE CHECKED FOR WEAR TO
DETERMINE IF THE ENGINE MAY BE OPERATED FOR ANOTHER SERVICE PERIOD.
LIKEWISE, OIL CONSUMPTION, OIL PRESSURE AND OTHER SIGNS OF WEAR SHOULD
BE ANALYSED DURING THE CHECK WEAR LIMITS AND OTHER INFORMATIONIS
AVAILABLE FROM DISTRIBUTOR AND DEALERS. (IT MUST BE CLEARLY UNDERSTOOD
THAT THE DECISION TO INSPECT KEY PARTS MUST BE ARRIVED THROUGH ROUTINE
OUTLINED IN POINT TWO ABOVE).
 CHAPTER 9
STATUTORY TESTING OF LPG CYLINDERS
9.0 All cylinders used for filling LPG are
required to be tested periodically to ensure
fitness of the cylinders for further service.
First retesting is required to be done after 7
years and subsequent retesting after every
5 years interval. Such tests are to be
conducted by the CCE approved parties
only.
9.1 TESTING PROCEDURE
9.1.1 DEGASSING OF LPG CYLINDERS
All the LPG cylinders are depressurised in
the approved premises by opening valves
by means of suitable adaptors 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.
9.1.2 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 takne up for surface
cleaning by immersing the cylinder in the
caustic soda bath and soap water and the
same is then rinsed with water.
9.1.3 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.
9.1.4 VISUAL INSPECTION :
a) The detailed visual inspection of the
cylinder body shall be carried out as per
IS:5845.
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.
d) LPG cylinders selected at random may be
cut into two holes for assessing internal
corrosion.
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.
9.1.5 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.
9.1.6 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.
9.1.7 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.
9.1.8 PAINTING OPERATIONS :
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 undermeath the foot ring.
c) The valve should be protected while
painting the cylinder.
9.1.9 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.
d) 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.
9.1.10 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 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.
9.1.11 COLOUR CODING OF CYLINDER :
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:

This is done primarily to facilitate easy

segregation of cylinders for repairs at plants

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

1989 1991 1996 Sea Green 217 Black

1990 1992 1997 Dove grey 694 Black

1991 1993 1998 Aircraft Blue 108 White

1992 1994 1999 Salmon Pink 443 Black

1993 1995 2000 Black 521 White

1994 1996 2001 Yellow 355 Black

1995 1997 2002 White 127 Black

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

c) Serial number of cylinder &

9.1.12 CERTIFICATION : name of manufacturer

A detailed record of each cylinder tested d) Month and year of test

at the plant or at the repairer's premises
should be maintained. The record e) Weight of cylinder
should include the minimum following
details : f) Punched on cylinder

a) Running serial number g) Observed weight

b) Date of testing h) Whether satisfactory/ rejected

 - Quarter/ year of retest punched on the
i) Visual defects cylinder

j) Internal - Stencilling/ colour coding for age

k) External
l) Whether passed/ rejected
9.1.13 HYDROSTATIC TEST/
HYDROSTATIC STRETCH TEST :
- Whether passed/ rejected
- Condition of bung threads (internal)
- Whether satisfactory/ rejected
Pneumatic Test
- Whether passed/ rejected
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
 ANNEXURE

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.

