SAFETY AUDIT

INTRODUCTION
Safety audit is a well recognised tool to improve the effectiveness of safety programme and loss prevention
measures by carrying out systematic and critical appraisal of potential safety hazards involving personnel,
plants and equipments.
For a structured and systematic safety audit of any plant/ facility, check lists are the most important
prerequisite. Check lists should cover all the operational areas, major equipments, operating/ maintenance
procedures, safety practices, fire prevention/ protection systems etc. Observations/ recommendations of
safety audit team should be presented in the form of a formal report and action plan for corrective measures
should be prepared and subsequently monitored for implementation
Identification of vulnerable areas and specific potential hazards, is one of the prime function of loss
prevention in oil industry. Safety audit is an important tool in undertaking this function.
OBJECTIVES OF SAFETY AUDITS
While the basic aim of safety audits is to identify the areas of weaknesses and strengths, safety audits are undertaken
to meet different specific objectives viz.1.
To identify any design deficiencies and also any weaknesses which might have cropped up during
modifications / additions of facilities.
2.

To ensure that fire protection facilities and safety systems are well
maintained.
3.
To ensure that operating / maintenance procedures, work practices are as per those stipulated in the
manuals and standards, which might have degraded with time.
4.

To check on security, training, preparedness for handling emergencies and disaster management etc.

To check the compliance of statutory regulations, standards, codes, etc.

6.
As a social objective to cater to public opinion and concern for safe environment. This also
improves public relation of the organization.
SCOPE OF SAFETY AUDITS
1.
2.

A Safety Audit subjects various areas of a company's activities to a systematic critical examination
with the objective of minimizing loss.
This includes all the components of the system viz. management policy, attitudes, training, design
(Process, Mechanical, Electrical, etc.) aspect, layout and construction of the plant, operating Inspection &
Maintenance procedures, emergency plans, personal protection standards, accident records.

TYPES OF SAFETY AUDITS

Two types of Safety Audits are proposed to be carried out as below:

Internal Safety Audit

External Safety Audit

Audit conducted by Internal Audit teams of the organisation is categorized as Internal Safety Audit.
External Safety Audits will be carried out by outside teams consisting of technical experts from other organizations
in oil industry, professional bodies and statutory authorities under the overall coordination of OISD.
METHODOLOGY OF INTERNAL SAFETY AUDITS
1. Frequency of safety audit:
The Audit should be covered minimum once in a year however any major modifications or addition can be
audited once in three years
2.

Grouping for Audit:

The area should be clearly identified and logically grouped. For Refinery Installation, the groupings are
given below:
Group I All LPG Storage, Filling and Dispatch Facilities
Group II All Dispatch Facilities like Tank Truck loading, Bitumen Filling and Dispatch Facilities
Group III Oil Movement and Storage (OM&S)
Group IV Process Units
Group V Power & Utilities, Electrical Substations and ETP
Group VI Miscellaneous Such as Work shop, ware house, laboratory, Buildings etc
Group VII Fire Fighting Facilities, Layout etc

FORMATION OF MULTI-DISCIPLINARY AUDIT TEAMS:

The Internal Audits should be carried out through multidisciplinary audits teams. The composition of the
Internal Safety Audit may vary depending on the Group and
areas to be audited, however, person(s)
concerned should have necessary experience and background to undertake in-depth audit in a particular
discipline. A team of 4 to 5 experienced officers from various disciplines viz. Process / Production,
Maintenance /Inspection, Electrical, Instrumentation, Fire & Safety and with the activity involvement of
concerned Plant / Area Manager is suggested. One of the team members should be nominated as the leader of the
audit team. In multi-unit organizations, the team members could also be drawn from the Head Office / Corporate
Office and other operating Units under its control.
DURATION OF AUDIT
Depending on the nature of audit and type / complexity of the installations in the selected group, the duration of
internal safety Audit can be fixed. This may vary from 2 to 7 working days for facilities under each group.
USE OF SAFETY AUDIT CHECK LISTS

Check lists are the most useful tool for undertaking systematic Safety Audit. Even for a skilled and well
qualified engineer a good check list would be necessary as a guide. Like a code of practice, a Check List is a means
of pooling the knowledge and hard won experience and ensures that no important aspect is overlooked or forgotten.
Such check lists help maintaining uniformity and speeding up the audits.
PREPARATION BEFORE SITE VISITS FOR INTERNAL SAFETY AUDITS:
Before the safety Audit team visits any particular facility for carrying out Safety Audit, it would be essential to
study all relevant documents as below to get complete picture :
1)
2)
3)
4)
5)

Layouts
P & IDs
Operating Manuals
Maintenance / Inspection Manuals
Fire and Safety Manuals, etc.

