Beruflich Dokumente
Kultur Dokumente
Prepared by
FUNCTIONAL COMMITTEE ON
LIQUEFIED PETROLEUM GAS (LPG)
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil
and gas industry under Ministry of Petroleum & Natural Gas. These are the
property of Ministry of Petroleum & Natural Gas and shall not be reproduced or
copied and loaned or exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby disclaims any liability or
responsibility for loss or damage resulting from their use.
These documents are intended to supplement rather than replace the prevailing
statutory requirements.
FOREWORD
The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies ,
operating and maintenance practices was hardly in existence at a national level.
This, coupled with feed back from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to review
the existing state of art in designing, operating and maintaining oil and gas
installations.
With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) for
formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of functional
committees comprising of experts nominated from the industry to draw up
standards and guidelines on various subjects.
Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as
well as with industrial applications due to its unique properties and
environmental benefits. The document on "LPG Bottling plant operations" was
prepared in 1994. The present document "LPG Installations" has been prepared
by the functional based on the accumulated knowledge and experience of
industry members and updation of national and international codes and
practices related to LPG.
The Coordinator,
Committee on “LPG”
Oil Industry Safety Directorate,
7th floor, New Delhi House,
27, Barakhamba Road,
New Delhi – 110001
FUNCTIONAL COMMITTEE
( Second Edition - October, 2005)
NAME ORGANISATION
LEADER
Sh. R. Krishnan Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS
Sh. A.N. Biswas Deptt. of Explosives, Nagpur
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
NAME ORGANISATION
LEADER
Sh. S.C. Tandon Indian Oil Corporation Ltd., ( Ref.)
MEMBERS
Sh. H.G. Bhinde Indian Oil Corporation Ltd., ( Mkt.)
MEMBER COORDINATOR
Sh. S. C. Gupta Oil Industry Safety Directorate, New Delhi
CONTENTS
---------------------------------------------------------------------------------
SR. No. ITEM PAGE NO
---------------------------------------------------------------------------------
1 Introduction
2 Scope
3 Definitions
4 Statutory Rules/ Regulations
5 Installation Layout
6 Design Considerations
7 Storage & Handling of Bulk LPG
8 Bottling Operations
9 Maintenance & Inspection
10 Statutory Testing of LPG Cylinders
11 Fire Protection Facilities
12 Gas Monitoring System
13 Emergency Management Plan
14 Safety Audit
15 References
---------------------------------------------------------------------------------
Kerb Wall : A wall of appropriate height The LPG installation & various facilities
and size constructed of suitable material are covered under many regulations and
and designed to contain the LPG spillage require specific approval / licence from
and to direct it to a safe location around concerned statutory authorities. The
the storage vessel. various regulations applicable to LPG
installation facilities are as below :
a. Vasudevan Committee - 1983
a. Gas Cylinders Rules, 1981 (under Ministry of Energy (Department of
Indian Explosives Act,1884) Petroleum).
Top surfaces of all the vessels installed in 5.5.7 The layout of the unloading
a group shall be on the same plane. It is location shall be such that tank
necessary to provide separate manifolds truck being unloaded shall be in
preferably with independent pumping drive out position.
facilities for bullets and spheres.
Alternatively, fail safe interlocks like two 5.5.8 The weigh bridge of adequate
way valves shall be provided so as to capacity shall be provided and
avoid any chances of overfilling of proper maneuverability for
adjacent vessels due to gravitation. vehicles.
There shall not be any deep 5.6.6 Cylinder storage shall be kept on
ditches in the surrounding areas or above grade and never below
at least within 15 M from storage grade in cellar or basement.
sheds to avoid settling of LPG
vapour. 5.6.7 Filled cylinders shall not be stored
in the vicinity of cylinders
5.6.2 LPG Bottling section shall be of containing other gases or
single storey. Antistatic mastic hazardous substances.
flooring conforming to IS-8374
shall be provided in the LPG 5.6.8 Escape routes shall be specified
filling shed/ cylinder storage and marked in LPG sheds for
including valve changing shed to evacuation of employees in
avoid frictional sparks. The shed emergency.
shall be supported by RCC
columns alternatively structure 5.6.9 There shall be sufficient no. of
steel columns shall be covered crossovers to avoid trapping of
with concrete or fire-proofing personnel in LPG sheds by
material upto full height of conveyors, cylinders and other
columns. Anti static mastic facilities. Further, sufficient no. of
coating upto 1.5 m (Min.) shall be escape routes shall be provided.
done of the supporting columns
of the shed. 5.6.10 All steps forming part of the
escape routes shall be minimum
5.6.3 The bottling operation shall be 1.2 M with treads 30 cms
carried out in the filling shed. (minimum) and maximum rise of
Separate sheds for filled 15 cms.
cylinders storage, valve changing,
degassing, if any, shall be 5.7 PROTECTION OF FACILITIES
provided. Valve changing unit
without evacuation can be 5.7.1 Properly laid out roads around
provided in filling shed itself. various facilities shall be provided
within the installation area for
Empty cylinders storage area shall smooth access of fire tenders etc.
be properly segregated from in case of emergency.
filling machines by 5 M (Min.).
Cylinders shall always be stacked 5.7.2 Proper industry type boundary
vertically with maximum stack wall atleast 3 M high with 0.6 M
height of 1.5 m. For details of barbed wire on top shall be
cylinders stacking pattern refer provided around the installation
Figure - I . unless the bottling plant is
protected as a part of refinery
complex.
5.7.3 Emergency exit with proper gate 5.8 UTILITIES
shall be provided in the
earmarked zone. Utilities consisting of fire water pumps,
admin. building, canteen, motor control
5.7.4 In case provision for green belt is centre, DG room, air compressors, dryers
made, the same shall be etc. shall be separated from other LPG
segregated from hazardous area facilities and located as per the separation
by 1 M high wall / chain link as specified in Table-I.
fencing. Alternatively, it shall be
treated as a part of hazardous
area.
TABLE - I
---------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8
---------------------------------------------------------------------------------------------------------------------------
3. Shed-LPG 30 30 15 30 50 30 15 60
7. Pump house/Comp.house 15 30 15 30 30 30 - 60
(LPG)
8. Fire Pump House/ storage tank 60 ** 60 60 60 60 60 -
---------------------------------------------------------------------------------------------------------------------------
Notes :
1. All distances are in metres. All distances shall be measured between the nearest points on the
perimeter of each facility. except in case of tank vehicle loading/unloading area where the distance
shall be measured from the centre of each bay and for storage vessels where the distance shall be
measured from the nearest point on the vertical shadow of the vessel.
2. Notation :
T-II - Refer Table - II
1/4 of sum of diameters of adjacent vessels or Half the diameter of the larger of the
two adjacent vessels, whichever is greater.
** Any distance for operational convenience.
3. Distance of stabling line shall be as per minimum Railway Standards.
4. Distance of stabling line shall be as per Railway guidelines.
TABLE - II
DISTANCE BETWEEN LPG STORAGE VESSELS AND PLANT BOUNDARY/GROUP OF
BUILDINGS NOT ASSOCIATED WITH LPG INSTALLATION
---------------------------------------------------------------------------------------------------------------------------
Capacity of each Distance
vessel (Cu.Mt. of water) ( in metre )
---------------------------------------------------------------------------------------------------------------------------
10-20 15
> 20-40 20
>40-350 30
>350-450 40
>450-750 60
>750-3800 90
> 3800 120
--------------------------------------------------------------------------------------------------------------------
A single code shall be adopted for The recommended design pressure and
design, fabrication, inspection and temperature shall be treated as
testing i.e. ASTM and BS shall not be MINIMUM requirement and other
combined.
design consideration and Statutory
requirements shall also be considered. Fire safe ROVs shall also be provided on
liquid line at TLD & Tank wagon gantry
v. Other Design Considerations & isolation valve (quick closing type) on
the entry of liquid lines at LPG filling
Corrosion Allowance : minimum 1.5 mm shed at a safe location.