GLOSSARY OF TERMS

1. Area Classification It is 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.
2. Bulk Vessels
A pressure vessel used for more than 1000 litres
water capacity for storage or transportation.
3. Bullet
A horizontal pressure vessel used for storage or
transportation by rail/ road.
4. 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 Deg C
or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50
Deg C or both.
5. Cylinders
A portable container upto 1000 litres water
capacity used for both domestic and industrial
purposes.
6. 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.
7. Earthing & Bonding
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 electrostatis
discharge.
Bonding is the process of connecting the
equipment/ system to be earthed to the ground
by the bond wire to prevent sparking between
two conducting bodies.
8. 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 deg. C.
9. 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.
10. Fire proofed
It is a passive concept of explosure protection of
structures, vessel surface or cables that could be
exposed to direct flame impingement, free
burning plus pressure torching conditions, and/
or prolonged periods of high intensity radiant
heat fluxes by the application of coating with a
specified rating.
11. Flammability
It is the percentage of volume of any flammable
vapour in air-vapour mixtures capable to form
an explosive mixture.
12. Flamable ( 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.
13. 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.
14. Hot Work
It is an activity which may produce enough heat
to ignite a flammable air-hydrocarbon mixture
or a flammable substance.
15. 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.
16. Liquefied Petroleum Gas (LPG)
The term applies to a mixture of certain light
hydrocarbon C2 to C5, derived from petroleum
which are gaseous at ambient temperature and
pressure test may be condensed to a liquid state
at normal ambient temperature by the
application of moderate pressure.
17. 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.
(A) 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.
(B) 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.
18. Reid Vapour Pressure
Reid Vapour Pressure is the vapour pressure in
pounds per square inch (psi) at 100 Deg F as
determined by Reid apparatus.
19. Spheres
A spherical pressure vessel used for storage.
20. Tare Weight
It is the weight of the cylinder together with any
fitting permanently attached to them and
includes the weight of valve.
21. Working Pressure
It is saturated vapour pressure at 65 Deg. C.
22. Water Capacity
The volume of water in litres that the container
can hold at 15 Deg. C.
 CHAPTER 10
FIRE PROTECTION FACILITIES
10.1 GENERAL
LPG Bottling Plants are generally located away
from populated areas in view of hazardous
nature of product. With the passage of time
these plants get surrounded by settlements/
residential localities in the absence of any
statutory regulations prohibiting their
construction.
Due to large quantities of highly inflammable
product stored in the Bottling Plants these pose
safety risk to the plant as well as to the
surrounding environment. Therefore, it is very
much essential that elaborate in-built Fire
Protection Facilities are installed at the LPG
Bottling Plants.
10.2 APPLICATION
i) This standard lays down the minimum
requirements of Fire Protection Facilities
at LPG Bottling Plants.
ii) For LPG bottling Plants located within the
Refineries the OISD Standard No. 116 -
Fire Protection Facilities for Refineries,
Gas Processing Plants shall also be
referred.
10.3 DESIGN CRITERIA
i) Facilities shall be preferably designed on
the basis that the city fire water supply is
snot available.
ii) The single largest fire risk shall be
considered.
iii) All LPG storage Vessels, Cylinder Storage/
Filling/ Repair Sheds, LPG Pump Houses,
Bulk Lorry and Tank Wagon Gantries shall
be fully covered by medium velocity water
spray system.
iv) 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. The layout shall permit
access from atleast two directions.
v) Detection of fire for automatic actuation of
medium velocity water sprinkler system
shall be provided at all critical places like
LPG Bulk Storage, Tank Truck/ Tank
Wagon Gantry, near Carousal, LPG pump/
Compressor House, Evacuation, Valve
Change Shed etc.
10.4 FIRE WATER SYSTEM
Water is used for fire extinguishment, fire
control, cooling of vessels/ equipment and
exposure protection of equipment and personnel
from heat radiation.
10.4.1 COMPONENTS OF FIRE WATER
SYSTEM
The main components of the system are :
- Fire Water Storage
- Fire Water Pumps
- Fire Hydrant/ Monitor distribution piping
network.
- Water Sprinkler/ Deluge system.
10.4.2 FLOW RATE DESIGN
The Fire Water pumping requirement shall be
calculated based on minimum spray density as
under :
Storage Vessels - 10 LPM/Sq.M
LPG Shed - 10 LPM/Sq.M
LPG Pump/compressor - 20 LPM/Sq.M.
House
LPG Loading racks - 10 LPM/Sq.M.
a) Storage Vessels
In case of Bulk Storage of LPG, automatic
detection of heat for automatic actuation of
medium velocity (MV) sprinkler system having
remote/ local operated deluge valve with spray
density of 10 LPM/Sq.M. of surface area shall be
provided. For water flow calculations adjoining
vessels within distance of R+30 Mts. (Where R
is the Radius of the LPG vessel and 30 Mts.
shall be measured from the periphery of the LPG
vessel), water density for cooling shall be
considered at the rate of 10 LPM/Sq.M. surface
area.
b) Sheds
MV sprinkler system having remote operated
deluge valve and at critical places like near
carousal, evacuation, valve chang eshed,
automatic detection of heat for automatic
operation of sprinkler system with spray density
10 LPM/Sq.M. shall be provided. The shed has
to be divided into suitable number of zones, each
served by independent deluge system. The
adjacent zones are required to be operative
around the zone under fire and the same shall be
considered as a single risk.
c) LPG Pump House
MV sprinkler system with automatic heat
detection having remote/ local operated Deluge
valve with spray density of Max. 20 LPM/Sq.M
shall be provided.
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 LPM/Sq.M of
surface area shall be provided. A maximum of 7
bays shall be considered as single risk area.
e) Tank Wagon Gantry
MV sprinkler system with automatic heat
detection having remote/ local operated deluge
valve with effective spray density of 10
LPM/Sq.M shall be provided. A minimum of
one gantry (600 MTs) shall be considered as
single risk. The spray system shall cover tank
wagons surface on either side of tank wagon
gantry as well as the associated LPG pipelines in
the gantry. The Zoning concept can be adopted
as described in 10.4.2(b).
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.
10.4.3 FIRE WATER SYSTEM DESIGN
i) The Fire Water pressure system shall be
designed for a minimum residual pressure
of 7.0 kgs/ Sq.cm 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 30 M
centre to centre. 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.
10.4.4 FIRE WATER STORAGE
i) Water for the hydrant service shall be stored