Depending upon the nature of audit more emphasis can be given to study specific documents. All the audit team
members should study these documents in advance to know the details of the installation.
BRIEFING:
Before beginning of each audit, all concerned persons of the area/installation be briefed by the team leader about the
purpose of the audit. No impression should be left that audit will throw bad light on them.
SITE INSPECTIONS:
Most of the information could be gathered through site inspection using ready-made check lists. The
auditors should enter their observations under the remarks column and not simply state "yes" / "no".
Wherever necessary, observations should be recorded in separate sheet. Inspection should be carried out
accompanied by Installation / Plant Manager or the assigned officials.

DISCUSSIONS:
Further information can also be gathered through discussions (formal & informal), with site personnel and
Installation / Plant Manager, who is in-charge of the area or other site officers. The audit team should interact with
persons from various disciplines such as Production, Maintenance, Electrical, Instrumentation, etc.. Formal
discussions could be in the form of brief periodical sessions while informal discussions could be over a cup of
tea with personnel working in the area.
STUDY OF DOCUMENTS:
In addition to the documents which are already studied before inspection of the facilities, other documents,
such as Operating Instructions, Standing Orders, Log Books, Log sheets, Accident Records, Minutes of Safety
Committee Meetings etc. may also be studied as required.
PREPARATION OF AUDIT REPORTS
The work of the Internal Safety Audit item should be presented in the form of a Safety Audit Report for
each group
which should contain observations & recommendations and also in brief the modalities
adopted in conducting audit and the names of the audit team members.

Before finalizing the report, the Safety Audit Team can give a presentation as feedback to the Operating /
Management personnel of the Area / Installation. Additions or deletions could be made in the draft report based
on the discussions and comments received during the presentation. This approach is always constructive and does
not undermine technical competence of the audit team.

FOLLOW UP OF AUDIT REPORTS

Generally, the Internal Safety Audit Reports are submitted to the concerned authority who appoints the audit team
for undertaking needful follow up actions. Only the appointing authority should exercise judgment in rejecting
any of the recommendations. The appointing authority shall be of senior management level (General Manager and
above).
The crux of the safety audits lie in removing the weakness identified during the audit. Sometimes audit reports
identify only the problem / weakness, but not the solution.
In such cases, it would be necessary to undertake a detailed study of the specific area and to identify the
rectification measures. Wherever the necessary in-house expertise is not available for detailed studies, help of
consultants / professional bodies should be sought for.
IMPLEMENTATION OF RECOMMENDATIONS
The final and most important phase is the implementation of recommendations. A senior person should be
nominated for coordinating implementation of all accepted recommendation under a time bound program. Senior
management should review the progress of implementation of recommendations periodically through
Management Safety Committee meetings and other review meetings.