There shall not be any other flanges, i) The storage vessel shall have
manhole, instrument tapping on this minimum two independent level
nozzle upto the ROV or on sphere/ bullet indicators and one independent high level
bottom. In order to avoid stress on the switch. High level alarms shall be set at
nozzle due to relative settling of support not more than 85% level of the
and storage vessel, suitable supports for volumetric capacity of the vessel. Audio
the bottom nozzle shall be provided. visual indication shall be at local panel &
control room. On actuation of high level
The top vapour zone of the vessel shall alarm, the ROVs of the affected vessel
be provided with nozzles for vapour shall close.
outlet, recirculation wherever applicable.
These lines shall be provided with fire ii) Each storage vessel shall have at
safe ROV. least two safety relief valves with
isolation arrangement set at different i. Excess flow check valve & non
values and at not more than 110% of return valve shall be provided in LPG
design pressure of the vessel and each loading lines.
having 100 % relieving capacity adequate
for limiting the pressure build up in the ii. A vapour return line with an isolation
vessel not more than 120% of design valve connected back to the storage
pressure. vessel/ suction line with NRV.
The relieving load for the safety valves, iii. Properly designed loading arm or
shall be based on fire condition and no LPG hoses shall be provided at the
credit shall be taken for fire proofing on end of filling and vapour return lines
the vessel, if provided. for connecting to the tank truck
vessel. The loading shall be provided
The discharge of safety valves shall be with break away couplings or smart
connected to flare system, wherever hoses shall be used. Loading arm
available. In this case, safety valves shall shall be of approved type and be
have lock open (or car seal open) type tested as per OEM recommendations.
isolation valves on both sides of safety In case, LPG hoses are used, it shall
valves. conform to OISD-STD-135.
In case of non availability of flare iv. The hose - coupling / flange joint
system, the discharge from safety valve shall be of Class 300 lb rating with
shall be vented vertically upwards to metallic gasket. The hose coupling
atmosphere at an elevation of 3 meter shall be provided with a cap or blind
(minimum) for effective dispersion of flange by which the nozzle can be
hydrocarbons. In this case, isolation closed when not in use.
valve on down stream of safety valve is
not required. A weep hole with a nipple v. Weigh bridges of suitable capacity for
at low point shall be provided on the vent road / rail movements and mass flow
pipe in order to drain the rain water meters for pipeline transfers shall be
which may get accumulated otherwise. provided. The mass flow meters shall
Weephole nipples shall be so oriented be certified for its use with LPG.
that in case of safety valve lifting and
consequent fire, the flame resulting from vi. A check valve shall be provided in the
LPG coming out from weephole does not vapour return line.
impinge on the sphere or structure. A
loose fitting rain cap with a chain (non Unloading of LPG from tank truck is
sparking) fitted to vent pipe shall be carried out with vapour compressors
provided on top of safety valve. using pressure differential method of
liquid transfer. The compressor used for
Typical safety fittings on a LPG storage unloading shall be provided with the
vessel are indicated in Figure-II. following facilities:
6.3 LPG LOADING/ UNLOADING (i) Vapour line with isolation valves
FACILITIES
(ii) Excess flow check valve & non
Each loading station shall consist of return valve shall be provided in LPG
the following : unloading lines with isolation valves
ii. Tank truck shall be loaded/ unloaded All carousels & leak detectors
with suitable arrangement for flaring including electronic shall be of
of hose content at the end of the approved type.
operations.
iii) Adequate lighting shall be
iii. The unloading arms shall be used for provided in the cylinder filling
unloading the LPG TT at LPG area. Emergency lighting shall
installation. In case, LPG hose are also be provided at critical places.
used, it shall conform to OISD-STD-
135 or equivalent as approved by iv) Water drains from the cylinder
CCOE. filling area where they enter an
outside drainage system, shall be
iv. The hose - coupling / flange provided with vapour seals.
joint shall be of 300 lb rating
with metallic gasket. The hose v) Proper access shall be made
coupling shall be provided with a available for other fire fighting
cap or blind flange by which the equipment i.e. fire tender, foam
nozzle can be closed when not in trolley etc.
use.
vi) Cylinder storage area
6.4 CYLINDER FILLING requirement shall be worked out
FACILITIES based on the stacking pattern of
filled and empty cylinders as
i) The cylinder filling area shall be described in Figure-I.
completely open type and vii) The filling machines shall be
covered from top with roof provided with auto cut-off system
designed to ensure good natural so that LPG supply is cut off
ventilation. RCC roofing shall not when the desired quantity of
be used. product has been filled in the
cylinders. The filling pressure
The filling area shall not be on shall not be more than the design
upper floors of building or in pressure of the cylinders i.e. 16.9
cellars unless specifically required kg/sq.cm.g.
on account of extreme weather
conditions. viii) Filling machines in a
carousel/ stationary filling
ii) As far as possible, the floor area machines shall not have a
shall not have any channels or weighment error of more than +
pits. Where these are necessary 150 gm of the net quantity of the
for conveyors or other equipment LPG filled in the cylinder, with a
like weigh machine etc., suitable capacity of 14.2 kg or as specified
gas detection system shall be in Weights and Measures Rules.
compressor cooling and in hose stations
ix) On-line check weigh scales with for washing etc.
a minimum of 50 gms.
graduation be installed so that all Water may be provided at a pressure of
the cylinders are check weighed about 3 Kg/sq.cm.g. If one pump is
after filling. envisaged to run normally, another pump
with 100% capacity shall be provided as
x) Compact Valve Tester to check a standby. Where more than one pump
valve and 'O" ring shall be running is envisaged, 50% capacity as
installed on line. Alternatively standby shall be provided.
electronic leak detectors shall be
provided. Water Quality
xi) Water test bath or electronic leak Water shall be of potable quality
detectors shall be provided to conforming to IS : 10500 - Specification
detect body and bung leak for Drinking Water.
cylinders.
(C) Emergency Power
xii) Vapour extraction system at
strategic locations near carousel, The installation shall be provided with
cylinder evacuation unit, valve battery / diesel generating set for
changing unit, degassing shed operating the essential systems such as
and at locations where leaking the instrumentation and safety systems
LPG is expected to accumulate (gas detectors, automatic fire water
shall be provided. Further, it shall sprinkler system) and minimum lighting
be interlocked with filling during the grid power failure.
machine so that filling do not start
without vapour extraction unit 6.6 LPG PUMPS
being functional.
i. LPG Pumps shall be designed for
6.5 UTILITIES handling of LPG and safely
withstand the maximum pressure
(A) Compressed air which could be developed by the
product and / or transfer
The quality of instrument air shall equipment. Pumps shall conform
conform to the requirements as to API 610 or equivalent.
recommended by the manufacturers of
instruments/ equipment: ii. Check valves shall be installed on
the delivery side of all centrifugal
If one compressor is envisaged to run pumps.
normally, another standby compressor of
100% capacity shall be provided. When iii. LPG Pumps shall be provided
more than one compressor running is with suction and discharge
envisaged, 50% standby capacity shall be pressure gauges, a high point vent
provided. to safe height or flare, and a
suction strainer.