in any easily accessible surface of
underground concrete reservoir or above
ground tank of steel or concrete. However,
above ground tanks shall be preferred in
view of the availability of flooded suction
condition for easy start of fire water
engines. The effective storage capacity
shall be not less than 4 Hrs. aggregate
working capacity of Fire Water pumps.
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.
10.4.5 FIRE WATER PUMPS
i) Centrifugal type fire water pumps shall be
installed to meet the designed fire water
flow rate and head. These pumps
prerferably should have a flooded suction.
ii) There shall be a Jockey pump of capacity not
less than 10 Cu.M./Hr. per 100 Hydrant
Point. (1 Monitor is equivalent to 4 Hydrant
Points). The system pressure has to be
maintained at 7 kg/cm2g with the help of
Jockey Pump operating automatically.
 The Jockey Pump shall be quick auto start-
stop type with the help of pressure switches.
A standby jockey pump shall be provided if
the number of hydrant points are more than
100.
iii) The fire water pump(s) including the stand
by pump(s) shall be of diesel engine driven
type. 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.
iv) No. of stand by pumps shall be provided as
per following criteria :
a) Minimum 1 no.
b) 50% upto 4 Nos. of Main pumps.
c) For 4 and above, minimum 2 Nos.
v) Fire water pump house/ Fire water tanks or
reservoir shall be located atleast 60 M
(minimum) away from LPG facilities.
vi) Fire water pumps shall be exclusively used
for Fire Fighting purpose only.
10.4.6 FIRE HYDRANT NETWORK
i) Fire hydrant ring main should be normally
laid above ground. Following prcautions
should be taken if fire water ring main laid
above ground :
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.
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.
d) The portion of fire water hydrant above
ground and within 15 M of the LPG storage
vessels shall be provided with suitable fire
retardant coating.
ii) However the ring main shall be laid
underground at the following places :
a) Road crossings.
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.
iii) If Fire water ring main laid underground the
following precautions shall be taken :
a) The Ring main shall have at least one meter
earth cushion in open ground and 1.2
meters cushion under the road crossings.
b) The Ring main shall be provided with
protection against soil corrosion by suitable
coatings/ wrappings.
c) In case of poor soil conditions it may be
necessary to provide concrete/ masonary
supports under the pipe line.
iv) Fire water ring main shall be sized for 120%
of the design water rate. Design flow rates
shall be distributed at nodal points to give
the most realistic way of water requirements
in an emergency.
v) The fire water network shall be kept
pressurised to a pressure of about 7
kg/sq.cm.g with the help of one or more
Jockey pumps.
vi) Hydrants/ monitors shall be located bearing
in mind the fire hazards at different sections
of the premises to be protected and to give
most effective service.
vii) Hydrant/ monitors shall be provided for
every 30 meters in case of hazardous areas
and may be spaced 45 meters in other areas.
viii) Connections for fire water monitors shall be
provided with independent isolation valves.
ix) Hose boxes with 2 nos. hoses and a nozzle
shall be provided between the hydrant
points.
x) Considering radiation levels in the event of
a fire hydrants/ Monitors/ Control valves
shall be located at a safe distance (minimum
distance of 15 mts.) and from hazardous
equipment/ buildings.
xi) 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.
10.4.7 MATERIAL SPECIFICATIONS
All the materials used in fire water system using
fresh water shall be of approved type as
indicated below.
In case of sea water service, the fire water main
pipes shall be concrete mortar lined internally.
i) Pipes CS as per
IS:3589/IS:1239
ii) Isolation Valves Cast iron/ Cast Steel
iii) Deluge valves Cast iron/ Cast steel
iv) Hydrant
Standpost C.S.
Outlet valves Gunmetal/ Aluminium
v) Monitors C.S.
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.
viii) Water monitor and hose box shall be
painted "Luminous Yellow'.
10.4.8 MEDIUM VELOCITY SPRAY
SPRINKLER SYSTEM
i) Medium velocity sprinkler system based on
heat and other detection shall be employed.
ii) Quartzoid Bulb protection can be provided in
open areas or in the sheds. The Quartzoid
Bulbs are designed to blow at 79 deg.
centigrade (max.) and Quartzoid Bulb
network shall be maintained with plant air
at a pressure of about 3.5 kgs/sq.cm.g
through a restriction orifice and is such that
the discharge of air through one Quartzoid
Bulb will depressurise the down stream side
of the restriction orifice.
iii) The Electro pneumatic (E.P) heat detectors
can be provided in the sheds and they work
on the following principle :
a) Rate of rise - 10 deg. C/
of temp. Minute.
b) At 79 deg. C(max.)
The EP detectors are divided into groups
and alternate detectors are connected in one
circuit. Two detectors from two different
groups shall function/ operate for actuation
of sprinkler system.
iv) The actuation of detectors shall initiate the
following :
a) Opening of deluge valve.
b) Audio-visual alarm at the fire pump
house/ control panel.
c) Fire siren.
d) The diesel pump will start based on their set
pressure to supplement/ to maintain the fire
water pressure in the ring main.
ROV's of Fire-safe type shall be provided.
The following areas shall be covered with
the medium velocity spray system in the
LPG Bottling Plants :
a) LPG Storage Area :
Automatic detection of heat for automatic
actuation of MV sprinkler system having
remote/ local operated deluge valve shall be
provided.
b) Tank Wagon Loading/ Unloading Area :
MV sprinkler system having remote/ local
operated deluge valves shall be provided. Tank
wagon loading/ unloading area shall be divided
into six zones and one deluge valve shall cover
12 LPG tank wagons at a time (60 Meters long
on each spur).
c) Tank Lorry Loading/ Unloading Area :
Detection of heat for automatic actuation of MV unloading gantries Extinguisher for every
sprinkler system having remote/ local operated 15/20 meters of
deluge valve shall be provided. One deluge gantry.
valve shall be provided for a maximum of 4
bays. Other Pump Houses 2 Nos. 10 kg DCP
Extinguisher
d) LPG Sheds:
Office/Canteen/ At least 2 Nos. 10 kg.
MV sprinkler system having remote/ local Stores DCP extinguishers in
operated deluge valve and at critical places like each building
carousal, evacuation, valve change shed,
automatic detection of heat for automatic MCC/DG Room/HT At least 2 nos. 4.5
operation of sprinkler system shall be provided. Room KG Co2
extinguishers in each
e) LPG Pump/Compressor House : room or for floor area
of about 100 Sq.m.
Based on heat detection automatic MV sprinkler & 4 sand buckets & a
system having remote/ local operated deluge stand shall be
valves shall be provided. provided in MCC/DG
Room.
10.5 FIRST AID FIRE FIGHTING
EQUIPMENT v) 100% spre CO2 cartridges and 50% (Min)
spare DCP bags (as per Fire Extinguisher
10.5.1 PORTABLE FIRE EXTINGUISHERS Capacities) shall be stored in the LPG plant.

