LPG Ops Manual March-2014-R2

LPG
Operations
Manual
Revision : 2.0
Version : 0.0
Contents
1. INTRODUCTION
2. STATUTORY REGULATIONS
3. PROPERTIES, CHARACTERISTICS AND HAZARDS OF LPG
4. SAFETY AT LPG PLANT
5. FIRE PREVENTION AND CONTROL
6. BULK STORAGE AND HANDLING FACILITIES
7. PLANT OPERATIONS: BULK LPG
8. LPG CYLINDERS, RELATED EQUIPMENT
9. STATUTORY TESTING OF LPG CYLINDERS
10. INSPECTION AND MAINTENANCE
11. MEASUREMENT AND STOCK CONTROL
12. QUALITY CONTROL
13. ADMINISTRATION
14. TRAINING
15. ANNEXURES
1
INTRODUCTION
ACT WITH CARE-

NEVER TAKE CHANCES-
The safety of thousands of
INDANE users depends upon
The way you handle LPG
Operations at the Plant

LPG OPERATIONS MANUAL
LPG CHAPTER TITLE: CHAPTER No.

DEPARTMENT 1
INTRODUCTION PAGE No.
March 2014 1-1
1.1 BACKGROUND
1.1.1 In earlier years when LPG was introduced in India in the kitchens for the
purpose of cooking, the average consumer was very much hesitant to
accept LPG as a cooking fuel. Presently, LPG has become an essential
commodity in everybody's life. LPG has proved to be safe, environment
friendly, economical and easily available fuel in the kitchens. Now LPG is
going to be closer to our day – to – day life by its use in automobiles also.
1.1.2 The main sources of availability of LPG are:
 Refineries
 Fractionators
 Imports of commercial propane and butane ( blended on
shore to LPG specifications) to bridge the gap between supply
and Demand.
The list of above LPG sources in India and production levels is given at
Annexure No. 1A. Import port locations are given at Annexure – 1B
1.2 GROWTH OF VOLUME
1.2.1 LPG was first marketed in India in the mid-fifties by the multi-national oil
companies, which were having marketing operations in India. The
bottling operations were, then, mainly confined to Refinery plants and
marketing operations limited to nearby areas.
1.2.2 Though IOC, under Public Sector, started functioning in the year 1959, it
actually started marketing of LPG in the year 1965 with the brand name of
"Indane" through its only bottling plant at Barauni Refinery, which had very
limited bottling capacity.
1.2.3 LPG marketing in India had no noticeable growth till 1980-81. However,
during mid-eighties, there was a tremendous spurt in the marketing of LPG
due to increase in the refining capacity in various refineries and also
availability through Bombay High and Assam Gas fields.
1.2.4 In the early eighties, the total number of customers in the country was
around 30 lacs and the LPG sales was around 4 lacs MT per annum. After
two decades, there is a multifold increase both in numbers of customers

DEPARTMENT 1
March 2014 1-2
and in LPG sales. As on 1st April 2001, there were 286 lacs of customers
belonging to IOC (MD) and 579 lacs of customers on Oil Industry basis.
LPG sales on account of IOC stood at 3,237 TMT per annum as on 31st
march 2001 and 6,609 TMT for entire Oil Industry.
As on 1st April 2013, there are 6467 distributors including 944 RGGLV( Rajiv
Gandhi Gamin LPG Vitrak) distributors enrolled with IOC (MD) catering to
7.34 Crore customers as compared to 12610 distributors including 2055
RGGLV distributors on Oil Industry basis catering to 15.04 Crore Customers
1.2.5 During 2012-13 about 1.32 crore of customers were enrolled by the Oil
Industry.
1.2.6 As per the Oil Industry figures, IOC’s share was 47.3 percent as on
31.03.2013 . The number of LPG bottling plants being operated by IOC’s
Marketing Division has increased to 88 Nos. as on 31.03.2013. with
aggregate annual bottling capacity of 6793 TMT including 143 TMT from
two bottling Plants operated by M/s CPCL and M/s OIL, Duliajan but
marketed by IOCL..
The list showing the bottling capacity and tankage of IOC’s bottling
plants as on 31.12.2013 is given in Annexure No. 2
1.2.7 In the initial stages, it was customary to fill LPG cylinders only at LPG
bottling plants within the Refineries. On account of economic and
logistic considerations, it became necessary to set up more number of
LPG bottling plants at different locations which could receive LPG in bulk
from the refinery points and bulk LPG storage installations of GAIL and
ONGC
and bottle the same for distribution in the surrounding areas. This type of
arrangement was primarily made with a view to reduce the marketing
costs by minimizing the cost of transportation and reducing the customer
/ cylinder ratio.
1.3 GRADES MARKETED / TYPES OF SALES

1.3.1 LPG, presently being marketed by IOC, is a mixture of commercial butane
and propane having typical specification as detailed in Chapter No. 3.

DEPARTMENT 1
March 2014 1-3
1.3.2 IOC markets LPG in bulk as well as packed supplies as under:
I. Bulk supplies to all Industrial customers through bulk tank trucks ex –

MI supply basis.
II. Packed supplies to all domestic users through a network of LPG
Distributors.
III. Packed supplies to commercial installations through LPG Distributors
(E.g. Hotels) and also directly.
IV. Auto LPG supply to Auto LPG Dispensing Stations ( ALDS )
1.4 OBJECTIVES
1.4.1 In view of the rapid expansion of LPG bottling operations being planned in
the coming years as detailed in Section 1.2 above, it is all the more
necessary to issue this Manual to provide field personnel adequate
knowledge of correct operating and safety practices.
1.4.2 The manual is intended to enable the field personnel to carry out their day
to day operational activities more effectively, efficiently and safely by
applying correct operating practices and procedures.
1.4.3 The manual is intended to achieve uniformity in operating practices at all

IOC’s LPG plants.
1.5 CLARIFICATIONS
1.5.1 Any additions or alterations to the texts of the manual will be issued only
by LPG Operations Department, Head Office. The same must be filed
serially in the manual folder itself. Instructions of transient nature will,
however, be issued through circulars.
1.5.2 This manual does not replace or supersede in any way the data /
instructions contained in the followings :
(a) HS&E manual (IOC)

(b) Engineering Manuals (IOC)
(c) OISD Guidelines and Standards
(d) Any other instructions pertaining to other aspects of LPG, other
than plant operations (e.g. Engineering, Accounting, Sales,
Technical, supply and Distribution etc.)

DEPARTMENT 1
March 2014 1-4
(e) Statutory Rules in force (e.g. The Gas Cylinder Rules, 2004; the
Static and Mobile Pressure Vessels (unfired) Rules, 1981
(amended in 1998); relevant Indian Standards/ Codes; Factory
Rules etc).
1.6 SCOPE
1.6.1 This manual covers the guidelines for correct operating procedures and
related activities within LPG bottling plants to ensure safe and efficient
working. The areas covered are :
(a) Properties of LPG
(b) Physical operations within the LPG plants covering :
(i) Receipt (bulk / packed)

(ii) Storage (bulk / packed)
(iii) Filling (bulk / packed)
(iv) Deliveries (bulk / packed)
(c) Operation, Inspection and maintenance
(d) Other related topics like safety, fire prevention and control,
statutory testing of cylinders, quality control, administration, training
etc.
1.6.2 The manual is intended to cover only operational aspects at the plants
and is not intended to serve as a code or a guideline for standard facilities
or equipment required at the plants. In certain cases, brief description of
the design aspect is covered only with a view to explain its relevance to
the operations.
1.6.3 The purpose of the manual is to provide a general guidance in safe

practices for storing, handling and transportation of LPG. Majority of the
manual covers the recommendations for safe practices rather than a set
of rigid rules. It must be stressed that in determining any required safe
procedure, the effect of any unusual circumstances, on which it is
impossible to generalize, should receive due consideration.

DEPARTMENT 1
March 2014 1-5
1.6.4 The manual is primarily intended for use at IOC's bottling plants operated
by the Marketing Division and personnel connected with their activities.
1.7 MANUAL REFERENCE GUIDELINES

1.7.1 It is recommended that before going through other chapters, “ The
Glossary Of Terms” given in Annexure No. 3 may be referred. This would
greatly help in understanding various terms used in the text of the
manual. The words mentioned in the “Glossary of Terms” are used in the
manual to interpret the meaning shown against each in the “Glossary of
Terms” irrespective of any other meaning of the words which may have in
other connections.
1.7.2 It is also recommended that the Properties, Characteristics and Hazards of

LPG as detailed in Chapter No. 3, are studied carefully and understood
properly.
1.7.3 Throughout the manual, the term “LPG” is used to indicate both the
phases; i.e., liquid and vapour. Liquid phase is expressed as liquid LPG
and vapour phase as LPG vapour.
1.7.4 Unless otherwise specified, the term "IOC’s plants" is used in the text of the
manual to cover only the plants owned and operated by IOC Marketing
1.7.5 It should be understood that every rule in the manual has been
included with a specific purpose and must not be ignored no matter,
howsoever, it may appear to be as unnecessary under certain
circumstances.
Strict observance of rules will ensure that safe operating practices

are followed while handling LPG and thus ensure safety.
1.7.6 If any topic is not understood or if there is some doubt, reference should
be made to the concerned State Office / Regional Office / Head Office.
1.7.7 Key points have been printed in bold letters to lay emphasis. Repetition of
certain points in various chapters may appear unnecessary but has been
deliberately done to lay emphasis.

DEPARTMENT 1
March 2014 1-6
1.7.8 The emphasis on safety throughout the manual should not be

misconstrued to mean that LPG is a dangerous product. Being a fuel, it is,
of course, flammable but is not dangerous at all, if handled with due care
and common sense.
BACK
2
STATUTORY REGULATIONS
All regulations pertaining to

LPG are aimed at SAFETY – safety
Of the Plant, Equipment and
People; and that include YOU


DEPARTMENT 2
STATUTORY REGULATIONS PAGE No.
March 2014 2-1
2.1 GENERAL
2.1.1 LPG plant operation must be carried out in accordance with all statutory
regulations in force. Presently, LPG plant operation in India is mainly
governed by the following regulations :
(a) The Gas Cylinder Rules 2004.
(b) Static and Mobile Pressure Vessels ( Unfired ) Rules 1981

(amended in 1998) under Indian Explosives Act 1884.
(c) The Factory Act 1948 (amended in 1987).
(d) Indian Electricity Rules with latest amendments.
(e) The Legal Metrology ( Packaged Commodities ) Rules, 2011 under

Legal Metrology Act, 2009.
(f) Liquefied Petroleum Gas (Regulation of Supply and Distribution Order

) 2000.
(g) The Motor Vehicles Act 1988 with latest amendments. & Central
Motor Vehicles Rules, 1989
(h) Contract Labour ( Regulation & Abolition) Act, 1970 and Contract
Labour ( Regulation & Abolition) Central Rules 1971
(i) Environmental Regulations :
i. Water (Prevention and Control of Pollution) Act 1974 (amended

up to 1988).
ii. Air (Prevention & Control of Pollution act 1981) (amended up to

1988).
iii. The Environment (Protection) Act 1986 and subsequent

amendment ( current amendment 1991 ) and Environment
(Protection) Rules 1986
iv. Manufacture, Storage and Import of Hazardous Chemicals

Rules 1989.

DEPARTMENT 2
March 2014 2-2
v. EIA Notification 2006.
(j) Recommendations of various committees :
i. Vasudevan Committee 1983 Ministry of Energy (Department of

Petroleum).
ii. Expert committee review of safety and operating procedures

in LPG facilities 1986 (Ministry of Petroleum & Natural Gas).
iii. ( Sudha Joshi committee for better services to LPG users 1987 (
Ministry of Petroleum & Natural Gas).
(k) Various OISD standards / guidelines.
(l) Indian Standards manuals for testing of LPG Cylinders in circulation

(Periodic checking).
(m) Other Indian Standard publications issued by Bureau of Indian

Standards (BIS).
It is important to note that there is always a possibility of

amendments/Revisions in the Rules/Acts or new Act/Rule may be
introduced applicable to LPG Plant Operations. All latest
revisions/amendments of relevant Rules/Acts/Standards shall be
applicable at all times. Officers working at Plants must keep themselves
updated on the latest revisions in the applicable Rules/Acts/Standards
etc. to ensure adherence to the same,
2.2 SAFE CUSTODY

2.2.1 The Plant Manager must ensure that the supervisory personnel at the
plant reads and correctly understands all the statutory and other
regulations. Operating department, including personnel from support
services must ensure safety in all activities of handling LPG on continuous
basis. Copy of all applicable Guidelines, Licenses, Certificates & Statutory
Rules & Regulations must be available at the Location and kept under
Safe custody.

DEPARTMENT 2
March 2014 2-3
2.3 LIST OF TOPICS
2.3.1 The List of various topics relevant to LPG operations covered in the
publications is listed under Clause No. 2.1.1.
2.4 LICENSES & CERTIFICATES

2.4.1 No facility should be constructed without construction approval &
commissioned without valid license and certificate as specified in the
relevant statutory regulations.
2.4.2 Copies of all licenses and abstract of Statutory Regulations / Acts must be
displayed in the office premises duly secured.
2.4.3 The licenses must be renewed on time and any queries raised on the
renewal application by the concerned authority must be replied to within
stipulated time to ensure speedy renewals..
2.4.4 A general list of various Statutory licenses / certificates is given in

Annexure No. 4. The list excludes licenses / certificates that may be
required as per state / local regulations. It may be noted that the list is
illustrative and not exhaustive and does not include test certificates of
Facility and equipment. Each plant should prepare and maintain an
exhaustive list of all licenses / certificates to verify that they exist at the
plant and also to monitor periodic renewals.
2.4.5 Proper record of test certificates of other installed facilities with

correct periodicity should be maintained at the plant as desired by the
various OISD guidelines and other Statutory Regulations / Acts /Rules. No
facility shall be allowed to operate, unless and until it is properly tested
and the test certificate is available.
3
PROPERTIES , CHARACTERISTICS AND

HAZARDS OF LPG
Understanding properties, characteristics

and hazards of LPG is the first
towards understanding LPG operations and
is the key to the safety of the Plant
and the people working around


DEPARTMENT 3
PROPERTIES & PAGE No.
March 2014 3-1
CHARACTERISTIC OF LPG
3.1 WHAT IS LPG ?
3.1.1 The term applies to a mixture of certain light hydrocarbon predominately

C3 & C4, derived from petroleum & natural gas which are gaseous at
ambient temperature and pressure, may be condensed to a liquid state
at normal ambient temperature by the application of moderate pressure
or by cooling to temperature beyond their boiling point at ambient
pressure and conforming to IS : 4576 or IS: 14861( Auto LPG )
.
3.2 CONSTITUENTS
3.2.1 LPG mainly consists of the following :
(a) Commercial Butane.

(b) Commercial Propane.
(c) A mixture of commercial Butane and Propane.
3.2.2 LPG widely marketed in India falls under the category (c), i.e., A Mixture
of Commercial Butane and Commercial Propane, each of which can be
either a mixture of saturated and unsaturated hydrocarbons. Their
compositions are not rigidly specified and they vary from one refinery to
another, depending upon the type of crude oil, refining process, etc.
3.3 TYPICAL SPECIFICATIONS

3.3.1 LPG marketed in India is governed by Indian Standard Code IS: 4576 and
by IS:14861( Auto LPG ). Specification for LPG and Auto LPG as per IS
4576 & IS 14861 respectively are given in Annexure No. 5.
3.3.2 Typical values of properties of Propane and Butane are given in

Annexure No. 6

DEPARTMENT 3
March 2014 3-2
3.4 PHYSICAL AND CHEMICAL PROPERTIES

3.4.1 DENSITY OF LIQUIDS
(a) It is defined as mass of unit volume of a substance at a given

temperature. It, therefore, implies that while reporting density, the
units of mass, volume and temperature should be stated. The SI unit
for density is Kg/m3
(b) Since the density of water is 1 gm/cm3 or 1000 kg/m3, and the
density of liquid LPG is about 0.55 gm/cm3, the latter is about ½ as
heavy as water. The density of the liquid is approximately half that of
water and ranges from 0.510 to 0.580 gm/cm3 @ 15 oC.
(c) The liquid density of LPG is important to determine the safe level to
which the containers can be filled i.e., to calculate the maximum
permissible filling capacity.
(d) The density range of liquid LPG for various temperatures is as under:
Density ( gm/cm3)
Temperature ( C)
Propane Butane
0 0.522 to 0.531 0.587 to 0.596
(+)10 0.508 to 0.517 0.576 to 0.585
(+)15 0.500 to 0.510 0.570 to 0.580
(+)20 0.492 to 0.502 0.564 to 0.574
(+)30 0.476 to 0.487 0.552 to 0.562
(+)40 0.458 to 0.470 0.539 to 0.550
(+)50 0.440 to 0.454 0.526 to 0.537
3.4.2 DENSITY OF VAPOURS
(a) It is defined as the mass of substance occupying a unit volume at a

stated temperature and pressure. While reporting the density of
vapour, the units of mass and volume used and the relative
temperature and the pressure must, therefore, be stated explicitly.
The vapour density is normally expressed in terms of Kg/m3 (at a
given temperature and pressure).

DEPARTMENT 3
March 2014 3-3
(b) Relative density is used to indicate the density of the gas in relation
to that of air at the same temperature and pressure. If the relative
density is greater than unity, the gas is heavier than air. LPG vapour
is about 1 ½ to 2 times as heavy as air. As a result of this property,
any leakage of LPG tends to settle down at the floor level
particularly in depressions, pits, drains, etc. Floor level ventilation to
disperse the gas and thereby prevent accumulation are, therefore,
most important.
(c) The ranges of vapour density of Propane and Butane at different

temperatures are given below:
Vapour density at Pressure of 760 mm of

Temperature mercury (10.33 m. of water)
Kg/m3
C Propane Butane
0 1.8 to 2.0 2.4 to 2.7
(+)15 1.7 to 1.9 2.3 to 2.6
(+)20 1.7 to 1.9 2.25 to 2.5
(+)30 1.6 to 1.8 2.2 to 2.4
Density, Specific Volume and Specific Gravity for Commercial Propane

and butane is summarized in the table below:
At Vap. Pressure Propane Butane
Liq Vap Liq Vap

Density, Kg/m3 15o C 510 15.3 580 5.62
Sp. Vol. m3/Ton 15o C 1.96 65.4 1.73 178
At Atmospheric Pressure
Density, Kg/m3 0o C -- 2.0 -- 2.6

Density, Kg/m3 15o C -- 2.0 -- 2.5
Sp. Gravity (water=1) .510 -- .580 --
Sp. Gravity ( Air=1 -- 1.5 -- 2.0

DEPARTMENT 3
March 2014 3-4
3.4.3 CO-EFFICIENT OF VOLUMETRIC EXPANSION
(a) The co-efficient of volumetric expansion indicates the change in

volume per unit volume of liquid for each degree of temperature
change. Its value varies slightly with temperature.
(b) Values of Co-efficient of cubicle expansion at 150 C are 0.00324 for

propane, 0.00230 for the butanes, both measured over the
temperature range, 10- 37.70C. Thes are of order of 100 times that of
steel. The rate of expansion or contraction also varies depending
upon the composition of the product. In the case of Propane, the
expansion rate between 0C and (+) 400C is approx. 13.2%, whereas
the expansion rate of Butane for the same temperature variation is
approximately 8.0 %. In general, it may be said that the lower the
density of the liquid greater is the rate of expansion or contraction.
(c) The above fact has to be taken into account in arriving at maximum
filling density pertaining to liquid storage vessels. Filling density is the
ratio of maximum liquid LPG content to water capacity of vessel at
150 C. LPG container must only be filled to a certain volume in order
to leave sufficient space for LPG expansion in case of rise in
temperature.
(d) While filling LPG container or while measuring a specific volume of

LPG liquid, it may be necessary to determine the volume of liquid at
a temperature other than the one that exists at the time of filling.
Therefore, through the use of volume correction factors, volume of
the different products may be pre-determined at a base
temperature or may be projected to the volume at some other
temperature. (ASTM table-54 of metric edition can be used for this
purpose).
3.4.4 MELTING OR FREEZING POINT
LPG can exist as a liquid over a wide range of temperatures. The lowest
temperature in the range at which liquid assumes the solid state is known
as the melting point. The value for propane and butane (the main
constituents of LPG) are –187 0C and – 137 0C respectively. It is such a low
temperature that it can not encountered in normal operations/handling
and, therefore, does not have any practical significance.

DEPARTMENT 3
March 2014 3-5
3.4.5 CRITICAL TEMPERATURE
The highest temperature at which a substance can exist in liquid state is

known as the critical temperature. Above this temperature, the
substance is gaseous and liquefaction is not possible irrespective of the
pressure applied.
3.4.6 CRITICAL PRESSURE
(a) To obtain the substance in liquid form at the critical temperature, a

certain minimum pressure is required which is known as the critical
pressure.
(b) Below the critical temperature, the substance can exist either as a
gas or as a liquid. When the substance exists as a gas and liquid
simultaneously it is stated that it is in a state of equilibrium between
gas and liquid. At any given temperature under these conditions
there will be a definite pressure.
3.4.7 BOILING POINT
(a) The temperature at which the vapour pressure of a liquid becomes

equal to the external pressure is its boiling point. This temperature
differs for the same liquid under different pressures. The normal
boiling point is the temperature at which the vapour pressure
reaches 760 mm of mercury or one atmosphere.
(b) The boiling point of LPG presently marketed is in the range of 0 C to

-180 C. At temperatures nearer to 0C or at sub-zero temperatures,
the pressure inside the container will be almost the same as
atmospheric pressure.
3.4.8 Molecular weight, Critical Temperature, Critical Pressure for Commercial

Propane and butane is summarized in the table below:

DEPARTMENT 3
March 2014 3-6
Parameter Propane Butane
Molecular weight 44 58
Boiling Point, 1 atm o C -45 -7
Critical temp o C 95 150
Critical Pressure, Atm 40 35
3.4.9 VAPOUR PRESSURE
The vapour pressure of liquid at a given temperature is defined as the

equilibrium pressure developed at that temperature in a closed container
containing the liquid and its vapour only. It is generally expressed in
kgf/cm2. In a closed container containing liquid LPG, the motion of the
escaping molecules is confined to the vapour space above. As an
increasing number of molecules strike and reenter, the point of
equilibrium is eventually reached when the rate of escape of molecules
from the liquid equals the rate of return to the liquid. The pressure exerted
by the escaping vapour at this point of equilibrium is vapour pressure.
i. The vapour pressure of LPG depends upon the temperature of the

liquid and the composition in terms of the primary hydrocarbons
present. The vapour pressure – temperature relationship for
commercial Butane and commercial Propane and related various
mixtures is shown in Diagram No. 1
ii. Vapour pressure plays an important part in the manufacture of LPG

containers as they are designed to withstand the maximum vapour
pressure likely to arise in actual use. In India, LPG Cylinders are
designed for vapour pressure of 16.87 kgf/cm2 at the assessed
temperature of 650C whereas un-insulated storage (spheres/bullets)
and transport vessels (tank trucks and tank wagons) are designed for
maximum temperature and vapour pressure of 550C and 15.85
kgf/cm2 respectively.
iii. Vapour pressure has no relation to the quantity of liquid present. If the
temperature of liquid LPG inside a container remains constant, the
pressure inside the container when full or when almost empty will
practically be the same

DEPARTMENT 3
March 2014 3-7
3.4.10 LATENT HEAT OF VAPOURISATION OF LIQUID
The latent heat of vaporisation of a liquid at a particular temperature is

defined as the heat needed to change a unit mass of liquid to vapour
without change in the temperature. It is expressed in Kilocalories per Kg.
of the substance. The temperature should also be stated since the value
decreases with an increase in temperature. Values are given below:
Latent Heat of Propane Kcal/Kg Butane Kcal/Kg

vaporisation at
-20 0 C 96 96
00C 90 92
+20 0 C 82 87
3.4.11 SPECIFIC HEAT
(a) Specific heat is defined as the quantity of heat required to raise unit
mass of a substance through a unit temperature interval. Specific
heat may also be expressed, as the amount of heat required to
warm a substance in the solid, liquid or gaseous state. Unit of
Specific Heat is Kcal/kg/o C
(b) Specific heat is expressed as the number of Kilo calories required to

warm 1 Kg of substance through 10 C. Specific heat depends, to a
degree, upon the temperature of the substance and therefore the
figure used in practice should be related to the temperature level..
For gases, moreover, it is necessary to indicate whether the pressure
or the volume is constant.

DEPARTMENT 3
March 2014 3-8
Values for Liquid at Constant pressure 1 Atm at 25oC
Propane Butane
0.60 0.57
Values for Vapour at Atm. Pressure
Propane N-Butane Iso-Butane
Cp 00 C 0.36 0.34 0.37

150 C 0.39 0.40 0.39
1000 C 0.46 0.44 0.44
Cv 150 C 0.34 0.36 0.35
The specific heat of liquid propane is about 0.6 kcal/kg/o C as compared

with a latent heat of almost 100 kcal/kg. Thus, if there is no external heat
input or loss from/to an open container having boiling propane liquid,
0.6% of its weight is evaporated for each deg centigrade fall in
temperature. The liquid continues to evaporate and cool until vapour
pressure reaches 1 Atmosphere. This is a process of auto refrigeration.
3.5 SENSIBLE PROPERTIES

3.5.1 COLOUR
Like air, LPG is colourless, therefore, it cannot be seen. However, when

liquid LPG is released from a container or a pipe it vaporizes almost
immediately. This produces a cooling effect in the surrounding air and
may cause water vapour in the air to condense, freeze and become
visible. In this way, LPG leak may be detected even though the gas itself
is invisible.
3.5.2 ODOUR
LPG by nature is odourless. However, it is distinctively odourised to give

warning in case of leakage. LPG is generally odourised by adding ethyl
mercaptan in the approximate proportion of 0.45kg/ 37.9 m3 so that its

DEPARTMENT 3
March 2014 3-9
smell is detectable in air at concentrations below 1/5th of the lower limit of

flammability. In other words, it can be smelt sufficiently before it
becomes dangerous enough to catch fire.
3.5.3 TASTE
LPG vapours are tasteless and non-toxic. Therefore, the presence of LPG
vapours in the atmosphere cannot be sensed by taste. However,
continued and heavy exposure to environment of LPG may cause mild
dizziness.
3.6 VAPOURISATION PROPERTIES

3.6.1 GENERAL
(a) LPG is generally stored or contained as a liquid under pressure and

then, by a relatively simple process, is converted into a gas or
vapour for ultimate consumption. This vaporization process of
conversion from the liquid phase to the gaseous phase is
accomplished through the addition of heat.
(b) There are two basic methods of vaporizing LPG. The most common
method is carried out within the LPG container, the product being
withdrawn directly from the container in gaseous form. In this
method the heat is drawn primarily from the surroundings of the LPG
container although some of the heat comes from the LPG
liquid and from the container’s body. The amount of gas which can
be generated by direct vapourisation is limited by :-
(i) The size of the container

(ii) The quantity and consumption of the product which it
contains
(iii) The ambient temperature surrounding of the container;
(iv) The movement of air around the container;
(v) The exposure of the container to direct sunlight
(c) The second method of vaporisation employs a special apparatus

known as ‘ Vaporiser’. In this process, liquid product is removed

DEPARTMENT 3
March 2014 3-10
from the storage container and delivered into a Vaporiser where

heat is applied to the liquid causing vaporisation within the device.
The product is drawn from the Vaporiser in gaseous form. Vaporizers
are not described in this manual since they are only involved with
the utilisation of the product and are not normally required at the
bottling plant.
3.7 COMBUSTION PROPERTIES

3.7.1 COMBUSTION PROCESS
(a) In simplest form, the combustion process in respect of LPG may be

defined as the oxidation of the product or the combination of
oxygen, usually from air, with LPG vapour to form carbon dioxide
and water vapour.
(b) One volume of liquid LPG will produce about 250 volumes of LPG
vapour and combined with 12250 volumes of air would form 12500
volumes of inflammable mixture which would cause combustion on
application of a temperature in the range of 410 0 C to 580 0 C or
more.
3.7.2 LIMITS OF FLAMMABILITY
The term is synonymous with “Limits of Inflammability”. For the combustion

process to take place in the atmosphere, it is necessary that the
proportions of LPG vapour and air be within certain limitations. In case
there is insufficient quantity of LPG vapour mixed with air, the
combination will not burn. Conversely, if an excessive amount of LPG
vapour is mixed with air in the atmosphere, combustion again cannot
take place. The minimum and maximum concentrations of a fuel gas in
gas/air mixture between which the mixture can be ignited are termed as
the lower and upper limits of flammability respectively. The range of fuel /
air mixture falling between and covering upper and lower limits of
flammability is known as “Flammability range”.
The range of flammability for LPG is considerably narrower than for other
common gaseous fuels, but the lower limit of LPG is reached quickly in
case of leakage. Upper and lower limits of flammability for common
gaseous fuels are as under :

DEPARTMENT 3
March 2014 3-11
Fuel Percentage of gas by Volume in Air / Gas mixture

Lower limit Upper limit
Propane 2.0 10
Butane 1.5 9
Coal Gas 4.0 29
Water Gas 5.0 46
Hydrogen 4.0 75
Acetylene 2.5 80
3.7.3 IGNITION TEMPERATURE
For the combustion process or burning of LPG to occur it is necessary that

an ignition source is applied. The flammable mixture of LPG vapour and
air will not ignite or explode unless the ignition source is present. The
source may be spark, flame or heated material possessing sufficient heat
to equalize or exceed the required ignition temperature, which is in the
range of 4100 C to 5800 C depending upon the proportion in which
propane and butane are mixed together. The auto ignition temperature
for propane and butane is 4660 C and 4300 C respectively.
3.7.4 CALORIFIC VALUE
Calorific value is defined as the amount of heat produced by complete

combustion of unit mass of the fuel. It is expressed in Kcal./kg. The
calorific value of LPG is very high and uniform which makes it an ideal
fuel. It is nearly 10900 -11000 K cal/Kg at 25oC.
3.7.5 VISCOSITY
Viscosity is defined as the fluid internal resistance to flow. LPG has low
Absolute or Dynamic viscosity approx. 0.15 cP at 15o C ( Centipoise)
which is much less than that of water which is unity. 1 Cp= .001 Pa-s. It is
also expressed in terms of Kg/m-s.
Kinematic Viscosity = Dynamic Viscosity/density. Its unit is cSt (

Centistokes)
1 cst= 1 mm2/s or 1 St = 1 cm2/s

DEPARTMENT 3
March 2014 3-12
3.8 BEHAVIOURAL CHARACTERISTICS

3.8.1 LPG vapour can be liquefied by compressing it. This change of state
generates heat and the product gets warmed up. The greater the
pressure, the higher the temperature of the product, and vice-versa.
3.8.2 LPG vapour can also be liquefied by refrigeration. The lower the
temperature, the lower the pressure and vice-versa. This helps in storage
of liquid LPG at near atmospheric pressure by refrigeration.
3.8.3 When pressure is released and liquid LPG changes to vapour, the change
of state requires heat. This comes from the product itself and from the
surrounding areas causing drop in temperature of both. The evaporating
product; especially in liquid form; can become cold enough to cause
frost burns on bare flesh, and to condense water vapour from the air,
forming a visible cloud.
3.8.4 LPG is stored and transported as liquid, either under pressure at the
ambient temperature (the normal method followed in marketing) or at
low temperature (refrigerated condition ).
3.8.5 The expansion of liquid LPG, when its temperature rises, is about 15/20
times greater than that of water and exceeds that of most other general
petroleum products. Sufficient ullage space for expansion of the liquid
must, therefore, be left in all storage/transport containers. Filling of
storage vessels up to 85% of its volume has been the accepted norm
among the oil industry.
3.8.6 One volume of liquid LPG will expand to approximately 250 volumes of
vapour in air. Liquid LPG, if leaks, it can create more hazards compared
to vapour leaks (Refer Diagram No. 2).
3.8.7 Liquid LPG has a low viscosity and can leak in situations in which
water/gasoline may not. It is also a poor lubricant and leaks are,
therefore, likely to occur through seals (of pumps, compressors etc.),
glands etc.