(B) Service Water
iv. Double Mechanical seal with seal
Service water is required for the cylinder failure alarms shall be provided.
washing equipment and leak check bath,
v. A pressure switch actuating a low - Discharge safety valve and a vent
pressure alarm in control room valve, their outlets leading to
and locally shall be provided, flare/ safe height outside the shed.
taken from discharge end. - Low Suction Pressure Trip
- Suction strainer
vi. Pumps shall be designed to build - High Discharge Pressure Trip
a discharge pressure such that the - High Temperature Trip
pressure at the carousel filling - Check valve in discharge
machine is at least 5.0 - A discharge to suction recycle
kg/sq.cm.g. above the vapour valve for achieving capacity
pressure at the operating turndown during startup.
temperature.
iv. A suitable size scrubber or liquid
vii. Pumps shall have a by-pass valve knockout drum shall be installed
and other suitable protection upstream of the vapour
against high discharge pressure compressor. It shall be equipped
on the delivery side. with a gauge glass, safety relief
valve, a drain and high liquid level
viii.The electrical motor drive and shut down device.
switchgear shall conform to area
classification as per OISD Typical sketch of compressor
Standard-113 / IS -5572. Belt installation is enclosed as Figure-IV.
drives shall be of the anti-static
type. 6.8 PIPING
ii) Normal lighting system shall be vii. The lighting fixtures on various
on 415/ 240V AC supply, circuits shall be suitably interlaced
whereas emergency lighting will so that failure of any one circuit
be either on 220V or 110V DC. do not result in complete
darkness.
iii) Lighting requirements provided
during the failure of power supply viii. Switches controlling the
for Normal lighting are intended lighting fixtures and exhaust fan
broadly, shall be installed outside the
battery room.
a. to facilitate carrying out of
specified operations, for safe ix. Switches of lighting panels
shutdown of the installation. installed in hazardous area, shall
have a pole to break the neutral in
b. to gain access and permit addition to the poles for phases.
ready identification of fire
fighting facilities such as fire When the means of isolation is located
in a non-hazardous area, the switch
shall break all poles including neutral Flexible earth provision for
or alternatively may break only live wagon, truck.
poles, the neutral being isolated by a
removable link. ii. Installation earthing design shall be
carried out in accordance with the
For details on inspection practices requirements of Indian Electricity
OISD standard 147 to be referred.. Rules and IS : 3043. All earth
connections should be visible for
6.15 Installation Earthing inspection to the extent possible.
6. While disconnecting
7.1 BULK HANDLING FOR hoses/arm, connections shall
MOVEMENT BY ROAD be loosened only slightly at
first to allow release of trapped
The tank truck for road movement pressure, if any.
shall be designed, constructed and
tested in accordance with the Static 7. Do not expose hands, face or
and Mobile Pressure Vessels clothing to liquid LPG. Always
(Unfired) Rules, 1981 and OISD- use personal protective
STD-159. equipment while making or
breaking the connections to
7.1.1 SAFETY PRECAUTIONS avoid cold burns.
6. Make earthing connections of the 13. The couplings may then be removed
vehicle at specified point to the fixed and plugs/caps replaced on the tank
grounding system. truck valves. Re-check tightness with
soap solution.
7. Connect liquid and vapour lines
suitably with the loading point. Crack
open valves on loading & vapour (b) Unloading Operations
return lines and inspect hoses &
connections for leakage. Loading 1. Operations described under Item
should start only when the system is 1 through 6 in para 7.1.2(a)
leak free. should be carried out.
8. Start the loading pump. 2. Liquid line and vapour line of the
tank truck shall be connected to
9. The quantity loaded into the truck the respective hoses fixed to the
can be determined by - unloading point.
5. Ensure fire system, safety 16. Once the filling is over, close
interlocks, communication the wagon filling and vapour
system are OK return lines valves and also
valves on filling and vapour
6. Take loading advice. return lines at the loading
point.
7. Connect earthing lugs to the
wagons. 17. Open the valve on flare line
connection to both feed line
8. Lower the flapper bridge and vapour return line slowly
slowly on the wagon. to avoid ice formation. Thus,
the hoses are depressurised.
9. Open the lid of the wagon. Then, close the flare line
connection valves.
10. Take the tare weight reading
and set the pointer of the 18. Disconnect the filling and
scale to zero. Compare this vapour return line hose
with the marked tare weight connections from the wagon.
on the wagon. Alternatively, Replace and tighten the plugs
use mass flow meter to fill the on filling and vapour return
wagons. lines.
11. Connect the filling hose or 19. Close the top cover of the
loading arm and vapour wagon and seal it properly.
return line hose or arm to the Remove earthing connections.
wagon. Ensure that the flare
connection valves are closed. 20. Release the hand brake of the
wagon.
12. Ensure that the header is
charged with LPG and the 21. Release all the wagons on the
bulk loading pump is running. loading points in the lot.
Precautions for storage of LPG in (v) The sampler shall wear protective
bulk : goggles, hand gloves, shoes etc.
while taking samples.
a) Liquid level in the vessel shall not
exceed the permissible limits. Filling (vi)Samples, after collection, shall be
shall not exceed safe permissible properly labeled and kept at
filling ratio. designated place.
b) Vessel shall be inspected daily for any (vii) Sampling of LPG should
LPG leakage and corrective action preferably be done in bombs with
taken. provision of pre-charge at one end.
This will not only eliminate the
c) All gauges, viz. High level alarm, possibility of undesirable presence of
measuring gauges, pressure gauges, air in the bomb, which may become a
temperature gauges should be kept in safety hazard, but also minimises
operating condition at all times and flashing of sample during collection,
be checked daily. thereby providing a truly
representative sample.
7.5 SAMPLING AND DRAINING
7.5.1 SAMPLING 7.5.2 DRAINING
GENERAL
- Properly fitted spark arrestor of make and
design approved by CCE, Nagpur. - First aid kit is available.
- Leakage from any fittings or joints. - Excess flow check valves are functioning.
The matter regarding tank wagon not complying with any of above checks shall be taken up with loading
location for corrective action.
ANNEXURE 7 - III
SHIP:_________________________________________DATE:______________
PORT &BERTH:_________________________________TIME:______________
We have checked with each other the items on the above check list and have satisfied ourselves
that the entries we have made are correct to the best of our knowledge.
Activity on bottling line including valve (c) Post Filling Operation - Cylinder
change, shall be carried out by trained shall be counter weighed with check
personnel. scale for accuracy of weight.
Variation of net weight. Variation of
8.2 BOTTLING OPERATIONS net weight shall not exceed
permissible limits. All under-filled/
The Bottling Operations can be classified over-filled cylinders should be
under following heads : corrected on correction scale.
- New cylinders and cylinders degassed Leaks and spills of mercaptan can be
for repairs shall be purged of air prior treated with commercially available
to be taken up for refilling with LPG. masking agents (e.g.Aldor and
Following safe procedure shall be Neutroleum Alpha etc.) to make them
observed for purging of LPG odourless. Large mercaptan spills
cylinders : shall be covered with sand or
activated carbon or any other
- Connect the cylinder valve to vacuum absorbing material, which are then
pump and evacuate air so that the buried or incinerated. The area over
pressure in cylinder is brought down the spill should then be washed with
to maximum 0.35 kg/cm2 absolute. ordinary household bleach solution
Inject LPG vapour in the cylinder so and then thoroughly with water. Dry
that pressure is minimum 1 kg/cm2 bleaching powder should never be
and not above working pressure of used in treating mercaptan spills. A
violent reaction could occur.