i) Portable fire extinguishers shall be located 10.5.2 WHEELED/ MOBILE FIRE

at convenient locations and shall at all times
be readily accessible and clearly visible.
i)
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.
ii) The Dry chemical powder used in the
iv) The fire extinguishers shall be provided at
various locations as under :
Area Portable Fire Extinguisher
FIGHTING EQUIPMENT
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.
extinguishers shall be Potassium/ Urea
based or Sodium Bicarbonate as per
IS:4308. Nitrogen/ Carbon Dioxide shall be
used as expellent gas.

LPG Storage 2 Nos. 10 kg DCP iii) Considering the large area, and no. of
Vessel(Each) extinguisher. operations involved in Mega LPG Plants,
special fire fighting facilities like DCP fire
LPG cylinder 2 Nos. 10 kg DCP tenders should preferably be provided.
sheds extinguisher per 200
Sq.M.Area. iv) A trolley with suitable first aid fire protective
accessories shall be readily available in the
LPG Pump 2 Nos. 10 kg. DCP LPG plant.
houses extinguisher per 50
Sq.m. Area. 10.5.3 HOSES, NOZZLES AND
ACCESSOREIS
Tank Truck loading/ 1 No. 10 kg. DCP
loading gantries Extinguisher i) Reinforced rubber lined hoses (63mm)
in each bay. conforming to IS:636 (type A or B) shall be
provided.
Tank Wagon loading/ 1 No. 10 kg DCP
ii) The hoses shall be of 15 Meters standard with one spare cyl.
length and shall be provided with Gun (Cap. 30 minutes)
metal/ Aluminium alloy male & female
couplings of instantaneous pattern. 15. Water jet blankets Min. 2 nos.

iii) 50% spare Hoses shall be stored in the LPG 16. Unitised type gas Min. 2 Nos.
plant. detector

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.
10.6 FIRE/ ALARM/ COMMUNICATION
v) The following accessories/ first aid items
shall be provided in the plant :
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.
SYSTEM

1. Fire hoses 100% of no. of 10.6.1 FIRE ALARM SYSTEM

hydrant points.
i) Sufficient No. of Manual call points shall be
2. Safety helmets As required ( Min. provided in the plant.
10 Nos.) 1 no. for
each. ii) Electricity operated Fire Siren shall be
audible to the farthest distance in the plant
3. Hose Boxes alternate hydrant (1 K.M. from the periphery of the plant).
point.
iii) Manually operated fire sirens shall be
4. Stretcher with Min. 2 Nos. each provided at strategic places.
blankets.
iv) For fire condition the siren shall be walling
5. First aid Box Min. 2 nos. sound for minimum `2 minutes and for all
clear signal it shall be straight run siren for
6. Rubber hand gloves Min. 2 pairs 2 minutes.
for electrical (BIS approved)
purpose. v) For Disaster condition the wailing sound
given shall be repeated thrice with a
7. Low temperature 4 pairs minimum 10 seconds gap.
rubber hand gloves
for LPG emergency. 10.6.2 COMMUNICATION SYSTEM

8. Low tem. protective Min. 2 sets i) Communication system like telephone/ PA

clothing for LPG or paging or walkie-talkie shall be provided.
emergency.
ii) In the hazardous areas flame-proof
9. Explosimeter Min. 2 Nos. telephones shall be provided.

10. Fire proximity suit Min. 1 No. iii) Wherever possible Hot line connection
between City Fire Brigade/ near by major
11. Fire entry suit Min. 1 no. Industries shall be provided.