DEPARTMENT 3
March 2014 3-13
3.8.8 AUTO REFRIGERATION OF LPG
The term "Auto Refrigeration" refers to the phenomenon, which occurs

when the pressure is rapidly released from a vessel containing liquid LPG.
(a) Liquid LPG "boils" or “Flashes” as the pressure is reduced. In the

process latent heat is taken out of the liquid LPG as a result of some
part of it changing its state to vapour; and the residual liquid
becomes increasingly cooler. For this reason, when emptying out a
vessel containing liquid LPG, the pressure must be maintained in the
vessel until entire quantity of liquid is disposed-off and only vapour
remains.
(b) if “Auto Refrigeration” is allowed to occur, extremely low

temperatures may result (below the lower permissible designed
temperature for the materials of construction) which may result in
embrittlement of the container metal. Any evidence of frosting
outside of the vessel is an indication that “Auto Refrigeration” is
occurring.
3.8.9 EFFECTS OF WATER IN LPG SYSTEMS
(a) If water in the product is in sufficient quantity it may cause rust and
corrosion to the vessel which might not otherwise be affected by
the product in any way.
(b) Water in the system is subjected to freezing temperature and may

prevent the operation of internal valves. This condition may prevent
the flow of the product with the formation of ice block. Under
certain conditions, the freezing of water may prevent the operation
of self-closing valves and may lead to false assumption regarding
the closure of " valves".
(c) A regulator "Freeze-UP " is perhaps the most noticeable effect of

water in a LPG system. It is the most undesirable occurrence and
can lead to serious complications. Ice crystals start to form in the
throat of orifice, thus plugging the orifice and stopping the flow of
the gas.

DEPARTMENT 3
March 2014 3-14
(d) Realizing that the atmosphere always contains certain amounts of

water vapour or humidity a container should always be sealed with
respect to the outside atmosphere. Even though the gas contents
may have been exhausted, all valves or openings in the container
should be closed and made gas-tight to the outside atmosphere.
Manually controlled valves should always be closed tight on empty
container. The valves without closure means, which are not
manually controllable, should be capped, plugged or covered by
closure means designed for the purpose to prevent the entry of
water from the atmosphere.
3.8.10 EFFECTS OF AIR IN LPG SYSTEMS
Presence of air in LPG systems is undesirable and must be avoided for

following reasons:
(a) With LPG vapour in the system, air can form combustible mixtures
creating a fire hazard.
(b) If LPG cylinders containing air are connected to consumer's

appliances the first off - take of vapour may be incombustible
mixture of LPG vapour and air. Hence, the ignition would not be
possible initially. This could create a hazard if the cause is not
detected. If not removed, the air builds up much higher pressure
than the normal vapour pressure, thus causing unnecessary
pumping effort during the filling operations.
(c) In view of adverse effects of the presence of air in LPG systems as

explained above, it must be ensured that air is purged from LPG
systems before commissioning a new facility or before re-
commissioning a facility after repairs or pneumatic tests. This should
not be limited to LPG cylinders only but should cover pressurized
system/ equipment handling LPG such as storage vessels, transport
bullets, pipelines etc.

DEPARTMENT 3
March 2014 3-15
3.8.11 FROM ABOVE POINTS IT CAN BE CONCLUDED THAT:
 LPG is safe provided it is kept within a properly designed and sealed

system.
 LPG becomes hazardous when released to the atmosphere and
mixed with air.
 Leakage of product, especially liquid, must be prevented.
 Presence of water and air in the LPG systems must be eliminated.
 Sources of ignition must be eliminated.
3.9 BEHAVIOUR OF LPG IN CLOSED CONTAINERS

3.9.1 The quantity of LPG that may be filled in a given container depends on
the size of container; the temperature of the liquid in the container and
the maximum permitted filling density. LPG containers MUST not be
completely filled with liquid; adequate vapour space MUST be left. The
LPG vapour exerts a pressure on the walls of the container. The pressure is
dependent on the temperature and the composition of LPG in the
container. Propane has a much higher vapour pressure than Butane;
and mixture of the two has a vapour pressure between that of Propane
and Butane depending upon the percentage composition. It is important
to remember that the pressure in the vessel is independent of the amount
of liquid within it as long as it is neither full nor empty of liquid. For any
given LPG, the temperature is the only variable factor governing the
pressure.
3.9.2 As more LPG is added into a container, the liquid level rises and the
vapour space becomes smaller. This compresses the vapour, condensing
some of it to the liquid state. This condensation produces heat which
warms the remaining vapour resulting into an increased pressure. Thus,
the addition of liquid has disturbed the temperature and consequently
the pressure equilibrium. It is, however, only temporary. When filling
ceases, the production of heat ceases and the system soon returns to its
equilibrium temperature and consequently to its equilibrium pressure.
Now the vessel has more liquid in it than before but there has been no
increase in pressure.
3.9.3 The reverse of the above will occur when liquid or vapour is withdrawn
from the container. There is first reduction in pressure and more vapour is
formed by vaporization of the liquid to replace the vapour drawn off. This

DEPARTMENT 3
March 2014 3-16
vaporization requires heat, which is obtained by absorption from the

liquid itself and from the walls of the container. The absorption of the heat
results in some pressure drop, but unless the container is emptied, it again
returns to its former pressure and temperature soon after withdrawal
ceases.
3.9.4 Should the container be completely filled with liquid LPG leaving no
vapour space, even a slight rise in temperature will cause the liquid to
expand and exert an excessive pressure on the container; because
liquids are practically non-compressible. Under these circumstances a
relief valve on the container opens to discharge liquid and relieve the
excessive pressure. However, if there is no pressure relief device, as in the
case of a cylinder, or if it fails to operate, the vessel itself may be distorted
or ruptured. If liquid LPG escapes, either from the relief device or from a
ruptured container, a fire or explosion may result, if a source of ignition is
present.
A spring actuated safety valve would re-set itself when the pressure is
reduced below the valve setting and thus prevent further escape of
product to the atmosphere.
3.9.5 From the above details, it could be summarized that vapour pressure
has no relation to the quantity of liquid present. If the temperature of
liquid LPG inside a container remains constant, the pressure inside the
container when full or when empty would be practically the same.
3.9.6 The possibility of a container becoming full of liquid by an increase in

temperature is minimized by working out safe filling capacities as
explained in Annexure No. 7.
3.10 EFFECTS OF LPG UPON MATERIALS

3.10.1 EFFECTS UPON METALS
(a) Commercial LPG has no harmful effect upon steel or the majority of
metals in common use.
(b) Aluminium may be affected by traces of caustic remaining in the
LPG after the refining processes.
(c) Odourants added to LPG are non-corrosive

DEPARTMENT 3
March 2014 3-17
3.10.2 EFFECTS UPON NON-METALS
(a) The effect of LPG upon non-metallic materials cannot be

generalized.
(b) Some plastic materials becomes either soft or spongy, others

become hard or brittle,
(c) Natural rubbers are usually affected whereas many synthetic

rubbers and plastics are unaffected.
(d) An indication may be obtained of the effect of LPG upon a

particular material in liquid Pentane for 72 hours. Any change in
weight or volume or evidence of any swelling or brittleness indicates
that the material would be unsatisfactory for long term usage.
3.11 HAZARDS OF LPG

3.11.1 HEALTH HAZARDS
(a) INHALATION – VAPOUR PHASE : LPG contains no toxic components

such as carbon monoxide and is, therefore, non-poisonous. If
leakage of large amount of LPG occurs in a closed space, difficulty
in breathing and asphyxiation due to lack of oxygen can be caused
but is improbable in practice. LPG is slightly anesthetic when high
concentrations are breathed in sufficient quantities over a period of
time, resulting in stomach-upset and headache, which themselves
are warning symptoms.
(b) INHALATION – PRODUCTS OF COMBUSTION : Assuming that the

product of combustion, which is being inhaled, is discharged into a
confined area and further the combustion process is being properly
controlled, the individual would be exposed to an increased
concentration of water vapour and carbon dioxide in the
atmosphere. The water vapour naturally increases humidity within
the atmosphere and in case it is excessive, the unpleasantness
associated with excessive humidity would be noticeable. The
liberation of carbon dioxide by the combustion process may result in
deficiency of oxygen in the atmosphere.

DEPARTMENT 3
March 2014 3-18
(c) BURNS BY FREEZING : LPG in liquid form should not come in contact
with the surface of the body. It is particularly important that
contact with the liquid propane or a product with relatively high
vapour pressure be avoided. In the event that LPG in liquid form
comes in contact with the skin, the product immediately vaporizes.
During this vaporization process, heat will be absorbed directly from
the skin and flesh causing a freezing effect. The ultimate result of
freezing is usually referred to as a burn. The results may be serious.
Therefore, if the possibility of exposure to liquid LPG exists, suitable
safety gloves, safety goggles and protective clothing should be
used.
(d) BURNS BY FIRE : Burns may result from the exposure to LPG flames or
by exposure of clothing directly to appliance flames or by
mishandling of portable devices such as torches and burners. In the
type of exposure in which the LPG Flame acts as an igniter, the
severity of the burns may be dependent upon the time required to
extinguish the burning clothing. In the event of exposure of an
individual to a flash fire or explosion of LPG vapours accidentally
discharged, the burns may be direct result of LPG flames
compounded by clothing if they are highly flammable such as those
made from synthetic fibre. In general, clothing which is not highly
flammable may provide a degree of protection when exposed to a
flash fire. For example, shirt of cotton or woolen material may
provide protection against the possibility of freezing burn and
likewise may provide a type of barrier against the flame of flash fire.
As a precaution to avoid exposure to flash fire or an explosion, an

awareness of the odour of the product, the observance of “NO
SMOKING” regulations and the elimination of possible ignition sources
within the area in which possible flammable mixture may exist, can
reduce and perhaps eliminate the possibility of burn injuries.
3.11.2 FIRE HAZARDS
(a) PRODUCT DISCHARGE – LIQUID PHASE : LPG has been described as a

safe fuel because of the fact that so long as it is contained within a
cylinder, vessel, or a pipeline, fire hazard is non-existent. It is only the
accidental discharge of the product from the container, which
creates a hazard. In the event of an accidental discharge it is

DEPARTMENT 3
March 2014 3-19
possible that either the liquid or vapour may discharge. A liquid

discharge is always more serious than a discharge in the vapour
phase. In the first place the volume of the product, which may
discharge, may be considerably less in the vapour phase than the
liquid phase through the same size of opening. As liquid discharges
and vaporises, the volume of the liquid changes into vapour of
volume approximately 250 times greater and therefore, a greater
hazard exists.
It is always important to arrange equipment so that if an accidental

discharges does occur, it will be in the vapour phase.
(b) PRODUCT DISCHARGE – VAPOUR PHASE : The accidental discharge

of vapour from a container or a pipe may result in the vaporization
of liquid within the container or pipe. This process will require heat
and will in effect have a cooling action upon the container. If a
container is exposed to surrounding fire, the cooling effect caused
by the vaporization within the container can aid in preventing the
development of excessive temperatures of the container.
(c) IGNITION SOURCE
i. Flame : As a general rule it may be said that if a flame is visible

it has sufficient heat to be used as a source of ignition for the
combustion of flammable LPG vapour mixture. A flame from a
match stick is sufficient to provide temperature considerably
above that is required, for ignition.
ii. Heat : A piece of metal heated to 600 C may not be

particularly noticeable and might not attract attention.
However, so long as the metal on its surface has a temperature
in excess of the ignition temperature of flammable LPG vapour
mixture, it can provide as an ignition source. Likewise heat of a
lighted cigarette or a bidi is sufficient source to provide ignition.
iii. Electric : Source of ignition may be developed electrically

through resistance in electrical circuit which heats an element
or a portion of the circuit to a temperature equal to or in
excess of the required ignition temperature. The making or
breaking of an open switch or the disengagement of a plug

DEPARTMENT 3
March 2014 3-20
from a receptacle may cause a “Spark" which has sufficient

temperature to cause ignition.
iv. Static Electricity and Friction Sparks : Static electricity or friction

sparks may be the source of ignition for a flammable mixture of
LPG vapour within the atmosphere. Static electricity may be
caused by agitation or pumping of liquid; venting liquid to the
atmosphere; sand blasting; non-conductive belts; the contact
of separation of materials such as synthetic clothing and
action of foot wear on certain type of floorings.
Static electricity is also produced by natural causes. Static

charge is induced from lightening discharges, by thunder
clouds either directly overhead or in the distance; by dust
storms; or in rare instances from a large volume of charged air.
Friction sparks are usually caused by the striking of one hard

object against another as in the case of striking a hardened
steel tool against a pipe or a casting; hitting of a cylinder
against a steel structure.
(d) COMBUSTION
i. Explosion : Rapid oxidation or rapid burning is the cause of

explosion. It may also be accompanied by such a release of
energy that structural damage may result. The rate at which
energy is released, rather than the amount of energy released, is
the criteria of an explosion.
The distribution of LPG vapour within the atmosphere in proper

proportions and within a confined space can create an
explosion, should the source of ignition be provided.
Following an LPG explosion a fire may be caused by the ignition
of other flammable materials or a continuing discharge of gas
may burn. In some cases if the discharge of gas has been
stopped prior to the explosion, there may be no fire following the
explosion.
ii. Fire : Depending upon the circumstances, the accidental LPG

Fire may take on any number of forms. In general, a fire fed by a

DEPARTMENT 3
March 2014 3-21
liquid discharge will be seen at ground level and may be remote

from the point of actual discharge. A fire fed by a vapour
discharge may be elevated and not impinging upon tanks,
buildings, etc. The vapour fed fire would normally burn relatively
close to the point of discharge
iii. BLEVE : Boiling Liquid Expanding Vapour Explosion (BLEVE) occurs

when LPG containers are accidentally surrounded by fire. Vapour
pressure in the container rises with the increase in temperature.
At the same time, temperature of the container wall in contact
with the vapour phase also rises. The wall strength deteriorates
and eventually even though a pressure relief valve may be
operating, the stress imposed by the vapour pressure exceeds the
reduced strength of the wall. The container then ruptures and
super heated liquid is released, expands and vaporize, in fraction
of a second. As the contents of the container are flammable,
they form explosive mixtures with the air. Catastrophic damage
usually results from the spread and/or ignition of the vapours. This
phenomenon is true for any pressure vessels storing LPG, be it a
storage vessel, tank wagon bullet, tank truck bullet, or a LPG
cylinder. However, larger the vessel, larger would be the
catastrophe.
iv. PUVCE : When large quantity of LPG is released to atmosphere

and it forms vapour clouds which, when unconfined, may travel
from one place to another. Vapour cloud can ignite and burn as
deflagrations or fire balls. This is termed as ‘Percussive Unconfined
Vapour Cloud Explosion’ i.e., PUVCE in short. Even though large
quantities of LPG emission is necessary, only a fraction of this
contributes to the percussive effect (more reactive molecules
such as ethylene in much smaller quantities). Rare though PUVCE
may be, their damage is large and sometimes enormous.
3.11.3 OTHER HAZARDS
(a) LPG is usually stored as a liquid under pressure. Leakage to

atmosphere, especially as liquid, will result in rapid vaporisation
creating large volumes of flammable vapour. Because LPG is
heavier than air, it will tend to flow along the ground or through

DEPARTMENT 3
March 2014 3-22
drains, and will sink to the low level of the surroundings. Unless efforts
are quickly made to disperse the accumulation of vapour it may
under normal conditions remain there for a long time, with the
possibility of fire through a source of ignition at some distance away
from the source of leakage.
(b) A very small proportion of vapour in the air will give rise to a
flammable mixture, which can cause fire, if source of ignition is
present.
(c) Thermal Expansion of LPG can lead to very serious hazards. LPG
streams under pressure in pipelines and equipment expand rapidly
as a result of only moderate increase in the temperature. For
example, the sun shining on a blocked line full of LPG, not provided
with a relief valve to protect against thermal expansion, can lead to
excessive pressures being built up within the line with eventual
rupture of the pipe.
The problem of thermal expansion also applies to laboratory sample

bombs where instructions must be clearly given not to fill the
container fully. The container should be filled up to a limit which
permits liquid expansion due to a normal rise in temperature without
danger of over- stressing the container. The maximum liquid level is
usually marked on the sample bomb.
(d) The low boiling point of LPG is liable to create a number of

operation hazards as under :
(i) The vaporization of LPG results into considerable cooling and

can lead to temperatures below the freezing point of water.
This must be clearly recognized while depressurizing
equipments containing liquid LPG and while draining water
from vessels containing liquid LPG.
(ii) While draining water from LPG storage vessel, vaporization of

LPG resulting from the pressure drop across the throttle valve
may result in the freezing of water making it impossible to close
the valve. The procedure for draining water from LPG storage
vessels is described in greater detail in Chapter No. 7.

DEPARTMENT 3
March 2014 3-23
(e) The relatively low viscosity of LPG (0.3 CS at 45 0 C) adds to the

problem of containing it within the pressurized system. LPG will leak
through the flanged joints and glands more rapidly than Kerosene or
Naphtha.
(f) When pyrophoric substances come in contact with air, they react
with the oxygen generating heat. If the heat is not dissipated, the
temperature would rise high enough to ignite a flammable mixture.
In Oil and Gas industry, major source of pyrophoric substance is iron
sulphide. Pyrophoric iron sulphide is a corrosive product that may
form on the wall of the vessels, pipes, flare headers, etc. which
contain or handle hydrocarbons containing sulphur compounds
(e.g. hydrogen sulphide, mercaptan etc.)

DEPARTMENT 3
March 2014 3-24
DIAGRAM-1

DEPARTMENT 3
March 2014 3-25
DIAGRAM-2
HAZARD OF LIQUID LPG LEAK COMPARED TO VAPOUR
Produces
Combines 12500 Vol.
with of
Produce
12250 Explosive
250 Vol. Vol. of Air Mixture
1 VOL of LPG
of LPG Vapours
Liquid
4
SAFETY AT LPG PLANT

If you disregard so much as one of the safety rules, you subject yourself
and others to the risk of accidents whose extent cannot be foreseen and
which can even cause a catastrophe. Therefore, adhere to safe practices.
NO SAFETY, KNOW ACCIDENTS

KNOW SAFETY, NO ACCIDENTS


DEPARTMENT 4
SAFETY AT LPG PLANT PAGE No.
March 2014 4-1
4.1 GENERAL
4.1.1 Because of the nature of the product handled, every activity at LPG
plant is closely connected with safety. With the increased public
awareness of safety and various statutory rules and regulations becoming
more stringent, currently safety plays a dominant role in the plant life
from the concept of commissioning and subsequent operation and
maintenance. It is, therefore, essential that all the personnel working in
the plant, including contractors’ work force and transport contractors’
crew are fully aware of the possible hazards in the plant. if the
characteristics of LPG are known, it by itself provides the guidelines as to
how it can be safety handled. The following factors contribute to the safe
operation of an LPG Plant :
(a) Sound engineering practices in the design, fabrication, installation

and maintenance of facilities.
(b) Careful selection and correct use of equipment.
(c) Observance of sound operating practices, statutory and security

regulations.
(d) Regular training and guidance to all personnel working in the

plant, including contractors' work force, transport contractors' crew
and security personnel as per OISD-154.
(e) Good house-keeping.
(f) Constant supervision and alertness.
4.1.2 All personnel working in the plant, should have sound knowledge not only
of properties and behavioral characteristics of LPG but also of the correct
operation and maintenance of the facilities provided therein.
4.1.3 All supervisory personnel working in the plant should be well conversant
and ensure compliance of the safety and statutory procedures at all
times.
Plant Manager should ensure that suitable instructions are issued to

both corporation’s and contractors’ personnel identifying the action

DEPARTMENT 4
March 2014 4-2
to be taken by each one in any emergent situation. This could be

achieved by the display of Organisation chart / posters and issuing safety
booklets to all depicting not only for actions to be taken during fire but
also for other likely emergencies.
4.1.4 There should be a system for managing safety comprising of the following
basic elements :
(a) Safety Organization

(b) Employees’ participation
(c) Safety hazard information on production process
(d) Operating procedures
(e) Training
(f) Security
(g) Pre-start up safety review
(h) Mechanical integrity
(i) Work permit
(j) Incident investigation
(k) Emergency planning and response
(l) Compliance audit
(m) Road transportation
4.1.5 SAFETY ORGANISATION
(a) Safety Policy : Organisation’s safety policy duly approved by the

Board of Directors is to be available with each plant. It contains
intentions and commitment from the top Management. It should
be made available to all employees in a language which can be
easily understood. It should be displayed at all LPG bottling plants.
Same is given below

DEPARTMENT 4
March 2014 4-3
Safety, Health & Environment Policy
Indian Oil Corporation is committed to conduct business with strong

environment conscience ensuring sustainable development, safe workplaces
and enrichment of quality of life of Employees, Customers and the
Community. We, at IndianOil, believe that good S, H & E performance is an
integral part of efficient and profitable business management. We shall :
 Establish and maintain good standards for safety of the people, the
processes and the assets.
 Comply with all Rules and Regulations on Safety, Occupational Health

and Environmental Protection.
 Plan, design, operate and maintain all facilities, processes and

procedures to secure sustained Safety, Health and Environmental
Protection.
 Remain trained, equipped and ready for effective and prompt response
to accidents and emergencies.
 Welcome audit of our S,H & E conduct by external body, so that

stakeholder confidence is safeguarded.
 Adopt and promote Industry best practices to avert accidents and

improve our S, H & E performance.
 Remain committed to be a leader in Safety, Occupational Health and

Environmental Protection through continuing improvement.
 Make efforts to preserve ecological balance and heritage
.

DEPARTMENT 4
March 2014 4-4
Location Specific Safety Policy: Apart from Organisation’s Safety

policy, location specific safety policy shall also be displayed at all
locations as per prevailing HSE guidelines. Typical Location safety
Policy for a LPG Plant is given below.
Safety, Health & Environment Policy
LPG Bottling Plant <Name of Plant> is committed to conduct business with

strong environment conscience ensuring safe work places and enrichment of
quality of life of Employees, Customers and the general public at large.
We shall :
1. Maintain good housekeeping & comply with all applicable Health, Safety
& Environment laws.
2. Have a defined Fire Organisational set up with defined roles.
3. Conduct reviews of our operations as appropriate to identify hazards,

prevent incidents and continuously improve Environmental, Health &
Safety performance.
4. Encourage employees participation in the reviews.
5. Promote awareness about health, safety & environment among our

employees, contractors, transporters & TT crew through training.
6. Have Disaster Management Plan covering anticipated risks and their

management.
7. Remain trained, equipped and ready for effective and prompt response
to accidents and emergencies.
8. Conduct mock fire drills & emergency response drills at regular

intervals.
9. Carry out Regular safety inspection of location


DEPARTMENT 4
March 2014 4-5
(b) Safety Committee : Safety Committee should be formed in each

plant. Duties and responsibilities of committee members shall be
defined, as per Factories act. Tenure of committee shall be two
years. The committee should have minimum 50% representation
from workmen and Management as per Factory Act. .Committee
should meet at least once in two months or as specified by the
Corporation ( Current frequency is one month as per Circular
reference: HSE/AKD/004-1 dated 25.02.2013) and minutes of the
meeting should be recorded. Recent Safety circulars, audits and
learning from accidents / near misses, new points to improve safety
should form part of the Agenda for the safety meetings. For
Implementation of the Safety Committee recommendations, time
bound program should be developed and action taken to be
reviewed in the subsequent meeting.
(c) Safety Circle : Safety circle meeting should be conducted every

month in different operating areas involving all the employees
deployed in that area. Safety aspects applicable for the particular
operating area to be discussed during the meeting and records to
be maintained.
(d) Enforcement of Safety : In the plant, safety should be ensured by

repeatedly highlighting its utility in preventing loss of life and
property and also providing training / re-training to the employees in
safe working practice. Following modes should be followed for
enforcing safety :
(i) Work permit system as per relevant OISD standards.

(ii) Surprise checks
(iii) Mock Drills
(iv) Safe operating practices
(v) Work instructions and do’s and don’ts at workstations.
(vi) Fire organization chart for on shift and off shift.
(e) Monitoring of systems : Following checks / inspections should be

carried out for effective implementation of safety systems:
(i) Daily Safety Audit in each operating shift.

(ii) Internal audits of plant /facilities in line with OISD-STD-
144/169/145.

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March 2014 4-6
(iii) Self CAP (Constructive Appraisal of Plant) and Monthly Safety

Audit by Plant Manager.
(iv) Regular inspections by SO/HO.
(v) Testing and inspection of equipment
(vi MDT Inspection of Plants.
(f) Safety promotion : Visuals play an important role in reminding

personnel of safety information. Therefore, following
information /documents should be available/displayed in the Plant
(i) Operational procedure for all Critical activities.

(ii) Accident free record
(iii) Fire Organization chart.
(iv) Fire fighting facilities layout.
(v) Safety posters
(vi) Safety precautions at strategic locations
(vii) Safety records
(viii) DOs & DONTs at handling / storage and operation areas.
(ix) Importance of wearing Personal Protective Equipment (PPE)
(x) Safety manuals and rules and regulations
(xi) Safety newsletters and bulletins
(xii) Dissipation of incident information
(xiii) Safety competitions
(xiv) Any other safety awareness programmes
4.1.6 Employee’s participation is necessary in safe working of the plant and

they should be explained about the operation of the plant, including
safety & health hazard associated with the product (LPG) and the work
environment. Employees should be trained in the use of Personnel
Protective Equipment(PPE)
Critical procedures and instructions should be prepared in English and

Hindi as also in local language which can be understood by all the
employees.

DEPARTMENT 4
March 2014 4-7
4.2 PLANT MODIFICATIONS

4.2.1 Although the design and construction of LPG bottling plants are usually
the responsibility of Head Office / Regional Offices / State Offices, Plant
Manager, while carrying out modifications to the existing LPG plant,
should ensure that :
a) No modification is carried out without the written approval from

State Office / Regional office / Head Office. Management of
Change (MOC)approval from competent authority is to be
obtained for changes in line with MOC guidelines
b) All proposed modification(s) to LPG facilities shall comply with the

Statutory Regulations. Only after obtaining necessary statutory
approvals should any modification work commence.
c) The section of the facilities undergoing modification is completely

segregated from the other parts of the plant still in operation.
d) The section undergoing modification is completely clear of LPG

and is gas-free.
e) Such work is undertaken only through required permits.
f) All such work is carried out under constant and proper supervision.
g) Adequate number of first-aid boxes and fire-fighting equipment

are properly placed at the work site.
h) All personnel engaged on the job are fully instructed regarding

the
a. action to be taken in case of emergency.
i) Modified sections of the plant are tested to ensure that they are
free from leaks, clean and purged before re-commissioning.
j) Works like hot repairs or repairs on pressurized systems (e.g.

storage vessels, pipelines etc.) are handled only through
competent / approved contractors and re-commissioning of such
facilities is done only after third-party inspection and approval of
CCOE wherever required.

DEPARTMENT 4
March 2014 4-8
4.3 MAINTENANCE
4.3.1 The serviceability and safety of LPG plant and equipment, especially in
the long term, are affected by the standard of preventive maintenance
undertaken so as to ensure that the maintenance is carried out safely
and the benefits of effective preventive maintenance are obtained. The
details are covered in Chapter No. 10.
4.3.2 Repairs /maintenance of pressurized systems and hot-work should be

entrusted to the competent agencies -and having sufficient knowledge,
background and facilities to undertake such work, wherever required, as
per statutory regulations.
4.3.3 Whenever any work is being done, permit systems (e.g. hot-work, cold
work, working at height, Electrical permits etc.) and other safety
precautions that may be necessary, MUST be followed. The work MUST
be constantly supervised by a competent person from the Plant. Repairs
/maintenance of pressurized systems and hot-work should be entrusted
to the competent agencies -and having sufficient knowledge,
background and facilities to undertake such work, wherever required, as
per statutory regulations.
4.3.4 Whenever any work is being done, permit systems (e.g. hot-work, cold
work, working at height, Electrical permits etc.) and other safety
precautions that may be necessary, MUST be followed. The work MUST
be constantly supervised by a competent person from the plan
4.4 MECHANICAL INTEGRITY OF THE PLANT

4.4.1 While carrying out maintenance, Mechanical integrity of the plant or
the facility need to be ensured so as to perform intended activities
without the chances of its failure.
4.4.2 EQUIPMENT DATA
(a) The list of equipment and instrumentation should be compiled and

categorized for including in the mechanical integrity programme.
The list should include pressure vessels, storage tanks, process

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March 2014 4-9
piping, relief and vent systems, fire protection system components,

emergency shutdown systems, alarms, interlocks and pumps.
(b) The list of equipment should be prioritized to determine which

piece of equipment requires closer scrutiny than others.
(c) Information pertaining to the equipment should include materials

of construction, piping and instrumentation diagrams, electrical
classification, relief systems design and design codes and standards
employed.
(d) Relevant OISD standards and guidelines should be used for

developing inspection and maintenance systems.
4.4.3 NON-ROUTINE WORK AUTHORISATION
All non-routine jobs should be carried out in line with OISD–STD-105. List of
non-routine jobs should be prepared and procedures defined to carry
out them. Roles and responsibilities for work authorization, issue / receipt
of permits, handing over/taking over should be documented and
implemented. In case of any change in the procedures and practices,
system of proper authorization should be instituted.
4.4.4 MAINTENANCE PROCEDURES
The maintenance procedures should cover the safety aspect with

regard to organization of the maintenance (System of work permit and
non-routine work). Use of personal protective equipment should be
emphasized for specific maintenance activities.
4.4.5 QUALITY ASSURANCE
In the construction of new plants and equipment, it should be ensured

that equipment as it is fabricated is installed properly and is consistent
with the design specifications and the manufacturer’s
recommendations.
“As Built “ drawings together with certification of coded vessels and

other equipment and materials of construction need to be verified and
retained in the quality assurance documentation.