LIQUIFIED PETROLEUM GAS

Liquefied Petroleum Gas (LPG) is a mixture of light hydrocarbons primarily C3 & C4 derived from petroleum,
which is gaseous at ambient temperature and atmospheric pressure, is liquefied at ambient temperature with
application of moderate pressure. LPG due to its inherent properties is susceptible to fire, explosion and other
hazards. Such hazards can have an impact on the property, equipment, plant personnel and public.
Liquefied Petroleum Gas (LPG) handling, bottling and distribution throw major challenges due to its inherent
properties. Major incidents i.e fires/explosions in LPG facilities in world have underlined the need for total in depth
review of design, procedures, maintenance, fire fighting and safety aspects in LPG handling.
The oil and gas industry over the years have learnt lessons from fires and explosions and have been updating and
standardising design, operations, bottling and distribution of LPG.
Some of the important properties of LPG are as below :
1) LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than air. It is
readily liquefied under moderate pressures. The density of the liquid is approximately half that of water and
ranges from 0.525 to 0.580 @ 15 oC.
2) The pressure inside a LPG storage vessel/ cylinder is equal to the vapour pressure corresponding to the
temperature of LPG in the storage vessel. The restriction on vapour pressure is stipulated by IS-4576.
3) 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.
4) Water, being insoluble in LPG, if present in LPG can cause rust and corrosion and freeze-up of valves,
drain valves, excess-flow check valves, cylinder valves and regulators thereby affecting their functioning
and at times can lead to leakage of LPG.
5) LPG liquid has low viscosity of around 0.3 CS @ 45 oC and can leak when other petroleum products
normally cannot, thus demand a very high integrity in the pressurised system to avoid leakage.
6) 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 poses mild
anesthetic properties.
7) LPG is colourless both in liquid and vapour phase. During leakage the vaporization 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.
8) The coefficient of expansion is around 0.00237 per oC. At liquid full condition any further expansion of
the liquid, the container pressure will rise by approx. 14 to 15 kg./sq.cm. for each degree centigrade.
9) LPG has only a very faint smell, therefore, ethyl mercaptan is normally used as stenching agent for
identifying the leakage as per IS: 4576.
10) The auto-ignition temperature of LPG ranges from 410 to 580oC.

STATUTORY RULES / REGULATIONS

The LPG installation & various facilities are covered under many regulations and require specific approval / license
from concerned statutory authorities. The various regulations applicable to LPG installation facilities are as below:
Gas Cylinders Rules, 1981 (under

Indian Explosives Act,1884)

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

STORAGE AND HANDLING OF BULK LPG

GENERAL
This section deals with the safe practices and provisions applying to unloading of bulk LPG and storage of bulk LPG
at installations. There should be strict compliance w.r.t selection, deployment of proper skilled manpower for
effective operation and maintenance.
1.1 BULK HANDLING FOR MOVEMENT BY ROAD
The tank truck for road movement shall be designed, constructed and tested in accordance with the Static and
Mobile Pressure Vessels (Unfired) Rules, 1981 and OISD-STD-159.
SAFETY PRECAUTIONS
Following precaution should be taken due to associated hazards during transfer of LPG to or from a tank truck.
a)

No source of ignition must be allowed in the area where product transfer operations are carried out.

b) Fire extinguishers shall be placed near the tank trucks during transfer operations.
c)

The first operation after positioning the truck should be to provide proper earthing. Earthing shall be
disconnected just before the release of the truck.

d) Before removing plugs or caps, always crack open to allow for release of trapped LPG and further to ensure
that the valves are effectively sealing.
e)

Hoses shall be handled with care and inspected periodically as per OISD-STD-135.

f)

While disconnecting hoses/arm, connections shall be loosened only slightly at first to allow release of
trapped pressure, if any.

g) Do not expose hands, face or clothing to liquid LPG. Always use personal protective equipment while
making or breaking the connections to avoid cold burns.
h) The master switch shall be put off immediately after parking the truck in position. No electrical switch on
the truck shall be turned " on" or " off" during the transfer operation.
i)

No repairs shall be made on the truck while it is in the loading area.

j)

Availability of wheel chokes.

k) New tank trucks vessels or vessels received after repair shall be purged as per laid down procedure.
l)

In case, the receiving vessel is having a pressure of less than 1 Kg/sq.cm.g, it shall not be filled. Such
vessel shall be taken for filling only after detailed safety checks.

m) Venting and purging of LPG during transfer operation shall not be carried out in open atmosphere. It shall
be piped to a suitable flare system. Where such facility does not exist, vent pipes shall be provided to carry
the vented product to a safe distance and released at a height not less than 1.5 m above the eves of the
structure.

PROCEDURES FOR OPERATION

LOADING OPERATIONS

Check for following in a tank truck as per statutory regulations before accepting it for filling:

Provision of two safety valves, level gauge, Excess flow check and control valve on liquid and vapour
lines, pressure gauge, temperature gauge on the vessel / bullet.

Fire screen between cabin and vessel is provided. For this purpose, cabins with metallic back cover without
any opening will be considered as fire screen.

Provision of 2 nos. of 10 Kgs. DCP Fire Extinguishers.

Fitment of Spark arrestors of approved quality.

No leakage in exhaust silencer pipe exists.