12. Resuscitator Min. 2 Nos. iv) Plant shall have a ` Mutual Aid' arrangement
with near by industries.
13. Red/Green Flags As required
10.7 SPECIAL FIRE PROTECTION
14. Self contained Min. 1 No.
breathing apparatus
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.
In the event of exposure of LPG vessel to fire it
is recommended that fire proofing provided on
the vessel and supporting legs shall be adequate
to protect the shell material from overheating
and consequent failure. The material provided
for fire proofing purpose shall be good enough
to provide this protection for the initial 30-60
minutes. Based on this it is recommended to
provide the minimum rating for fire proofing as
follows :
LPG storage vessel & connected 1 hour
lines upto the fire safe ROVs
Supporting legs of all above 2 hour
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.
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.
10.8 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.
10.8.1 FIRE WATER PUMPS
i) Every Pump shall be in test run for atleast
10 min. 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.
10.8.2 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.
iii) All valves on the ring main/ hydrant/
monitor valves shall be checked for leaks/
operation and lubricated once in a month.
10.8.3 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) The sprinkler system in the sheds shall be
tested 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.
10.8.4 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/ Facilities to make up water during fire fighting
fungus/ vegetation in the reservoir. shall be provided.

10.9 MAKE UP WATER :

 CHAPTER 11

EMERGENCY MANAGEMENT PLAN

11.1 GENERAL a) Through water drain valve while

draining.
11.1 The best way to manage any emergency is
to prevent it. Following guidelines for b) Leaking sample valve.
emergency prevention shall be followed :
c) Breakage of glass on Sight Flow Indicator
Ensure : on the pipeline.

a) Sound engineering practice in the d) Opening of pot-off valve, gland/ packing

design, fabrication, installation and etc.
maintenance of facilities.
e) Leakage through LPG compressor/ pump.
b) Careful selection and correct use of
equipment. f) Leakage due to bursting/ rupture of hose
or through sviwel joints of body arms.
c) Observance of safety and security
regulations. g) Leakage from the filling guns.

d) Proper and constant training and
guidance to all pesonnel working in
the Plant, with particular reference to
product knowledge and maintenance
practices.
h) Escape of liquid/ vapour LPG during
maintenance/ repairs.
11.1.4 BEWARE OF COMMON CAUSES
OF FIRE, SOME OF WHICH ARE:

e) Good House-keeping. (a) ELECTRICAL :

f) Constant supervision and alertness. i) Short circuiting due to loose wiring

11.1.2 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.
11.1.3 BEWARE OF LPG LEAKAGE AT
PLANTS, THESE ARE :
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.
vi) Lighting
vii) Smoking.
11.2 BASIC ACTION IN EMERGENCIES :
11.2.1 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.
11.2.2 Fire Fighting Operations :
a) Enlist support of local fire brigade and
neighbouring industries.
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 disperson
of vapour cloud.
c) Fire Fighting personnel working in or
close to unignited 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.
11.2.3 Action in the event of LPG leakage
without fire :
a) Take basic action as detailed in 11.2.1
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.
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 a seriously exposing LPG
equipment or serious leakage of LPG
without the fire.
11.2.3 Action in the event of LPG leakage
without fire :
a) Take basic action as detailed in 11.2.1
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 raodway 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.
11.2.4 Action in the event of LPG fire :
a) Take basic action as detailed in 11.2.1
above.
b) Extinguishing Fires - A small fire at the
point of leakage should be extinguished
by enveloping with a water spray or a
suitable smoothering 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 11.2.2. 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/sq.cm.g
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
smoothering with a thick non-synhetic
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.
(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.
11.2.5 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 occures, 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.
(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.
(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 adaptors 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.
11.2.6 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.
(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.
(viii) 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.
 CHAPTER 12

SAFETY AUDIT

12.1 GENERAL: These check lists can be further supplemented

and modified suitably to meet the specific
Safety audit is a well recognised tool to improve requirements of individual plant.
the effectiveness of safety programme and loss Recommended minimum safety audits at
prevention measures by carrying out systematic different levels, their frequencies and broad
and critical appraisal of potential safety hazards check lists to be used are indicated below :-
involving personnel, plants and equipments.
Daily audit essentially shall cover the
For a structured and systematic safety audit of compliance of recommended operating
any plant/ facility, check lists are the most procedures/ safety practices. Reports of audit
important prerequisite. Check lists should cover shall be reviewed by the Plant Manager on daily
all the operational areas, major equipments, basis and corrective action be undertaken on
operating/ maintenance procedures, safety priority wherever required.
practices, fire prevention/ protection systems etc.
Observations/ recommendations of safety audit In case of external safety audit, following areas
team should be presented in the form of a besides the points given in check list of
formal report and action plan for corrective Annexure III shall be covered.
measures should be prepared and subsequently
monitored for implementation. 1. Safety Organisation

General guidelines on safety audit 2. Security System

methodologies and techniques are also given in
OISD - GDN- 145. 3. Fire prevention/ protection system

12.2 TYPE OF SAFETY AUDIT AND 4. Preparedness to handle any emergency

PERIODICITY : --Disaster control plan and mock drills.

In view of the high hazard potential of LPG, 5.
safety audits at frequent intervals by the teams/
personnel of various levels are advocated, Broad 6.
check lists for different recommended safety
audits are given in the Annexure I, II, III, IV.
Skill level and training needs for HRD.
Operating manual/ instructions, display
of Do's/ Dont's etc.