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March 2014 4-10
4.4.6 WORK PERMIT
In case work is required to be performed in the plant / facility by any

person other than the operating personnel of that area, a duly
authorized written work permit should be obtained by the person /
agency executing the work before commencement of the work. Based
on the nature of the risk, the work would be undertaken under different
types of permits. For example, the following jobs should be undertaken
with the duly issued hot- work permits :
Cutting, welding, Excavation, Road / Dyke cutting, Confined space

entry, Boxing up of vessel, Radiography, etc.
For further details on work permit system, OISD –STD-105 /137/192 may be
referred.
4.5 SAFE OPERATING PRACTICES –( General )

4.5.1 The details of safe operating practices are covered in the text of
individual chapters for the related operations. The basic safety points are
as follows :
a) LPG Storage / transport vessels and cylinders MUST never be

filled beyond 85% and MUST contain sufficient ullage to allow
for liquid expansion caused by specified / assessed
temperature rise. For arriving at safe-filling quantities for
various LPG containers, chapter 11 may be referred, in which
various sample calculations are given.
b) Air MUST be purged from any vessel, cylinder or pipeline

system when it is commissioned before it is filled with liquid
LPG. This is also applicable to re-commissioning of system
after pneumatic test or repairs.
c) Venting / leakage of LPG to atmosphere must be minimized.

Such operation MUST be continuously supervised. If the
venting vapor i necessary to be released without flaring, it
should be ensured that the vapour is released under
controlled conditions at a point away from the flame or other
sources of ignition.

DEPARTMENT 4
March 2014 4-11
d) Water from the storage vessels MUST be drained off regularly

and carefully under constant supervision. Instructions
regarding correct draining off procedures should be displayed
on a board near the storage vessels. The instructions should be
displayed in English, Hindi and the local language.
e) For all product movement, the receiving vessel must be

electrically bonded and the discharge vessel and the whole
system must be earthed. The bonding / earthing connection
should be made before any operation is started and should
be disconnected after all operations are over.
f) For the receiving vessel, gas-tightness and ullage should

always be checked before transferring the product into it.
g) Vessels/cylinders MUST never be filled with the product that

has a vapour pressure higher than that for which they are
designed.
h) Transport vessels / cylinders MUST be checked after filling to

ensure that they are free from leaks.
Product MUST never be filled into a container which is not

apparently suitable for the product, such as cylinder of
unknown of standards.
i) LPG MUST never be used for application for which it is not

intended.
j) Smoking, welding, cooking or any other processes which

require heat by the use of flame or resistance coils, must be
eliminated in the plant areas or wherever LPG is received or
discharged.
k) As a precaution against fire, dry vegetation and inflammable

material must be permanently removed from the areas
surrounding storage vessels and from all other areas in the
plant vulnerable to fire-risks.

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March 2014 4-12
l) Protective hand gloves MUST be worn while breaking away

any connections after unloading the tank trucks, tank
wagons etc.
m) When repairs are made on the pipelines, it must be ensured

that the valves on both sides of the section are closed tightly
and that the section of the pipeline and equipment is purged
of LPG, and made ‘gas-free’.
n) Nobody should enter into a storage vessel for inspection until

all lines leading to it are disconnected and blanked of and
the vessel is thoroughly purged of residual gases and made
‘gas-free’.
4.5.2 Various other safe operating practices are summarized and given in the
list of DOs and DONTs at Annexure No. 8
4.6 PRECAUTIONS AGAINST PYROPHORIC MATERIAL
4.6.1 Pyrophoric material is a potential source of ignition in LPG handling. It is

therefore essential to understand the behaviour of such material for safe
handling of LPG. OISD Std. 112 (Safe handling of Air-Hydrocarbon mixture
and Pyrophoric Substances ) to referred in this regard
4.6.2 Certain substances react spontaneously with oxygen at normal

temperature. Large amount of heat energy is released in this process.
This energy, if not dissipated quickly, can raise the temperature of
surrounding materials causing fire. This tendency is all the more likely
when the substance has a large surface area as compared to its mass.
Examples of such substances are iron sulphur compounds, certain
carbonaceous materials (charcoal and soft grade of small coal), and
some vegetable and animal oils. Of these materials, the most likely to
behave as a local source of ignition where petroleum products are
handled or stored, are the iron-sulphur compounds formed by the
combination of iron (whether in the containing vessel, pipeline, or valve)
with hydrogen sulphide or other sulphur compounds present in sour
crude oils or distillates.

DEPARTMENT 4
March 2014 4-13
4.6.3 Certain sulphates reducing bacteria can live in the water that may be
present under the oil in the bottom of storage tanks and this bacteria is
capable of reducing sulphates dissolved in the water to form hydrogen
sulphide, which then forms iron sulphide. Iron sulphide formed without
any air contact inside a storage vessel is very active chemically and
when exposed to air, it rapidly oxidizes becoming so hot that it glows
visibly and reaches a temperature sufficient to ignite a mixture of
hydrocarbon with air. It is appropriately described as “PYROPHORIC”.
4.6.4 From the above, it may be noted that chances of pyrophoric material
are more in the equipment (pipelines, vessels, flare headers, columns,
pumps and strainers etc.) handling hydrocarbons in closed condition.
During cleaning of LPG strainers, statutory testing of LPG Storage
vessels/pipelines, probability of release of pyrophoric iron sulphide into
atmosphere is high and thus due care in handling should be taken as
detailed here under.
4.6.5 Pyrophoric iron sulphide deposits may be kept under control by

:exclusion of air by, for example, plugging the open ends of the
pipelines, or blanketing with an inert gas / steam etc; andcooling
usually by wetting the deposit with water and keeping it wet.
` Purging with inert gas or steam may not always be feasible in marketing
locations. Hence, in addition to the precaution to keep the pyrophoric
material wet in the vessel till it becomes hydrocarbon free, following
additional precautions for handling pyrophoric material must be taken :
(a) Pyrophoric material should be kept wet till it is buried in the pit and
pit is covered with earth.
(b) The passage through which the sludge is transported and

surrounding area should be cleared of flammable / combustible
material (hydrocarbon vapours, dry vegetation, rags, papers,
combustible chemical etc.).
(c) Pit for disposal of this sludge should be located sufficiently away
from hydrocarbon area so that the plant / equipment is not in
danger at any time.
(d) Surrounding area of the pit should be cleared of all flammable /

combustible material as mentioned in (b) above.

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March 2014 4-14
(e) It is desirable to keep the areas (including surroundings) through

which sludge passes and is buried, wet to the extent possible.
(f) Spillage of pyrophoric sludge, wherever occurred should be

cleared off immediately and buried properly in the pit.
(g) Sludge should be transported in closed containers to avoid the

possibility of spillage during handling.
(h) competent person should supervise the disposal of pyrophoric

sludge. Plant Manager must ensure that the job is being carried out
by the contractor under proper supervision.
4.6.6 Pyrophoric material may be present in lumps and not uniformly

throughout as sludge mass. Hence, continuous vigil has to be maintained
even for minor spillage / presence of sludge till the operation of
handling and disposal is completed.
4.7 BASIC ACTION IN EMERGENCIES

4.7.1 Although correct observance of safety procedures described in the
Manual will minimise the incidents of LPG emergencies, planning and
training to deal with emergencies are essential. The details of basic
action in the event of LPG fire are covered in Chapter No. 5.
The basis for preparing an Emergency Plan should be derived from the
hazard analysis and the consequences of identified maximum credible
accident scenarios .The objective of the Emergency Plan is to provide
measures to contain and minimise the effects of such incidents.
4.7.2 ON–SITE EMERGENCY PLAN:
On-site Emergency Response and Disaster Management Plan (ERDMP)

shall be prepared as per PNGRB ( Petroleum & Natural Gas Regulatory
Board ) Regulations 2010 and same shall be required to be vetted by
PNGRB approved 3rd party.
As per the Regulations, the following shall comprise the ERDMP


DEPARTMENT 4
March 2014 4-15
(a) classification of emergencies;

(b) implementation schedule;
(c) consequences of defaults or non-compliance;
(d) statutory requirements;
(e) pre-emergency planning;
(f) emergency mitigation measures;

(g) emergency preparedness measures;
(h) emergency response procedures and measures;
(i) emergency organisation and responsibilities;
(j) infrastructure requirements;
(k) declaration of on-site and off-site emergency;
(l) resources for controlling emergency;
(m) demographic information;
(n) medical facilities;
(o) evacuation;
(p) public relations and information to public;
(q) reporting of the incident;
(r) emergency recovery procedures;
(s) ERDMP for tank trucks and pipelines carrying petroleum products;
(t) integration of the ERDMP with National Disaster Management
Authority (NDMA) guidelines and action plan on Chemical Disasters
(Industrial);
(u) security threat plan and action plan to meet the eventualities
The guidelines given in PNGRB Regulations 2010 and subsequent

amendments, if any, under the above heads shall be followe d for
preparation of ERDMP of the location
4.8 SAFETY IN ROAD TRANSPORTATION

4.8.1 Large volumes of petroleum products are transported through road tank
trucks. To ensure safety of product and human beings involving directly
or indirectly, it is essential that such vehicles are designed as per the
standards and driven by competent persons.
4.8.2 To meet the objective, following aspects should be taken into

consideration in the case of vehicles :

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March 2014 4-16
(a) Design : In accordance with , SMPV Rules 1981, Motor Vehicle Act
1989 .
(b) Periodical inspection of vehicles :
(i) Periodical statutory inspection in line with SMPV rules, should be

carried out by the competent persons.
(ii) Inspection at the loading / unloading locations should be
carried out and documented in line with the provisions of SMPV
rules, Petroleum rules and OISD standard 144.
(ii) System should be in place to correct the deviations observed
during the inspection of the vehicles.
(c) The relevant provisions of Central Motor Vehicles Rules should be

adhered to.
(d) Defensive driving : By exercising the defensive driving skills,

thedrivers maintain a safety zone around the vehicle. The
defensive driving skill is intended to make allowance for the
following :
(i) Handling characteristics of the vehicle.

(ii) Lack of skill and knowledge or unpredictable actions on the
part of other drivers.
(iii) Vulnerability and unpredictable behaviour of pedestrians and
cyclists.
(iv) Unpredictable behaviour of animals.
(v) Hazardous climate conditions.
(e) The skill and art of defensive driving should be inculcated with the
drivers by :
(i) Improving awareness.

(ii) Sharpening skill of observation, perception and anticipation.
(iii) Providing time for driver to correctly assess and respond to a
developing situation.
(iv) Hazardous road features e.g. curves, hills, narrow roads,
bridges, absence of signs or signals and obstructions.
(v) System of assessment of driver training program in line with
OISD-STD-154 should be in place.

DEPARTMENT 4
March 2014 4-17
4.9 SAFETY OF ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS

4.9.1 In order to ensure that electrical equipment does not become a source
of ignition in an oil / gas handling installation, it is necessary that
equipment is suitably selected for installation in hazardous areas.
4.9.2 Following factors shall be considered for proper selection of electrical

apparatus and equipment for the areas where risks due to flammable
gases or vapours may arise :
i) Areas classification i.e. Zone 0,1, or 2.

(ii) Gas group classification i.e. the gas group IIA, IIB or IIC.
(iii) Temperature classification.
(iv) Environmental conditions in which the apparatus is to be installed.
Where practicable electrical apparatus in general and switch and
control apparatus in particular shall be installed in safe area.
Substation and control room shall be located in safe area. While
deciding the route of overhead power lines, necessary
considerations shall be given to avoid overhead lines passing
through hazardous areas.
4.9.3 PLANT EARTHING
(a) It is recommended that all electrical equipment are suitably

earthed. Earthing system shall, in general, cover the following:
 Equipment earthing for personnel safety.

 System neutral earthing and
 Protection against static and lightening discharges.
 Lightening protection of Flare lines
(b) The earthing system shall have an earthing network with

required number of earth electrodes attached to it. The following
shall be earthed:
 System neutral.
 Current and potential transformer secondary neutral.

DEPARTMENT 4
March 2014 4-18
 Metallic non-current carrying parts of all electrical

apparatus such as transformers, switchgears, motors, lighting /
power panels, terminals boxes, control stations, lighting
fixtures, receptacles etc.
 Steel structures, loading platform, Sheds etc.
 Cable trays and racks, lighting mast and poles.
 Storage tanks, spheres, vessels, columns and all other
process equipment.
 Electrical equipment fencing(e.g. transformer, yard etc.)
 Cable shields and armour.
 Provision of flexible earthing for tank truck and tank wagon.
(c) Plant earthing design shall generally be carried out in accordance

with the requirements of Indian Electricity Rules, code of practice of
earthing IS : 3043 and Earthing guidelines issued by Head Office.
 As far as possible all earth connections should be visible for

inspection.
 All utility, process pipelines and flanges shall be earthed on
entering or leaving the hazardous areas, except where
conflicting with the requirements of cathodic protection. In
addition, steel pipe racks in the process units and off-site area
shall be earthed at every 25 metres.
Earth electrodes shall be periodically tested and maintained. In

case of high resistivity during dry season, water shall be poured in
the earth pits to lower the resistance. Earth grid resistance shall be
measured and recorded regularly.
4.9.4 Lightning protection shall be provided as per the requirements of

IS : 2309 and Corporation guidelines issued in this regard. Self
conducting structures may not require lightning protection with aerial
rod and down conductors. They shall, however, be connected to the
earthing system, at least, at two points at the base. An independent
earthing network shall be provided for lightning protection and this shall
be bonded with the main earthing network below ground, minimum at
two points.
4.9.5 Earth rods and conductors shall be designed to cope with the
conditions imposed. The earth conductors shall be adequately sized

DEPARTMENT 4
March 2014 4-19
to carry the applicable maximum earth fault current without undue

temperature rise. All joints shall be protected against corrosion.
All the electrical equipment operating above 250 volts shall have
two separate and distinct connections to earth grid.
4.9.6 The main earthing network shall be used for earthing of the
equipment to protect it against static electricity.
An approach for removing fire or explosion danger is to provide means

for adequate dissipation and prevention of accumulation of static
electricity, thereby ensuring that static discharges do not occur.
Principal method of accomplishing this is by grounding and bonding.
Electrostatic changes in conductive objects may be rapidly dissipated
by earthing the objects. In all cases, connection to earth should be
made in accordance with IOCL guidelines and IS 3043
The requirements for robustness and corrosion resistance of earthing

conductors are that the resistance of an installed conductor shall be in
the order of a few ohms. The connection to the general mass of the
earth should be by an earth electrode installed so as to ensure an
effective and permanent connection. ideally, the resistance of earth
between the actual earthing conductor plus electrode shall not exceed
2 ohms. For details on static electricity and guidelines for its control,
OISD standard 110 may be referred.
4.9.7 It shall be ensured that the electrical installation is protected from

rust/corrosion. This should be achieved by painting all equipment at
regular intervals by the use of zinc passivated / cadmium plated
hardware, stainless steel hardware, through provision of canopies for
outdoor equipment and covering of terminal boxes to prevent
ingress of water etc. Battery rooms shall be kept dry and well
ventilated and all terminals shall be kept covered with
petroleum jelly to avoid corrosion.
4.9.8 During maintenance, if any equipment is removed from panel doors,

etc. which leaves an open cut-out on the equipment, the same shall
be promptly sealed by using blanking plates or other means to ensure
that there is no loss of degree of ingress protection and also that this
does not provide a means of access for entry of dust / vermin. It shall be
ensured that all unused cable entries are blanked off.

DEPARTMENT 4
March 2014 4-20
4.9.9 All battery banks shall be routinely checked for healthy cell voltage,
specific gravity of cells, electrolyte level etc. Insulation resistance of all
electrical equipment, such as, all switchboards, motors, transformers,
cables etc. shall be routinely measured and logged to ensure
healthiness of equipment.
4.9.10 Dielectric strength of the transformer, insulating oil, oil circuit breakers
etc. (if any) shall be measured and oil filtration carried out wherever
necessary.
4.9.11 All cable terminals, bus-bar joints, etc. shall be tightened, more so for
equipment subjected to vibrations, to ensure that there are no hot
spots which could lead to fire / equipment failure. Settings of
protective relays shall be checked yearly to ensure that they
are set and operating as per the recommended settings. If
replacement components such as cable glands, conduits or
conduit accessories, are available only with thread forms which
differ from those provided on the apparatus, suitable adaptors
having necessary certification and approval shall be employed.
4.9.12 Equipment enclosures and fittings shall be examined to see that all
stopping plugs and bolts are in position and properly tightened.
Locking and sealing devices shall be checked to ensure that they are
secured in prescribed manner. Replacement towards fasteners, nuts,
studs and bolts shall be of type specified by the manufacturers
for the particular apparatus. No attempt shall be made to
replace or repair a glass in a flameproof enclosure e.g. in a luminary
or other enclosures, except by replacement with the complete assembly

or part obtainable from the manufacturers, complying with the
approval certificate. All switch boards shall be provided with safety
interlocks as covered under OISD – 149.
4.9.13 Repairs of apparatus with type of protection Ex(d) shall be

performed preferably by the original manufacturer, his authorized
agent or a repairer who is conversant with the manufacturing
standards of flameproof equipment.

DEPARTMENT 4
March 2014 4-21
4.9.14 Surrounding areas of Transformer and switch boards shall be maintained

free of vegetation/dry grass. Special emphasis shall be laid down on the
maintenance of equipment installed in hazardous areas.
4.9.15 No alteration to any apparatus that might invalidate the certificate

or other documents relating to the safety of the apparatus, shall be
made without appropriate approval from authorities such as CCOE /
DGMS / DGFASLI, as applicable.
4.10 SAFETY AND ENVIRONMENT MANAGEMENT

4.10.1 Any accident while handing LPG, during processing, storage or transport
is always accompanied by one or combination of following :
 Fire
 Explosion
 Spillage of LPG from storage or during handling / transportation.
To reduce the chance of accidents, it must be ensured that the design /

operation / maintenance of the plant and facilities meets highest
standards and codes and to maintain environment and ecology to the
condition of pre-start facilities, various statutory rules and regulations
have been formulated by the Govt. In some cases, new Acts have been
published in the Gazette or in some other cases old rules have been
streamlined.
4.10.2 To achieve and maintain high standards of plant integrity, management

and control, Acts & Rules as detailed in Chapter No. 2 should be
followed rigidly.
4.10.3 COMMON CAUSE OF ACCIDENTS
For details of common cause of accidents HSE Manual may be referred.
4.10.4 COMMON SOURCES OF LPG LEAKAGE AT PLANTS
Common sources of LPG leakage at plants are as under :
(i) Through water drain valve while draining.

(ii) Leaking through sampling valve, if provided.
(iii) Breakage of glass on ‘Sight Flow Indicator’ on the pipeline.

DEPARTMENT 4
March 2014 4-22
(iv) Opening of pop-off action valve, gland/packing etc.

(v) Leakage through LPG compressor.
(vi) Leakage through LPG pump.
(vii) Leakage due to bursting/ rupture of LPG hose or swivel joints of
body arms.
(viii) Excess filling in the storage vessel and the product coming out of
the vapour line into LPG compressor and thereafter venting into
atmosphere.
(ix) Excessive leakage from the cylinders e.g. leaky valve, Body
leak cylinders, venting of excess filled cylinder, resulting in
concentration of the vapour in the atmosphere.
(x) During degassing /purging operations if method of free venting is
followed.
(xi) Leakage from the filling guns.
(xii) Escape of liquid / vapour LPG during maintenance/repairs
(xiii) Leakage from flange joints.
4.10.5 COMMON SOURCES OF IGNITION
Common sources of ignition are as under :
(i) Static electricity as a result of improper bonding/grounding of

tanks, conveyor system, Tank truck, tank wagon, etc.
(ii) Cylinder hitting the ground and causing a spark.
(iii) Burning a match stick to light a cigarette, bidi, or a lighted
cigarette / bidi butt.
(iv) Short circuit due to loose wiring including that of automobiles
moving in the area.
(v) Use of non-flame proof fittings such as lights, torch, motors,
etc. (Flame-proof fittings become non-flame proof due to poor
maintenance e.g. gap in the junction boxes increases due to
missing nuts, bolts, or glands used for connection to the
junction boxes, sealing compound not used in the junction boxes,
etc.).
(vi) Exhaust of vehicles, if spark arrestors are not provided or not
effective.
For further details HSE Manual may be referred.


DEPARTMENT 4
March 2014 4-23
4.10.6 COMMON CAUSES OF FIRE
Common causes of fire are as under :
(i) Creation of hazards as a result of non-observance of ‘Hot work

permit’ system.
(ii) Keeping the engine of truck in ‘on -position’ while the
operation is in progress.
(iii) Poor /inadequate house-keeping.
(iv) Use of non-flame proof fan, telephone, temporary lighting
etc.,
(v) Landing of crackers (flying type) in hazardous areas.
(vi) Spark through exhaust of car, motor cycle, scooter, cement
concrete mixers etc.
(vii) Lighted agarbatti in a truck.
(viii) (viii) Excessive release of vapour beyond safe limits
resulting in
(ix) spread of vapour outside the plant area and consequently
fire due to outside source of ignition.
(x) Spark from the loose Electrical connection / loose contacts on
vehicle batteries.
(xi) Spark from the studded shoes with steel buttons by friction
against ground /metal.
(xii) Spark from exhaust of railway engine.
(xiii) Non- flame proof electrical equipment in plant premises
(though in un-licensed area).
(xiv) Spark on account of generation of static charge.
(xv) Spark from locomotives.
(xvi) Flaring during lighting
4.11 ACCIDENT INVESTIGATION, REPORTING & ANALYSIS
4.11.1 All accidents should be investigated immediately. Near-miss accidents

and accidents resulting in property loss should also be investigated. The
investigation Reporting and analysis should be done as per details given
in IOC’s HSE Policy Guidelines for Accident reporting, investigation and
analysis. Some basic guidelines are attached.( pl. see attachment to this
manual )
a. When a person or persons are injured, immediate action should be

taken to have first-aid administered, obtain professional medical

DEPARTMENT 4
March 2014 4-24
attention at once, and to protect fellow employees and equipment.

The investigation MUST then begin immediately into the circumstances
of the accident.
b. For the purpose of investigation, the investigating officer should use

Accident Report Form as given in the HS&E Manual. In case any specific
details that cannot be covered in the columns provided in the form,
separate sheets should be used. The report should elicit significant
information about an injury in order to get into the real cause of the
situation-those factors which, if eliminated, will prevent a recurrence.
c. The knowledge of elements of an accident and how they contribute to

an injury should be used as a tool for securing the right facts upon which
corrective action is based. No mystery should surround an accident. It
can be taken apart to find out what went wrong. Each contributing
element should be analysed, and then reported, so that the information
can be used for preventing other accidents. Main elements of the
accidents are as under :
(i) Agency or source of accident : (the item involved, such as gas

cylinder, tank wagon, tank truck etc.). Also the part of the
tool, material, equipment involved, in order to pinpoint the
corrective action.
(ii) The type of accident or the manner in which the person was
injured (Such as by falling, by being struck by an object, or by
getting liquid LPG burns etc.).
(iii) Listen for the clues from the conversation around you.
Unsolicited comments often have merit.
(iv) Encourage people to give their ideas for the cause of
the accidents and measures to prevent recurrence.
(v) Study possible causes- both unsafe conditions and unsafe
practices.
(vi) Confer with interested persons about possible solutions. The
problem may have been solved by someone else.
(vii) Follow-up to make sure that the conditions are corrected. If
they cannot be corrected immediately, report this to all
concerned.
(viii) Publicize any corrective action taken so that all may
benefit from the experience.

DEPARTMENT 4
March 2014 4-25
d. While following the above procedures, two basic points must be kept
in mind :
 That most of the accidents involve both unsafe conditions

and unsafe acts and
 that the main purpose of accident investigation is
prevention of future accidents and not for fixing the blame.
4.11.2 INCIDENT INVESTIGATION
(a) For the management, an incident investigation is a critical feedback

about the system of control of a hazard. This form of control is
valuable as it helps to prevent recurrence of the incident. An
incident is a failure in the control of any hazard that results in
unplanned event like fire , explosion, run away reaction, release of
toxic or flammable material, injury or fatality. A work place incident is
an indication that the prevention was ineffective and that prompt
changes need to be made. Feed back control gives management
the capability to use information on past performance to improve
upon the future performance and to meet planned objectives and
acceptable standards. A near-miss incident is little better situation in
that it is a warning given before actual injury. It gives an opportunity
for concurrent control which has the advantage of permitting
corrective action before an injury, illness , death or property loss.
Therefore, every incident and near-miss incident must be recorded
and thoroughly investigated.
Incident investigation should be initiated as promptly as possible

but not later than 24 hours following the incident. The basic purpose
of an incident investigation is to determine the physical cause of
the incident and to formulate control system to prevent its
recurrence.
(b) Who should investigate : The immediate and first level investigation
should be performed by the immediate supervisor of the affected
area. The immediate supervisor who is closest to the scene, knows
the nature of the work, the employees, who do the work and the
nature of the hazards associated with the work.
(c) What does an investigation report contain : A detailed

investigation report, prepared at the conclusion of the

DEPARTMENT 4
March 2014 4-26
investigation should include minimum the date of incident , the date

on which the investigation began, a description of the incident, the
factors that contributed to the incident and any recommendations
emerging out of the investigation. For further details, format given in
OID-STD-107 can be referred.
(d) The role of safety professional : A safety professional should also be

called in to review the investigation. An independent review and a
second opinion in such situations will help. If necessary, (e.g. if the
first investigation was deemed to be inadequate or if the initial
investigators do not have sufficient expertise) a second investigation
should be performed. The safety professional can conduct a joint
investigation with the primary investigation. The primary safety
responsibility rests with the immediate line management. When the
nature of the accident is complex and the causative factors are
elusive ,an outside expert can be engaged to provide additional
knowledge.
(e) Investigation by the committee : In case of a major incident,

management should establish a multidisciplinary team to enquire
into the incident. Such safety Committee for an accident
investigation has the advantages of bringing in a good mix of
knowledge/ viewpoints as also injects a new dose of objectivity into
the investigation. In case of catastrophe or disaster where the losses
are very heavy and the consequences are severe , an adhoc senior
level of inquiry or investigation can be instituted and assigned with
completing an independent investigation.
(f) Latest Accident Reporting and investigation policy (attached )shall

be referred. OISD 206 may be referred for salient parameters for
accident / incident investigation.
4.11.3 ACCIDENT REPORTING
Incidents involving LPG spillage / leakage (with or without fire) which

require emergency action should be treated as accidents. Each incident
should be fully investigated by the Plant Manager as explained above. In
general, guidelines regarding ‘Accident Reporting’ as covered in :

DEPARTMENT 4
March 2014 4-27
(a) Accident Reporting, Investigation & Analysis policy guidelines of

Corporation
(b) The Gas Cylinder Rules, 2004
(c) The Static and Mobile Pressure Vessels (Unfired) Rules, 1981;
should be followed.
All efforts should be made to establish the reasons for the accident.
All accidents must be reported immediately by the Plant Manager to

the State Office / Regional office / Head Office through telephone / FAX
/ e-mail with available details followed by a detailed investigation report :
(a) In case of accidents involving loss of life or serious injury to persons or

property, the notice of accident MUST be given to :
(i) The Chief Controller of Explosives (CCOE) by express

telegram, followed within 24hours by letter, giving particulars of
the occurrence.
(ii) Oil Industry Safety Directorate.
(iii) To the Officer -in-charge of the nearest Police Station by
the quickest route.
(b) Pending the visit of CCOE or his representative, or until instructions are
received from CCOE that he does not wish to make any further
investigation or enquiry, all wreckage and debris should be left
untouched except in so far as removal may be necessary for the
rescue of the persons injured.
Notice of the accident MUST also be sent to other Authorities

as per applicable statutory rules(e.g. Factories Act, Workmen’s
Compensation Act, etc.).
(c) In case of fatal accidents caused to Corporation employees

within or outside the plant premises and to contractor’s employees
within the plant, accident investigation should be carried out
Immediately by the functional department in Head Office
together with the functional department of the Region concerned
and HS&E Department.
(d) While the investigation process is on, the ED of the concerned

Region in consultation with ED (Supplies) /ED (LPG) should set up

DEPARTMENT 4
March 2014 4-28
an Enquiry Committee to go into the cause of the accidents and

evolve future preventive measures
4.12 PERSONAL PROTECTIVE EQUIPMENT
4.12.1 When a hazard is found to exist, every effort should be made to

eliminate it or control it by modifying the design. Where this is not
possible, isolation of the process or guarding of the hazard should be
attempted. Personal Protective Equipment (PPE) should be considered
only as a last resort. Judicious use of the Personal Protective Equipment
sometimes, however, can greatly simplify the operation in case of
break-downs or other emergencies. People, who must be alert where
hazards cannot be eliminated or controlled at the source and where
ordinary work clothes do not provide sufficient protection, should use
Personal Protective Equipment, to protect the person. Some of the
Personal Protective Equipment required to be used at LPG plants and
the conditions, under which each one is to be used, are described
below :
(a) Hands Gloves : These are required for use for protection against
liquid LPG burns by the Workmen handling filled cylinders. They are
also required to be used by Maintenance staff to prevent cuts,
scratches, bruises and burns on fingers, palms and hands. There are
variety of hand gloves available and selection of the right type is
essential.
(b) Safety Shoes : They provide protection against injuries to feet

resulting on account of accidental fall of the cylinders or other
objects. All personnel working in the plant; particularly at cylinder
filling shed or connected with cylinder handling operations; must be
provided with this protection.
(c) Safety Helmet : This provides protection against head injury by

accidental fall of any object from a height or hitting of head
against any low lying structures while crossing. Safety helmets
should be used by the personnel engaged in constructional
activities
(d) Safety Belts / Harnesses : Safety belts and harnesses with life lines
attached should be worn by those who work at high levels or
enclosed places where air supply may not be adequate

DEPARTMENT 4
March 2014 4-29
(particularly when they are wearing Gas Mask). These are also
required to be used by the personnel manning the hose line during
the course of fire fighting. With the help of this equipment, a person
wearing it can be pulled out in an emergent situation.
For further details on other PPEs, the HSE Manual and OISD-STD-151
&152 may be referred.
4.13 SAFETY INSPECTIOIN / AUDIT

4.13.1 Safety audits are periodic examination of the functioning of safety
system. It gives an idea about how effectively the safety system is
implemented and how they are being accomplished. It is the feedback
mechanism that provides management with the status and
measurement of effectiveness of the various safety system elements and
activities and leads to the appropriate control over these efforts. 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 equipment. For a structured and systematic safety audit of
any plant / facility, check lists are the most important pre-requisite.
Checklists covers all the operational areas, major equipment, operating /
maintenance procedures, safety practices, fire prevention / protection
systems etc.. Detailed guidelines for carrying out internal safety audits
are given in OISD-GDN 145 & OISD STD 144 and should be followed.
4.13.2 It should be ensured before commissioning of a new plant that each

employee before being involved in plant operation should be trained in
an over view of the plant process and in the following:
(a) Operating procedures viz., initial start-up, normal operations,

temporary operations, emergency shut downs including the
conditions under which emergency shutdown is required,
emergency operations, normal shutdown and start up following a
turnaround or after an emergency shutdown.
(b) Operating limits viz., consequences of deviation and steps required

to correct or avoid deviation.