Manufacturer's name plate with date of testing is fitted on the vessel.

Valid Explosive Licence and RTO certificate is available.

Approved drawings of vessel are available.

Blind flanges/caps are provided on vessel.

Availability of Earthing cable.

Bonding between vessel and chassis and between flanges is satisfactory.

Earthing / bonding point is available.

Third party inspection/test certificates for vessel/fittings are available.

Liquid / vapour line valves are in

Move truck to the loading bay/weigh bridge and record the weight of the empty tank truck.

Place the truck on loading bay and place choke blocks at front and rear wheels. Keep the truck in neutral
mode with hand brakes "ON".

Stop the engine and switch off all electrical equipment.

All persons should leave the driver's cabin.

Make earthing connections of the vehicle at specified point to the fixed grounding system.

Connect liquid and vapour lines suitably with the loading point. Crack open valves on loading & vapour
return lines and inspect hoses & connections for leakage. Loading should start only when the system is
leak free.

Start the loading pump.

good condition.

The quantity loaded into the truck can be determined by -

Liquid level

Weighment

Positive displacement meter

Mass flow meter

The quantity of LPG filled shall not exceed the RLW of the tank truck.

Liquid level may be determined by roto-gauge or fixed liquid level gauge. Percentage volume to be filled
shall not exceed 85 % at 55OC i.e. the allowable filling limit as per CMV Rules.

Where weigh bridge is used, it is necessary to determine the density of the product being loaded to avoid
excess filling in terms of volume. The weigh bridge shall be periodically calibrated and stamped by
Weights & Measures Authorities.

When the filling operation is in progress, the pressure within the tank truck vessel shall be observed to
ensure that it does not approach the start-to-discharge pressure of the relief valve. Filling rate may be
regulated as required.

The couplings may then be removed and plugs/caps replaced on the tank truck valves. Re-check tightness
with soap solution.

Unloading Operations

Operations described under Item 1 through 6 in para 7.1.2(a) should be carried out.

Liquid line and vapour line of the tank truck shall be connected to the respective hoses fixed to the
unloading point.

Test the connections for leaks by slightly opening the valves for pressurising. When satisfied, valves on the
tank truck and the receiving vessel shall be opened.

Start the LPG compressor. Vapours will be sucked from the receiving vessel and will be discharged into the
vapour space of the tank truck vessel creating pressure differential thereby pushing the liquid from the
tank truck vessel to the receiving vessel.

Care should be exercised to see that the pressure created within the delivering vessel does not reach or
exceed the set pressure of the relief valve.

An authorised person of the company shall supervise the transfer operation and respond immediately in the
event of an emergency.

After the liquid has been expelled, the vapour recovery operation may be started. Care should be taken not
to bring down the pressure of the delivering vessel below 1.5 Kg/cm2g.

BULK HANDLING FOR MOVEMENT BY RAIL

LPG is moved in Tank Wagons by the Railways. These wagons are designed by RDSO and are fitted with various
devices as shown in Figure-VII.
The loading facilities are similar as for tank truck loading while unloading of LPG from tank wagons shall be done
with the help of compressor. The compressor is used to create a differential pressure between the receiving and
discharging vessels by withdrawing vapors from the receiving vessel and forcing it at high pressure into the
discharging vessel thereby establishing a smooth flow. The content of tank wagons can be ascertained by weighment
on weigh bridge before and after emptying or, alternatively, mass flow meters can be used.
Checklist for bulk LPG tank wagons at unloading locations is given at Annexure 7 II.
SAFETY PRECAUTIONS
Do not allow the locomotive to come on the weigh bridge unless its capacity is designed to take the locomotive load.
Sufficient number of dummy wagons may be used to avoid electric loco coming closer to the gantry. Maintain the
distance of 15 m from first fill point.
The first operation after positioning the wagon shall be to provide for proper earthing. Earthing shall be
disconnected just before the release of the wagon.
For connecting and disconnecting hoses, only non-sparking tools shall be used.
After the wagons are placed on weigh bridge and before the loco is detached, the hand brakes on each and every
wagon shall be applied.
Like-wise, before the wagons are moved from the weigh bridge, release brakes on all the wagons.
Do not use footwear with protruding nails.
Ensure that the lower portion of flapper bridge at wagon side is fitted with rubber or wooden padding.
Ensure that electrical continuity of the system is intact.
Ensure that all fittings on the wagons are checked physically.
Hoses shall be tested as per OISD-STD-135 and records maintained.
The loading/unloading operation shall be carried out under close supervision of authorised person.
During unloading operation, after the liquid transfer is over, the wagon pressure shall not be reduced below 1.5
Kg/sq.cm.(g).
DEGASSING OF SICK/LEAKY TANK WAGONS
Recommended Procedure
In the degassing system recommended for LPG wagons, vacuum cycle purging technique should be followed as
outlined below :
a)