S.No. Type of Safety By Frequency Checklist

Audit (Annexure)
-----------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5
-----------------------------------------------------------------------------------------------------------------------------

1. Inspection Safety LPG Plant Daily I

audit of LPG Bottling Safety
Plant. Officer

2. Electrical audit of Expert Annual II

LPG Bottling plants personnel
from electrical
discipline

3. Detailed safety audit Multi disciplinary Annual III

of LPG Bottling Plants team of region/
corporate level

4. Inspection and Expert Annual IV

maintenance audit of personnel of
LPG Bottling plants Inspection/ Maintenance

5. External safety audit Panel As decided Based on

of LPG Bottling plants constituted by OISD observations

by OISD and OISD

Checklist

--------------------------------------------------------------------------------------------------------------------------------
 ANNEXURE - I

DAILY SAFETY AUDIT - CHECKLIST

FOR LPG BOTTLING PLANTS

LOCATION ______________

Audit/ Inspection by _________________

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Description Observation Corrective Action Remarks
1 2 3 4 5
--------------------------------------------------------------------------------------------------------------------------------

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-08 Any signs of beedi/ Yes/No

cigarette butts/ used matches
observed in the area- particularly at toilets.

A-09 Regular surprise checks/ testing Yes/No

being done at gate/ at the plant.
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Description Observation Corrective Action Remarks
1 2 3 4 5
--------------------------------------------------------------------------------------------------------------------------------
A-10 Caution signs displayed Yes/No
at appropriate places.

A-11 Direction of wind Yes/No

(specify in remarks column by
observing wind sock).

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

C. TANK WAGON UNLOADING

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

D. BULK TRUCK UNLOADING

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Description Observation Corrective Action Remarks
1 2 3 4 5
--------------------------------------------------------------------------------------------------------------------------------

D-01 Are all vehicles allowed in licensedYes/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

E. PUMP HOUSE/ COMPRESSOR ROOM

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Description Observation Corrective Action Remarks
1 2 3 4 5
--------------------------------------------------------------------------------------------------------------------------------

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

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 adaptors used
for cylinder filling/emptying are leaking.

--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Description Observation Corrective Action Remarks
1 2 3 4 5
--------------------------------------------------------------------------------------------------------------------------------

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
(physical check).

F-11 Housekeeping is in order. Yes/No

F-12 Rotary equipment/ coupling etc Yes/No

properly graded.

F-13 Gas detection system working. Yes/No

G. CYLINDER STORAGE/ HANDLING

G-01 Are cylinders stacked properly in Yes/No
demarcated areas. (filled/empty/
defectives).

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 Explosimeter/ portable lead gas detector Yes/No

used to detect gas leaks periodically in
stacking area.

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.
 ANNEXURE - II.

ELECTRICAL AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________ Dated ____________

AUDIT/ INSPECTION BY ______________________

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

A. ELECTRICAL SUBSTATION/ SWITCH ROOM

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

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

A-03 MCC Panel condition :

a) Doors okay and closed

b) Dust/soot/ cobwebs not existed

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

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

e) Control wiring condition satisfactory.

f) Jumper condition between bus and distribution okay.

g) Grounding OK

h) Alarm/ trip circuit working.

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

A-05 No temporary electrical connection existing.

A-06 Condition of cable duct

a) Cables are on rack

b) Cable deck clear

c) Sealing of duct

d) Cable identification tags.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-07 Rubber mats (with ISI mark) existing are enough in number.

A-08 Protective relays set at recommended values.

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

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

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

A-12 Emergency lighting system in order.

A-13 All energised equipment provided with caution boards.

A-14 Condition of transformer :

a) Grounding OK

b) No oil leak

c) Silica gel OK

d) Oil level OK

e) Terminal box earthing OK

f) Oil/winding temp. OK

g) Periodic oil quality test conducted.

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

A-16 Housekeeping is good.

B. MOTORS IN PUMP HOUSE/ COMPRESSOR

ROOM/ FILLING & STORAGE SHED ETC.

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

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

B-03 a) Is terminal box and gland OK

Flame proofness maintained and not tampered.

b) Existing cable termination are proper

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

B-05 Ground resistance at motor/ push button measured and found okay.

B-06 No motor abnormality

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

excessive noise, high body temperature.
B-07 Existing preventive maintenance schedule OK.

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

b) Earthing pit condition OK

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

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

B-10 Conveyor system bonding and earthing maintained.

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

C. UNIT LIGHTING

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

C-02 Whether flame proof condition of fixtures ensured ?

C-03 Whether proper earthing of fixture provided ?

C-04 Condition of wiring good.

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

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

C-07 Any other unsafe point observed.

D. MAST LIGHTS (AREA LIGHTING)

D-01 Whether grounding of mast OK ?

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

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

D-04 Condition of flood lights :

a) Is gasket present ?

b) Is glass cover in good condition ?

c) Is control gear condition OK

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

D-05 Is earthing electrode of mast OK and its

connnection with mast proper ?

E. TANKAGE AREA, PIPELINES, LOADING/

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

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

E-03 Condition of grounding electrode OK

E-04 Continuity of location, hoses maintained.

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

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

F. GENERAL

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

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

room etc. and their compliance.

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

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

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

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

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

DETAILED SAFETY AUDIT OF LPG BOTTLING PLANTS

LOCATION _____________ Dated ____________

AUDIT/ INSPECTION BY ______________________

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

A. BULK STORAGE AREA

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

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

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

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

c) Safety instructions for draining operations displayed prominently

and water draining is done under supervision.