DEPARTMENT 4
March 2014 4-30
(c) Safety and health considerations viz., properties of and hazards

presented by LPG used, precautions necessary to prevent
exposure, including engineering / administrative controls and PPE.
(d) Control measures to be taken if exposed (Physical, air borne),

quality control in operations.
(e) Safety systems and their functions.
(f) Each employee should be given training on Operating Procedures

& safe work practices, emergency preparedness or Disaster
Management Plan, safety procedures, work permit system and the
areas pertinent to production, safety and health.
(g) Each employee should be explained of the action to be taken in

the event of unwanted release of LPG.
4.13.3 The training should also include / reflect current operating practice,
changes that result from the changes in equipment and the changes in
facilities and safe work practices to provide for the control of hazards
during the operation such as confined space entry and opening process
of equipment and piping for maintenance.
Refresher training should be provided at least every three years and

more often, if necessary, to each employee involved in operations to
assure that employee understands and adheres to the current operating
procedures relevant to the plant.
Record should be prepared containing the identity of the employee, the

date of training and the means used to verify that the employee
understood the training. OISD–STD-154 can be referred for further
information.
4.13.4 In case contractors are deployed to accomplish various types of jobs of

different nature, it is very much essential to formulate an elaborate
system for ensuring their safety at work place. To meet the requirement,
following measures should be incorporated in the system:
(a) Plant Manager should ensure that the contractor personnel

are trained in the work practices necessary to perform their job
safely.

DEPARTMENT 4
March 2014 4-31
(b) Contractor should provide & maintain work places, plant,

equipment, tools, machinery and organise construction work, so
that there is no risk of accident or injury to workers.
(c) Contractor’s personnel is to be informed about the known potential

of fire, explosion or toxic release hazards related to their job and in
the applicable provisions of the emergency preparedness plan.
(d) Contractor must ensure that each of their personnel has received
and understood their roles in safe working practices by preparing a
record and should verify the efficacy of dissemination of the safety
information. He should also ensure the use of PPEs at work place.
(e) Contractor should ensure that each member of their crew follows
safety rules of the plant facility including safe work practices.
(f) Contractor should keep Plant Manager informed about any unique
hazard presented by their personnel’s at work.
(g) Plant Manager should ensure for regular safety inspection of

construction equipment / tools & tackles by competent person.
(h) Contractor should assign their workers only to employment for

which they are suited by their age, physique, state of health and
skill.
(i) Contractor should be responsible for application & enforcement of

safety & health measures in respect of the workers at site and
should maintain constant liaison with management.
4.13.5 SAFETY AUDIT
While due care is taken at the time of initial installation to ensure that the
equipment, or the facility provided is safe as required under the relevant
codes/ rules, periodic checking of these facilities is a MUST to ensure
that they remain in the same and safe condition as designed and
installed. For example a flame-proof electrical installation could be
rendered unsafe during the course of maintenance / repair, if the cover
is not properly tightened or glands are removed. Likewise, to ensure that
all recommended safe operating practices are allowed at the plant, a
periodic safety audit of the plant, to cover both facilities and operation;

DEPARTMENT 4
March 2014 4-32
is a MUST. The following basic forms have been designed for this
purpose:
(a) Brief Inspection Report-cum-Daily Safety Audit of LPG Bottling

Plant : The report is required to be filled in every operating shift by
the Safety Officer posted / designated safety officer at the plant
and should be reviewed daily by the Plant Manager. Immediate
corrective action, wherever required, must be taken to eliminate
unsafe conditions and unsafe acts observed.
(b) Self Constructive Appraisal of Plant Operations (Self-CAP) : A

detailed Safety cum Operations audit of each plant is required to
be done by the Plant Manager every month and the deviations are
to be recorded. The deviations to be complied with a time bound
action plan so that the safe operating conditions prevail in the
Plant.
The latest CAP format issued by HO shall be followed for the

purpose.
(c) Multi Disciplinary Team Audit(MDT): Inspection of the plant is being

carried out once in a year as per the MDT format by the officials
from State Office/Regional Office/Head Office.
(d) External Safety Audit (ESA): External Safety Audit shall be

conducted as per Factories’ Act.
(e) Electrical Audit : Electrical Audit once every year by an internal

electrical engineer nominated by State office and every four years
by external agency, in line with guidelines. Internal electrical audit
need not be done in the year when audit by external agency is
scheduled.
(f) Quarterly Safety inspection by SO in line with HO Guidelines.
BACK
5
FIRE PREVENTION AND CONTROL

“PREVENTION IS BETTER THAN CURE”
This phrase cannot be more relevant
to anything else than to a fire at LPG
Plant. Remember, “ THE BEST WAY TO
FIGHT A FIRE IS TO PREVENT IT. “


DEPARTMENT 5
FIRE PREVENTION & CONTROL PAGE No.
March 2014 5-1
5.1 GENERAL
5.1.1 The Characteristics of LPG necessitates the use of fire fighting and control
techniques different from those applicable to general petroleum
products. However, as it may be necessary to protect LPG plant and
facilities from fires in the adjacent plant and property, personnel
engaged in LPG operations should know how to deal with all types of
fires, not necessarily those involving LPG.
5.1.2 Knowledge of characteristics and hazards of LPG as detailed in Chapter

No.3 is extremely helpful in preventing, controlling and fighting LPG fires.
5.1.3 Fire in an LPG plant could result in a catastrophe. Besides huge financial
losses as a result of property loss and loss of production, it involves
considerable risk to human lives and Corporation image. Efforts should,
therefore, be concentrated on ‘prevention’ aspect of fire, while at the
same time remaining fully equipped and alert to face all possible
emergency situations is essential.
5.2 FIRE PREVENTION

5.2.1 For an LPG fire to take place, presence of LPG vapour, air and source of
ignition are essential; needless to say that vapour and air mixture should
be within the flammability range. Fire prevention efforts are, therefore
concentrated on :
(a) minimising escape of vapour to the atmosphere;

(b) eliminating source of ignition.
Escape of certain amount of vapour while operating the plant, cannot

be totally eliminated. What, therefore, MUST be prevented at all cost, is
the source of ignition within the plant area.
5.2.2 Most LPG fires can be prevented. The most effective way of achieving
this is by using only equipment suitable for LPG service and by strict
observance of safe operating procedures which must be taught to all
personnel engaged in LPG Operations. Ignorance of basic characteristics
of LPG and also of proper handling procedures is often the root cause of
LPG accidents.

DEPARTMENT 5
March 2014 5-2
5.2.3 Most LPG fires result from the ignition of the product which used to
escape from its containing system. Escape of LPG is sometimes due to
equipment failure but is more often a result of human error i.e. following
incorrect procedures.
5.2.4 Proper training of all personnel working in the plant; including those
engaged by the contractors and transporters; is very significant factor in
preventing LPG leaks/fires.
5.2.5 Various causes of leakage. sources of ignition and causes of fire as

detailed in Chapter No.4 (Clause No. 4.10.4 to 4.10.6) should be studied
carefully. All out efforts must be made to eliminate these for an effective
fire prevention scheme. Like for any other hazards (damages, disease
etc.), ‘Prevention’ should be given top priority in Safety Management.
Carrying of match-sticks, lighters and smoking within the licensed
premises can be potential source of ignition and all effective measures
must be taken to prevent this. The measures would include adequate
education /training to new entrants and security checks at the gates
and within the plant area.
5.2.6 Regulations to be strictly followed for prevention of fire
5.2.6.1 Ban On Carrying Of A Potential Source Of Ignition
Fire or naked light, matches, petrol or other lighters or any apparatus,

which is capable of causing ignition, is not permitted to be taken inside
the plant premises by any person.
Persons entering the plant premises shall deposit match boxes, lighters
etc with the Security Department at the main entrance gate of the plant.
The same can be collected by them on their return.
In case any apparatus, which could be a source of ignition, is essential to

be taken into the plant premises, a written permit shall be necessary from
persons duly authorized by the Plant Manager. The permit must be
returned to the Security Department on expiry.
5.2.6.2 Ban On Smoking
Smoking is prohibited in all parts of the plant premises


DEPARTMENT 5
March 2014 5-3
5.2.6.3 Ban On Carrying Lamps
Ordinary torches will not be allowed to use within the plant premises.
Flameproof torches/lamps of only approved manufacturers shall be used.
5.2.6.4 Use Of CCOE approved Spark / Flame Arrestors
All vehicles must have spark/flame arrestors duly welded to exhaust pipe
& these should be duly approved by the Chief Controller of Explosives.
Truck number should also be painted on the body of the Spark arrester.
5.2.6.5 General Precautions
(a) Good housekeeping is to be maintained.
(b) Personnel working in the plant should be vigilant for the abnormal
presence of hydrocarbons in operating environment.
(c) The laid down procedures are to be strictly followed,
(d) Draining water from LPG vessels should be done under strict
supervision.
(e) Loose wiring, temporary and non-standard fittings are not permitted
inside the plant premises
(f) Regular checks on equipment health (vibration, lubrication etc.)

must be carried out faithfully.
(g) Light hydrocarbons viz. Petrol etc., should not be used for washing
the hands, area, equipment or personal belongings.
(h) No equipment should be operated un-authorisedly and without

clarity.
(i) It must be ensured that the availability of fire protection equipment

whenever hot job is in progress.

DEPARTMENT 5
March 2014 5-4
(j) Beware of operational activities and risks involved (e.g. high

temperature, pressure, reactivity of the product with atmospheric
gases etc.) in carrying out them.
(k) Anticipate the hazards (e.g. presence of pyrophoric iron) during

cleaning the vessel and take preventive steps in advance.
(l) Use only approved type of tools. This will prevent spark due to
hammering, cutting, rubbing actions.
(m) Safe operating practice described in the Manual must be adhered

to for preventing accidents which may lead to fire.
5.3 FIRE CONTROL TECHNIQUE

5.3.1 LPG is normally stored and handled as a liquid under pressure and the
liquid or vapour is ejected if the leakage occurs. Under normal
atmospheric conditions, escaped liquid LPG boils violently forming
dense vapour clouds. The fire control-technique is, therefore, based on
preventing the escape of LPG from its containing system and dealing
with the vapour in case of leakage.
5.3.2 Chemical Foam is an unsatisfactory agent for dealing with either a jet of
vapour or violently boiling liquid LPG. Therefore, CO2 or Dry Chemical
Powder, which provides a smothering cloud and excludes air from the
flame, must be used in case of a small fire.
5.3.3 Because of the dangers of accidental re-ignition of vapour clouds which

can be explosive and affects larger areas, LPG fires are generally not
extinguished (except in case of circumstances described in Clause 5.3.4
below) unless the escape of product can be stopped immediately.
5.3.4 If the flames touch directly on LPG containers (irrespective of size) the
container wall will get overheated and rupture on account of the high
pressure developed within the vessel. As rupture of the vessel can create
a catastrophe, immediate putting off the fire should be considered in
such cases.

DEPARTMENT 5
March 2014 5-5
5.3.5 Except in the case of circumstances explained in Clause 5.3.4 above,

LPG fires should be allowed to burn out, even when a leaking unit has
been isolated from its supply source.
5.3.6 LPG fires, that are being allowed to burn out, should be prevented from
involving other facilities and property and should be controlled in size and
intensity. This can be achieved by limiting the rate of leakage. For this
purpose, the pressure of the supply source (e.g. vessel on fire) should be
reduced by reducing the temperature of the supply source through
cooling by water spray.
5.3.7 To protect LPG containers / equipment against any failure (refer Clause
5.3.4 above) and to control the intensity of the fire, all such items exposed
to or involved in the fire must be cooled by sprinklers, fixed monitors, hose
stream, etc.
5.3.8 The top portion of LPG vessel, which is in contact with vapour and not
liquid, is more vulnerable to failure when vessel is exposed to fire. Cooling
water must, therefore, be sprayed to the top of the vessels and to their
supports to prevent collapse.
LPG vessels are provided with Pressure Relief Valves (PRVs), designed to
relieve excessive pressure developed (e.g. as a result of fire exposure).
When hose streams containing water are sprayed on vessels, operation of
Pressure Relief Valves should not be interfered with. The discharge
from Pressure Relief Valves should not be deflected, unless it is
endangering other facilities and the jet of the escaping vapour should
not be extinguished if it has been already ignited.
5.4 IMMEDIATE ACTION AND FIRE CONTROL

5.4.1 Immediate action is the most important factor in fire control. The first few
seconds count very much, as LPG fire develops and spreads very quickly.
Hence, prompt and efficient action is to be taken. In the event of fire
within the plant, the following action should be taken as quickly as
possible:-
a. Take immediate steps to stop LPG leakage / fire and the fire alarm
should be sounded immediately by the person locating the fire.
Emergency trip button shall be operated to trip the power and to
operate the siren. The information about fire should be reported

DEPARTMENT 5
March 2014 5-6
quickly to the control room and the Plant Manager, indicating the
location nature and gravity of the fire. At the same time, with the
help of available persons, following actions should be initiated in
quick succession or simultaneously if possible.
b. Initiate action as per Fire Fighting Organisation Plan or Disaster

Management Plan, based on gravity of the emergency. At the
sound of fire alarm, all personnel should take up their duties as
outlined in “Fire Fighting Organisation Plan” for the plant. Personnel
without specific duties should assemble at the nominated place.
Check should be made to ensure that all persons are accounted
for.
c. Stop all operations and ensure closure of all Remote Operated

Valves (ROVs) and isolation valves. All loading, filling and discharge
operations in the plant should be stopped.
d. All out effort should be made to contain the spread of leakage /

fire. Saving of human life shall get the first priority In comparison to
stocks / assets.
e. If possible, the fire should be isolated at the point of leakage and

allowed to burn out. Adjacent facilities must be protected as far as
practicable. If the feed to the fire cannot be cut-off, the fire must
be controlled and not extinguished.
f. All pumps, compressors, etc. should be stopped and valves on

product lines, manifolds, and tanks in the affected area should be
closed. Electrical system except for controlling supplies, utilities,
lighting and fire fighting system, should be isolated from the section
of the plant affected.
g. The water sprinkler system should be started on all zones including

adjacent zones which are involved in or exposed to the fire. At most
of our plants, the water sprinkler/sprayer system gets activated
automatically. To conserve water, sprinklers should not be activated
on facilities which are not directly exposed to fire risk. Water should
be applied as quickly as possible to the vessel shells and supports
and to the pipelines, structures and equipment exposed to the fire.

DEPARTMENT 5
March 2014 5-7
h. Fire Brigade and Police Authorities must be alerted and their

assistance is sought, if necessary. Police assistance should be sought
to seal off the roads and surrounding area. Enlist support from
neighbouring industries.
i. Vehicles not connected with fire-fighting operation should be

withdrawn from the plant in an orderly and safe manner and
parked at a place, where they will not interfere with the fire fighting
and other emergency services.
j. Cylinders and other portable equipment exposed to the risks of fire

should be moved to a safer location.
k. If the escaping vapour cannot be stopped, water fog should be

used for dilution and rapid dispersion of vapour cloud.
l. Exercise care to ensure that static charge is not generated in LPG

vapour cloud. For this purpose, solid jets of water must be avoided
and instead fog nozzles should be used.
m. If a valve near to fire can be closed for stopping the leakage, the
same should be tried after wearing Fire Proximity Suit., The attempt
should be directed by the trained persons only. The person
attempting the closure of the valve should be continuously
protected by means of water spraying (through fog nozzles), or any
other approved equipment. The person must be equipped with a
safety harness and manned lifeline. Under no circumstance, should
a person try to enter fire or go closer than the permitted range of
Fire Proximity suit.
n. In the case of any emergency situation, it is of paramount
importance to avoid endangering human life in the event of fire
involving or seriously exposing LPG equipment or serious leakage of
LPG without fire.
5.5 CONTROLLED CONTAINMENT AND PROTECTION OF

PERSONNEL AND PROPERTY
5.5.1 CONTAINMENT : If the flow of LPG, feeding a fire, cannot be stopped
quickly, the first fire- fighting effort must be directed at containing it; that

DEPARTMENT 5
March 2014 5-8
is to prevent spreading of fire to the adjacent plant and property. The

main aspect of containment and protection is as follows :
(a) Structures exposed to flame or close to it should be protected by

water streams, using spray nozzles.
(b) Through continuous spraying of water, if carried out with

determination, will often prevent the ignition of combustible
structures, even if they are enveloped in flame.
(c) LPG vessels and other facilities exposed to fire must be thoroughly
cooled by means of sprinkler system, fixed monitors and hose
streams. The top of LPG vessel shells, which are in contact with
vapour and their supports are the most vulnerable areas.
(d) LPG cylinders or other portable containers exposed to fire must

be continuously protected/cooled with water sprays, if it is not
practicable to move them to a safe area
(e) Fire fighting personnel working in or close to un-ignited vapour

clouds or close to fires must wear protective clothing and
equipment, including safety harness and manned lifelines.
(f) Fire fighters and other personnel dealing with vapour clouds must
be protected continuously by water sprays. Continuity of water
supply for this purpose must be ensured by means of two hoses
connected to different supply points. Care should be exercised to
ensure that static charge is not generated in LPG vapour cloud. For
this purpose, solid jets of water must be avoided, instead, fog nozzles
should be used.
(g) Fire fighters should advance towards a fire, down--wind if possible,

protected by streams of water from hoses, Cylinder fire should
be approached using proper barricades/protection to guard
against direct hit.
(h) Water protection for fire fighters should never be shut-off, even
though flames appear to have been extinguished, until all
personnel are safely out of the danger area.

DEPARTMENT 5
March 2014 5-9
(i) Vapour clouds can be dispersed/deflected by air movements

induced by hose streams.
(j) LPG storage vessels exposed to fire will be protected against over-
pressure by Pressure Relief Valves (PRVs) to a certain extent.
However, in some situations, PRVs may not provide total protection
to the spheres and attention should be always paid to the pressure
inside the vessels. If the pressure gauges are mal-functioning, the

only indication is the rate at which the product escapes from the
PRVs (or the point of leakage). Any rapid increase in the pressure or
noise level of the product discharged should be treated as a
warning of over-pressurization. In such cases, all personnel should be
evacuated immediately.
5.6 HANDLING LPG EMERGENCIES / FIRES

5.6.1 GENERAL
a. If the principles of good operating practices outlined in the manual

are observed, the probability of leakage, fire and explosion will
be minimized. However, accidents do occur and it is, therefore,
important to know the basic methods of handling accidents arising
out of LPG leakage or fire.
(b) When LPG leaks or spillage occurs, it may be discovered either

before or after it is ignited. Action to be taken in either case is
described later separately.
(c) As in the case of any emergency situation, it is of paramount

importance to avoid endangering human life in the event of fire and
involving or seriously exposing LPG equipment with serious leakage
of LPG without a fire.
(d) The knowledge of “Fire Control Technique”:, “immediate Action”,

and “Containment of LPG fires” as described in the previous
chapters is essential in effectively handling LPG emergencies or
fighting a fire.

DEPARTMENT 5
March 2014 5-10
5.6.2 ACTION IN THE EVENT OF LEAKAGE WITHOUT FIRE
(a) Action should be taken as detailed in Clause No. 5.4 above

(Immediate Action and Fire Control) to stop or minimize escape of
the product.
(b) If the escaping LPG is not on fire, the valve should be closed to
stop the flow. Automatic gas detectors are provided at the Plants.
Wherever these are provided, they would give “Gas Leakage
Alarm” and give a signal on control panel also. This will help to
identify easily and timely the location of the trouble spot for
quick remedial action.
(c) Water spray is effective in helping to disperse the LPG vapour. It

should be used as soon as possible, directing the spray streams
across the normal vapour path and dispersing the vapour to a
safe location. Those handling the hoses should keep the hoses low
behind the spray so that they get protected to some extent from
the radiant heat, if the vapour happens to get ignited
unexpectedly. In such cases, water hose operators should be
provided with aluminized suits and water spray cover as protection
against the effects of accidental ignition of the vapour. Unless
absolutely necessary, hose operators must remain outside the
vapour cloud. Hose operators and personnel required to enter into
the vapour cloud should be equipped with a safety harness and in
addition, manned life-line protection should be provided.
(d) If the flow of gas cannot be stopped, an attempt should be made

to disperse the vapour cloud. The escape of un-burnt gas forming a
vapour cloud may pose a greater danger to life and property
compared to LPG already on fire, particularly when there is no
existence of valve by which the gas can be quickly shut-off . This,
however, does not mean that the escaping vapour should be
deliberately set on fire, as there are many factors to be considered,
such as possible dangers to persons and property, due to ignition
of the gas and serious liability that might result from the gas set on
fire.
(e) In some case of leakage from a pressure vessel without a fire (such
as leak from tank truck bullet on over-turning ) it may be desirable
to move the vessel to some remote area, such as block of isolated

DEPARTMENT 5
March 2014 5-11
roadway or open field, where it can be allowed to leak safely

without a source of ignition. However, if this is to be done, the vessel
must be turned back in an upright position. The vessel should not be
dragged in a manner which might damage the valves or pipelines.
While turning a vessel back in an upright position so as to move to
some remote location, it should be done carefully without any
damage.
(f) If the flow of LPG feeding a fire cannot be stopped quickly the
first fire-fighting effort must be directed towards cooling the
container so as to prevent spreading of fire to adjacent vessels and
property.
(g) Water protection for fire fighters should never be shut-off until all
are safely out of the vapour cloud /danger area.
(h) Attempts should be made to deflect leaking LPG liquid from flowing
towards work areas, equipment etc, by means of low earth walls,
sand bags, etc. Such barriers can hold vapour and therefore,
should be treated as hazard, until all vapour is dispersed following
their removal.
5.6.3 ACTION IN THE EVENT OF LPG FIRE
5.6.3.1 Extinguishing Fires : A small fire at the point of leakage can be

extinguished by enveloping with a water spray or a suitable smothering
agent such as CO2 or Dry Chemical Powder or by directing attack at
the base of the flame. However, it is again stressed that LPG fire should
not, except under special circumstances explained earlier, be
extinguished until the escape of product is stopped
5.6.4 LPG STORAGE VESSEL / HORTON SPHERE
5.6.4.1 Top Fire
(a) Flames should not be extinguished except by fuel elimination, as

described in the following paragraphs because accumulation of
leaking gas can result in an explosion due to accidental ignition.
Hence, flamed part may be isolated from the tank, if possible.

DEPARTMENT 5
March 2014 5-12
(b) to the top valve assembly and to the top of the vessel so that
water flowing from the top will cover the shell. Cooling streams
should be continued even after extinguishing the flames until all
danger of re-ignition from the hot steel is eliminated. Cooling of
other adjacent vessels/spheres should also continue by applying
water sprays in an adequate manner.
Cooling water streams are to be applied
(c) Stop immediately movement of product to / from the tank.
(d) Pump out the tank contents of unaffected storage vessels, if

possible.
5.6.4.2 Bottom Fire
(a) Do not extinguish flames except by fuel elimination as described

below, because accumulation of leaking gas can result in an
explosion due to accidental ignition. Isolate flamed part, if possible.
(b) Apply cooling water streams to the top of the vessel so that the run-
off water covers the shell. Also apply water to the supporting

DEPARTMENT 5
March 2014 5-13
structure and to the bottom piping assembly. Cooling streams

should be maintained even after extinguishing the flame until all
danger of re-ignition from the hot steel is eliminated. Cooling of
other adjacent vessels/spheres should also continue by applying
water sprays in an adequate manner.
(c) Stop movement of product to / from the vessel.
(d) Pump water to the vessel to float the flammable material above the
leak. This will extinguish the flames if the water pumping rate
exceeds the rate of leakage.
(e) Should a shell failure occur below the liquid level of the tank and
result in leakage, which exceeds the capacity of water pumping
facilities, spray several solid streams of water on the shell surrounding
the leak. Try to form a curtain of water spray and maintain it until all
the flammable material i.e. LPG is consumed and the vessel
becomes gas free by natural ventilation or by the introduction of
steam (if available to the vapour space of the tank).
5.6.5 FIRE FIGHTING PROCEDURES
Fire fighting procedures will vary depending upon various factors of

fire such as nature, source, size, location, etc.. Basic fire control
techniques have been explained earlier in Clause No. 5.3. However, for
the purpose of guidelines, fire fighting techniques for few common
cases are illustrated as under :
5.6.5.1 Case – 1
Cylinder Fire : If a filled container is involved in a fire, several things may

happen. If the rising internal pressure is not relieved, the built-up pressure
can rise above 70kgf/cm2(g){1000 ib.f/in2(g)} and ultimately rupture the
container, but premature failure may occur at lower pressure if the metal
is weakened by direct flame impingement. Ruptured containers are likely
to propel considerable distance by jet reaction and in this case, the
hazard to life and property will be serious. Heat exposure may,
sometimes results only in leaks developing at the screwed valve
connections (bung joints) as a result of the differential expansion
between the steel and the brass. Ignition of the escaping gas will
aggravate the fire, but the release of the pressure will reduce the

DEPARTMENT 5
March 2014 5-14
possibility of rupture of the container. No attempt should be made to

extinguish the burning gas, but this container and other containers in
the vicinity should be kept cool by spraying water until the contents of
the container completely burn away. If the gas leakage does not get
ignited, the container should be approached from up-wind direction (if
in the open air ) and be removed to a remote place of safety keeping
away from the source of ignition. Filled containers are not likely to
rupture, if they are not directly involved in the fire and preventive action
should be taken by removing such containers away from the heat
exposure and simultaneously cooling water sprays should be applied on
the containers directly involved.
5.6.5.2 Case - 2
Fire on Storage Vessels : The main defence against the accidental fires
are the inherent safety of vessels constructed to an authoritative pressure
vessel design code, correct operational procedures, the provision
made to prevent overfilling and uncontrolled liquid escape, and
the exclusion of sources of ignition from the storage area. If a pressure
vessel is exposed to radiant heat from external fire, it should be kept
cool by water sprays to prevent excessive pressure rise in the vessel.
The most serious condition arises, when there is direct flame impingement
on the part of the vessel surface which is in contact with the vapour and
not with liquid. Cooling water sprays must be applied without delay to
heat the affected area. For this purpose, fixed water sprinklers, which are
capable of covering the vessel surface area at the desired rate and
which can be put into operation quickly either automatically or by one
man, are of great value. If fixed sprinklers are not fitted, equivalent
coverage of water spray through fixed monitors or other equipment
should be brought into action as soon as possible. Correctly sized
pressure relieving devices protect the vessel from overpressure due to
heating of the liquid contents. Cooling of the vessel with water sprays
reduces the heat input to the vessel and thereby reduces the pressure,
thus, reducing the rate of discharge from relief valves.
5.6.5.3 Case – 3
Tank Truck Fires : In case LPG tank truck is involved in a collision which
results in leakage of LPG, not followed by fire, immediate action should
be taken to stop the leakage. All possible ignition sources should be
extinguished and escaping vapour is dispersed by water spray, if

DEPARTMENT 5
March 2014 5-15
available, which should be directed to divert the vapour away from the
nearby occupancies. If the flow of liquid or Vapour cannot be stopped
within short time, the area within at least 100 Ms. (300ft) radius of the
Tank truck should be evacuated and attempts should be made to
disperse the vapour. In case the leakage cannot be stopped until the
bullet is empty, consideration should not be given to deliberate Ignition
of the escaping gas in order to prevent further spread of gas. The
wisdom of such a decision is doubtful because it may result in direct
flame impingement on the bullet shell or a severe explosion may cause
further damage and accentuate the leakage. If, on the other hand, the
escaping gas is ignited by chance, then it should not be extinguished,
but every effort should be made to stop the flow of fuel feeding the
fire, and at the same time, the bullet should be kept cool with copious
application of water spray, particularly on areas where there is direct
flame impingement. Water spray is also useful in giving protection to
persons when approaching valves in an attempt to close them and
thereby stop the flow.
It is likely that in a short time after the bullet is directly involved in fire, the
safety valve will start discharge. Water jets or spray should be continuously
applied to the bullet to reduce the heat input, but if there is a shortage of
water and there is a marked increase in the noise of escaping gas or in
the size of the flame at the safety valve, the rupture of the tank may be
imminent and the surrounding area should be evacuated
5.6.5.4 Case – 4
Burning of LPG leaking at the outlet of a cylinder valve :
 Extinguish the fire by means of a portable fire extinguisher, or

smothering with a thick non-synthetic cloth (preferably wet) or
sand/earth etc. Fix the safety cap on the valve to prevent further
leakage. Immediate extinguishing of fire is necessary because it
facilitates closure of the valve, which will stop further leakage.
 After the fire is extinguished, if the valve cannot be closed, the

cylinder should be moved carefully to a safe location to vent out
the contents under the controlled conditions.