Vessel should be evacuated repeatedly by a vacuum pump.

b) Vapour should be discharged through high rise vent, keeping the steam on.
c)

Maximum possible vapours should be sucked out in first step depending on the capacity of vacuum
pump/compressor. As per RDSO, vessel can sustain the full vacuum also.

d) Between the two vacuum cycles, nitrogen/inert gas should be used for breaking the vacuum.
e)

- Cycle should be repeated till the LPG concentration is found below the end point of LPG (for
butane, it is 4% by volume when purging is done by nitrogen). Periodically, samples should be drawn from
suitable location and analysed for LPG concentration.

f)

Finally the vessel should be flushed with air to displace the nitrogen. Barrel should be tested finally with
explosive meter to ensure that hydrocarbon concentration is below 10% of LEL.

STORAGE OF BULK LPG

Precautions for storage of LPG in bulk :
A. Liquid level in the vessel shall not exceed the permissible limits. Filling shall not exceed safe permissible
filling ratio.
B. Vessel shall be inspected daily for any LPG leakage and corrective action taken.
C. All gauges, viz. High level alarm, measuring gauges, pressure gauges, temperature gauges should be kept
in operating condition at all times and be checked daily.
SAMPLING AND DRAINING
SAMPLING
a)

Sampling is primarily required at supply locations i.e. Refineries, Gas Processing Plants, Import Terminals,
etc. Sampling of LPG for different analytical tests shall be carried out in accordance with IS:1448. During
handling of LPG samples, the following safety precautions shall be followed :

b) Special sampling bombs shall be used for LPG sampling. Arrangement of rupture disc or any other suitable
safety relief device shall be incorporated in the sampling bomb.
c)

Sampling bombs shall be inspected periodically and tested hydrostatically at regular intervals. Record of
such inspection/test shall be maintained.

d) Sample bombs shall be earthed effectively before and during discharge of sample.
e)

LPG samples shall be collected only in open/ventilated areas and the person taking the sample shall stand
on the windward side.

f)

The sampler shall wear protective goggles, hand gloves, shoes etc. while taking samples.

g) Samples, after collection, shall be properly labeled and kept at designated place.
h) Sampling of LPG should preferably be done in bombs with provision of pre-charge at one end. This will
not only eliminate the possibility of undesirable presence of air in the bomb, which may become a safety
hazard, but also minimises flashing of sample during collection, thereby providing a truly representative
sample.

DRAINING
a.

Storage vessel should be drained regularly for its water content, sediments, caustic contents etc.
Draining operation should be carried out under the supervision of an authorised person.

b.

For draining of water from LPG vessels , following procedure shall be followed :

c.

The valve nearer to the vessel shall be opened first and closed. Then, draining shall be carried out
by gradually opening the valve farther from the vessel. The operation shall be repeated till LPG
release starts.
It shall be ensured that the drain outlet is at a safe distance from the vessel so that accidental
ignition of any escaping vapour would not expose the vessel to flame impingement.

d.
e.

It is important not to attempt removal of the entire quantity of water as considerable liquid LPG
may escape in the process. At the first sign of appearance of LPG, the operation shall be stopped.
Escape of LPG may lead to formation of ice block at the valve seat, preventing closure of valve.
This will result in escape of uncontrolled vapour to the atmosphere causing a very serious hazard.

f.

The valve shall be operated slowly to avoid ice formation.