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

b) Isolation valves in locked open condition.

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

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

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

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

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 electricl fittings provided.

b) Earthing connections properly maintained.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-11 Statutory inspection/ hydro test records maintained.

B. PUMPS/ COMPRESSORS AREA

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

b) Flame proof light fittings provided.

c) Earthing resistance test conducted periodically and record maintained.

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

B-03 a) No leakage from mechanical seals.

b) Double seal provided to minimise chances of leakage.

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

d) Coupling guards in position.

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

B-05 Operating instructions Do's and Dont's displayed.

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

C. CYLINDER FILLING/ STORAGE AREA

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

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

C-03 Transfer of cylinders from truck to conveyor.

- Telescopic conveyor

- Trolley use

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

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

b) Segregated storage marked for -

i) Spurious

ii) Hot repairs

iii) 5/7 years testing due cylinders

iv) Other defects

C-06 Gross weight filling :

- Auto cut off after completion of filling

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

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

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

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

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

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

- CVT with verifier

- Electronic

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

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

C-15 Capping/ Pilfer proof sealing facilities provided.

- Aluminium foil

- PVC sealing

C-16 Neck label being put

- Plastic

- Paper

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

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

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

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

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

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

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

C-22 a) Cylinders stacked in vertical position

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

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

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

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

D. BULK LPG UNLOADING FACILITIES

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

D-02 Effective earthing system provided and working satisfactorily.

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

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

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

D-05 Blocked hoses/ pipelines provided with TSVs.

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

b) Fire hydrant/ long range monitors provided.

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

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

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

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

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

c) Explosive licence, safety certificate, fitness certificate.

d) Proper earthing cable with clamps.

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

E. SAFETY/ FIRE PROTECTION SYSTEM

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

E-02 Contigency 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 operting para meters maintained.

E-08 Static water storage tank -

- capacity and adequacy

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

- Source of water supply and rate of replenishment.

E-09 a) Fire vehicles well maintained.

b) Mutual aid scheme with neighbouring industries/ district

authorities existing.

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

tamper seals on retainer clips.

b) Maintenance procedures/ records of fire extinguishers.

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

b) Testing schedule/ maintenance.

E-12 Protective clothing :

- Availability of special fire fighting suits (Aluminised suits)

- Breathing apparatus & its upkeep

- Water jel blankets.

- Use of nylon clothes prohibited.

E-13 Automatic Gas Detection System :

- Working satisfactorily

- Regularly tested.

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

E-15 First aid facilities maintained.

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

b) Flame-proof torches available

F. MANPOWER AND TRAINING

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

F-02 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.

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

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

fire fighting/ emergency handling etc. for

a) Regular staff

b) Contractor workmen

c) Security staff

d) Tank truck operators/ drivers

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

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

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

in English/ Hindi/ Local language.

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

 G. GENERAL

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

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

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

d) Adequate escape route available for operational facilities.

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

b) Spot checks being done.

G-03 a) Valid CCE licences available for :

- Storage of LPG

- Storage of LPG cylinders

- Filling of LPG cylinders

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

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

G-04 Accident records maintained and updated.

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

G-07 Following manual/ documents available:

a) LPG operating manual.

b) Safety and Fire Prevention manual

c) Emergency/ disaster control plan

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

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

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

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

c) Inspection records of underground pipelines etc.

d) Weights & Measures certificates.

G-09 Updated P&I Diagrams, drawing of layout and other facilities available.
G-10 Records of "Daily Safety Audits" reviewed. Corrective action taken.

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

G-12 Pipeline colour code system maintained.

 ANNEXURE - IV

INSPECTION & MAINTENANCE SYSTEM AUDIT

LOCAL _______________ DATED: _________

AUDIT/ INSPECTION BY ________________

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

A. GENERAL

A-01 Whether standard system of inspection/ maintenance schedule

developed and followed and records maintained.

A-02 Whether equipment documents supplied by vendors are readily

available and recommended maintenance procedures are strictly
adhered to.

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

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

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

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

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

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

A-09 Whether Explosimeters are periodically checked and calibrated.

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

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

A-12 Whether inspection/ testing of pressure vessels carried out periodically as per statutory
requirements and records maintained.

--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
 B. BULK STORAGE HANDLING FACILITIES

B-01 Whether design of pressure storage vessels conform to relevant

BIS/BS/ASME code with standard engineering practices. All
required fittings/ instruments/ safety valves have been provided.

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

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

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

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

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

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

B-06 Preventive maintenance and servicing schedules for pumps and

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

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

visual alarm/ security logic system maintained in working condition.

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

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

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

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

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

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

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

C. CYLINDER FILLING

C-01 LPG filling carousel - Drive unit, central column, running rails, etc.
are daily checked, scheduled maintenance (weekly, monthly, quarterly,
annual) are carried out and records maintained.
C-02 Introduction/ Ejection devices and filling machines are checked daily and
scheduled maintenance/ overhaul work carried out.