9.0 MAINTENANCE & INSPECTION OF EQUIPMENT
Valves shall be dismantled at the time of 9.5.2 Flanges, Gaskets and Bolts
specified comprehensive inspection or
during the shutdown of the line to permit The gasket faces of flanged joints, which
examination of all internal parts. Body have been opened, shall be inspected
thickness measurements shall be made at visually for corrosion and for defects
locations inaccessible before, dismantling, such as scratches, cuts and gouges which
particularly at locations showing might cause leakage. The gasket faces
evidence of erosion. Bodies of valves shall be checked for true flatness or
operating in severe cyclic temperature warping by placing a straight edge across
service shall be checked internally for the diameter of the face of the flange and
cracks. rotating it about an axis through the
center line of the flange. Grooves and
Gate valves, which have been used for rings of ring joints shall be checked for
throttling, shall be measured for thickness defects.
at the bottom between the seats, as
serious deterioration may have occurred Flanges bolts should be inspected
because of turbulence. This is for stretching. Where excessive
particularly weak point because of the bolt loading is indicated or where
wedging action of the disc when the flanges are deformed, nuts may be
valve is closed. The seating surface shall rotated along the entire length of
be inspected visually for defects which the stud. If studs are stretched,
thread pitch will be changed and iii) Ultrasonic thickness
nuts will not turn freely. measurement
Inspection involve checking to iv) Dye penetration test or
determine whether bolts of the Magnetic particle test
proper specification have been v) Hydrotest
used and may involves chemical
analyse or physical tests to (iv) Piping in coastal installations and
determine the yield point and the in corrosive environment shall be
ultimate strength of the material. visually inspected once a year.
If flanges are bolted too tightly, Years of inspection experience
they may bends until the outer have revealed that failures of
edges of the flanges are in most of the Offsite pipelines are
contact. When this occurs, there due to external corrosion and that
may be insufficient pressure on internal corrosion failures are
the gasket to assure a tight joint. minimum.
Visual inspection of the gasket
will reveal this condition. (v) The underground lines having
Permanently deformed flanges wrapping and coating as well as
must be replaced. cathodic protection shall be
inspected whenever current leaks
are observed and/or any damage
9.5.3 PIPELINES to the coating is suspected.
Parameters of cathodic protection
(i) Inspection data as well as like pipe-to-soil voltage or pipe-
thickness data of newly to-water voltage shall be
constructed pipelines shall be monitored once a month.
collected at the earliest and with
in two years of their (vi) All underground lines having only
commissioning to function as wrapping and coating shall be
base for establishment of inspected once in three years
corrosion rates. using Pearson Survey for locating
coating damage, if any.
(ii) External inspection of LPG Additionally, all these lines shall
pipelines within the installation be visually inspected at random
shall be carried out once in three once in ten years by digging at a
years which shall include both few locations. Pipelines crossing
visual inspection and ultrasonic the roads and dykes shall be
thickness readings taken inspected once in ten years by
externally. digging and exposing the line
completely.
The details of thickness survey
shall be maintained on an Provisions of OISD Standard ; OISD-
isometric sketch. STD-130 on "Inspection of Pipes and
Valves and Fittings" shall be followed.
(iii) Comprehensive inspection of
LPG pipelines shall be carried out 9.5.4 HOSE AND FLEXIBLE
once in 6 years which shall cover CONNECTION :
the following :
LPG hoses shall be inspected & tested at
i) Visual inspection maximum interval of 4 months as detailed
ii) Hammer test in OISD Standard ;. OISD-STD-135 on
"Inspection of Loading and Unloading a) Inspection and test of the valve shall
Hoses for petroleum products" and be done in as received condition. This
records maintained thereof. is important and helps in establishing
the frequency of inspection.
LPG hoses shall be discarded after 3
years of service or earlier in case the Provisions of OISD Standard ;
permanent elongation exceeds 5%. OISD-STD-132 on "Inspection of
Pressure Relieving Devices" shall be
9.5.5 STRAINERS AND FILTERS : followed.
COMPRESSORS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
1. Check Lub. Oil Level of plunger *
pump unit & top up if necessary.
12. Change lube oil filter and clean LPG Suction filter. *
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly
(1) (2) (3) (4) (5) (6)
--------------------------------------------------------------------------------------------------------------------------------
MAINTENANCE SCHEDULE
CENTRIFUGAL PUMP
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Annually
Yrly
(1) (2) (3) (4) (5) (6) (7)
--------------------------------------------------------------------------------------------------------------------------------
10. Overhaul. *
--------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-III
MAINTENANCE SCHEDULE
FILLING EQUIPMENTS
--------------------------------------------------------------------------------------------------------------------------------
Sr. Equipment Checks PERIODICITY
--------------------------------------------------------------------------------------------------------------------------------
Daily Weekly Monthly Qrtly Half Annually
Yrly
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
I. CAROUSEL :
(A) DRIVE UNIT :
2 Grease bearing. *
--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
(D) INTRODUCTION AND EJECTION DEVICES:
--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
8. Complete overhauling. *
--------------------------------------------------------------------------------------------------------------------------------
(1) (2) (3) (4) (5) (6) (7) (8)
--------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-IV
DIESEL ENGINES
MAINTENANCE STEPS
7. PREVENT OVERSPEEDING.
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
8. REMOVE AND CLEAN AIR COM- 8A FILL WITH CLEAN OIL, UPTO
PRESSOR BREATHER, IF MARK.
EQUIPPED.
DIESEL ENGINES
"A" CHECK EVERY DAY
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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.
--------------------------------------------------------------------------------------------------------------------------
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
DIESEL ENGINES
DIESEL ENGINES
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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.
15. CHECK FAN HUB AND DRIVE. 14B USE SPECIAL TOOL FOR
TIGHTENING THE FAN HUB NUT.
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
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
12. TIGHTEN ALL MOUNTING BOLTS 12C TIGHTEN AS REQUIRED. OVER TIGHTEN-
AND NUTS. NING MAY RESULT IN DISTORTION OR
DAMAGE.
14. CHECK SEA WATER PUMP 14C CHECK FOR LEAKS/ OPERATION/
(MARINE APPLICATION ONLY) PERFORMANCE.
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)
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).
DIESEL ENGINES
----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS REMARKS
----------------------------------------------------------------------------------------------------------------------------
1. REPEAT ALL MAINTENANCE STEPS 1D
OF CHECKS "A", "B" & "C".
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.
All cylinders used for filling LPG are 10.1.3 CHECKING TARE
required to be tested periodically to WEIGHT :
ensure fitness of the cylinders for
further service. First re-testing is All the LPG cylinders shall be
required to be done after 7 years and weighed and if the loss in tare
subsequent re-testing after every 5 weight is more than 5% of
years interval. Such tests are to be original weight such cylinders
conducted by the CCE approved shall be segregated and scrapped.
parties only. At the time of weighing the
weight of valve is also accounted.
10.1 TESTING PROCEDURE
10.1.4 VISUAL INSPECTION :
10.1.1 DEGASSING OF LPG
CYLINDERS a) The detailed visual inspection of the
cylinder body shall be carried out as
All the LPG cylinders are per IS:5845/ IS : 13258.
depressurised in the approved
premises by opening valves by b) Depending upon the visual
means of suitable adapters to ensure inspection, cylinders are segregated
that the internal cylinder pressure is for scrapping, for cold repairs and for
reduced to atmospheric pressure. hot repairs in case required.
Only after depressurising the
cylinder, cylinder valve is removed c) The interior of the cylinder shall be
and LPG cylinder is taken up for examined by means of infra low
water filling and water is overflown voltage FLP lamp. The internal
and retained in the cylinder for not examination shall be carried out as
less than one hour to remove any per IS:5845 / IS : 13258.
traces of LPG. Degassing can also
be achieved by stripping, Nitrogen d) LPG cylinders selected at random
purging, etc. may be cut into two holes for
assessing internal corrosion.
10.1.2 SURFACE CLEANING
e) In case of dented/ buckled cylinders,
a) After depressurising the cylinder and visual inspection of welds needs to be
emptying out the water, the same is done more carefully since the welds
kept in inverted position and stroked are more susceptible to cracking.
gently with a non-sparking hammer Denting or buckling by more than
such as wooden mallet to remove nominal plate thickness may be
any dust, rust or any loose remnants attended by repairs/ replacement.
in the cylinders.