FIRE PROTECTION FACILITIES

FIRST AID FIRE FIGHTING EQUIPMENT
PORTABLE FIRE EXTINGUISHERS
Portable fire extinguishers shall be located at convenient locations and shall at all times be readily accessible and
clearly visible.
The maximum running distance to locate an extinguisher in working areas shall not exceed 15 meters.
The top surface of the extinguisher shall not be more than 1.5 meter high.
The fire extinguishers shall be provided at various locations as under :
Area

Portable Fire Extinguisher

LPG Storage Vessel (Each)

.

2 Nos. 10 kg DCP extinguisher

LPG cylinder sheds

2 Nos. 10 kg DCP extinguishers per 200 Sq.M.Area.

LPG Pump houses

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

Tank Truck loading/ gantries

Tank Wagon loading/ unloading gantries

of gantry.
Other Pump Houses

1 No. 10 kg.DCP Extinguisher in each bay.

1 No. 10kg DCP Extinguisher for every 15/20 meters
2 Nos. 10 kg DCP extinguishers

Office/Canteen/ Stores

2 X 10 kg DCP extinguishers in each building

WHEELED/ MOBILE FIRE FIGHTING EQUIPMENT

1 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.
The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based or Sodium Bicarbonate as per
OISD-GDN-115. Nitrogen/ Carbon Dioxide shall be used as expelling gas.
A trolley containing first aid fire protective accessories shall be readily available in the LPG plant.
HOSES, NOZZLES AND ACCESSOREIS
Reinforced rubber lined hoses (63mm) conforming to IS : 636 (type A or B) shall be provided.
The hoses shall be of 15 Meters standard length and shall be provided with Gun metal/ Aluminium alloy male &
female couplings of instantaneous pattern.
Minimum of two or 25% spare Hoses shall be stored in the LPG plant.
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.
The following accessories/ first aid items shall be provided in the plant :
1.
Fire hoses
2 nos. for each
Hose Box
2.

Safety helmets

1 for each person (min. 10 nos.)

3.

Hose Box

At each hydrant point.

4.

Stretcher with
Blankets.

Min. 2 Nos.

5.
6.

First aid Box

Rubber hand gloves
for electrical
purpose.

Min. 2 nos.
Min. 2 pairs (BIS approved)

7.

Low temperature
rubber hand gloves
for LPG emergency
as per OISD-GDN-115

4 pairs

8.

Low tem. protective

clothing for LPG
emergency.

Min. 2 sets

10.

Fire proximity suit

Min. 1 No.

11.

Resuscitator

Min. 2 No.

12. Red/Green Flags

As required

13. Self contained

breathing apparatus
with one spare cyl.
(Cap. 30 minutes)

Min. 1 No.

14. Water jel blankets

Min. 2 nos.

15. Portable Gas detectors

min. 2.
/ Explosimeter
The above are guidelines and minimum requirements of each item and can be increased depending upon the scale of
operations, statutory/ mandatory requirement of local bodies/ State Governments or any other expert body.
EMERGENCY CONTROL / ALARM SYSTEM
FIRE ALARM SYSTEM
Manual call points near to filling shed, storage area, tank truck/ wagon gantry, pump house, etc. shall be provided
and clearly marked in the installation. Operation of these points shall raise audio visual alarm in control room.
Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1 K.M. from the periphery of the
plant).
Manually operated fire sirens shall be provided at strategic places.
For fire condition the siren shall be wailing sound for minimum `2 minutes and for all clear signal it shall be straight
run siren for 2 minutes.
For Disaster condition the wailing sound given shall be repeated thrice with a minimum 10 seconds gap.
COMMUNICATION SYSTEM
Communication system like telephone/ PA or paging or walkie-talkie shall be provided.
In the hazardous areas, flame-proof / intrinsically safe telephones shall be provided.
Wherever possible Hot line connection between City Fire Brigade/ near by major Industries shall be provided.
Plant shall have a ` Mutual Aid' arrangement with near by industries.
SPECIAL FIRE PROTECTION
The most hazardous situation in LPG vessel is the possibility of BLEEVE. This usually takes place when
the vessel is subjected to external fire.
The unwetted (vapor 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. Passive measures like fire proofing/ insulation or fire retardant coating will provide protection in
the initial period of fire which is very crucial. This will give some breathing time for activating other fire
fighting measures like starting of pumps, organising people, opening of valves etc. This will also take care
of automation failure wherever it is provided.
The fireproofing of LPG storage vessel should be decided based on the risk analysis keeping in view local
considerations, availability of water and societal risk.