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

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

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

schedule followed.
 GLOSSARY OF TERMS
1. Area Classification
It is 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.
2. Bulk Vessels
A pressure vessel used for more than 1000 litres
water capacity for storage or transportation.
3. Bullet
A horizontal pressure vessel used for storage or
transportation by rail/ road.
4. 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 Deg C
or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50
Deg C or both.
5. Cylinders
A portable container upto 1000 litres water
capacity used for both domestic and industrial
purposes.
6. 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.
7. Earthing & Bonding
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 electrostatis
discharge.
Bonding is the process of connecting the
equipment/ system to be earthed to the ground
by the bond wire to prevent sparking between
two conducting bodies.
8. 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 deg. C.
9. 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.
10. Fire proofed
It is a passive concept of explosure protection of
structures, vessel surface or cables that could be
exposed to direct flame impingement, free
burning plus pressure torching conditions, and/
or prolonged periods of high intensity radiant
heat fluxes by the application of coating with a
specified rating.
11. Flammability
It is the percentage of volume of any flammable
vapour in air-vapour mixtures capable to form
an explosive mixture.
12. Flamable ( 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.
13. 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.
14. Hot Work
It is an activity which may produce enough heat
to ignite a flammable air-hydrocarbon mixture
or a flammable substance.
15. 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.
16. Liquefied Petroleum Gas (LPG)
system by an inert substance, and replacement of
the later by air.
18. Reid Vapour Pressure
Reid Vapour Pressure is the vapour pressure in
pounds per square inch (psi) at 100 Deg F as
determined by Reid apparatus.

The term applies to a mixture of certain light 19. Spheres

hydrocarbon C2 to C5, derived from petroleum
which are gaseous at ambient temperature and A spherical pressure vessel used for storage.
pressure test may be condensed to a liquid state
at normal ambient temperature by the 20. Tare Weight
application of moderate pressure.
It is the weight of the cylinder together with any
17. Purging fitting permanently attached to them and
includes the weight of valve.
It is the act of replacing the atmosphere within a
container by an inert substance in such a manner 21. Working Pressure
as to prevent the formation of explosive mixture.
It is saturated vapour pressure at 65 Deg. C.
(A) Purging into Service : is the replacement
of air in a closed system by an inert substance 22. Water Capacity
and replacement of the later by combustible gas,
vapour, or liquid. The volume of water in litres that the container
can hold at 15 Deg. C.
(B) Purging out of service : is the replacement
of normal combustible content of a closed

APPENDIX

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

BIS CODES PERTAINING TO LPG OPERATIONS

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

IS:2825-1969 - CODE FOR UNFIRED PRESSURE VESSELS

IS:2827-1976 - METHODS FOR CALIBRATION OF PRESSURIZED

STORAGE TANKS
IS:3196(PART 1)-1992 - WELDED LOW CARBON STEEL GAS CYLINDER
EXCEEDING 5 LITRE WATER CAPACITY FOR
LOW PRESSURE LIQUEFIABLE GASES CYLINDERS
FOR LPG.

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

AND INSTALLATIONS

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

GAS.

IS:4093-1981 - NON-REFILLABLE LPG CONTAINERS

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

USE WITH LIQUEFIED PETROLEUM GASES

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

CYLINDERS

IS:4576-1978 - SPECIFICATION FOR LIQUEFIED PETROLEUM GASES

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

BUTANE GASES

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

PROPANE GAS

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

WITH LPG

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

STRUCTURES FOR EXPLOSIONS ABOVE GROUND

IS:5116-1985 - GENERAL REQUIREMENT FOR DOMESTIC AND

COMMERCIAL EQUIPMENT FOR USE WITH
LPG

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

FOR HAZARDOUS AREAS

IS:5572 - CLASSIFICATION OF HAZARDOUS AREAS (OTHER

THAN MINES) FOR ELECTRICAL
INSTALLATIONS

BIS CODES PERTAINING TO LPG OPERATIONS

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

BIS CODES PERTAINING TO LPG OPERATIONS

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

BIS CODES PERTAINING TO LPG OPERATIONS

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

IS:9281(PART 3)-1981 - REQUIREMENTS

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

INSTALLATION

IS:9583-1981 - EMERGENCY LIGHTING UNITS

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

OF LOW PRESSURE WELDED STEEL GAS
CYLINDERS IN USE

IS:9777-1981 - DATA SHEET FOR SELECTION OF

WEIGHBRIDGES FOR BULK
HANDLING EQUIPMENT
IS:9798-1981 - LOW PRESSURE REGULATORS FOR USE WITH
LPG

IS:9902-1982 - RECOMMENDED PRACTICE FOR LEAK

TESTING

IS:9975 - `O' RINGS

IS:9975(PART 1)-1981 - DIMENSIONS

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

ACCEPTANCE CRITERIA

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

TOLERENCES

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

IS:10733-1983 - ELECTRICALLY BONDED ROAD AND RAIL

TANKER HOSE OF RUBBER,
RESISTANT TO PETROLEUM PRODUCTS

IS:10908-1991 - FLEXIBLE RUBBER TUBING FOR LPG

IS:11498-1985 - LEVER TYPE DIA GAUGES

IS:12936-1990 - CODE FOR BASIC REQUIREMENTS FOR

DELIVERY PERSONS ENGAGED IN
THE DELIVERY OF LPG CYLINDERS

BIS CODES PERTAINING TO LPG OPERATIONS

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