10.1.5 HYDROSTATIC TESTING :
b) The depressurized cylinder bung is
plugged and is taken up for surface a) All the LPG cylinders shall be taken
cleaning by immersing the cylinder in up for hydrostatic test at an interval
the caustic soda bath and soap water of 7 years for first testing and
subsequent testing after every 5 years a) The Pneumatic test should be applied
in accordance with IS:8868. Only to the cylinder at a pressure of 7
water should be used as a medium for kg/sq.cm. for a minimum of 60
hydrostatic testing and the pressure seconds as per IS:3196. This is
to be applied should be the test basically to check the tightness of the
pressure marked on the cylinder body valve cylinder joints.
(25.35 kg/sq.cm) and the same
should be retained for a minimum b) With the cylinder under pressure, a
period of 30 seconds. Any reduction soap solution should be applied to the
in pressure noticed during the test, cylinder valve bung joint to ensure
any leakage, visible bulge or that there is no leak. The same can
deformation should be treated as a be checked by dipping the cylinders
case of failure. Such cylinders should in water bath. Depressurise the
be properly marked, observation cylinders. All the Pressure Gauges
recorded and segregated for used for Pneumatic test shall be
scrapping and disposal. calibrated at least once in 3 weeks
and the Pressure Gauge used for
b) Pressure Gauges shall be calibrated at verification should be tested once in
least once a week and the Pressure every three months.
Gauges used for verification should
be tested once in every three months. 10.1.8 PAINTING OPERATIONS :
a) Before commencing the fitting of b) All LPG cylinders are painted with
valve operation, all the water inside one coat of zinc chromate primer and
the cylinder should be drained and the a coat of super synthetic enamel paint
cylinder should be made dry with the of signal red colour (IS:2932 shade
use of hot air jet. Before refitting the 575). Special care should be taken to
valve, internal threads of the cylinder paint the cylinders in vulnerable areas
bung should be cleaned with 3/4" like underneath the foot ring.
NGT thread tap and checked against
thread damage. In case old valves c) The valve should be protected while
are being refitted the same should be painting the cylinder.
tested by compressed air at 7
kg/sq.cm for leakage from seat. 10.1.9 CHECKING MARKING THE
TARE WEIGHTS
b) Teflon paste/ suitable sealing
compound should be used as a a) Tare Weight of the cylinder should be
sealing material for tightening the ascertained and if in variance with the
valve and the torque of 20+/-2 kg. m. original tare weight (this could be as
should be applied. In no case a result of change of cylinder valves )
spanners and ordinary wrenches be the observed tare - weight should be
used for tightening the valves. punched as close to the original tare
weight marking as recorded in the
10.1.7 PNEUMATIC TEST : register maintained.
b) The observe tare weight should be b) Code marking for the Test Plant/
stencilled with paint on the shoulder Repairer.
and as well as on inside of one of the
vertical stay. c) Tare weight of the cylinder should
be stencilled with black paint
c) Gross weight punched/ stencilled on within the V.P. Ring circle
the cylinder should be changed in diameter at 3 places for easy
case of change of tare weight. identification by filling operators.
The recommended lettering size is
- Weighing machines used for 25 mm and the thickness of the
checking the tare weight should numerals is 6-7 mm.
be duly certified by Weights &
Measures Authority. The d) It is also recommended that the
machine should be tested daily net weight of LPG to be filled
with the standard weights to should be stencilled on the body
verify accuracy. The test used for of the cylinders outside the V.P.
checking should be tested against Ring diameter. The size of the
standard weights and the same lettering recommended is 18 mm
must be stamped periodically by and the thickness of the numerals
Weights and Measures Authority. is 4-5 mm.
The minimum graduations of 50
gms. must be available. Sequence of operations for
statutory pressure testing of LPG
e) Weighing scale error should not be Cylinders is given at Annexure
greater than 1.0%. 10-I.
--------------------------------------------------------------------------------------------------------------------------------
Cylinder Cylinder Next Background Shade as Lettering
Manufactured retested/hot Retesting colour IS:5 colour
in the repaired Date
year in the year
-------------------------------------------------------------------------------------------------------------------------------
1997 1999 2004 Dove grey 694 Black
1. Receipt of Cylinders
2. Depressurising
3. Recording details
(like Sr.No., Test Dates, Tare weight, Manufacturer's name)
4. Valve Removal
5. Degassing
17. Tapping the bung thread, cleaning the same by brass wire
brush and checking the bung threads by L-1 & L-9 plug gauges.
CHAPTER 11
iii) The fire water pump(s) including the b) The mains shall be supported at
stand by pump(s) shall be diesel regular intervals not exceeding 6
engine driven . The pumps shall be meters or as per design approved.
capable of discharging 150% of its
rated discharge at a minimum of 65% c) The system for above ground
of the rated head. Each engine shall portion shall be analysed for
have an independent fuel tank of flexibility against thermal
suitable size for 6 Hrs. continuous expansion and necessary
running. expansion loops where called for
shall be provided.
In case of sea water service, the fire
ii) However the ring main may be laid water main pipes shall be concrete
underground at the following places : mortar lined internally or other
suitable coating material shall be
a) Road crossings. used.
Horizontal dry piping down stream of ii) In case, Quartzoid Bulbs are used for
the block valve and after deluge detection, the same shall be designed
valve shall have adequate drain to blow at 79 deg. centigrade (max.)
facilities at selected locations. and Quartzoid Bulb network shall be
maintained with plant air at a
11.11 AUTOMATIC FIRE pressure not more than 3.5
PROTECTION SYSTEM kgs/sq.cm.g and shall be such that the
discharge of air through one
i. Automatic fire protection (Fixed) Quartzoid Bulb will depressurise the
system based on heat detection system to actuate the deluge valves.
through thermal fuses/ quartz bulbs/
EP detectors shall be employed. iii) In case of Electro pneumatic (E.P)
Sensors shall be installed at all critical heat detectors, it shall actuate the
places wherever medium velocity deluge valve in any of the following
spray system has been installed as conditions :
described below :
a) Rate of rise - 10 oC/min
a. In LPG storage area, such of temp.
detectors shall be provided
encircling each vessel, equi- b) At 79 deg. C (max.)
spaced with a maximum spacing
of 1 meter at an elevation of The EP detectors shall be divided in
about 1.5 to 2.0 meter from groups and alternate detectors shall
bottom of vessel. Also minimum be connected in one circuit. Two
2 nos. detectors shall be provided detectors from two different groups
at the top of the vessel and atleast shall function/ operate for actuation
one near the liquid line ROV to of sprinkler system.
take care of failure of flanges. In
case of an automatic thermal fuse iv) Water spray nozzles and heat
based fire protection system the detection system shall be of
instrument air supply pressure to approved type and duly certified for
thermal fuses shall be maintained the performance.
through a pressure control valve
and a restriction orifice. iv) The actuation of detectors shall
initiate the following :
b. Detectors shall be placed at
critical locations in LPG sheds i) Opening of deluge valve of the
(filling, cylinder storage, testing, affected zone as well as adjacent
evacuation, etc.) loading/ zones.
corrosion and cleaned if necessary at
ii) Audio-visual alarm indicating intervals of not more than 12 months or
the affected zone at the fire earlier based on actual experience.
pump house and manned
control panel. The control Care shall be taken in positioning
panel shall also have status nozzles so that water spray does not
indications for deluge valves miss the targeted surface and reduce
with facility for actuation. the efficiency or calculated discharge
rate.
iii) Fire siren of l km range
11.12 FIRST AID FIRE FIGHTING
iv) Closure of all Remote EQUIPMENT
Operated Valves in affected
facility. 11.12.1 PORTABLE FIRE
EXTINGUISHERS
v) Tripping of main power
supply barring the emergency i) Portable fire extinguishers shall be
power located at convenient locations and
shall at all times be readily accessible
vi) The water spray from all and clearly visible.
nozzles within 30 seconds.
ii) The maximum running distance to
vii) The fire water pump(s) shall start locate an extinguisher in working
based on their set pressure to areas shall not exceed 15 meters.
supplement/ to maintain the fire
water pressure in the ring main. iii) The top surface of the extinguisher
shall not be more than 1.5 meter high.