 The fireproofing of LPG storage vessel shall be decided based on the fire safety analysis keeping in view
local considerations, population density, availability of water, societal risk and fire protection measures
provided.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect the shell material from
overheating and consequent failure. The minimum rating for fire proofing shall be as under :
1. LPG storage vessel & connected
lines up to the fire safe ROVs
2.Supporting legs of all above

1 hr.
2 hr.

Fire proofing is not required for diagonal bracing, including tie rods, or redundant members that are not
necessary for supporting the static loads.
Before fire-proofing application, protected metal surfaces shall be prepared through such means as sandblasting and corrosion-protective primers. Particular attention shall be given to the top junction of the fireproofing with the protected metal to prevent water ingress. OISD-STD-164 on "Fire proofing" shall be
referred for details on fire proofing.
Fire water line to each sphere should be so routed that it is not exposed to direct fire. This is to protect it
from failure in the initial period when water flow has not commenced. It is recommended that riser should
be located away from bottom ROV. The horizontal run of the Fire Water line may be buried if fire
engulfment cannot be avoided otherwise. Fire proofing shall include connected LPG lines and pipe
supports within 15 M of a storage vessel or in the drainage paths.
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.
FIRE WATER PUMPS
Every Pump shall be in test run for at least 10 minimum twice in a week at the rated conditions.
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.
The Jockey pump operation shall be checked periodically. Frequent start/ stop condition of Jockey pump indicates
that there are water leaks in the system.
FIRE WATER SPRINKLER SYSTEM
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.
Testing of sprinkler system in the sheds shall be carried out by closing the outlet of the deluge valve for correct
remote operation once in a quarter.
The strainers provided in the Fire water sprinkler system shall be cleaned once in a quarter and records maintained.

TYPE OF SAFETY AUDIT AND PERIODICITY:

In view of the high hazard potential of LPG, safety audits at frequent intervals by the teams/ personnel of various
levels are advocated. Broad check lists for different recommended safety audits are given. These check lists can be
further supplemented and modified suitably to meet the specific requirements of individual plant. Recommended
minimum safety audits at different levels, their frequencies and broad check lists to be used are indicated below:Daily audit essentially shall cover the compliance of recommended operating procedures/ safety practices. Reports
of audit shall be reviewed by the Plant Manager on daily basis and corrective action is undertaken on priority
wherever required.

-----------------------------------------------------------------------------------------------S.No.

Type of Safety
By
Frequency
Audit
----------------------------------------------------------------------------------------------------------1.

Inspection Safety
Audit of LPG Installation
Electrical audit of
LPG Installation
Detailed safety audit
of LPG Installation
Inspection and
Maintenance audit of
LPG Installation
External safety audit
Of LPG Installation

2.
3.
4.
5.

LPG Plant
Safety Officer
Authorised
electrical Engineer
Multi disciplinary
team of region/ HQ
Personnel from
Inspection/ Maintenance

Daily
Annual
Annual
Annual

OISD

check list of external safety audit:

a.

Safety Organisation

b.

Security System

c.

Fire prevention/ protection system

d.

Preparedness to handle any emergency --Disaster control plan and mock drills.

e.

Skill level and training needs for HRD.

f.

Operating manual/ instructions, display of Do's/ Don'ts etc.

ELECTRICAL AUDIT OF LPG BOTTLING PLANT

LOCATION _____________

Dated ____________

AUDIT/ INSPECTION BY ______________________

-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------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 :
Doors okay and closed
Dust/soot/ cobwebs not existed
Lugs existing at each cable, termination not loose.
Visual condition of switch contact fuse etc. O.K.
Control wiring condition satisfactory.
Jumper condition between bus and distribution okay.
Grounding OK
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
Cables are on rack
Cable deck clear
Sealing of duct
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 :
Grounding OK
No oil leak
Silica gel OK
Oil level OK
Terminal box earthing OK
Oil/winding temp. OK
Periodic oil quality test conducted.
A-15 Whether location/type of transformer in conformity with area classification drawings.
A-16 Housekeeping is good.
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.
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.
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.
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.
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 :
Is gasket present ?
Is glass cover in good condition ?