DEPARTMENT 5
March 2014 5-16
5.6.5.5 Case – 5
Fire at pressure relief valves of vessels exposed to adjacent fire :
 Allow the fire at the relief valves to continue; meanwhile cool the
vessel and tackle the adjacent fire.
 When the vessel is cooled sufficiently, the pressure inside the vessel
drops and the PRVs close automatically extinguishing the fire at the
PRV.
5.6.5.6 Case - 6
Fire of LPG vapour escaping from a damaged vessel fitting- flame not
playing on vessel :
 Allowing fire to continue till exhaustion.

 Spray water on the vessel to cool, if the vessel is being heated by
radiation from the flame or if the flame is endangering other plant
equipment.
 Cool adjacent vessels and structures.
5.6.5.7 Case – 7
Fire from overturned bulk LPG lorry - lorry on it’s side with fire enveloping
pressure vessel :
 The fire must be extinguished as quickly as possible because flame

is playing on the pressure vessel.
 Because the vehicle is on its side, the capacity of its PRVs may be
seriously affected due to damage and /or contact with liquid
instead of vapour. The surrounding area should be evacuated of all
but essential fire fighters, who must also be prepared to retreat, if
they do not succeed in extinguishing the fire quickly.
 Fire fighters must not position themselves in line with the dished ends
of the bullets.
5.6.5.8 Case - 8
Fire in Oil storage area adjacent to LPG storage :


DEPARTMENT 5
March 2014 5-17
 Start water spray only on those LPG vessels exposed to fire / heat.
 Isolate affected vessels and run out fire water hoses in case hose
stream cooling becomes necessary.
 Watch pressure in LPG Vessels.
 If PRVs fitted to the LPG vessels have started blowing vapour, take
no further action (apart from cooling), unless the pressure inside the
vessel continues to rise.
 If the fire enters LPG storage area, concentrate on available water

for cooling LPG vessels, which are most affected.
 Do not try to empty LPG vessels exposed to fire : They become more
vulnerable to overheating as their liquid content decreases.
5.7 FIRE FIGHTING EQUIPMENT

Water based protection system for the purpose of Fire Fighting is provided
as per OISD norms. Other fire fighting equipment such as number and size
of the fire extinguishers, fire hoses, hydrant points etc. are provided as per
the guidelines given in HSE Manual and OISD-STD-144/169. For different
types of firefighting equipment and for different types of fire fighting
strategies OISD-STD-115 may be referred. A general arrangement of fire
fighting facilities provided are described below :
5.7.1 FIRE WATER SYSTEM
Water is used for extinguishing or control of fire, cooling of

vessels / equipment and exposure protection of
equipment and personnel from heat radiation.
5.7.1.1 COMPONENTS OF FIRE WATER SYSTEM
The main components of the system are :

 Fire Water Storage
 Fire Water Pumps
 Fire Hydrant / Monitor distribution piping network.
 Water Sprinkler / Deluge system.

DEPARTMENT 5
March 2014 5-18
5.7.1.2 DESIGN CRITERIA
(a) Fire water Facilities shall be preferably designed on the basis of

water supply sources available in the plant and surrounding areas.
(b) The single largest fire risk shall be considered.
(c) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG
Pump Houses, Bulk Lorry and Tank Wagon Gantries shall be fully
covered by medium velocity water spray system.
(d) Fire Protection Facilities shall have fire fighting access, means of
escape in case of fire and also segregation of facilities so that the
adjacent facilities are not endangered during the fire. The layout
shall permit access from at least two directions.
(e) Detection of fire for automatic actuation of medium velocity water

sprinkler system shall be provided at all critical places like LPG Bulk
Storage, Tank Truck / Tank Wagon Gantry, near Carousal, LPG
pump / Compressor House, Evacuation, Valve Change Shed etc.
5.7.1.3 FLOW RATE DESIGN
The Fire Water pumping requirement shall be calculated

based on minimum spray density as under or actual
whichever is more:
Storage Vessels - 10.2 LPM/Sq.m

LPG Shed - 10.2 LPM/Sq.m
LPG Pump/compressor House - 20.4 LPM/Sq.m
LPG Loading racks - 10.2 LPM/Sq.m
Storage Vessels : In case of Bulk Storage of LPG, automatic detection of

heat for automatic actuation of medium velocity (MV) sprinkler system
having remote / locally operated deluge valve with spray density of
10.2 LPM/Sq.m of surface area shall be provided. For water flow

calculations for adjoining vessels within the distance of R+30 m. (Where R is
the Radius of the LPG vessel and 30 Ms. shall be measured from the

DEPARTMENT 5
March 2014 5-19
periphery of the LPG vessel), water density for cooling shall be considered
at the rate of 10.2 LPM/Sq.m surface area.
Sheds : MV sprinkler system having remote operated Deluge valves at

critical places like near carousal, evacuation, valve change shed,
automatic heat detection for automatic operation of sprinkler system with
spray density 10.2 LPM/Sq.m shall be provided. The shed has to be divided
into suitable number of zones, each served by independent deluge
system. The adjacent zones are required to be operative around the zone
under fire and the same shall be considered as a single risk area.
LPG Pump House : MV sprinkler system with automatic heat detection

having remote / locally operated Deluge valve with spray density of
Maximum 20.4 LPM/Sq.m shall be provided.
Tank Lorry Gantry : In case of Tank Lorry Gantry, automatic heat detection
for automatic actuation of MV sprinkler system having remote/local
operated Deluge valve with spray density 10.2 LPM/Sq.m of surface area
shall be provided. A maximum of 8 bays shall be considered as single risk
area.
Tank Wagon Gantry ; MV sprinkler system with automatic heat detection

having remote/local operated Deluge valve with effective spray density of
10.2 LPM/Sq.m. shall be provided. A minimum of one gantry (600 MT) shall
be considered as single risk area. The spray system shall cover tank wagon
surface on either side of the tank wagon gantry as well as the associated
LPG pipelines in the gantry. The concept of Zones can be adopted as
described in OISD 144.
Fire Water Flow Rate : Typical examples for calculation of fire water
flow rate for various sections in the bottling plant are given in Appendix
No. I
5.7.1.4 FIRE WATER STORAGE
Water for the hydrant service shall be stored in any easily accessible
surface of underground concrete reservoir or above ground tank of steel
or concrete. However, above ground tanks shall be preferred in view of
the availability of flooded suction condition for easy start of the fire water
engines. The effective storage capacity shall be not less than 4 hrs.
aggregate working capacity of fire water pumps.

DEPARTMENT 5
March 2014 5-20
Storage tank / reservoir shall be in two inter connected compartments to

facilitate cleaning and repairs. In the case of steel tanks, there shall be a
minimum of two tanks.
5.7.1.5 FIRE WATER PUMPS
5.7.1.5.1 Centrifugal type water pumps for fire service shall be installed to meet the
designed rate of discharge and total head. These pumps preferably
should have a flooded suction
5.7.1.5.2 There shall be a jockey pump of capacity not less than 10 Cu.m/hr. per
100 Hydrant Points. ( one Monitor is equivalent to 4 Hydrant Points). The
system pressure has to be maintained at 7 kg/cm2 (g) with the help of
Jockey Pump operating automatically. The Jockey Pump shall be quick
auto start-stop type with the help of pressure switches. A standby jockey
pump shall be provided if the number of hydrant points are more than
100.
5.7.1.5.3 The fire water pump(s) including the stand by pump(s) shall be of diesel
engine driven type. The pump shall be capable of discharging 150% of its
rated discharge at a minimum of 65% of the rated head. Each engine
shall have an independent fuel tank of suitable size for 6 hrs. continuously
running.
5.7.1.5.4 Number of stand by pumps shall be provided as per following criteria :
(a) 1 no upto 2 main fire pumps

(b) 2 Nos. for 3 or higher no. of Main pumps.
5.7.1.5.5 Fire water pump house / fire water tanks or reservoir shall be located
at least 60 M. (minimum) away from LPG facilities.
5.7.1.5.6 Fire water pumps shall be exclusively used for fire-fighting purpose only.

DEPARTMENT 5
March 2014 5-21
5.7.1.6 FIRE HYDRANT NETWORK
Fire hydrant ring main should be normally laid above ground. Following
precautions should be taken for laying fire water ring main above ground
:
a. Pipe line shall be laid at a height of 300 mm to 400mm above the
finished ground level.
b. The mains shall be supported at regular intervals not exceeding 6
meters.
c. The system for above ground portion shall be analyzed for
flexibility against thermal expansion and necessary expansion loops,
wherever required, shall be provided.
However the ring main shall be laid underground at following places :
(a) Road crossings.

(b) Places where above ground piping is likely to cause obstruction to
operation and vehicle movement.
(c) Places where above ground piping is likely to get damaged
mechanically particularly in the LPG storage area where water
supply lines are laid for feeding sprinkler deluge system.
(d) Where frost conditions warrant and ambient temperature is likely to
fall below zero deg. centigrade, underground pipe lines at least 1
meter below the ground level should be provided.
(e) If fire water ring main is laid underground, the following
precautions shall be taken :
(i) (The ring main shall have at least one meter

earth cushion in open ground and 1. 2 meters. cushion under
the road crossings.
(ii) The ring main shall be provided with protection against soil
corrosion by suitable coatings/ wrappings.
(iii) In case of poor soil conditions, it may be necessary to provide
concrete / masonry supports under pipe line.
(f) Fire water ring main shall be sized for 120% of the designed water
rate. Designed flow rates shall be distributed at nodal points to give
the most realistic way of water requirements in case of an
emergency.
(g) The fire water network shall be kept pressurised to a pressure of
about 7 kg/sq.cm.(g) with the help of one or more Jockey pumps.

DEPARTMENT 5
March 2014 5-22
(h) Hydrants / monitors shall be located bearing in mind that the fire
hazards at different sections of the premises are to be anticipated
and to give most effective service.
(i) Hydrant / monitors shall be provided for every 30 meters in case of
hazardous areas and may be spaced 45 meters in other areas.
(j) Connections for fire water monitors shall be provided with
independent isolation valves.
(k) Hose boxes with 2 nos. of hoses and a nozzle shall be provided at
each hydrant points.
(l) Considering radiation levels in the event of a fire, hydrants /
Monitors / Control valves shall be located at a safe distance
(minimum distance of 15 meters) and from hazardous equipment /
buildings.
(m) The Deluge valves shall be located out side the kerb wall at a safe
distance in case of LPG spheres / bullets and 15 meters away from
the limits of LPG cylinder sheds. A fire wall shall be provided for the
protection of Deluge valve and for operating personnel.
(n) The above ground fire water main and the fire hydrant stand post
shall be painted with corrosion resistant "Fire Red" paint.
(o) Water monitor and hose box shall be painted with "Luminous Yellow”
paint.
5.7.1.7 MEDIUM VELOCITY SPRAY SPRINKLER SYSTEM
a. Medium velocity spray sprinkler system based on heat and other

detection shall be employed.
b. Quartzoid Bulb protection can be provided in the open areas or in

the sheds. The Quartzoid bulbs are designed to break at 79 deg.
centigrade (max.). Quartzoid bulb network shall be maintained with
plant air at a pressure of about 2.5 - 3.5 kg/sq.cm2.g through a
restriction orifice such that the discharge of air through one
Quartzoid bulb will de-pressurize the downstream side of the
restriction orifice.
c. The actuation of QB detectors and actuation of Deluge Valves

through local air bleeding or from remote control panel shall initiate
the following :
(I) An audio visual alarm at the local / main control panel and
fire water station, indicating the vessel on fire.

DEPARTMENT 5
March 2014 5-23
(ii) Remote operated valve of the affected area will close.

(iii) LPG Pumps and compressors will trip.
(iii) The deluge valves on fire water supply lines of affected area
will open.
(v) The diesel pump will start based on the set pressure
to supplement / to maintain the fire water pressure in the
ring main.
d. ROV’s of fire-safe type shall be provided.
5.7.2 FIRST AID FIRE FIGHTING EQUIPMENT
Requirement of First Aid Fire Fighting equipment shall be OISD 144/169 for
LPG Bottling Plants
5.7.2.1 PORTABLE FIRE EXTINGUISHERS
a. Portable fire extinguishers shall be located at convenient locations

and shall at all times be readily accessible and clearly visible.
b. The maximum running distance to locate an extinguisher in the

working areas shall not exceed 15 meters.
c. The top surface of the extinguisher shall not be more than

1.5 metres high.
d. 100% spare CO2 cartridges and 50% (Min) spare DCP bags (as per
Fire Extinguisher Capacities) shall be stored in each plant.
5.7.2.2 WHEELED / MOBILE FIRE FIGHTING EQUIPMENT
a. One No. Mobile 75 Kg DCP Fire Extinguisher each shall be provided in

the filling shed, LPG storage vessels / LPG pump house area, tank
truck loading / unloading gantry area & tank wagon loading /
unloading gantry area.
b. The Dry Chemical Powder used in the extinguishers shall be

Potassium / Urea based or Sodium Bicarbonate as per IS:4308.
Nitrogen / Carbon Dioxide shall be used as expellant gas.

DEPARTMENT 5
March 2014 5-24
c. Considering the large area and number of operations involved in

Mega LPG plants, special fire fighting facilities like DCP fire tenders
should preferably be provided.
d. A trolley with suitable First Aid Fire Protective Accessories shall be

readily available in the LPG plant.
5.7.2.3 HOSES NOZZLES AND ACCESSORIES
a. Reinforced rubber lined hoses (63mm dial.) conforming to IS:636 (type

A or B) shall be provided.
b. The hoses shall be of 15 Meters standard length and shall be provided

with Gun Metal / Aluminum alloy male & female couplings of
instantaneous pattern.
c. 50% spare Hoses shall be stored in the LPG plant.
d. 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 Triple Purpose Nozzles in the plant.
5.8 FIRE ALARM COMMUNICATION SYSTEM

5.8.1 FIRE ALARM SYSTEM
a. Sufficient number of manual call points shall be provided in the plant.

b. Electrically operated Fire Siren shall be audible to the farthest distance
in the plant (1 K.M. from the periphery of the plant).
c. Manually operated fire sirens shall be provided at strategic places.
5.8.2 COMMUNICATION SYSTEM
Good communication is an essential element in the fire protection system

of any plant. The following communication systems should be provided in
the LPG plants :
5.8.2.1 Telephone : For general communication, a separate telephone should

be provided. Hot line telephone for contacting mutual aid parties shall

DEPARTMENT 5
March 2014 5-25
be provided wherever possible. In the hazardous areas, flame-proof

telephones shall be provided.
5.8.2.2 Public Address System : Public address system should be connected to all
control rooms, administration building (all floors), all departmental heads,
security etc. Telephone exchange should control and take care of this
system.
5.8.2.3 Fire Sirens : The Fire siren(s) should be located suitably to cover the whole
area with the operational control in the Fire station control room. These
should be tested at least once in a week to keep them in working
condition. Fire siren code should be as follows :
(a) Fire situation: A wailing siren for two minutes. Sirens will be sounded
three times for thirty seconds with an interval of fifteen seconds in
between.
(b) Disaster: Same type of siren as in the case of fire but the same will
be sounded for three times at an interval of one minutes.
(c) All clear (for fire): Straight run siren for two minutes.
(d) Test: Straight run siren for two minutes.
5.8.2.4 Walkie-Talkie / Wireless :All the Fire Tenders shall be provided with a
walkie-talkie/ wireless system which will help in communicating with the
people, in case other systems fail. Besides, key personnel coordinating
emergency operations should also be provided with walkie-talkie.
5.8.2.5 Fire Alarm System : Fire alarm points shall be provided at suitable
locations like access point, approach roads, walkways etc. to cover the
critical areas with a control panel in the Fire station control room. The
location should be conspicuously marked for proper identification.
5.9 SPECIAL FIRE PROTECTION

5.9.1 The most hazardous situation in LPG vessel is the possibility of BLEVE. This
usually takes place when the vessel is subjected to external fire.

DEPARTMENT 5
March 2014 5-26
5.9.2 The vapour space portion of the shell gets overheated and fails even at
the operating pressure. As such, it is important that the metal
temperature in the vapour space is protected from overheating by some
measures. A passive measure like fire proofing/ insulation or fire retardant
coating will provide protection in the initial period of fire which is very
crucial. This will give some breathing time for activating other fire fighting
measures like starting of pumps, organizing people, opening of valves
etc. This will also take care of automation failure wherever it is provided.
5.9.3 The fireproofing of LPG storage vessel should be decided based on the
risk analysis keeping in view the local considerations, availability of water
and societal risk.
5.9.4 Fire-proofing provided on the vessel and supporting legs shall be

adequate to protect the shell material from overheating and
consequent failure. The material provided for fire-proofing purpose shall
be good enough to provide this protection for the initial period of 30-60
minutes. Based on this, it is recommended to provide the minimum
rating for fire proofing as follows :
(a) LPG storage vessel & connected - 1 hour

lines up to the fire safe ROVs
(b) Supporting legs of all above - 2 hours
5.9.5 Before the fire-proofing application, protected metal surfaces shall be

prepared through such means such as sand-blasting and corrosion
protective primers. Particular attention shall be given to the top junction
of the fire-proofing with the protected metal to prevent water ingress.
5.9.6 Fire water line to each sphere should be so routed that it is not exposed
to direct fire. This is to protect it from the failure in the initial period, when
water flow has not commenced. It is recommended that the riser should
be located away from the 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 the storage vessel or in the drainage paths.
5.10 EQUIPMENT UTILISATION / LIMITATIONS

5.10.1 Each fire control medium (i.e. Dry Chemical Powder, CO2, water) and
each piece of equipment is more suitable for some emergencies than

DEPARTMENT 5
March 2014 5-27
others, and all have their own limitations. The following points should be
remembered:
(a) For any equipment, the field of effectiveness and capacity are
the two important characteristics.
(b) Portable extinguishers, wheeled units and water streams from

small bore nozzles fitted to hoses are useful on small fires.
(c) Because the volume of extinguishing agent (CO2, or Dry Chemical

Powder) available from portable extinguishers is necessarily
limited, they must be used carefully (but without loss of time) and
sufficient numbers should be available in reserve
(d) . Water spray is satisfactory for protecting the adjacent

equipment / facilities, for controlling the intensity of fire and for
inducing air movement to disperse or dilute vapour.
(e) Combination type spray nozzles, which provide a high velocity jet
for reach and hitting power, are specially useful. They can be
used both for ‘know down’ fires under pressure and to provide
water screen protection for personnel, important equipment and
pressure vessels.
In general, the scale of fire-fighting equipment needed depends

upon the size of the risk to be covered.
5.11 AUTOMATIC DETECTION / PROTECTION SYSTEMS

5.11.1 AUTOMATIC GAS DETECTION /ALARM SYSTEM
The system consists of sensors provided at various vulnerable points

in the plant area which give audio/visual alarm to the control room
and required locations in the plant whenever concentration of
LPG vapour exceeds the pre-set values. This helps in taking
immediately corrective action and preventing possible accidents
by limiting the hazard.
The minimum detectors facility wise are as given below as per OISD 144
& OISD 150. Any Changes in the same shall become applicable:

DEPARTMENT 5
March 2014 5-28
Storage vessels (above ground) – 1, No. top and 1 No. near bottom
ROV. LPG pump house 1 No. in pump house and 1 No. in manifold. Filled
cylinder shed - 2 Nos. Valve change shed – 1 No. Empty-cum-filling shed –
2 Nos. near carousel, 1 No. near evacuation unit tank, 1 No. weight
correction unit, 1 no. at degassing shed ( if separate shed is there), 1 no.
at 47.5 Kg Filling machine if provided. TLD – one at each manifold and at
ends. Tank wagon gantry – 1 no. for every two bays or 30 m whichever is
less at bottom. Additionally, some detectors at selected locations shall be
provided at the top of platform. The number and location of the
detectors required over and above the minimum requirements specified
above shall be as per the specific requirements identified in the risk
analysis / HAZOP study report.
Audio visual alarms showing the location of gas leakage shall be

provided on the control panel. First level alarm can be set at 20%
(Warning) Low Explosive Level (LEL )and second level alarm at 60% LEL
(Alarm) during which all LPG related activities in the affected area shall
be stopped and necessary action to control leakage shall be taken.
Care shall be taken to avoid spark generation in such situation and
therefore all vehicular engines in the surrounding area to be stopped and
local start/stop of electrical switches/ buttons to be avoided.
Plant shall prepare and display instructions prominently for action

to be taken in case an alarm is sounded in the GMS. The
instructions prepared shall distinctly tell about action to be taken at
different level of LPG concentrations . All employees and security
personnel shall be trained with respect to action to be taken in
case of such emergency.
5.11.2 VAPOUR EXTRACTION SYSTEM
A gas extraction system having suction points at critical places

where gas concentration is likely to be such as near carousal, evacuation
unit, valve change shed , Degassing shed, etc., shall be provided. Further,
it shall be interlocked with filling machine so that filling do not start without
vapour extraction unit being functional.

DEPARTMENT 5
March 2014 5-29
5.11.3 AUTOMATIC SHUT-OFF SYSTEM (ROVS)
The system is provided for closing shut-off valves ( Remote Operated

valves- ROVs) quickly on liquid lines in the event of an emergency. The
system is operated pneumatically. The valves connected to the system
get closed automatically when the air pressure in the pneumatic system is
reduced through bleeder valves provided at various points in the plant
for quick access. The shut-off ROVs are normally located on the storage
vessel outlets, pipe lines leading to tank wagon gantry, and tank truck
bays and pipe lines leading to the filling shed. Whenever the bleeder
valve is opened to actuate closure of the valves, the system gives
automatic audio/visual alarm and also a signal to the control room, if
provided with EP System. All ROVs to be provided with manual air drain
valves for closure of ROV from safe distance. Each ROV shall also be
provided with prominent open-close indicators.
5.12 INSPECTION AND MAINTENANCE OF FIRE-FIGHTING

FACILITIES
5.12.1 GENERAL : Automatic gas detection systems and fire-fighting systems
incorporate very sophisticated instrumentation. Recommendation of the
manufactures should, therefore, be referred not only for operation, but
also for inspection and maintenance.
All the key points in the fire fighting system should be checked daily and
corrective action should be taken wherever required. The following
points are to be checked :
(i) Water level in the static water tanks.

(ii) Water supply arrangement
(iii) Water level in the priming tanks in fire pump house.
(iv) Pressure on delivery system.
(v) Pump on automatic / manual start position.
(vi) Power supply in the pump-house.
(vii) Level in fuel tanks of fire-pumps.
(viii) Engine-oil level in diesel driven pumps.
(ix) Line-up of valves.
(x) Line pressure on hydrant lines.
(xi) Free rotation of water monitors.
(xii) Lugs on hydrant points available / acting free.
(xiii) Hoses/nozzles available in hose box.

DEPARTMENT 5
March 2014 5-30
(xiv) Deluge valves, Pressure switches, nozzles on sprinkler system.

(xv) Alarm on annunciation panel.
(xvi) Electric siren / hand operated siren in working condition.
5.12.2 WATER SUPPLY : Interval for inspection of water supply facilities is

suggested every month. The determination of the volume could be
gained by discharge through hydrants or other outlets, observing the
supply pressures. An inspection of the actual supply source is
recommended with the objective of determining that an adequate
supply could be made over a projected period of time. Sufficient water
should be made available in the storage vessels in the plant as per OISD
norms.
SPRAYING SYSTEM : If the storage vessels and other fixed equipment

within the plant are protected by fixed water sprays, they should be
tested minimum once in a week. When automatic actuating
equipment is included in the system, an emergency condition should
be simulated so that the working of the automatic system could be
checked.
5.12.3 SPRINKLERS : Periodically, the complete system should be put into

operation, taking into consideration whatever precautionary measures
that may be necessary to protect the machinery and equipment, which
might be exposed to water discharge from the sprinklers. During the
quarterly checks, the effectiveness of the operation of the automatic
control devices should be verified including interlock shutdown system as
per OISD 144 11.11 (iv) and records should be maintained in the standard
formats
5.12.4 FIRE EXTINGUISHERS : To be effective, fire extinguishers must be kept in

perfect operating condition at all times. They should be visually
inspected externally at least once in a month and detailed inspection
should be conducted quarterly internally also. Each fire extinguisher
should have the date of inspection stenciled on its body. For further
details on maintenance and record of fire extinguishers “ Safety and
Environment Protection Manual” can be referred. DCP Fire extinguishers
shall be hydro tested once in 3 years. For further details HSE manual shall
be referred
5.12.5 PRECAUTIONS AGAINST SYSTEM FAILURE : In the event of an inspection, if

the plant water system or the sprinkler system reveals deficiencies,

DEPARTMENT 5
March 2014 5-31
immediate corrective action should be taken. A report should be made

immediately to the Plant Manager with the objective of immediately
determining whether or not normal plant operation can be continued
during the time that remedial work is being undertaken. Any condition
which materially reduces the effectiveness of the fire protection system
should be immediately reported to the Plant Manager for taking
corrective/ preventive actions.
5.13 FIRE FIGHTING ORGANISATION PLAN
5.13.1 A plan of action for use in the event of a major LPG product leakage with
a fire or risk of fire is essential. Such plan should be carefully prepared by
the Plant Manager. It must be fully understood by all the plant supervisory
personnel and other personnel responsible for taking action as per plan. It
can be based on the following
(a) Plant personnel should be fully trained for the specialised

techniques necessary for combating LPG leakages and LPG fires.
(b) If leakage and / or fire occurs, it is the duty of all personnel to use
the equipment provided, and to carry out their allotted tasks as
detailed in the “Fire Fighting Organization Plan’.
(c) All personnel must know how to identify fire control equipment
suitable for use with LPG also its location and how to use it.
(d) Plant personnel must know the position and method of

operation of all safety valves and remote operated valves in the
plant.
(e) Plant personnel must be familiar with the standard recognition

markings of fire control, first-aid and all safety equipment. They
must know the location of emergency exits and water hydrant
points and must be familiar with the sound of the emergency (fire)
alarm.
(f) The “Fire Fighting Organization Plan” together with layout of fire
fighting and safety devices must be displayed at prominent places
after explanation to all personnel. It should include the following
functions, expanded to suit the local facilities / requirement :

DEPARTMENT 5
March 2014 5-32
(i) Sounding the emergency (fire) alarm.

(ii) Shutting off the LPG supply to any leakage point / fire.
(iii) Summoning the Fire Brigade / Police.
(iv) Fire control, with first-aid and firefighting equipment.
(v) LPG vapour dispersal.
(vi) Operation of LPG vessel’s fixed water sprinkler systems,
starting of fire pump(s) and application of water hose jets /
sprays for containing / extinguishing fires.
(vii) Cooling of vessels / cylinders and other equipment / facilities.
(viii) Closing down all operations in the plant including closure of
valves and stopping of pumps.
(ix) Preventing all sources of ignition in case of LPG leakage.
(x) Evacuation and mustering of personnel.
(xi) Establishing an emergency fire-control centre.
(xii) Traffic control.
(xiii) Stations and duties of all personnel.
(xiv) Policing of affected areas.
(xv) Any other specialised duties.
(xvi) Display of Fire Brigade, Ambulance, Police telephone
numbers, etc.
(xvii) All clear signal by a competent person.
5.13.2 LIAISON WITH LOCAL FIRE BRIGADE
The local fire brigade should be made familiar with the plant layout
showing in addition to the operating facilities, the position of all fire
control equipment, water sprinkler system, mains and hydrants, and
the position of all important equipment including the emergency / safety
valves. They should also be well informed regarding the extent of the
operation carried out, e.g. volume of product normally held in bulk,
cylinders, vehicles, etc.
Close co-operation with the local fire authorities is essential and should
take the following form :
(a) The Fire Brigade should be made familiar with the location of
important facilities, all the fire control equipment / facilities
provided, and their method of use. The holding of fire drills /
exercises jointly by the plant personnel and local fire-brigades
should be considered.

DEPARTMENT 5
March 2014 5-33
(b) Fire Fighting equipment at the plant should be compatible with the
fire brigade equipment. Otherwise, adaptors should be kept ready
for hoses, hydrants, etc.
(c) The fire brigade should be aware of “Fire Fighting Organisation

Plan” of the plant and the views held at the plant regarding the
most effective LPG fire control methods.
(d) In the event of an emergency / fire, the Plant Manager and /or his
representative must advise the Fire Officer about the particular or
potential hazards that may be present, e.g. stocks of filled cylinders
at that particular point of time.
(e) Liaison should also be maintained with other nearby oil Companies
/ Industrial plants to provide mutual assistance in case of an
emergency.
5.13.3 MOCK FIRE DRILL TRAINING
(a) Mock Drills for all plant personnel, making use of the “Fire fighting
Organization Plan” and practicing the specialised techniques
required for fighting LPG fires or dispersing / diluting LPG vapour
clouds, should be held minimum once in 30days.
(b) (The drills should cover various types of incidents , e.g. major
spillage of LPG, bulk tank truck fire, cylinder fire, etc.
(c) Extinguishers due for re-charging should be discharged during drills

and replenished subsequently. The fire pump should be operated,
sprinkler system activated, emergency systems tested, water hoses
run out and spray / jet techniques practiced during drills.
(d) Fire alarms should be tested for proper sound (neighbouring plants /
factories and the Fire Brigade should be warned in advance of this
test.)
(e) Protective clothing, breathing apparatus and any other specialised

safety equipment available must be tried out during drills to train all
concerned in their application.