Additionally suitable systems like push
buttons etc. for initiating all the above iv) The fire extinguishers shall be
actions shall be provided on remote provided at various locations as
operating panel. Further similar system under :
like push buttons, air release valves etc
shall also be provided in the field at safe Area Portable Fire
location for enabling manual actuation by Extinguisher
an operator. In case, the zoning concept
is used for MV sprinkler system, the LPG Storage 2 Nos. 10
operations of sprinklers in various zones Vessel(Each) kg DCP
shall be clearly earmarked on the push extinguisher.
buttons. In the field, manual bypass
valves of fire water deluge valves shall LPG cylinder 2 Nos. 10 kg DCP
also be provided. sheds extinguisher per
200 Sq.M.Area.
The performance test certificates after
installation in respect of spray density, LPG Pump 2 Nos.10 kg. DCP
flow rate, response time for each facility houses extinguisher per
to be protected provided by 50 Sq.m. Area.
manufacturer shall be maintained at the
LPG Installations and verified once in 6 Tank Truck loading/ 1 No. 10 kg.
months and records maintained thereof. loading gantries DCP Extinguisher
Further, all spray nozzles shall be in each bay.
inspected for proper positioning,
Tank Wagon loading/ 1 No. 10kg
unloading gantries DCP Extinguisher i) Reinforced rubber lined hoses
for every 15/20 (63mm) conforming to IS : 636 (type
meters of gantry. A or B) shall be provided.
10. Fire proximity suit Min. 1 No. v) For Disaster condition the wailing
sound given shall be repeated thrice
11. Resuscitator Min. 2 No. with a minimum 10 seconds gap.
14. Water jel blankets Min. 2 nos. ii) In the hazardous areas, flame-proof /
intrinsically safe telephones shall be
15. Portable Gas detectors min. 2. provided.
/ Explosimeter
iii) Wherever possible Hot line
The above are guidelines and connection between City Fire
minimum requirements of each item Brigade/ near by major Industries
and can be increased depending upon shall be provided.
the scale of operations, statutory/
mandatory requirement of local iv) Plant shall have a ` Mutual Aid'
bodies/ State Governments or any arrangement with near by industries.
other expert body.
11.14 SPECIAL FIRE PROTECTION
11.13 EMERGENCY CONTROL /
ALARM SYSTEM The most hazardous situation in LPG
vessel is the possibility of BLEEVE. This
11.13.1 FIRE ALARM SYSTEM usually takes place when the vessel is
subjected to external fire.
i) Manual call points near to filling
shed, storage area, tank truck/ wagon The unwetted (vapour space) portion of
gantry, pump house, etc. shall be the shell gets overheated and fails even at
provided and clearly marked in the the operating pressure. As such, it is
installation. Operation of these points important that metal temperature in the
shall raise audio visual alarm in vapour space is protected from
control room. overheating by some measures. A passive
measure like fire proofing/ insulation or
ii) Electricity operated Fire Siren shall be fire retardant coating will provide
audible to the farthest distance in the protection in the initial period of fire
plant (1 K.M. from the periphery of which is very crucial. This will give some
the plant). breathing time for activating other fire
fighting measures like starting of pumps,
iii) Manually operated fire sirens shall be organising people, opening of valves etc.
provided at strategic places. This will also take care of automation
failure wherever it is provided.
iv) For fire condition the siren shall be
wailing sound for minimum `2 The fireproofing of LPG storage vessel
should be decided based on the risk
analysis keeping in view local 11.15 INSPECTION AND TESTING
considerations, availability of water and
societal risk. The fire protection equipment shall be
The fireproofing of LPG storage vessel kept in good operating condition all the
shall be decided based on the fire safety time.
analysis keeping in view local
considerations, population density, The fire fighting system shall be
availability of water, societal risk and fire periodically tested for proper functioning
protection measures provided. and logged for record and corrective
actions. In addition to routine daily
Fire proofing provided on the vessel and checks/ maintenance the following
supporting legs shall be adequate to periodic inspection/ testing shall be
protect the shell material from ensured.
overheating and consequent failure. The
minimum rating for fire proofing shall be 11.15.1 FIRE WATER PUMPS
as under :
i) Every Pump shall be in test run for
LPG storage vessel & connected 1 hr. atleast 10 minimum twice in a week
lines upto the fire safe ROVs at the rated conditions.
Supporting legs of all above 2 hr. ii) Once in a month each pump shall be
checked and tested and the shut-off
Fire proofing is not required for diagonal pressure observed and logged. Also
bracing, including tie rods, or redundant the pump performance shall be
members that are not necessary for ascertained.
supporting the static loads.
iii) The Jockey pump operation shall be
Before fire-proofing application, checked periodically. Frequent start/
protected metal surfaces shall be stop condition of Jockey pump
prepared through such means as sand- indicates that there are water leaks in
blasting and corrosion-protective the system.
primers. Particular attention shall be
given to the top junction of the fire- 11.15.2FIRE WATER RING MAIN
proofing with the protected metal to i) The ring main shall be kept
prevent water ingress. OISD-STD-164 pressurised at 7 kg/sq.cm.g with the
on "Fire proofing" shall be referred for help of one or more jockey pumps.
details on fire proofing.
Fire water line to each sphere should be ii) The ring main shall be inspected for
so routed that it is not exposed to direct any visual leaks, detects, damage and
fire. This is to protect it from failure in corrosion at least once in week and
the initial period when water flow has not records maintained thereof.
commenced. It is recommended that
riser should be located away from bottom iii) All valves on the ring main/ hydrant/
ROV. The horizontal run of the Fire monitor valves shall be checked for
Water line may be buried if fire leaks/ operation and lubricated once
engulfment cannot be avoided otherwise. in a month.
Fire proofing shall include connected
LPG lines and pipe supports within 15 M 11.15.3 FIRE WATER SPRINKLER
of a storage vessel or in the drainage SYSTEM
paths.
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.
12.0 GENERAL
Amongst the various methods of
The best method of prevention of detection available, the following
explosion is to avoid basic build up of proven systems for LPG can be
gas concentration immediately on considered.
occurrence of leakage. This would
require basically a reliable and i) Catalytic detectors
continuous detection system with ii) Infra-red detectors
warning annunciation to alert the
plant personnel to take corrective 12.3 CONTROL SYSTEMS
action.
i) This is a critical equipment for plant’s
The Gas Monitoring system shall safety. Hence, the system should have
provide early warning on build up of independent control equipment,
dispersed gas concentration below power supply, UPS to ensure that the
the LFL limits. system remains in operation even if
the plant DCS or other common
The system shall be designed process controls are not functioning.
considering small leaks (leaks which In case of bottling plant in Refineries,
have secondary closures) such as dropping of the signals on the DCS is
mechanical seals failure, sampling acceptable wherever hot standby
point left open, gasket leaks, hose DCS control system is available.
pinholes, valves gland leakage, drain
point left partially open, TSV’s relief ii) In case of failure or during
discharge in manifold area, filling/ maintenance when the system is not
evacuation hoses leakage. in operation, the plant safety officer
should keep the plant personnel on
12.1 APPLICATION alert to be more vigilant during
operations and night security
i) The detectors for the gas monitoring patrolling.
system shall be strategically located
in LPG Bottling Plant at all facilities iii) The control equipment should have
close to the potential source of data logging facilities to provide print
leakage. outs of the history of the events with
date and time of leakages.
ii) The detection control equipment
should be provided in the control iv) The control equipment should be able
room for continuous monitoring to generate at least two alarms at
even during power failure. different levels of LEL concentration
of gas.