Is control gear condition OK

-------------------------------------------------------------------------------------------------------------------------------S.No.
ITEM DESCRIPTION
AUDITORS REMARKS
1
2
3
-------------------------------------------------------------------------------------------------------------------------------D-05 Is earthing electrode of mast OK and its
connection with mast proper ?
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.

ELECTRICAL SAFETY AUDIT

LOCATION: LPG storage / / LPG bulk filling / cylinder filling areas/ Hexane loading
AUDITED AS PER OISD STD-144.
ELECTRICAL OBSERVATIONS:
a.

Electrical Junction box, rainhood cover corroded in hexane loading area.

b.

Hexane filling hose not bonded.

c.

The unwanted loose electrical cable found lying near LPG BFS- L 20 in between sphere compound wall
and bulk loading point.

d.

Isolated Junction box and cables to be removed near I /C SS-7A -MCC-1-F3-3.

e.

Cable dressing is to be done in east of bulk loading point.

f.

Electric cable going through water culvet GCV-3.

g.

Base support found damaged in LPG lamp post 716-L-03.

h.

Rainhood cover missing in the two junction boxes on the north of sphere 718.

i.

Rainhood cover found in loose condition in junction box near 20-MG 718 B.

j.

Base support found damaged in lamp post LPG 718- L-08.

k.

Rainhood covers missing in junction box 20 MG 718-A.

l.

Supply cable tray corroded and not properly dressed in junction box 718 A / 718 B.

m. Electrical cable trench is to be properly covered in north of 20 MG-329-A.

LOCATION: 6.6 MGR,SUBSTATION 7A/7B&6.

AUDITED AS PER OISD STD-144
ELECTRICAL OBSERVATIONS:
The junction box found in open condition in IOCL Co-ordination office wall facing on the road 9.
Earthing found disconnected in motor 20 GM-387 BN-Wax.-ATLF
6.6 MGR
The lighting cable not routed properly (zigzag condition) on pump bay OF 6.6 MGR.
Junction box found in open condition on 23-L-08.
Earthing found disconnected on 23 G-1 B.
Junction box found open condition and rainhood corroded near 23 G-02-A.
Lighting junction box was found with temporary cover on 23 L-09.
Two motors left abandoned south of 23-G 22B and terminal cables found exposed.
Start and Stop switch came out of its position in 23 G 22B.
Motor body not earthed in 23 G 52C,D.
SUBSTATION 7A/7B&6.
Painted line diagram of power & lighting distribution not provided as per
OISD STD-144 in all the above substations.
Electric cable came out of the rack opposite to SS-7B along the road 9.
Lighting cable from SS-7A was routed above ground level upto materials building compound wall.
Earthing pit covers totally damaged in front of SS-7A,B and also in open condition.
Lighting switch box open condition inside SS-7B.
Flooring Rubber mat not available in front of MCC-3 and LDB on SS-7A.
Roof exposed above MCC-2 and tarpaulins kept on the panel in SS-7A.
Cable supply board covers missing in Logicstat isolation transformer on SS-7A.
Supply cable on redundant motor lying on the floor for quite long distance near
20-G 312.

 Cables found inside water culvert F CV-13 and adjacent one opposite to ROV-803-20 along the road 9.
Excess cables are lying near the culvert FCV-12 along road 9.
Redundant panel boards and tube light fittings dumped in the technician room of SS-6.
Many Panel boards is in off and doors found in open condition in SS-6.
(As per OISD-STD-144 ,Shall not be kept open)
Switches are provided in panel boards 3.4,4.2,4.5 instead of isolators in SS-6.
Roof exposed above panel boards and tarpaulins provided in SS-6.
The used cable wires kept below the stairs at the south entrance of SS-6.
Cable trench at the south entrance of SS-6 is not covered.

RECOMMENDATIONS:
1)
2)
3)
4)
5)
6)
7)
8)

The unwanted loose electrical cable should be properly disposed.

Isolated Junction box and cables to be removed
Proper bonding must be done in hexane filling area.
Base support must be strong..
Rainhood must be covered in junction box.
Care must be taken to avoid corrosion in junction box, rainhood, electric cables
Supply cable tray must be properly dressed.
Earthing connection must be done properly.