DEPARTMENT 5
March 2014 5-34
(f) The local Fire Brigade could be encouraged to participate in the

fire-drills periodically. Any shortcomings noticed during the drills
should be explained to the participants and rectified immediately.
5.13.4 RECORDS AND REPORTS ON DRILLS
a. The Plant Manager should ensure that records of all LPG emergency
(fire) drills held are maintained in the ‘Fire Drill Record‘ book.
b. Records should include details of the equipment used, demonstrations

staged, emergencies simulated, shortcomings observed and
corrective action taken.
c. Testing / maintenance of all fire control and safety equipment and

alarms should be recorded. Any deficiencies should be noted and
rectified as quickly as possible.
5.14 FIRE PROTECTION SYSTEM -INSPECTION AND TESTING

The fire protection equipment shall be kept in good operating condition
all the time and the fire fighting system shall be periodically tested for
proper functioning and logged for record and corrective actions. In
addition to the routine daily checks/maintenance, the following
periodical inspection/testing shall be ensured:
5.14.1 FIRE WATER PUMPS
Every pump should be test run for at least half an hour minimum two
times a week. Once in a month, each pump should be checked and
tested and the shut off pressure observed and logged. Once in six
months each pump should be checked for performance. This may be
done by opening the required number of hydrants/monitors depending
on the capacity of the pump and by verifying that the discharge
pressure, flow and motor load are in conformity with the design
parameters. For the flow measurement suitable device, like ultrasonic
instrument may be considered.

DEPARTMENT 5
March 2014 5-35
5.14.2 FIRE WATER MAIN
The ring main should be checked once in a year for the leaks etc. by
operating one or more pumps with the hydrant points kept closed as
required to get the maximum operating pressure. The ring main, hydrants,
monitors, valves should be visually inspected every month for any
pilferage, defects and damage. All fire main valves should be checked
for operation and lubricated once in a month. Flushing of fire water
header ring main shall be flushed weekly section/loop-wise through a
return line provided for the purpose from the header to fire water tanks as
per HO guidelines. Pipeline sections having dead ends shall be flushed
through blow down drain at the dead end.
5.14.3 FIRE WATER SPRAY SYSTEM
Fixed water cooling spray systems on storage tanks should be tested at

least once in three months. Deluge systems on LPG spheres and bullets
should be tested at least once in three months for proper performance.
Spray system in the plant should be tested at least once in every quarter.
Trailer mounted pumps should be tested for running at least once in a
week. All the fire hoses should be hydraulically tested at least once in six
months. Records shall be maintained of all maintenance, testing and
remedial/ corrective action taken wherever necessary.
5.14.4 COMMUNICATION SYSTEM
Electrical Fire sirens should be tested at least once in a

week.
5.14.5 GAS DETECTORS
The operability of Gas Detectors should be tested once in every months

for audio-visual indication in the control panel by subjecting the sensors
to leaked gas in controlled manner. Calibration of gas detectors using
test gas should be done once in every quarter or as per manufacturer's
recommendation, whichever is earlier.
5.15 FIRE PROTECTION TRAINING

5.15.1 All the plant personnel shall be trained on fire prevention and fire fighting
aspects. Fire fighting refresher training shall be given periodically. The fire

DEPARTMENT 5
March 2014 5-36
crew belonging to the fire fighting department shall be given intensive

training for the use of all equipment and in various fire fighting methods
for handling different types of fire.
5.15.2 A mock fire drill should be conducted once in a month to rehearse the
fire emergency procedures and to keep the fire fighting team trained
and alert and facilities in top order.
5.16 FIRE EMERGENCY PROCEDURES

5.16.1 Each installation shall prepare a detailed "Fire Emergency Procedures"
manual for the use by the plant. The fire emergency procedures including
fire fighting plan should be prepared for fighting fire in the process units, in
and around storage vessels and bullets, product loading gantries,
separators, electrical system, warehouses and buildings etc.
5.17 PASSIVE FIRE PROTECTION MEASURES

5.17.1 Although adequate fire protection is provided in the plant, passive fire
protection measures as indicated below should be adopted wherever
required:
(i) Fire proofing of structural members.

(ii) Spark arresters and flame arresters.
(iii) Fire separation walls in concealed space / Electrical substation /
transformer yard / bays / cable galleries.
(iv) Vapour seals in all the drains leaving Battery area / dyke walls.
(v) Lightening arresters.
(vi) Venting facilities.
(vii) Electrical relays and Fuses, earth leakage circuit breakers,
neutral current circuit breakers.
(viii) Fire retardant coatings and tapes for cables.
(ix) Fire resistant low smoke insulation cable.
(x) Flame proof electrical enclosure and trippings as per
recommendation of the equipment manufacturer.
(xi) Check valves shall be provided in the downstream of each
pump in order to minimize back flow.
(xii) Level switch shall be provided in seal oil system to trip the LPG pump
in the event of seal failure.

DEPARTMENT 5
March 2014 5-37
APPENDIX No. I
TYPICAL EXAMPLE FOR CALCULATION OF FIRE WATER FLOW RATE
1. DESIGN BASIS
The fire water system in the plant shall be designed to meet the
highest fire water flow requirement of a single largest risk of any of
the facilities at a time plus 288 Cu.m/Hr. for operating 2 Nos. Fire
water Monitors/ Supplementary Hose requirements. The Fire Water
pressure system shall be designed for a minimum residual pressure
of 7.0 kg/ cm2 g at the remotest place of application in the plant.
The calculations given below are illustrative. OISD standards and
guidelines from HO LPG latest as applicable to be referred for
details.
2. LPG SPHERES AREA PROTECTION
(a) Data:
No. of spheres in one area = 3
Diameter of each sphere = 17 meters.
(b) Cooling water requirement:

water rate for cooling = x17X17 x 10.2
= 9526.09 lpm
= 555.365 m3/hr
Considering other 2 spheres located within (R+30) ms. from

centre of sphere and fire cooling water rate for 3 spheres
= 3 x 555.365m3/hr = 1666.096 m3/hr
(c) Hose stream requirement = 288 m3/hr
(d) Total water requirement = 1954.096 m3/hr
(e) Fire Pump capacity ( given ) = 410 m3/hr
(f) No. of Fire Pumps required = 1954.096/410 ~ 5
(g) total Fire engine required = 5 + 2 standby = 7
(h) Fire water Storage required for 4 hrs.= 410*5*4 = 8200 KL
( Aggregate pumping capacity of main fire pumps )

DEPARTMENT 5
March 2014 5-38
Note: Manifold area & any other connected facility with vessel
covered by sprinklers, to the sphere area to arrive at actual flow
requirement )
3. SHED /PROCESS UNIT PROTECTION
i) Cold Repair Shed: 19.6 meter*19.60 meter=384 SQ MS
(a) At 10.2 lpm/m2, water required: =235 m3/Hour

(b) Roof Cooling/Structural/Manifold =266 m3/hour
(c) Hose stream requirement =288 m3/hour
(d) Total water required =789 m3/hour.
ii) Empty cum filling shed : 1332 SQ MS area for 3 zones
(a) At 10.2 lpm/m2, water required: =815.184m3/Hour

(b) Roof Cooling/Structurals/Manifold =635 m3/hour
(d) Total water required =1739.184m3/hour
iii) Filled cylinder shed =1443 SQ MS
a)At 10.2 lpm/m2, water required: =883.116m3/Hour

b)Roof Cooling/Structurals/Manifold =755 m3/hour
c)Hose stream requirement =288 m3/hour
d)Total water required =1927.116m3/hour.
iv) TLD Gantry : (15.0 m*4.5 m* 8 nos)= 540 SQ MS
(a) At 10.2 lpm/m2, water required: =330.48 m3/Hour

(b) Roof Cooling/Structurals/Manifold =266 m3/hour
(d) Total water required =884.48 m3/hour.

DEPARTMENT 5
March 2014 5-39
v) TOTAL DESIGN FIRE WATER RATE
Fire water rates for 5 cases are given below :
Sphere = 1954.096 m3/hr

CR Shed = 789 m3/hour.
Empty cum filling shed : = 1739.184m3/hour
Filled cylinder shed = 1927.116m3/hour.
TLD Gantry = 884.48 m3/hour.
Highest fire water flow requirement of a single largest risk of any of

the above facilities at a time including 288 Cu.m /Hr. for operating
2 Nos. Fire water Monitors/ Supplementary Hose requirements
Total design fire water rate required is = 1954.096 m3/Hour.
BACK
6
BULK STORAGE AND HANDLING FACILITIES

THE GUIDING PRINCIPLE GOVERNING
DESIGN, CONSTRUCTION, OR OPERATION
OF ANY LPG FACILITY SHOULD BE “SAFETY”


DEPARTMENT 6
BULK STORAGE & HANDLING PAGE No.
March 2014 6-1
FACILITIES
6.1 GENERAL
6.1.1 This chapter covers the description of various facilities and equipment
provided at LPG bottling plants for storage and handling of bulk LPG.
6.1.2 Details of operation, Inspection and maintenance of the facilities are

covered in the Chapter No.7. The details regarding safety and fire
protection arrangements are covered in the Chapter No. 5.
6.1.3 Bulk storage facilities at LPG plants are installed in accordance with “The
Static & Mobile Pressure Vessels (Unfired) Rules, 1981” (SMPV Rules). The
conditions of the relevant licenses required as per the rules must,
therefore, be complied with. This should be ensured before
commissioning of any facility / equipment and thereafter during
operation of the vessels.
6.1.4 For further detailed information on bulk storage and handling facilities
OISD STD-144 may be referred.
6.2 STORAGE FACILITIES

6.2.1 MECHANICAL DESIGN PARAMETERS
6.2.1.1 The mechanical design of storage vessel are based on the following
considerations:
(a) Design Code : ASME SEC. VIII or IS-2825 or PD 5500 ( formerly BS 5500
) or equivalent duly approved by CCOE.
Design shall take into account “Static and Mobile Pressure Vessels
(Unfired) Rules 1981” and subsequent amendment revisions , if any .
A single code shall be adopted for the design, fabrication,
inspection and testing, i.e. ASME and BS shall not be combined.
(b) Material : Micro-alloyed steel containing Ni, Mo, VA is not

considered.
For Marketing installations, where H2S is not present, ASTM A 516

Gr.70 or SA 537 CLASS 1 is recommended.

DEPARTMENT 6
March 2014 6-2
FACILITIES
(c) Marketable LPG conforming to IS: 4576 & IS: 14861 is having a
maximum vapour pressure of 16.87 Kg/cm2. (g) at 650 C
temperature
(d) Presently, the pressure vessels are being designed for a design
temperature of -270 C to 550 C with a design pressure of 15 Kg/cm2
at the top of the vessel at 55o C
(e) Other Considerations :
(i) Corrosion Allowance : 1.5 mm (minimum)

(ii) Radiography : Full
(iii) Stress Relieving : 100% irrespective of thickness.
(iv) Wind pressure : as per IS: 875
(v) Earthquake pressure : as per IS: 1893
(vi) Hydro test pressure : As per design code
6.2.2 VARIOUS METHODS OF STORAGE
6.2.2.1 Above Ground Storage
(a) Pressurised storage of liquid LPG at ambient temperature : LPG to

remain in liquid form at ambient temperature, application of
pressure is required. For storage under pressure, the vessels are
designed to withstand safely the maximum vapour pressure which is
likely to reach at the maximum assessed ambient temperature. The
assessed maximum temperature for un-insulated pressure vessels as
per Statutory Rules is 55C. However, for the purpose of additional
safety, even for insulated / mounded vessels, the maximum assessed
temperature is considered as 55C.
(b) Refrigerated Storage of LPG around atmospheric pressure :

Refrigeration plant and the storage of cooled product at
approximate atmospheric pressure may, in certain instances, prove
less costly than installing a pressure vessel. The initial cost and day-
to-day running cost vary from place to place and will depend on
the climatic conditions and the rate of off-take ex storage plant. This
form of storage is normally used for carrying the product in sea-
going tankers. It could be economical for inland storage also, if the
quantity to be stored is sufficiently large (normally above 5000 m3).

DEPARTMENT 6
March 2014 6-3
FACILITIES
(c) Cavern Storage :
This type of storage is useful in rocky terrain for huge quantities and is
cost effective. For identification of most favorable site, assistance of
expert geologists is required for determining the rock conditions and
water level by drilling number of bores at suitable depth. There are
3 types of such storage systems :
(a) Unlined Pressurised system.

(b) Lined Pressurised System.
(c) (Refrigerated System.
These storage systems are isolated from external hazards like fire,
war, sabotage, explosions and natural calamities. This type of
storage requires less area of land. In some countries (especially in
U.S.A.), large quantities of LPG are stored underground. One cavern
storage of 60000 MT LPG storage capacity was commissioned in
2008 at Visakhapatnam.
6.2.3 TYPES OF ABOVE GROUND PRESSURISED STORAGE VESSELS
6.2.3.1 The aboveground pressure-vessels are normally of three types as follows :
(a) Bullets : These are cylindrical tanks, laid horizontally on cement

concrete pedestals. Bullets are normally having maximum water
capacity up to 400m3. A typical horizontal storage vessel (Bullet),
with orientation of various fittings, is shown in Drawing No. 1. It may
be noted that at one end, the tank support is firmly anchored,
whereas the other end has a provision for sliding to allow for
thermal expansion / contraction of the bullet. Secondly, the vessel
is slightly inclined towards the liquid nozzle side to facilitate water
draining.
(b) Horton Spheres : These are spheroids, supported on vertical

columns. Horton Spheres are the most economical form of storage
for capacities more than 400m3. The area of ground required in the
case of Horton Spheres is less than that required for the equivalent
capacity using horizontal tanks. A typical horton sphere with
orientation of various fittings is shown in Drawing No. 2. As a fire
protection measure, the vessel’s supports are encased in cement
concrete and based on the recommendation of risk analysis, the

DEPARTMENT 6
March 2014 6-4
FACILITIES
fire proofing of spheres and columns may be carried out. In no

case Fire Proofing of Tie Rods should be done. Horton Spheres with
storage capacity of 400 MT- 1400 MT have been provided at IOC
plants.
(c) Mounded Storage : Mounded type storage vessels are sited above
ground, horizontally placed cylindrical vessels and completely
covered by a mound of earth or similar inert, non combustible, non-
corrosive material except for nozzles, manhole covers and
inspection covers fitted on the vessels. The mounded storage of
LPG has proved to be safer compared to above ground storage
vessels since it provides intrinsically passive and safe environment
and eliminates the possibility of Boiling Liquid Expanding Vapour
Explosion (BLEVE). The cover of the mound protects the vessel from
fire engulfment, radiation from a fire in close proximity and acts of
sabotage or vandalism. The area of land required to locate a
mounded system is minimal compared to conventional storage.
Mounded vessels with storage capacity of 100 -2100MT, have
been provided at IOC plants.
The design criterion of the mounded vessels is similar to the bullets

except additional features like earth / sand cover load, overall
differential settlement, Cathodic / protection, SRV calculations,
draining system etc. Mounded vessel, are to be provided with
Cathodic protection and shall be isolated form the unprotected
structures / surfaces by installing monolithic joints i.e. one each on
liquid and vapor lines close to vessel. ll nozzles except liquid inlet /
outlet are provided at the top of the vessel on a dome or box.
Liquid inlet / outlet nozzle shall be accessible through inspection
gallery. Six Monthly readings to monitor settlement of mound
throughout the life of the vessel shall be taken. To monitor health of
Cathodic Protection System, Pipe to Soil Potential(PSP) readings
should be recorded at regular intervals. PSP reading shall be
between (-)0.85V to (-)1.2V as per the HO Guidelines
(Refer Drawing No. 3 for bottom outlet with inspection tunnel

,Drawing No. 4 for construction methodology and Drawing No. 5
for typical nozzle arrangement mounted on top of the dome with
sprinkler system).

DEPARTMENT 6
March 2014 6-5
FACILITIES
6.2.4 CAPACITY OF TANKS
The safe maximum capacity of pressure vessels is given at Annexure No. 7

(Working of Safe-Filling Quantities For LPG Containers). LPG has relatively
high coefficient of expansion. If sufficient vapour space is not left in the
vessel, pressure inside the vessel will shoot up rapidly once the vessel
becomes liquid full on expansion due to temperature rise., Hence care is
exercised in limiting the filling of storage vessel to the filling density of LPG.
The filling density is determined so as to leave a guaranteed free space of
five percent at the reference temperature of 550C. As per Static and
Mobile Pressure Vessels (unfired) Rules - 1981, the design pressure of a
vessel without insulation or refrigeration shall not be less than the vapour
pressure of the gas in the vessel at 550C .
6.2.5 MARKING ON VESSELS
The Pressurised vessels used for storage of LPG must have following
details affixed on them :
 Manufacturer’s name and identification mark.

 The standard and code No. , on which the vessel is fabricated.
 Official stamp of the Inspector.
 Design pressure in Kg/cm2.
 Date of initial hydrostatic test and subsequent test
 Hydrostatic test pressure in kg/cm2.
 Water capacity in litres.
 Capacity for storage of LPG at 85% of water capacity
 Name of the product stored ( i.e. Liquefied Petroleum Gas).
6.3 VESSEL ACCESSORIES

6.3.1 GENERAL
(a) All fittings and accessories of the storage vessel shall be conforming
to” Static & Mobile Pressure Vessels (Unfired) Rules, 1981".
(b) Each storage vessel shall be provided with fittings as shown in the
following table:

DEPARTMENT 6
March 2014 6-6
FACILITIES
Sl. DETAILS OF FITTINGS QUANTITY

No
.
1 Inspection manhole on top 1
2 Pressure relief valves (SRV) connected to the 2
vapor space
3 Bottom nozzle for liquid inlet and outlet 1
4 Pressure gauge connected to the vapor 1
space
5 Temperature measuring device installed on 1
the Pipeline after ROV
6 Vapour inlet / outlet nozzle 1
7 Independent High Level Alarm 1
8 Fixed Liquid Level Gauge 1
9 Independent Level Gauges 2
(c) Spheres and bullets shall have a single nozzle at the bottom for the
inlet and the outlet. The nozzle shall be of seamless pipe fully
welded to the bottom of the vessel, stress relieved along with the
vessel and shall extend minimum 3 (three) metres from the shadow
of the sphere / bullet. A fire safe Remote Operated Valve (ROV)
shall be provided on this bottom nozzle at a distance of at least 3
(three) meters from the shadow of sphere / bullet. The nozzle pipe
shall have a slope of 1.5 degrees.
(d) There shall not be any other flanges, valves, manhole and
instrument tapping on this nozzle up to the ROV or at the bottom of
sphere / bullet. In order to avoid stress on the nozzle due to relative
settling of supports and sphere, support legs from the vessel
supporting the bottom nozzle should be provided. The top vapour
zone of the vessel shall be provided with nozzles for vapour inlet /
outlet, which shall also be provided with fire-safe ROV.
(e) All the fittings shall be suitable for use at not less than the design
pressure of sphere / bullet and for the temperature appropriate to
the worst operating conditions. The remote operated valves on the
lines connected to the sphere / bullet shall be fire-safe type. The
flange joints of these valves shall have spiral wound metallic
gaskets. Plain asbestos sheet gaskets should not be used. All flange
joints shall be fitted with SS Spiral wound metallic gaskets with

DEPARTMENT 6
March 2014 6-7
FACILITIES
properly sized standard studs and nuts suitable for the rating of the
flanges.
6.3.2 PRESSURE RELIEF VALVE
(a) Pressure Relief Valve is a device to protect the vessel against the
damages as a result of excessive build-up of pressure beyond the
prescribed safe limits. It is also known as ‘Safety Relief Valve’ (SRV).
Basically, there are two types of pressure relief valves:
 Single Port (Refer Drawing No. 6)
 Multi Port (Refer Drawing No. 7)
(b) Multi Port relief valves have more than one port and are used on
large containers such as horton spheres and storage bullets. For
small containers such as tank wagon bullets and tank truck bullets,
single port pressure relief valves are used. In the case of multi port
pressure relief valves, each of the ports can be isolated from the
container by the operation of the built-in isolating valve, thus
facilitating removal of that port for inspection and maintenance.
(c) While the valve retains vapour at normal working pressure, it opens
to relieve excess pressure in case of any build-up of pressure beyond
safe limits. The situations which may cause abnormal rise in pressure
are due to :
 Fire
 over-filling
(d) Minimum two pressure relief valves with 100 % relief load each are
provided on a pressure vessel as per statutory rules. The pressure
relief valves provided MUST be spring loaded. Weight loaded relief
valves are not permitted.
(e) Each relief valve MUST have the following markings :
 ‘Start-to-discharge pressure in Kg./cm2.

 Actual rate of discharge in cubic meters per minute of the gas
at 15oC and at atmospheric pressure.

DEPARTMENT 6
March 2014 6-8
FACILITIES
 Manufacturer’s name.
 Date of Manufacture and Batch/Serial Number
 Test date of the SRV
(f) A positive shut-off valve MUST be provided between the vessel and
relief valve. The valve must have direct communication with the
vapour space of the vessel. For storage vessels, valve must be fitted
with extended vent(s), adequately supported and having outlet at
least three metres above the top of the vessel. The vent pipes must
be fitted with rain caps (loosely fitted). Isolation valve shall be kept
locked in open condition or wheel removed in open condition.
(g) The valve must be tested every year by competent person

approved by CCOE for correct operation and record of such tests
are to be maintained. Date of testing shall be painted on the SRV.
(h) The valve is set and sealed at the factory to function at a specific
“Start-to discharge” pressure. The two SRVs on LPG storage vessel
shall be set at two different set pressures in line with OISD 144. If the
container pressure reaches the set value , the valve will open
slightly. Despite this, if the pressure in the container rises, the valve
will suddenly pop wide open. This action is accompanied by a
sharp noise of escaping vapour.
6.3.3 EXCESS FLOW CHECK VALVE (EFCV)
(a) Excess Flow Check Valve closes automatically to prevent excessive

flow of gas or liquid in a particular direction of flow. In the event of
breakage of a line, the flow will be shut off automatically by the
Excess Flow Check Valve provided at the vessel outlet. These valves
are fixed on various points as under :
(i) Pressure Vessel
 Liquid Inlet / Outlet

 Vapour Inlet / Outlet.
 Water drain.
 Fixed tube level Gauge
 DP level Gauge

DEPARTMENT 6
March 2014 6-9
FACILITIES
(ii) Pipelines
 Tank wagon loading / unloading points.
 Tank truck loading / unloading points.
(b) In the normal condition, the excess flow check valve is kept in open
condition by a means of a spring, i.e. when the rate of LPG flow
is below the rated capacity. When the flow rate increases more
than the setting, the valve seat closes, thereby stops the flow of LPG.
At a pre-determined rate of flow for the valve to open again, it is

necessary that the pressure is built up downstream, by shutting off
closest line valve (down-stream). During this process, LPG flows
through a small orifice in the valve seat (of excess flow check valve)
and makes the valve open, by equalising the pressure on both
sides.
(c) Following type of Excess Flow Check Valves are being used:
 Screwed Type (Refer Drawing 8)

 Sandwich Type(Refer Drawing 9 A & 9 B)
6.3.4 FIXED LIQUID LEVEL GAUGE
Fixed Maximum Liquid Level Gauge indicates the liquid level at which the
container is filled to its maximum permitted filling capacity i.e. 85%.
This device is installed and set to the maximum level to which the vessel
can be safely filled. It is a tube with bleeder valve at the top. The length
of the tube inside the tank is pre-determined with the result that when the
liquid level reaches the bottom of the tube, the liquid comes out as a
spray through the bleeder valve when opened. Since this gauge has the
limitation of indicating only one particular level, it is installed only as an
auxiliary gauge from the safety point of view. This type of gauge is
installed on storage vessels as well as tank trucks / tank wagons. ( Refer
Drawing No.10 )
6.3.5 VARIABLE LIQUID LEVEL GAUGE
This type of gauge indicates the liquid level in a vessel through a range of
levels. Following gauges fall into this category :

DEPARTMENT 6
March 2014 6-10
FACILITIES
(i) Magnetic Level Indicator
The gauge has two SS floats, which move up down with rise or fall of the
liquid level of the Vessel. Each float has inside a special annular ring
magnet. The floats travel along a 40 mm NB SS tube called "Guide Tube".
This "Guide Tube" is sealed at the bottom. Inside the guide tube, a
calibrated gauging rod fitted with magnet at its lower end travels.
Assuming that the bullet is empty and filling is about to start, both the
floats as well as the gauge rods would be in the lowermost position. The
gauge cover at the top is unscrewed so that the gauge rod can move
out. When the filling starts, the float slowly starts moving upwards along
the guide tube. The magnet inside the float causes the gauging rod to
move up. The calibrated gauging rod carries the level markings, which
can be read easily. (Refer Drawing No. 11)
(ii) Rochester Gauge
It is a gauge constructed with a float inside the vessel resting on the liquid
surface, which transmits its position through a suitable leverage to a
pointer and a dial outside the container indicating the liquid level. The
motion is transmitted magnetically through a non-magnetic plate so that
no LPG is released to the atmosphere. This type of gauge is normally
provided on the storage bullets / evacuation vessels (Refer Drawing No.
12 and 13). With the addition of accessories like explosion proof
transmitter and remote display, the reading of the level of Liquid LPG can
also be transmitted to the pump house and control room. This gauge can
be used only in the LPG bullets / mounded storage vessels up to
diameter of 6metres.
(iii) Servo Gauge
Servo Gauge is a micro processor based electronic level gauging

instrument, which uses digital technology for accurate measurement of
product level interface, density and temperature (with external
temperature sensors). It has facility for reading at the gauge as well as at
a remote location.
Servo Gauge is made up of a main housing, which is flame proof /

weather proof, containing servo motor, measuring drum, magnetic
coupling etc. (Refer Drawing No. 14).

DEPARTMENT 6
March 2014 6-11
FACILITIES
A very thin measuring wire B is wound on to a measuring drum C. The

measuring drum C is connected to a drive shaft F through magnet
coupling D,E and rotates forward and backwards according to the
movement of gear down unit J,K and stepping motor N. A worm gear J,
which is located on the same axis as driving shaft F, is connected to the
driving shaft F through a spring.
By this arrangement, tension on to measuring wire C can be precisely

detected by measuring distortion of spring I, balancer G. A displacer A, of
which density is higher than that of liquid to be measured, is connected
to one end of measuring wire B. The weight of the displacer A always
gives down force tension to driving shaft F. In the normal measurement
condition, stepping motor N is controlled by signal from balancer G to
give measuring wire B a slightly less and constant tension than the weight
of displacer A. In this way, displacer A always follows liquid surface with
stable draft line. Thus, rotating angle of measuring drum C that
corresponds to length of unwound measuring wire B represents the height
of liquid in tank.
(iv) Radar Level Gauge
The Radar Gauge is mounted on top of the tank on a suitable nozzle

having extended steel well pipe going inside the vessel. The head of the
gauge sends radar signals which bounce back from the liquid level
surface. The time taken for the signals to travel is translated into the
actual height of the level from the tank bottom. Measurement can be
taken even under boiling and turbulent conditions, as this gauge has no
moving parts and has no contact with the liquid. Typical installation
drawing is given in Drawing No.15
(v) Differential Pressure Type Gauge :
This gauge works on the principle of hydro-static head created by the

level of liquid LPG in the vessel. In the DPG, there are two inputs, one
from the vapour space of the vessel and one from the bottom liquid line.
The DPG measures the difference of pressure which translates as the
height of the liquid level from vessel bottom and displayed in terms of
percentage.
Level reading can be displayed on a suitable explosion proof indicator

installed in the Pump House.

DEPARTMENT 6
March 2014 6-12
FACILITIES
(vi) Ultrasonic level instrument
These gauges have recently come in the market. An ultrasonic transmit-

receive sensor, mounted on the underside of the vessel emits a series of
ultrasonic pulses. The time taken for an echo to be received from the
liquid surface is measured electronically by the signal processing unit. This
time is directly proportional to the distance to the liquid surface
6.3.6 HIGH LEVEL ALARM
The high level alarm is provided to allow pre-determined minimum vapour

space. It is independent of the mechanical level gauging devices. It
transmits an audio & visual signal at the desired place when pre-
determined level of the liquid LPG is reached. One signal is also taken for
closure of liquid ROV of the vessel.
Simple buoyancy and magnetic field are the underlying principles of this
instrument. This instrument has a float (called displacer), which is
suspended across a spring. When the vessel is filled with liquid, the
displacer is submerged below the surface of the liquid. When this
happens, the buoyancy causes the spring to contract. This longitudinal
movement displaces a drive magnet, which then attracts a follower
magnet, provided on the outside of the lead pipe. This actuates a micro
switch, which gives an output signal. This output signal is fed to an audio-
visual alarm located at any convenient place. This output signal is also
used to close the ROV on the liquid line of the vessel. This shall be
checked once a month by competent person and record maintained.
(Refer Drawing No. 16).
6.3.7 WATER DRAIN CONNECTION
It is normally provided with a shut off valve of 50mm (2-inch) dia. nominal
size. This shut-off valve is provided with a length of pipe terminating
with a second shut off valve of 50 mm (2 inch) diameter nominal size.
The first valve nearer to the water drain point shall be of quick shut off
type and the second upstream valve near vessel shall be of throttle type
(globe valve). Between these two valves, EFCV of suitable rating is
provided. The length of pipe between the valves is such that the risk of
simultaneous obstruction of both the valves is minimised. A sufficient
length of piping is provided downstream of the throttle valve to ensure
that the discharge will not take place beneath the vessel / pipeline

DEPARTMENT 6
March 2014 6-13
FACILITIES
manifold. The second valve and the connected pipeline are adequately
supported and secured to prevent breakage by jet forces. The throttle
valve shall be locked in closed condition and shall be opened by
operator only for the draining purpose. End flange with blind shall be
provided at the drain mouth. The blind flange shall be removed only
during water draining purpose and shall be re-fixed after completion of
water draining
6.4 TRANSPORT FACILITIES

Transportation of bulk LPG falls within the purview of the ‘Static and
Mobile Pressure Vessels (Unfired) Rules,1981’ and as such all the related
rules must be strictly adhered to and relevant license conditions are
complied with. Presently the following modes of inland LPG transports are
available in India :
6.4.1 LPG TANK WAGON ( Railway nomenclature – Type TPGLR)
6.4.1.1 Classification Mark : LPG Tank wagons are identified as TG (4 wheeler

- 15 MT)or BTPGLN (8 wheeler - 37MT). There are three categories of
ownership of LPG tank wagons as under :
(a) Fully owned by Railways

(b) Joint ownership (Railway / IOC)
(c) Joint ownership (Railway / OMCs)
In the case of first category, the Railways own the under-frame as well as
the bullet. In the case of joint ownership tank wagon, the under-frame is
provided by the Railways whereas the barrel (Bullet along with fittings) is
provided by a marketing company.
LPG is moved in tank wagons by the Railways. These wagons are

designed by Directorate, Research, Design, and Standards Organization
(RDSO).
Design Criteria : All tank wagons used for transportation of LPG shall be
as per the approved design of RDSO. RDSO of Indian Railways issues the
design parameters for the tank wagons used for transportation by rail. The
design parameters of the LPG wagons are as follows:

DEPARTMENT 6
March 2014 6-14
FACILITIES
(a) Design Pressure (max.) : 16.65 Kg/Sq.cm.