12.2 DETECTORS
v) The control equipment is not required additional expansion/ construction if
to have automatic corrective action undertaken, the detectors will have to
capabilities on sensing leakages as be pre-positioned.
this is basically a warning device.
However, in case of any specific v) The minimum detectors facilities-wise
recommendations made in the risk are as given below:
analysis / HAZOP studies, the same
should be implemented. Storage vessels (above ground) – 1
No. top and 1 No. near bottom ROV.
12.4 ANNUNCIATION SYSTEMS
LPG pump house 1 No. in pump
Appropriate annunciation system shall be house and 1 No. in manifold.
available to ensure that all the alarms
generated, both, audio and visual are Filled cylinder shed - 2 No.
reported to the plant personnel, who are
authorized to take corrective action. Valve change shed – 1 No.
Depending on the manning practice of
the plant, the alarms both, audio and Empty-cum-filling shed – 2 Nos. near
visual can be repeated at additional carousel, 1 No. near evacuation unit
location to ensure corrective action is tank, 1 No. weight correction unit.
taken.
TLD – one at each manifold and at
12.5 LOCATION OF DETECTORS ends.
i) The behaviour of the gas leakage Tank wagon gantry – 1 no. for every
governs the positioning of the gas two bays or 30 m whichever is less
detector. As LPG is heavier than air, at bottom. Additionally, some
the height of the detector should not detectors at selected locations shall
be more than 0.3 M from the be provided at the top of platform.
mounting level.
The number and location of the
ii) The pre-dominant wind direction detectors required over and above the
should be considered with respect to minimum requirements specified
the potential source of leakage to above shall be as per the specific
ensure positioning of the detector on requirements identified in the risk
the down stream side of the wind analysis / HAZOP study report.
direction.
The location can be decided by
iii) The detectors especially the catalytic assessing the behaviour of gas drift
type should not be positioned very and consequential safety risk.
close to the potential source of
leakage to avoid poisoning of the vi) Inspection and testing
detectors(temporary malfunctioning).
The detectors should be located at The gas monitoring system shall be
least 0.3 mtrs. away from the kept in good operating condition all
potential source of leakage. the time.
The inspection of the system shall be
iv) In case of infra-red detectors, the done at an interval of 1 month in
same shall be installed on the down which the gas shall be released at all
wind side ensuring the path is free the detectors and the performance of
from obstructions. In case any the systems shall be established.
in maintenance history log book
The calibration of the equipment shall during calibration and the detectors
coincide with the monthly inspection with abnormal or wide drift in
schedule every three months for sensitivity.
calibration of the gas detectors the
calibrated gas with known and The plants should have at least 2
certified level of concentration shall Nos. spare detectors for each system
be used. maintained at all times to facilitate
immediate replacement of defective
The drift in the sensitivity of the detectors.
individual detectors shall be recorded
CHAPTER 13
Plant Manager shall ensure that suitable 13.1.4 SOME OF THE COMMON
instructions are issued to both CAUSES OF FIRE :
Corporation's and contractor's personnel
identifying the action to be taken by each (a) ELECTRICAL :
one in an emergency. This should be
achieved by display of organisation chart/ i) Short circuiting due to loose
posters not only for fire-fighting but also wiring including that of
for other likely emergencies. Likewise, automobile moving in the area.
for emergencies of large magnitude
Emergency Response Plan (or Disaster ii) Use of non-flame proof fittings
Management Plan) to be drawn out in such as lights, torch, motors,
coordination with related outside fan, telephone, temporary
agencies, such as local administration, lighting etc. (Note : Flameproof
Police authorities, Fire Brigade, hospital fittings become non-flame proof
due to poor maintenance e.g. 13.2 ACTION DURING
increase in gap in junction EMERGENCY
boxes, due to missing nuts and
bolts or improper glands used 13.2.1 Immediate action is the most
for connection to junction box, important factor in emergency
or sealing compound not used control because the first few
in junction boxes etc.) seconds count, as LPG fires
develop and spread very quickly
iii) Static electricity as result of unless prompt and efficient action is
improper bonding/ grounding to taken. In the event of fire/ gas leak
tanks, conveyor system, tank within LPG Plant the following
truck, tank wagon etc. action shall be taken as quickly as
possible:
(b) VEHICLE :
a) Take immediate steps to stop LPG
i) Exhaust of vehicle, if effective leakage/ fire and raise alarm
spark arrestors are not provided. simultaneously.
Allow fire to continue till exhaustion. (i) Plant personnel shall be fully trained
for the specialized techniques
Spray vessel with water to cool it, if necessary for combating LPG
vessel is being heated by radiation from leakages and LPG fires.
the flame or if flame is endangering other
plant equipment. (ii) If leakage and/ or fire occurs, all
personnel should use the equipment
Cool adjacent vessels and structures. provided and to carry out their
allotted tasks as detailed in the fire
(v) Fire at Safety Relief Valves of fighting organisation plan.
vessels exposed to adjacent fire.
(iii) All personnel should be conversant
(vi) Fire in Oil storage area adjacent with fire control equipment and
to LPG storage : also its location.
Start water sprays only on those
LPG vessels exposed to fire/ heat. (iv) LPG plant personnel should know
the position and method of
Isolate affected vessels and run out operation of all Remove Operation
fire water hoses in case hose stream valves (ROVs) in the plant.
cooling becomes necessary.
(v) Plant personnel should be familiar
Water pressure in LPG vessels. with the standard recognition
markings of fire control, first aid
If LPG vessel's SRVs have started and all safety equipment, must
blowing vapour, take no further know the location of emergency
action (apart from cooling) unless exits, and they should know the
vessel pressure continues to rise. location of water hydrant points/
monitors and must be familiar with
If fire enters LPG storage area, the sound of the emergency (fire)
concentrate available cooling water alarm.
on LPG vessels, most affected.
(b) The Fire Fighting Organisation Plan
Do not try to empty LPG vessels together with layout of fire fighting
exposed to fire. They become more and safety devices shall be
vulnerable to overheating as their displayed at prominent places and
liquid content decreases. explained to all personnel. It shall
include the following functions,
expanded to suit the location
13.2.5 Fire Fighting Organisation Plan facilities/ requirement:-
(a) A plan of action for use in the event (i) Sounding the emergency (fire)
of a major LPG product leakage alarm.
(ii) Shutting off the LPG supply to any Close co-operation with the local fire
leakage point/ fire. authorities is essential and shall take the
following form :
(iii) Summoning the fire brigade/ police.
(i) The fire brigade should be made
(iv) Fire control, with first aid, fire familiar with the layout of the plant
fighting equipment. and the location of important
equipment/ facilities provided, and
(v) LPG vapour dispersal. their method of use. Mock fire
drills/ exercise jointly by plant
(vi) Operation of LPG vessel's fixed personnel and local fire brigades
water sprinkler system, starting of shall be planned.
fire pump (s) and application of
water hose jets/ sprays for (ii) Fire fighting equipment at the plant
containing/ extinguishing fires. shall be compatible with the fire
brigade equipment, otherwise
(vii) Cooling of vessels/ cylinders and adapters shall be kept ready for
other equipment/ facilities. hoses, hydrants etc.
(viii) Closing down all operations in the (iii) The fire brigade shall be aware of
plant including closure of valves the plant's fire fighting organisation
and stopping of pumps. plan and the views held at the plan
regarding the most effective LPG
(ix) Preventing all sources of ignition in fire control methods.
case of LPG leakage.
(iv) In the event of an emergency/ fire,
(x) Evacuation of vehicles. the plant manager and/ or his
representative shall advise the Fire
(xi) Evacuation and mustering of Officer about particular or potential
personnel. hazards that may be present e.g.
stocks of filled cylinders at that
(xii) Establishing an emergency fire- particular point of time.
control centre.