(b) Working pressure : 15.85 Kg/Sq.cm.
(c) Test Pressure : 21.65 Kg/Sq.cm.
6.4.1.2 Standard list of Dome fittings on LPG Rail Tank Wagon :
SL NAME OF SINGLE TWO

No. SERVICE THE FITTING DOME DOMES
(4WHEELER (8WHEELER
) )
1 Liquid inlet / Liquid Eduction Valve 2 Nos. 4 Nos
Outlet
2 V Vapour Inlet Vapour Eduction Valve 1 No 2 Nos
/outlet
3 Protection for Excess F Excess Flow 3 Nos. 6 Nos.
Excess flow for Check Valve(Max
valves at Sr.no capacity 180 GPM of
1&2 Propane)
4 Level Gauge Magnetic gauging 1 No. 2 Nos.
Device (With 10” body
height)
5 Pressure Safety Valve (set to 1 No 2 Nos
Relief discharge at pressure of
225 PSI). Discharge
capacity minimum
21800 cfm. of air.
6 Sampling Sampling valve 1 No 2 Nos
of LPG
7 Protection for Excess flowCheck 1 No. 2 Nos.
Excess Flow of Valve
Valve at Sr. 6
With 2” NPT main connection, filling capacity (water)=430GPM approx and
unloading capacity =243 GPM(approx)
6.4.1.3 Filling Considerations : The maximum quantity of LPG filled in any tank
wagon shall be limited to the filling density of the LPG and shall be such
that the tank wagon shall not be liquid full due to expansion of the
contents with rise in the temperature to 55 degree C. or limited to
specified gross weight on the wagon, whichever is less.

DEPARTMENT 6
March 2014 6-15
FACILITIES
6.4.2 LPG TANK TRUCK
6.4.2.1 Types : There are basically two types of LPG tank trucks :
(a) Rigid trucks (Conventional type).

(b) Articulated/semi-articulated tank trucks.
The capacities of the above trucks vary considerably depending on

R.T.O. regulations and areas of plying. The existing capacity of the tank
trucks is in the range of 6 to 18 MT.
6.4.2.2 Essential Components of LPG tank truck : The essential components of

an LPG tank truck include the following :
(a) Suitable type of chassis with driving unit

(b) Tank designed as a pressure vessel (Bullet)
(c) Tank appurtenances and fittings
6.4.2.3 Design :
The design parameters of LPG tank truck are as follows :
Sl. ITEM UNIT DESIGN DETAILS

No.
1 Design code - IS-2825-1969
2 Design pressure Kg/Sq.cm. (g) 16.65
3 Working pressure Kg/Sq.cm. (g) 15.85
4 Test pressure Kg/Sq.cm. (g) 21.65
5 Design temperature Degree (-)6 deg. C to
centigrade (+) 55 deg. C
6 Working temperature Degree Ambient
centigrade
Specific Gravity of Liquid LPG
-Ambient 0.54
-At (+) 55 deg C 0.47
-Corrosion allowance 0.5 mm
-Material specification for bullets as per IS 2825 or ASME Sec. VIII.

DEPARTMENT 6
March 2014 6-16
FACILITIES
6.4.2.4 Applicable rules : LPG tank trucks fall under the purview of the ‘Static
and Mobile Pressure Vessels (Unfired) Rules,1981’ . All applicable rules
pertaining to the tank truck, which would include driving unit with chassis,
as well as the bullet, must be followed.
6.4.2.5 Fittings : The following fittings are provided in LPG tank trucks :
(a) Safety Relief Valve (SRV) : There shall be minimum two Safety Relief
Valves with each one sized in such a way to suit the full relieving
capacity of the vessel. SRV shall be so installed that it does not
project out of the top surface of the vessel. If necessary, recessed
cup formation on the vessel shall be made to house the SRV. Safety
relief valves shall have the following marking punched :
(i) Manufacturer’s name and Serial no.

(ii) Set pressure
(iii) Rate of discharge of the gas in cu.m. per minute at 150 C. &
(iv) Date of first test
(v) Name of the Inspecting Agency with their stamp.
(b) Liquid / Vapour Connections : 1 or 2 Nos. of 50 mm dia. size liquid

inlet / outlet and 1 no. of 40 mm dia. size vapour connections shall
be provided at the bottom of the vessel. The vapour line shall
extend internally with a clearance of 50 mm from the top of the
vessel surface. All fittings should be of class 300 rating.
(c) Internal Valve with Excess Flow Check Valve : Internal valves with
EFCV of appropriate ratings shall be installed on LPG liquid and
vapour lines. This valve shall have an in-built internal excess flow
check valve(Refer Drawing No17). All tank trucks used for Auto LPG
supply to ALDS(Auto LPG Dispensing Station) shall be provided with
Internal EFCVs on LPG liquid and vapour lines.
(d) Liquid Level Gauging Device - Roto Gauge : The vessel is equipped
with a liquid level gauging device for determination of the liquid
level in the vessel at any time. The liquid level gauging device is to
be operated manually for determination of liquid level at any point
of time. When the level has to be measured, the lever outside the
gauge is rotated slowly till a vapour cloud becomes visible thru a

DEPARTMENT 6
March 2014 6-17
FACILITIES
tiny opening on the nut of the lever. Hence, a very small leakage
of the product to the atmosphere takes place.
This liquid level gauging device is located on the shell near the
midpoint / top upper half of the vessel in a recessed cup formation.
To avoid damage to this liquid level gauging device, a suitable
hinged cover is provided.
(e) Pressure Gauge : 1 no. dial type (100 mm) glycerin filled pressure
gauge with EFCV shall be provided on the rear dished end in the
vapour space. This shall be protected by 10 mm thick U-type shield
metal plate. The range of the pressure gauge shall be from 0 to 21
kg/sq. cm (g).
(f) Temperature Gauge : A thermometer well is fitted on the dish end of

the bullet. It is designed to take a mercury thermometer in a glass
jacket. The thermometer well is provided with a sealing cap.
(g) Drain : Suitable drain of maximum 25 mm NPT plug to be provided

on the bottom side of vessel with proper shield.
(h) Manhole : 1 no. manhole of size as per IS 2825 or code followed for
the design and fabrication of vessel shall be provided on the rear
dished end.
(i) Markings : Each vessel shall have a non-corrosive metal plate

permanently affixed by brazing or welding on the rear dished end in
a place readily accessible for inspection and be maintained legibly.
Neither the plate itself nor the means of attachment to the vessel
may be subjected to the impingement by the tank contents. The
plate shall be plainly marked by stamping or embossing or by other
means of forming letters on the metal of the plate with the following
information, in addition to that as required by the local regulations :
1. Vessel Manufacturer
2. Vessel Manufacturer’s Serial No.
3. Design code
4. Radiography
5. PWHT
6. Design Pressure

DEPARTMENT 6
March 2014 6-18
FACILITIES
7. Design Temperature
8. Hydrostatic test pressure
9. First test date and subsequent test dates
10. Water capacity in litres
11. Licensed Product capacity in MT and symbol or chemical
name.
12. Name of the Inspection Agency with its stamp.
13. Certificate number of Inspecting Agency.
14. Shell thickness & Dish End Thickness
15. This vessel shall not contain any product having vapour
pressure in excess of 120 RVP at 55 deg. C.
16. Next hydro test date of the vessel shall be painted on the body
of the vessel.
(j) General requirements :
(a) General Safety Considerations :

I. Each tank truck shall be provided with at least one
rear robust bumper, designed to protect the vessel and
the piping in the part of the colliding vehicle striking the
vessel. The design shall be such as to transmit the force of
a rear end collision in a horizontal line to the chassis of the
vehicle.
II. Extension to chassis, if any, shall not be more than 300

mm and the extension piece shall not be welded to the
chassis.
III. The maximum width and height of the vessel and its service
equipment shall be such that these do not project beyond
the overall width and height of the rest of the vehicle. The
maximum height of the vehicle shall be in accordance
with Motor Vehicles Act, 1989.
IV. Each vessel shall be provided with a height barrier and

designed as stipulated in OISD Std. 160.
(b) Stability Considerations : Stability of the vehicle shall be In

accordance with IS : 9618, 1969.

DEPARTMENT 6
March 2014 6-19
FACILITIES
(c) Safety Equipment : The vehicles shall carry the following :
I. A First aid box.

II. 2 nos.10 Kg DCP (ISI marked) one on each side and
accessible from outside the cabin, shall be provided.
Periodicity of testing to be followed as per OISD Std. 142.
III. Leather hand gloves and heat resistant hand gloves.
IV. Safety Goggles
V. 2 nos. red flags
The above equipment should be in good working condition. In

addition, each vehicle must carry an emergency kit as
specified by CCOE.
An emergency information board should be displayed on

both side of the vessel as well as on the top the vehicle
mentioning the important telephone nos. of the contractor, oil
company’s loading base, attached bottling plants and easier
contact nos. in the event of accident in addition to other
details given above.
(d) Mountings : Vessel should be securely attached to the chassis.
(e) Design Safety Requirements – Mechanical : The engine of the

vehicle shall be of Internal Combustion (IC) type.
I. Where the fuel system is gravity-fed, a quick action cut-

off valve shall be fitted to the fuel feed pipe in an easily
accessible and clearly marked position
II. The engine and exhaust system together with all

electrical generators, motors, batteries, switch-gears, and
fuses shall be efficiently screened from the vessel or the
body of the vehicle by a fire-resistant shield or by an
enclosure within an approved fire resistant compartment.
All vehicles carrying LPG should be equipped with a
CCOE approved make & design spark arrestor. As per
Static and Mobile Pressure Vessel Rules 1981 and
Petroleum Rules 2002, the exhaust of all such vehicles is
required to be routed to the front side of the vehicle and
spark arrestor shall be welded to the exhaust.

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FACILITIES
III. In such cases where the fuel used to propel a vehicle

gives off a flammable vapour at a temperature less than
65 deg. C, the fuel tank shall not be mounted behind the
shield unless the following requirements are complied
with namely :
(a) The fuel tank is protected from external blows by

stout steel guards or by the under frames of the
vehicle.
(b) The fill pipe of fuel tank of the vehicle is provided

with :
I. an arrangement facilitating breathing of the

fuel tank and preventing spillage of fuel in
the event of overturning of vehicle and
II. suitable locking arrangement.
(c) The fuel feed apparatus placed in front of fire

resisting shield is used to lift the contents of the fuel
tank.
IV. The cabin shall be painted with color scheme as

stipulated by the Transport Authority.
V. The overall height of the vessel shall not exceed the

height of the driver’s cabin including the height barrier, if
any.
VI. For fixed chassis, a guard railing of 50 mm (2” ) dia. pipe

should be provided along the entire length of the vessel.
The height and width, however, shall not exceed as that
stipulated by the Transport Authority.
(f) Design Safety Requirements – Electrical : Following

requirements shall be complied with, in connection with the
electrical and anti-static properties of the vehicle, namely :

DEPARTMENT 6
March 2014 6-21
FACILITIES
I. The electrical system :
a. The battery shall be mounted inside the cabin

within a metallic cover with openings in easily
accessible position. Rubber caps shall be provided on
exposed terminals of battery to prevent accidental
short circuit
b. A readily accessible double pole cut-off switch of not
less than 300 amps rating shall be provided.
c. Electrical wiring shall be properly insulated and
adequate for maximum current loads to be carried.
Electrical wirings shall be provided with suitable over
current protection in the form of fuses or automatic
circuit breakers and encased in the metal conduits so
as to get protection from the physical and chemical
damages on contact with the possible product spill
either at the location or on the road. Fuses shall be of
adequate rating and standard type. No naked wire
shall be used for fuses
d. All junction boxes should be sealed.
e. Lighting other than those permitted by the
Transport Authority shall not be allowed.
II. Earthing boss on the saddle of the vessel shall be

provided on both sides.
III. The vehicle should carry minimum six reflector cones

having base of 300mm (12”) dia. and height of 75 cm
(2.5 feet). These cones are to be used for marking out
of the area where the vehicle is parked or segregating
it from other portion of road in the event of an accident.
6.4.2.6 Pipe line ( For Pipe line transfer) :
Receiving product in a plant by means of a pipeline is the most desirable

method and presents fewer hazards that may be associated with any
other method. In this system of transportation, products are pumped at
one end of the line and received at the other end through metering
units as explained in Chapter No, 7 (section 7.10). Sections of the
pipeline are expected to remain closed, when there are no operation.
Adequate arrangement for the pressure relief must be provided by way

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March 2014 6-22
FACILITIES
of “Pop-Action” pressure relief valves. If sufficiently large quantities have

to be transferred, the facility becomes economically viable.
6.4.2.7 Valve and Fittings:
Steel valves and fittings conforming to relevant API standards shall be

used. Cast iron valves should not be used.
6.4.2.8 Thermal Pressure Relief System (TSV) :

Any equipment or section of the pipe line in which liquid LPG may be
trapped should be protected against the excessive pressure developed
by thermal expansion of the contents by providing suitable thermal
pressure relief valve(s) in the form of TSVs ( Thermal Safety Valve ). If the
pressure-relieving devices discharge vapour to atmosphere, the
discharge should be arranged in a safe manner. I.e. vent discharge at 2
to 3 .0 metres above grade.
6.5 TRANSFER FACILITIES

6.5.1 GENERAL
6.5.1.1 The word ‘transfer’ is used to indicate the movement of bulk LPG within
the plant area. It could be between any two points as follows :
(a) Storage vessel and storage vessel.

(b) Storage vessel and tank wagon
(c) Storage vessel and tank truck
(d) Storage vessel and Filling shed.
6.5.2 The various facilities / equipment used for the purpose are described
below :
6.5.2.1 Pipe line / Pipe line Manifold
(a) Pipeline, manifold and pumping facilities are provided basically to

cater to the requirements of following operations which may have
to be carried out simultaneously :
I. Receipt of product from the tank wagons / tank trucks.

II. Delivery of product to the tank wagons and tank trucks.
III. Delivery of product to the filling plant.

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FACILITIES
IV. Product transfers between the storage vessels.
(b) There are two categories of LPG pipelines at the plant; one carrying
LPG in the liquid form and other in vapour form. The lines should be
properly color coded to differentiate liquid lines ( Yellow) and
vapour lines ( Green).
(c) Section of the pipelines which are expected to remain blocked at

either end by closed valves are provided with pressure relief (pop-
off) valve to avoid excessive build up of pressure in the line, which
will otherwise cause damage to the line. The ‘pop-action’ valves
should be inspected / tested periodically to ensure that they are
functioning at the desired pressure. Suitable isolating valve
between the ‘pop-off’ valve and the pipe line is desirable for
convenient mounting / dismounting without escape of vapour from
the pipeline. The idea of hazards that can be created on account
of non-provision of ‘pop-Action’ relief valve for thermal expansion
can be had from the following case history :
“Case History”
“At a major refinery outside India, thermal expansion in a blocked-in

150 mm (6”) dia. butane pipe line of 580 metres (1900 ft) long,
resulted into fracture of all 12 bolts on the flanges of a 150 mm (6”)
dia. split-body ball valve, with dislodgement of the ball itself. This
resulted in a very large release of butane vapour, which fortunately
was not ignited. It is estimated that pressure had reached in the line
in the order of 70 Kg/cm2 (1000 Psig) and the thrust created by
liquid butane under pressure led to the line at the point of fracture
being thrown 3.5 metre (11 ft) away and also led to severe
distortion of the line along the majority of its length. Parallel piping
also received impact damage from the distortion of the line which
had fractured”.
6.5.3 LPG PUMPS
6.5.3.1 Following specific aspects are considered for LPG pumps :
 Pumps shall conform to API 610 standards.


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March 2014 6-24
FACILITIES
 Double Mechanical seal for sealing the shafts of all rotary pumps
designed specifically for these liquids with seal failure alarms shall
be provided.
 LPG Pumps shall be provided with suction and discharge pressure
gauges, a high point vent to safe height or flare, and a suction
strainer.
6.5.3.2 Types of Pumps : There are two types of pumps used for LPG service :
(a) Centrifugal Pump(Horizontal/ Vertical Can type) :
Centrifugal Pumps are suitable for filling cylinders, loading tank

trucks / tank wagons and also product transfer between the
vessels. They may be operated against closed delivery valves
without undue pressure rise, but such use will cause heating and
vaporisation of the product. Provision is, therefore, made for re-
circulation of product by means of a by-pass arrangement. Check
valves shall be installed on the delivery side of all centrifugal pumps.
(b) Positive Displacement Pumps :
Positive displacement pumps operate with low suction heads and

can deal with vapours for a short period. They are particularly useful
in small plants and also on Emergency Response Vehicles. A by-pass
arrangement with a differential relief valve is always provided on
such pumps to avoid damages on account of excessive pressure
build-up . To minimise heating of the product, the discharge
through the by-pass is normally left back to the vessel rather
than to the pump suction. Positive displacement pumps tend to be
noisy in operation and require more maintenance than centrifugal
pumps.
6.5.4 COMPRESSORS
6.5.4.1 An LPG compressor is basically a vapour pump. It has distinct advantages

over the liquid transfers through pumps, as under :
(a) Higher flow rates are rendered possible.

(b) Recovery of vapours is possible thus reducing stock loss.
(c) Problem of vapour locking in the system is eliminated.

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FACILITIES
6.5.4.2 The compressor method of product transfer is based on the principle that
the compressor creates a differential pressure between the receiving and
discharging vessels by withdrawing the vapour from the receiving vessel
and forcing it at high pressure into the discharging vessel, thereby
establishing smooth product flow. The procedure is explained in detail in
Chapter No. 7.
6.5.5 FLOW METERS
6.5.5.1 Positive displacement type liquid flow meters and Mass Flow Meters are
used for LPG service. A suitable strainer, vapour eliminator and
differential valves are provided as integral parts of the metering system.
 The ‘strainer’ is essential to eliminate solid contaminants getting into

the system.
 Since these flow meters can handle only single phase i.e. liquid or
vapor, ‘Vapor Eliminator’ is provided to eliminate vapor from
entering these meter and thereby ensuring accurate measurement.
 The ‘differential valve’ ensures that adequate product pressure is
maintained across the meter and the chance of vaporisation of the
product is eliminated.
6.5.5.2 Meters cannot be used when method of ‘Pressure Differential system’ is

adopted in loading / discharge operations because liquid LPG lines will
also contain some quantities of vapour during the operation, thereby
registering wrong quantities.
6.5.6 HOSES
6.5.6.1 There are 3 different types of hoses. Type-1, 2 and 3. In general, LPG hoses
are made utilising three basic components as follows :
(a) Carcass : The strength member or body of the hoses is the tube of
woven fabric cords or woven wires, which make up the inner body of the
hose and provides both form and strength. The number of plies or layers
may vary depending upon the diameter or working pressure of the unit.
This structural form is secured in place by vulcanisation of an elastomer
about the individual plies.
(b) Tube : With the carcass there is a cylindrical tube, which is vulcanized
directly to the inner surface. The purpose of the tube is to provide seal

DEPARTMENT 6
March 2014 6-26
FACILITIES
preventing the leakage of liquid or gas. It is not the strength member

since it is retained in place through the entire length of the hose by the
carcass.
(c) Cover : Hoses are usually provided with a cover, which is

vulcanized directly to the outer ply of the carcass. The primary function
of the cover is to protect the carcass against physical damages
6.5.6.2 Flexible connectors are normally made for LPG hoses. Suitable end
connections are attached so that the connectors fit into the connections
at loading / unloading points and also on liquid / vapour connections on
tank wagons and tank trucks. (Refer EN-1762 ( Earlier BS : 4089 )-
Specification for Rubber hose and Hose assembly)
6.5.6.3 BIS has also standardised the specification for LPG Hoses vide IS:9573.
Basic details are as under:
(a) Following details are marked on each length of hose, at least once
every 3metres :
 The manufacturer’s name, trademark, if any, and hose

denomination.
 The words “LPG 2 MPa Max W.P.” (Note: Abbreviations : W.P.
stands for Working Pressure & 1 MPa = 10.2 kgf/cm2 )
 ISI Certification mark (In case hoses are made conforming
to BIS Specifications)
(b) Hoses are manufactured with varying bore diameter ranging from
8mm to 75mm. Length of a hose can be specifically ordered on the
manufacturer.
(c) Representative samples of hoses are tested at the manufacturing

stage for the bursting pressure. The hose should not burst below an
internal hydraulic pressure of 10.0 MPa (102 kgf/cm2)
(d) The hoses are suitable for use of LPG in vapour phase as well as
liquid phase.
6.5.6.4 Basically hoses subjected to vessel pressure are designed for a bursting
pressure of not less than five times the design pressure of the vessel and a
test pressure of not less than twice the design pressure of the vessel. The

DEPARTMENT 6
March 2014 6-27
FACILITIES
hoses are tested at 25 Kg/sq.cm. and the pressure must be maintained for 5
minutes. Subsequently the hoses shall be tested pneumatically for 3.5
Kg/sq.cm. and the pressure shall be maintained for 10 minutes.
6.5.6.5 Hoses should be mechanically and electrically continuous. The hose should
have electrical continuity from one end to the other; with the resistance
of not more than 0.75 ohm/m.
6.5.6.6 Hoses conforming to IS: 9573 or meeting with higher standards should only
be used for LPG service.
6.5.6.7 LPG Hoses shall be inspected and hydrostatically tested at an interval of not
exceeding 4 months in line with OISD std 135.
6.5.7 UNLOADING / LOADING ARMS
6.5.7.1 The unloading / loading arms are made of steel pipes with swivel joints and
get rotational freedom connected with special couplers. They are provided
for making quick connection / disconnection of LPG tank truck outlet
nozzles to the plant pipe lines. These are provided as a replacement to the
conventional rubber hoses for unloading / loading of LPG tank trucks. The
advantages are :
 Long life and does not require frequent replacement

 Considerably safe as it is tested for a pressure up to 40 Kg/cm2
 Ease in connection and disconnection
 Time consumed for connection /disconnection after the arrival of
tank trucks on the bays is reduced to nil.
 Unloading / Improve productivity
6.5.7.2 Loading arms are also provided at LPG Railway tank wagon gantry
without ‘Quick Connect Dry Break Couplers’, wherever the volume of
handling of LPG tank wagons is very high. Such locations could be LPG
Import Facilities or TOPs.
6.5.7.3 Functions :
The function of LPG unloading / loading arms is to make connection

quickly with the tank truck nozzles both for liquid and vapour and to carry
out the operation of unloading / loading of LPG, thereby reducing the

DEPARTMENT 6
March 2014 6-28
FACILITIES
time lost in making the connections using hoses and reducing the efforts
of handling.
6.5.7.4 Components of Unloading / Loading Arms :
Steel pipes, swivel joints, balancing arrangement, couplers & mounting

stand.
6.5.7.5 Types of Unloading/ Loading Arms :
(i) There are two types of unloading / loading arms as under :
(a) For tank trucks
 Unloading / Loading arms with quick connect dry break coupler.

 Unloading / Loading arms with quick connect dry break coupler
and emergency break away coupler.
 All loading arms are to be provided necessarily with Break-away
couplers.
 Break –Away Coupling that gets safely disconnected during
accidental movement of Tank trucks without disconnection of
the arm
(b) For Railway Tank Wagons
 LPG Unloading / Loading arm with screwed coupler.
(ii) LPG Unloading / Loading arms with Quick Connect Dry Break
Coupler
The unloading / loading arm at the end connections can have a

normal flange which can be directly connected to the truck nozzle
flange. However, for ease in operation and to improve safety &
productivity, quick connect dry break coupler is provided for each
unloading / loading arm. Typically at the end of the unloading /
loading arm, the female coupler is permanently fixed to the arm.
The male adapter is fixed separately on the waiting tank truck so
that the connection can be made immediately on arrival of the
tank truck at the unloading / loading bay.

DEPARTMENT 6
March 2014 6-29
FACILITIES
(iii) LPG Unloading / Loading arms with Quick Connect Dry Break
Coupler and Emergency Break Away Coupler
This type of unloading / loading arm is very similar to the above (i)
except that it has emergency break-away coupler. The emergency
break-away coupler is provided to enable the unloading / loading
arm to get separated from the tank truck under the emergency
situation when the tank truck drives out of the unloading / loading
bays even without disconnection. The breakaway coupler operates
on the mechanism that on experiencing a pulling shear force due to
the tank truck being driven out of the bay causes the two halves of
the break-away coupler joints by shear pin or spring loaded clamps
to get separated and consequently closes the spring loaded valves
to stop the leakage of LPG from both the halves of the couplers.
After the emergency is over, the break away coupler can be re-
assembled and fixed with a new shear pin or sprng clamps as per
the design.
6.5.7.6 Sizes and Quantity of LPG Unloading / Loading Arms :
For the tank truck LPG unloading / loading facilities at bottling plants, LPG
TOPs and Import Facilities, the arm size of 50 mm dia. end connection is
considered to be adequate. For Railway tank wagons, the piping size of
75 mm dia. is considered to be adequate with end nozzle/ coupler of 50
mm dia. For LPG unloading application, two arms per bay are
required, one for liquid and the other for vapour. At loading locations no.
of arms is decided depending on the process. In case vapour balancing
line is provided, two arms are not required and only one liquid arm will
be sufficient. However, for weight correction / sick tank truck
decantation, the bay should have both liquid & vapour arms.
6.5.7.7 Sequence of Operation for Tank Trucks :
 LPG tank truck, when it reports to near the TLD bay before the earlier
a batch is about to be released, has to be fixed with the spare male
adapters provided in the plant. In some older versions, along with
adapters, spool pieces may have to be attached. All flanged
connections are to be made using 8 nos. studs of proper size (
around 2-4 threads shall be visible after full tightening on both sides )
and metallic gasket of standard rating ( Class 300 ). No fibre/CAF
gaskets are to be used .

DEPARTMENT 6
March 2014 6-30
FACILITIES
 After positioning the TT to desired position, Master switch is cut-off

 Hand Brakes are applied
 Two Fire extinguishers are placed in easily accessible place near the
TT cabin
 Wheel Chokes are placed at front and back tyres to prevent
accidental movement. Vehicle is kept in neutral mode.
 Tank Body and Chassis are earthed by two independent earthing
cable by means of earthing clamps affixed to the cables.
 Roto-gauge reading is taken to note the initial % volume. Pressure
gauge and temperature gauge reading are recorded.
 The arm is safely moved to the desired position after verifying the
liquid / vapour nozzle of the tank truck.
 When the female coupler is fixed on to the male adapter, the
coupling gets locked, and then the flow valve lever is set in open
position.
 Isolation valve on the LPG manifold to be crack opened for
checking any leakage from the coupler.
 After ensuring and verification of leak free condition valves are fully
opened slowly to start the decantation/loading process.
 All Valves are to be closed after the decantation /filling process is
over.
6.5.7.8 Sequence of Operation for Tank Wagons :
(i) LPG tank wagon after positioning at the gantry, will require
threaded spool piece to be screwed into the top Liquid outlet valve.
The threaded spool piece has flanged end on the other side.
(ii) The unloading / loading arm parking lock is opened and the end
flange of the arm is aligned with the spool piece flange and fixed
with a gasket and studs / bolts.
(iii) The unloading / loading arm valve is opened and the flow of liquid
for transfer is commenced.
(iv) While closing down, the reverse operation is to done.
6.5.7.9 Maintenance :
The general tips for maintenance are given below but however, for
comprehensive maintenance plan, it is suggested to follow the
manufacturer’s recommendations.

DEPARTMENT 6
March 2014 6-31
FACILITIES
 The unloading / loading arms have to be checked for smooth

effortless operation.
 The bearing unit of the unloading / loading arms should be
greased regularly.
 All the swivel joints should be examined once every month
visually to see if there is any abnormality. In case of any leak, ‘O’
rings and seals should be replaced immediately. The ball
bearing should be changed, only if the movement is not smooth
and ball bearings are worn out.
 The balancing arrangement should be checked every month for
the slackness in the spring tension. This can be adjusted to the
required level of balance. Similarly the gas (Nitrogen) can betopped
up in the case of hydraulic piston arrangement.
 The coupler seals should be checked for any leakage annually
and replaced immediately. Only genuine spare parts are to be
used.
6.5.8 Sight Flow Indicator :
Sight flow indicators are provided on the pipe lines near the tank truck /
tank wagon loading / unloading points and also near the pump house
to find out the flow of liquid through the line. It consists of a flanged unit
fixed on the pipeline with transparent glasses on two sides. The flow in
the pipeline can be visually seen through the glass.
6.5.9 Other Facilities :
(a) Weigh Bridge
(i) There are two types of weigh bridges :
(1) Mechanical and

(2) Electronic.
(ii) This is an essential feature for every LPG plant, since it is the
basic means to check the quantity loaded into or unloaded
from the bulk Tank Trucks in terms of weight. Despite having
loading through Mass Flow Meters at some of the plants, Weigh
bridge is used for final measurement for invoice preparation.
(iii) Weigh bridges are also used for loading tank wagons.

DEPARTMENT 6
March 2014 6-32
FACILITIES
(iv) While providing weigh bridges of adequate weighing

capacity, the size of the platform is considered taking into
account the likely capacities and sizes of the tank trucks (or
tank wagons) to be handled.
(v) Provision of Electronic weigh bridge interlinking with
computer is also available in many plants.
(b) Tank Wagon Gantry
(i) This is provided for loading / unloading of LPG tank

wagons.
(ii) Liquid and vapour lines are provided on each loading /
unloading point. In addition, there are arrangements for sight-flow
indicator and bleeder valve on each of the points.
(iii) (Weigh bridge is provided for loading tank wagon on weight basis.
(iv) (As per CCOE’s guidelines not more than 600 MTs of LPG should be
unloaded / loaded on a railway siding at a time in the plant. If full
rake loading/ unloading is envisaged this shall be done on two
separate rail gantries separated by a minimum distance of 50M.
(c) Tank Truck bays :
Depending upon the requirement of number of tank trucks, loading /

unloading points are provided within the plant area. At each of the
points, arrangements similar to tank wagon loading / unloading
points are provided. For unloading operations, one weigh bridge
away from the unloading points may be adequate. However, for
loading operations, provision of weight bridges for each loading
points or Mass Flow Meters at bay is to be provided.