(d) Fire Drills & Training :
(xiii) Traffic control.
a) Drills for all Plant personnel,
(xiv) Stations and duties of all making use of the "Fire fighting
personnel. Organisation Plan" and practicing
the specialised techniques required
(xv) Policing of affected areas. for fighting LPG fires or
dispensing/ diluting LPG vapour
(xvi) Any other specialised duties. clouds shall be held minimum once
in a month.
(xvii) Display of fire brigade, ambulance,
Police telephone numbers etc. b) The drills should cover various
types of incidents, e.g. major
(xviii) All clear signal by competent spillage, LPG bulk lorry fire,
person. cylinder fire etc.
14.1 GENERAL:
14.2 TYPE OF SAFETY AUDIT AND
Safety audit is a well recognised tool to PERIODICITY :
improve the effectiveness of safety
programme and loss prevention measures In view of the high hazard potential of
by carrying out systematic and critical LPG, safety audits at frequent intervals
appraisal of potential safety hazards by the teams/ personnel of various levels
involving personnel, plants and are advocated, Broad check lists for
equipments. different recommended safety audits are
given in the Annexure 10-I, II, III, IV.
For a structured and systematic safety These check lists can be further
audit of any plant/ facility, check lists are supplemented and modified suitably to
the most important prerequisite. Check meet the specific requirements of
lists should cover all the operational individual plant. Recommended
areas, major equipments, operating/ minimum safety audits at different levels,
maintenance procedures, safety practices, their frequencies and broad check lists to
fire prevention/ protection systems etc. be used are indicated below :-
Observations/ recommendations of safety
audit team should be presented in the Daily audit essentially shall cover the
form of a formal report and action plan compliance of recommended operating
for corrective measures should be procedures/ safety practices. Reports of
prepared and subsequently monitored for audit shall be reviewed by the Plant
implementation. Manager on daily basis and corrective
action be undertaken on priority
General guidelines on safety audit wherever required.
methodologies and techniques are also
given in OISD - GDN- 145.
-----------------------------------------------------------------------------------------------------------------------------
S.No. Type of Safety By Frequency Checklist
Audit (Annexure)
-----------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5
-----------------------------------------------------------------------------------------------------------------------------
1. Inspection Safety LPG Plant Daily 14-I
audit of LPG Installation Safety Officer
2. Electrical audit of Authorised Annual 14-II
LPG Installation electrical Engineer
3. Detailed safety audit Multi disciplinary Annual 14-III
of LPG Installation team of region/ HQ
4. Inspection and Personnel from Annual 14-IV
maintenance audit of Inspection/ Maintenance
LPG Installation
5. External safety audit OISD
of LPG Installation
--------------------------------------------------------------------------------------------------------------------------------
Daily audit essentially shall cover the Manager on daily basis and corrective
compliance of recommended operating action be undertaken alongwith the target
procedures/ safety practices. Reports of dates shall be done immediately. The
audit shall be reviewed by the Plant compliance to other audit
recommendations along with target
schedules shall be monitored on monthly 3. Fire prevention/ protection system
basis. Alternate, safety measures shall be
taken till the recommendations are 4. Preparedness to handle any
complied in totality. emergency --Disaster control plan
and mock drills.
In case of external safety audit, following
areas besides the points given in check 5. Skill level and training needs for
list of Annexure 14- III shall be covered. HRD.
LOCATION ______________
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
S.No. Item Observation* Action Plan Target Date Review date
1 2 3 4 5 6
(status)
--------------------------------------------------------------------------------------------------------------------------------
* Put specific observation wherever the conditions are not in line with specified
requirement levels.
ANNEXURE 14 - II.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-02 Is the equipment easily accessible for operation, inspection & maintenance.
g) Grounding OK
c) Sealing of duct
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-07 Rubber mats (with ISI mark) existing are enough in number.
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) Grounding OK
b) No oil leak
c) Silica gel OK
d) Oil level OK
f) Oil/winding temp. OK
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-11 First-aid chart for treating electrical shocks displayed prominently in MCC room.
C. UNIT LIGHTING
C-05 Does water enter and accumulate in fixture distribution boxes etc ?
a) Is gasket present ?
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
E-05 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.)
F. GENERAL
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.
Note : For developing a detailed check list refer OISD-GDN-145-09 document on safety audit check list
for electrical system.
ANNEXURE 14- III
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-01 Area under the sphere is having concrete pavement with proper
slope leading to shallow sumps.
A-04 Last safety valve test done as per statutory requirement and record maintained.
A-05 Remote operated valves provided on liquid inlet/outlet lines with push
buttons/ indication control and located at safe distance.
A-06 Two independent level instruments and high level alarm provided in
storage vessels and are in working condition.
A-07 All leg supports of Horton spheres/ vessels encased in concrete with
fire proof coating/ motor.
A-08 a) Sprinkler system provided on all vessels and are in working condition.
b) Deluge valve is remote operated and is located at safe distance from storage vessels.
A-09 Gas detection system provided and in good working condition (To be checked).
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A-11 Statutory inspection/ hydro test records maintained.
B-01 a) All electrical motors/ push buttons properly earthed and flame proofness maintained.
c) No abnormal sound and vibration from motor and bearings condition OK.
B-04 Drain points/ vent points/ sample points capped when not in use.
B-06 Long range monitors/ fixed water spray with proper throw/ sprinkler system
installed and in good condition.
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.
- 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.
i) Spurious
C-08 Vapour extraction system provided for carousel and system is working satisfactorily.
C-10 Accuracy of check scales being checked daily and records maintained.
C-12 Check facilities provided for valve seat leakage and working satisfactorily.
- 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.
- Aluminium foil
- PVC sealing
- Plastic
- Paper
C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily.
--------------------------------------------------------------------------------------------------------------------------------
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-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-01 Whether the location and layout of the facilities meet statutory distances/ design guidelines.
D-04 Hose contents after unloading are released to high vent located at safe distance.
D-06 a) Sprinkler system provided on the railway siding/ tank truck loading/
unloading area are and working satisfactorily.
D-09 a) Vehicles are properly checked for any sign of leak, proper fittings and
other valid documents.
D-10 Loading/ unloading procedures along with safety precautions prominently displayed.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
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.
- corrosion protection
- material of construction
e) Strainers provided at inlet of deluge/ sprinkler water supply main piping. Strainers are
cleaned periodically and records maintained.
- Working satisfactorily
- Regularly tested.
E-14 No smoking cautions/ signs in Hindi/ English local languages displayed at prominent places.
E-16 a) Emergency lighting system provided in strategic locations and system working satisfactorily.
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
--------------------------------------------------------------------------------------------------------------------------------
a) Regular staff
b) Contractor workmen
c) Security staff
G. GENERAL
G-01 a) Plant approach/ access roads well maintained and at least two emergency
exits are there.
- Storage of LPG
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
G-06 Hot work permit/ clearance issued - proper procedures followed and
documents maintained.
e) Gas Cylinders Rules, 1981, SMPV Rules 1981 and other relevant
BIS Standards with latest amendments.
G-09 Updated P&I Diagrams, drawing of layout and other facilities available.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS
1 2 3
--------------------------------------------------------------------------------------------------------------------------------
A. GENERAL
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-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-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-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.
--------------------------------------------------------------------------------------------------------------------------------
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-04 Check scales are well maintained and calibrations carried out on daily basis
with standard weights.
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS:1436-1991 - WEIGHBRIDGES
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS:2825-1969 - CODE FOR UNFIRED PRESSURE VESSELS
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
IS:8737 - VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF
MORE THAN 5 LIT. WATER CAPACITY
--------------------------------------------------------------------------------------------------------------------------------
CODE NO. NAME
--------------------------------------------------------------------------------------------------------------------------------
--------------------------------------------------------------------------------------------------------------------------------
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
vi. ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American
Society of Mech.Engrs., New York