DEPARTMENT 6
March 2014 6-33
FACILITIES
DRAWING-1

DEPARTMENT 6
March 2014 6-34
FACILITIES
DRAWING NO.2

DEPARTMENT 6
March 2014 6-35
FACILITIES
DRAWING NO.3
DETAILS OF A MOUNDED STORAGE BULLET


DEPARTMENT 6
March 2014 6-36
FACILITIES
DRAWING NO.4

DEPARTMENT 6
March 2014 6-37
FACILITIES
DRAWING NO.5
MOUNDED STORAGE BULLET – TOP NOZZLE ARRANGEMENT


DEPARTMENT 6
March 2014 6-38
FACILITIES
DRAWING NO.6

DEPARTMENT 6
March 2014 6-39
FACILITIES
MULTI PORT SAFETY RELIEF VALVE DRAWING NO.7


DEPARTMENT 6
March 2014 6-40
FACILITIES
DETAILS OF A EXCESS FLOW CHECK VALVE DRAWING NO.8


DEPARTMENT 6
March 2014 6-41
FACILITIES

DEPARTMENT 6
March 2014 6-42
FACILITIES
DRAWING-9B

DEPARTMENT 6
March 2014 6-43
FACILITIES
DRAWING NO.10

DEPARTMENT 6
March 2014 6-44
FACILITIES
DRAWING NO. 11
MAGNETIC LEVEL INDICATOR


DEPARTMENT 6
March 2014 6-45
FACILITIES
DRAWING NO.12

DEPARTMENT 6
March 2014 6-46
FACILITIES
DRAWING NO.13
ROCHESTER GAUGE – INTERNAL ARRANGEMENT


DEPARTMENT 6
March 2014 6-47
FACILITIES
DRAWING NO.14 .
FLOAT TYPE SERVO GAUGE


DEPARTMENT 6
March 2014 6-48
FACILITIES
DRAWING NO.15
TYPICAL INSTALLATION OF RADAR LEVEL GAUGES ON
MOUNDED LPG BULLETS

DEPARTMENT 6
March 2014 6-49
FACILITIES

DEPARTMENT 6
March 2014 6-50
FACILITIES
DRAWING NO.16

DEPARTMENT 6
March 2014 6-51
FACILITIES
DRAWING NO.17
Stages of Operation of Internal Type EFCV


DEPARTMENT 6
March 2014 6-52
FACILITIES
DRAWING NO.17
7
PLANT OPERATIONS: BULK LPG
“SAFETY should be upper - most

In mind while handling any
Operation in the Plant”.


DEPARTMENT 7
PLANT OPERATIONS: BULK LPG PAGE No.
March 2014 7-1
7.1 GENERAL
7.1.1 This chapter covers the details of operations at LPG Bottling Plant
pertaining to handling of bulk LPG.
7.1.2 Bulk LPG operations at the plant are governed by the ‘Static & Mobile
Pressure Vessels (Unfired) Rules,1981’ . Therefore, all related rules and
conditions for the licenses granted under the “Static & Mobile Pressure
Vessels’ (unfired) Rules, 1981” must be complied with. However, These
Rules undergo revisions/amendment and same shall be applicable once
they comes into force
7.2 BASIC SAFETY PRECAUTIONS
7.2.1 The total storage of bulk LPG shall be restricted to the licensed capacity
approved by CCOE and the capacity of the individual storage vessel
should be restricted to 85 % of the level of the approved water capacity
of the storage vessel. This reading must be painted prominently near the
storage vessel and in LPG pump house.
7.2.2 Where LPG is transferred from one vessel to another or is moved through
a pipeline system, hazards like over filling, very high pressure leading to
failure of hoses / pipelines, leakages etc may develop unless all relevant
safety precautions are observed. The transfer of LPG in or out of mobile
vessels (e.g. tank truck or tank wagon) requires special attention as
accidental movement of these mobile vessels may cause rupture in the
transfer equipment. The precautions applicable to most of the transfer
operation in mobile/static vessels are as follows :
(a) LPG, when discharged to atmosphere often, forms a flammable

mixture with air. Therefore, any source of ignition, such as open
flame, smoking, matches, lighters etc. must not be allowed inside
any location where the product is being transferred.
(b) Fire extinguishers shall be placed near the advantage points as per
the guidelines of OISD standards during the transfer operations.
(c) Gas detection system shall be provided in line with OISD-STD-144 and
150 (for Mounded Storage) .

DEPARTMENT 7
March 2014 7-2
(d) While removing the plugs / blinds / caps on hoses, loading /

unloading points, always slightly open / loosen the plugs/blind
flanges to allow for the discharge of any entrapped LPG, and
further, to ensure that the valves are effectively preventing the
discharge of the product.
(e) Hoses / arms should be handled with care and inspected

periodically (Refer OISD Std. 135 on Inspection of Loading /
Unloading Hoses / Arms for Petroleum Products and our internal
Circular on the same). Unloading / loading arms must be checked
for free movement or any seal failures/leakages. Hoses/arms with
any defect shall not be used for operation till such defects are
rectified fully.
(f) While disconnecting the hoses / arms / pipes, vents should be

utilised to discharge the entrapped contents to a safe height and all
connections should be loosened slightly at first. In a sense, the
mechanical integrity of the hose / arms should be retained until it is
ensured that the valves adjacent to the hose/arms on risers of the
plant are fully closed & are effectively preventing the discharge into
the hose/arms. All pressure gauges/ Pressure switches should be
connected with isolation valve and drain/bleed valve. Pressure
gauges/switches to be opened only after closing the isolation valve
and draining entrapped product through bleed valve.
(g) Do not place any part of the heavy material over any gauging
device, or over the discharge end of a pressure relief valve.
(h) Do not expose hands, face, or clothing to liquid LPG. Always wear
protective gloves to avoid skin burns, while connecting /
disconnecting the connections, which may discharge liquid LPG.
(i) Venting and purging of LPG during the transfer operation normally
should not be carried out in open atmosphere. In case the same is
warranted for operation, then it should 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 meters above the eve of the
shed . The vent pipe shall be properly earthed and its exhaust be
covered with copper non corrosive material double wire mesh(Size
:11 linear) between the end flanges provided for the purpose.

DEPARTMENT 7
March 2014 7-3
(j) Any vessel (tank trucks, storage vessels etc) having a pressure of less
than (one) 1 Kg/ sq.cm.(g) should be investigated for such low
pressure before unloading/loading.
(k) In the case of any transfer operations, always determine in

advance that :
(I) The equipment in use is designed for the product being

transferred and is suitable for the operation and valid CCE
license is available, if applicable.
(II) The equipment does not have any visible sign of leaks
or defects.
(III) Competent persons are available to handle operations.
(IV) The site and surrounding areas are free of hazards and will
remain free during the transfer operations.
(V) All safety systems are in place and are in working condition.
(VI) Fire-protection facilities are in state of readiness and fire
extinguishers are available close-by.
(l) At the end of transfer operations or end of the day, whichever is

earlier, it must be ensured that all the equipment are switched off
and all the liquid / vapour valves are closed and the same should
be logged.
(m) Ensure that log book is maintained properly for all transfer operation
and readings of the vessels under operation should be recorded in
the log book on hourly basis.
(n) Once the liquid line ROV closes on actuation of HLA of storage
vessel , the ROV is to be manually opened locally ( manual mode )
or through pneumatic override for taking the product out for
filling/TT loading, inter vessel transfer etc. and immediately put back
into Auto mode once the HLA is deactivated. Any ROV that is put
into manual/local mode is to be logged in the log book by the
concerned Operator/supervisor with reason for the manual mode
and against such entry , date and time for putting back into manual
mode is to be logged.

DEPARTMENT 7
March 2014 7-4
7.3 GROUNDING AND BONDING

7.3.1 Grounding and bonding are essential safety measures. Bonding means
connecting two objects together with metal, preferably a copper strip to
ensure that there is no potential difference between the two objects.
Grounding consists of connecting an object to earth with an electric
conductor, again preferably a copper wire / cable to neutralize the
charges.
7.3.2 For further details on specification, provision regarding grounding and

bonding, the guidelines given in OISD std.-137 & Engineering Manual
Volume No. VII. may be referred
7.3.3 A positive bonding must be provided between any mobile vessel (i.e.
tank wagon or tank truck) and the receiving or discharging vessel or
system. The bonding should be completed before any operation related
to the transfer procedure is commenced. The bonding should remain
effective throughout the operation. Locations where Automated Loading
Facilities are available, earthing of TT is checked through earthing relay.
Any discontinuity in earthing leads to stoppage of flow and alarm at
control station. The bonding should be disconnected only after the
transfer operation has been completed and the system is secured with all
openings plugged, capped or flanged.
7.3.4 Stationary equipment such as storage vessels, equipment, loading /

unloading points, pipings, rails,, etc. must be adequately and
permanently grounded.
7.3.5 Bonding cable should be provided at each loading / unloading point.

One end of the bonding cable should be permanently connected to
the grounding by means of suitable lugs, pressure connectors or clamps.
The other end of the bonding cable should be equipped with a suitable
device, (e.g. crocodile clip) which would make a metallic connection
with the equipment (e.g. tank wagon or tank truck), to which it is
clamped by scratching any protective coating, accumulation of dirt, oil,
or scale to expose bare metal. Test records of continuity should be
maintained as per OISD standards / internal guidelines.

DEPARTMENT 7
March 2014 7-5
7.4 TRANSFER METHODS
7.4.1 GENERAL
The high volatility of LPG calls for transfer techniques different from the
conventional pumping system used for the less volatile petroleum liquids.
LPG may be transferred by gravity or pumping or pressure differential
between the ullage space of the vessel being discharged and the ullage
space of the receiving vessel or by a combination of these methods.
7.4.2 TRANSFER THROUGH GRAVITY FLOW
Flow by gravity alone is rarely used as a means of transferring LPG, since it

is slow and inflexible. Gravity head is, however, an important
consideration for transfer by pump, since a certain minimum suction head
at the pump inlet is necessary.
7.4.3 TRANSFER THROUGH LIQUID PUMPING
7.4.3.1 If LPG is pumped from vessel ‘A’ to vessel ‘B’ along a single line system
[Refer Drawing No. 19(a) ], the pressure in the ullage space of vessel ‘A’
gradually falls and may reach the atmospheric pressure. When this
happens, the liquefied gas in the vessel ‘A’ commences to boil and this
boiling will continue as long as pumping continues. The latent heat of
vaporisation absorbed from the liquid and the vessel surroundings cools
the liquid and in consequence, the vapour pressure of the liquid falls. If
the vapour pressure inside the vessel falls below the vapour pressure of
LPG, vapour lock may take place in the pumps resulting in stoppage of
LPG transfer.
In the receiving vessel ‘B’, the vapour in the ullage space is

compressed. when the vessel is getting filled. Some of the compressed
vapour condenses and this gives out heat to cause a further rise in the
pressure in the ullage space of vessel ‘B’. With the falling vapour pressure
in the vessel ‘:A’ and the rising vapour pressure in the vessel ‘B’,
pumping becomes increasingly difficult.
7.4.3.2 Pumping difficulties at times encountered with single line system may be
overcome by equalising the ullage space pressure through the

DEPARTMENT 7
March 2014 7-6
‘equalising’ or ‘vapour return’ lines as shown in Drawing No 15(b). The

vapour displaced from the vessel ‘B’ passes to the vessel ‘A’ through the
vapour return line and this help to maintain the desired suction head at
the pump.
7.4.3.3 By-pass valve {Refer Drawing No. 15(c)} on the discharge side of the LPG
pump helps to relieve the pressure in the event of development of
pressure above the pre-determined limit due to accidental closure of
discharge valve. The by-pass valve discharges into the pump suction or
back to the supplying vessel. While either manually controlled or
automatic by-pass valve set to operate at a pre-determined differential
pressure can be used with centrifugal pumps, it is necessary to provide
automatic by-pass valve set at pre-determined differential pressure with
positive displacement type pumps.
7.4.4 TRANSFER THROUGH LPG COMPRESSOR.
7.4.4.1 This method involves withdrawing vapour from the receiving vessel,
compressing the vapour and discharging the compressed vapour into
the ullage space of the delivering vessel. The method of pressure
differential is well suited for unloading operations.
7.4.4.2 An important additional advantage of compressor over liquid pump is

their ability to recover vapour from the delivering vessel. The vapour
recovery can be achieved from the discharge vessel by reversing the
compressor connections at the end of the discharge operation.
7.4.4.3 Differential vapour pressure of 1.5 to 2.0 kg/cm2 is usual for most of the
unloading operations.
7.4.5 PRECAUTIONS FOR PRODUCT TRANSFER
7.4.5.1 In order to prevent operational errors, it is a good practice to write out

and display specific loading and unloading instructions, DOs and DON’Ts
(Annexure No.8) taking into consideration the transfer methods adopted,
since the fittings on the vessels (e.g. filling and vapour return connections)
are not always of the same type or located in the same position.
7.4.5.2 Before LPG is transferred from a vessel to any other vessel, whether it is a
storage vessel, tank truck or tank wagon, the following precautions are
to be followed :

DEPARTMENT 7
March 2014 7-7
(I) Receiving vessel is designed to store the product being transferred.

(II) Valid CCE license is available for receiving vessel.
(III)The receiving vessel should be checked to ensure that it is safe
and the gauges are in working condition and correct grade of LPG
is being received.
(IV) The receiving vessel should be checked to ensure that it has
sufficient ullage to receive the parcel which is being transferred in
to it.
(V) The inter-connecting system (i.e. pipelines, fittings, valves, hoses,
unloading / loading arms etc.) should be checked to ensure that it is
in safe working condition and that only the correct valves are
opened.
7.4.5.3 During LPG transfers from tank trucks / wagons or one vessel to another,
regular monitoring is to be done by the competent person to ensure that
the receiving vessel is not being over filled. On completion of the
operation also, the receiving vessel should be checked to ensure that it is
not filled above its safe filling level. To ensure safe operation, the ROVs of
all LPG vessels shall be interlocked for closure with HLA (High Level Alarm).
7.4.5.4 In the case of tank truck / tank wagon operations, the procedures given
below should also be followed, in addition to the precautions listed
above :
(I) The vehicle should be prevented from accidental movement during

the transfer operation by providing choke blocks for TTs and the
hand/vacuum brakes of the tank truck / tank wagon be applied.
(II) Ignition keys of the TT should be handed over to the person
supervising operations before the start of product transfer operation.
(III) Any driving unit or electrical equipment not required and not
specifically designed for the transfer operation should be stopped
and / or isolated.
(IV) The vehicle should be bonded to the fixed ‘grounding ‘ before any
product transfer operation is carried out. The same is done by
connecting the earthing cable from the earthing grid to the tank
truck/ wagon at two designated places.
(V) (v) Before the vehicle is moved out, it should be ensured that
bonding cable, liquid / vapour connections are disconnected and
wheel chokes removed. The area around the vehicle should also be
checked to ensure that LPG which may have leaked or vented has
been dispersed fully. In case of any doubt, explosimeter should be

DEPARTMENT 7
March 2014 7-8
used for checking the gas concentration. Truck ignition should be

switched on only after ensuring that surrounding area is free from
any LPG concentration.
7.4.6 ATTENDANCE DURING OPERATION
7.4.6.1 It should be ensured that a competent person should always remain in

attendance during all transfer operations. In emergent cases if such
transfers take place outside the protected area, the necessary warning
notices against ‘smoking and the use of naked lights’ should be displayed
and ensure that requirements as detailed in Clause No. 7.4.5 are
complied with.
7.4.6.2 Any drain valve, bleeder valve, etc. in the LPG system which
communicates directly to the atmosphere should not be left open
without a competent person in attendance unless positive measures are
taken to prevent escape of the product.
7.4.6.3 In case it is necessary to discontinue vehicle loading / unloading

operation temporarily and start later to complete it, the loading /
unloading arms/hoses should be disconnected from the vehicle for the
period of suspension of operation. Logbook should be maintained on
operation and if there is any change of person due to shift change,
proper handing / taking over should be recorded in the logbook.
7.4.6.4 The person in charge of operation should ensure that transfer operation is
stopped and all valves are closed in case of the following
occurrences :
(a) Uncontrolled leakage.

(b) A fire in the vicinity.
(c) In case of lightening when the operation involves venting of LPG.
7.4.7 LIGHTING IN STORAGE AND OPERATING AREAS
7.4.7.1 No operation should be carried out during the hours of darkness unless
adequate lighting as per SMPV rules is available. Permission for carrying
out transfer operation after sunset must be available with the plant for
carrying out any operation after sunset.. Generally, endorsement for
carrying out the operation after sunset is given by CCOE for the LPG
Plants on applying for the same.

DEPARTMENT 7
March 2014 7-9
7.4.8 PURGING AND FILLING OF STORAGE TANKS
7.4.8.1 When new vessels and connected facilities are to be commissioned or

the vessels, which have been gas-freed, are to be filled, they should first
be cleared off air as per purging procedures.
7.5 TANK WAGON UNLOADING OPERATIONS
7.5.1 PREPARATION WITHIN PLANT
7.5.1.1 All relevant precautions listed in Clauses Nos. 7.4.5 to 7.4.8 and their sub-
clauses should be observed for the operation.
7.5.1.2 The unloading area must be free and clear of any material that might
cause a potential fire hazard. The surface of the ground together with
stairs, ladders, and platforms, if any, must be in such a condition that the
operator can perform his duty without any hazard. Wherever overhead
gantry is provided, gantry platforms (swing type) and hoses / unloading
arms are to be raised and secured in position after completing the final
inspection and before the entry of the tank wagon rake.
7.5.1.3 All tools, hoses, unloading arms and pipe fittings must be clean and free
of oil dirt or grit so that the pipe connections can be made conveniently
and safely.
7.5.1.4 Ensure that necessary operational / safety equipment and tools required
for the operation are kept ready.
7.5.2 PREPARATION FOR UNLOADING
7.5.2.1 Determine the tank wagon number and verify the particulars with the
shipping advice or challan or any other relevant document.
7.5.2.2 Check for the correct placement of the tank wagons in relation to the
hoses / arms connections at the unloading point.
7.5.2.3 Set the brakes of the tank wagons, in coordination with the Railways.
Place the appropriate caution signs such as “STOP-TANK WAGONS
CONNECTED” on the open end or ends of the siding. The signs should be
placed at least one tank wagon length away from the last tank wagon at
the open end. These signs must remain in place until all the tank wagons

DEPARTMENT 7
March 2014 7-10
on that siding are unloaded, hoses disconnected, brakes released, and

tank wagons are ready in all respects for release.
7.5.2.4 Whenever separate gate is available for the Railway siding, the same
should be closed and locked after the placement has been made.
7.5.2.5 Individual Wagons shall be suitably earthed at minimum two places

before commencement of unloading operation.
7.5.2.6 Before unloading, the wagons shall be visually examined. Check for
physical damage to the barrel and for leakages for dome fittings.
7.5.2.7 Check that wagon surface is free from rust and deep pitting and the
painting is in good condition.
7.5.2.8 Before opening the lid of the dome, ensure that the seals and locks, if
any, are intact. Break the seal, remove the dome cover pin and carefully
lift the dome cover.
7.5.2.9 The operating personnel should not position their faces over the relief
valve.
7.5.3 SAMPLING
7.5.3.1 7.5.3.1 Whenever required, a sample may be obtained through the

sample valve located within the dome. A pipe or a tube to the bottom of
the tank connects the valve and hence, the sample will be
representative of the material at the bottom. In case water is observed or
the product does not appear to be representative of the one
mentioned in the despatch advice, investigation of the causes should
be carried out.
7.5.4 GAUGING OF TANK WAGONS
7.5.4.1 The tank wagon may be gauged by means of ‘magnetic gauge’

located inside the cover. This device permits determination of the liquid
level within the tank wagon bullet. Following procedures are to be
adopted for gauging :

DEPARTMENT 7
March 2014 7-11
(a) Operating personnel should not lean over or position their head or
body directly over the tank wagon gauging device, while releasing
the hold-down latch.
(b) Remove the cover that protects the magnetic gauge. This must be
done slowly and carefully since the slip tube gauging device may
have become unlocked and be pressed against the cover. High
pressure may force the gauge tube to come out rapidly and
therefore, should be prepared to prevent it from popping up when
the cover is freed. If the gauge has not come up by itself pull out
the same, but do not bring it to the extreme lower end.
(c) Slowly pull out the magnetic level gauge till a resistance is felt due
to magnetic pull by the opposite pole floating magnet on the liquid
around the magnetic gauge pipe. The gauge shall be held at this
position by itself. Read the gauge mark on the side of the slip tube
corresponding to the top surface of the gauge pipe mouth and
record the reading. This reading is indicative of the liquid level in the
tank wagon.
(d) As soon as the gauge is read, bring the magnetic gauge down to
the lowest position and lock it in its place. Secure the gauge cover
back over the slip tube.
(e) Record the gauge tube readings. The difference in the dip reading
of the loading location and the unloading location is to be noted.
This is to be correlated with the loading and unloading temperatures
to ascertain whether it is due to temperature difference. The
difference in dip reading is to be within logical limit. If the variation is
consistently on the negative side, the matter is to be taken-up with
respective source with complete facts and figures to try to ascertain
the reason & the issue to be highlighted. This data is to be analyzed
source wise. The data to be randomly cross-verified for correctness.
Each unloading location must maintain two dip rods separately for
BTPG and TG of standard specifications and company e.g. Midland
USA, or ARIECKAL Industries, Panvel, Mumbai etc. In case of wagons,
where dip rods are not functioning, the average of remaining
wagons to be taken for reference. However, the actual stock
accounting would be made through Servo gauges taking LEV into
account. Railways to be intimated about these defects along with
all loading locations.

DEPARTMENT 7
March 2014 7-12
Caution: The gauge tube cover must be kept in place at all

times except during the gauging operations.
7.5.5 VOLUMETRIC CALCULATION AND WEIGHT DETERMINATION
7.5.5.1 Based on the observed liquid level, liquid volume can be determined
through the relevant tank wagon calibration chart.
7.5.5.2 For conversion of volume determined through the calibration chart to

volume at 15C or weight in metric tons, the method described in Chapter
No.11 should be followed.
7.5.5.3 In the event of weighbridge(s) available in the rail system, the weight
should be determined by weighing the tank wagons before and after
unloading operation. The difference would give the quantity of LPG
unloaded from the tank wagons.
7.5.5.4 Compare the quantity worked out as above with the shipped quantity.
Investigate for abnormal variation, if any.
7.5.6 UNLOADING OF TANK WAGONS BY COMPRESSOR
7.5.6.1 Ascertain that the liquid discharge valve and the vapour valve within the
tank wagon cover are in the closed position.
7.5.6.2 Open the port covers in the side of the dome shell, if exists. Unscrew the
plugs in the outlets of the vapour valve and the liquid valves using a box
wrench. This must be done slowly.
7.5.6.3 If there is any sound of escaping vapour or if there seems to be pressure

behind the plugs, the pressure must be allowed to be relieved through
the threads before the plugs are entirely disengaged.
7.5.6.4 If the vapour discharge continues or if there is evidence of a liquid

discharge, the valves should be re-tightened and further investigation be
carried out till the solution is found for the leakage problem.
7.5.6.5 With the plugs removed, screw pipe nipples into the outlets of the valves
after first having applied a modest quantity of sealant to the male
threads, keeping the sealant away from the end of the thread. Tighten
nipples with a pipe wrench.

DEPARTMENT 7
March 2014 7-13
7.5.6.6 Connect the two liquid transfer unloading swing arms or hoses to the
nipples attached to the liquid discharge valves. Connect the vapour or
equalizing swing arm or hose to the nipple attached to the vapour valve.
In most of the cases, these connections will be made by means of either
a ground joint union or a hose coupling.
7.5.6.7 In the event, a ground joint union is used, no gasket will be required. If a
hose coupling is employed, ensure that the appropriate gasket is in
place. Make sure that they are secured tightly by appropriate means.
7.5.6.8 Recheck the lines and connections to make sure they are properly
connected.
7.5.6.9 After the vapour and liquid hoses have been connected and before any
valve is opened, the valves on the tank wagon are slightly opened in
order to apply pressure to the hoses / arms as a test for any leak.
7.5.6.10 If any leak appears, the valve should be immediately closed and
corrective measures be taken.
7.5.6.11 After the liquid and vapour lines are secured and tested, both liquid
eduction valves should be opened slowly and completely. Then, open all
other valves in the liquid line from the tank wagon to the storage tank.
7.5.6.12 Open the storage tank filling valve slowly and take extra care not to open
this valve too far if the tank wagon pressure is in excess of the storage
tank pressure. Otherwise the tank wagon excess flow check valve may
get closed.
7.5.6.13 If the tank wagon pressure is higher than that in the storage tank, do not
open the valves of vapour line or operate the compressor. When the rate
of liquid flow drops to an unsatisfactory level, open the vapour valves
between the tank wagon and the storage tank.
7.5.6.14 At this point, make sure that the control valves of the compressor are in a
position that allows the compressor to draw vapour from the storage tank
and force it into the tank wagon. If so, start the compressor.
7.5.6.15 For proper unloading, the tank wagon pressure should be maintained
between 2.0 to 2.5 Kg/sq. cm. above the storage tank pressure. If the

DEPARTMENT 7
March 2014 7-14
differential pressure is too low, the flow of LPG liquid will be slow and may
stop and if it is more, the excess flow valves of the headers and wagon
may get closed.
7.5.6.16 Flow of gas instead of liquid through the sight-flow glass in the unloading
line indicates that the wagon is empty of liquid. Recheck this by opening
the sample valve in the tank wagon dome.
7.5.6.17 When the tank wagon is emptied of all liquid, stop the compressor and
close the liquid valves beginning at the storage tank and progressing to
the tank wagon.
7.5.6.18 To remove concentrated vapour from the tank wagon, the valves in the
manifolds should be manipulated suitably to reverse the flow so that the
compressor will draw the vapour from the tank wagon, and force it into
the storage vessel. The sequence of piping line-up during unloading liquid
LPG and vapour LPG is shown in Drawing No. 18
7.5.6.19 Restart the compressor and continue to draw vapour from the tank
wagon till pressure inside the wagon reduces to about 1.5 Kg/cm2. Once
the pressure reaches about 1.5 Kg / cm2, stop the compressor and close
all the valves in the vapour line.
7.5.6.20 After bleeding off the pressure in the hoses through cold flaring line,
disconnect both the liquid and vapour lines. Replace all the plugs in the
tank wagon valves and the unloading fittings.
7.5.6.21 Recheck sample valve and gauging device to determine that they are
returned to their original condition and are closed tightly. Lower the
dome cover carefully and lock it in place with the locking pin or secure
by appropriate means.
7.5.6.22 Remove bonding connections. Wherever overhead gantry is provided,

gantry platforms (swing type) and hoses / unloading arms are to be
raised and secured in position before release of tank wagons.
7.5.6.23 Reverse or remove and replace the "FLAMMABLE" placard with

"DANGEROUS - EMPTY" placard, if applicable.
7.5.6.24 Remove the "STOP-TANK WAGON CONNECTED" sign .


DEPARTMENT 7
March 2014 7-15
7.5.6.25 Any defect observed in the tank wagon should be recorded in the
appropriate forms and routed in accordance with acceptable
procedures.
7.5.6.26 Notify the Railways in writing about the release of wagon and ensure that
it is removed from the siding promptly. Gauge the storage tanks, within
the plant, which have received the LPG to determine that the liquid level
is appropriate.
7.5.6.27 In the event of LPG received on weight basis, the tank wagon may
require weighing after the completion of the unloading operation.
7.5.7 UNLOADING BY PUMP
7.5.7.1 The tank wagon can also be unloaded with the help of liquid pump, but it
is impossible to remove residual vapour from the tank wagon if this system
of unloading is followed. The compressor is a more desirable means of
unloading. The basic procedure for unloading through pump is the same
as that of unloading using a compressor except that the liquid line from
the tank wagon is connected to the pump suction and the pump
delivery is connected to inlet line of the storage vessel. However, there is
practical difficulty of using pumps at lower levels of LPG as vapour shall
enter the pumps when any of the wagon becomes empty which causes
pumping to stop due to vapour lock
7.5.7.2 In case of LPG tank wagons, the liquid inlet is at the top of the tank with
eduction pipes extending to the bottom so that the effect of the
‘flooded suction’ does not normally occur initially. The liquid from the
tank wagon, which enters the eduction pipe at the bottom of the tank
wagon, rises in the pipe and passes through the pipeline or hose on the
unloading point and drops to the pump suction. This flow pattern is an
effective siphon so long as the pressure differential remains appropriate
and vapour does not enter or form within the eduction pipe or the line
to the pump suction.
7.6 TANK TRUCK UNLOADING OPERATIONS
7.6.1 PREPARATION WITHIN PLANT
7.6.1.1 Gauging, Weighment and Scheduling


DEPARTMENT 7
March 2014 7-16
(a) The ullage should be calculated based on the gauge reading of the
vessels, before taking the tank trucks for unloading. On the basis of
available ullage, vessel should be identified for receiving the
product.
(b) Only the required number of tank trucks for unloading should be
allowed inside the plant based on the ullage. The TTs to be checked
for the shipment advice and also details in challan before
permitting inside for unloading.
(c) Based on operational convenience without endangering the safety

of the plant, maximum no. of tank trucks at any point of time should
be fixed and displayed prominently at Plant. At no point of time, the
actual no. of TTs present at the plant should exceed the maximum
permissible limit,
7.6.1.2 Inspection
(a) The unloading area must be inspected to determine that it is free of

hazards and is in satisfactory condition and safety systems are
functional for the operation to be performed.
(b) All the required equipment, tools and tackles should be inspected to
determine that they are in good working condition and kept ready
for use.
7.6.2 TANK TRUCK UNLOADING OPERATION
7.6.2.1 Checks Required Before/During/After unloading of Tank Trucks
(a) Before allowing the entry of tank truck inside the licensed area for
unloading, the following checks are required to be made :
(I) TT is carrying a challan for the plant, where it has reported for
unloading.
(II) Time taken between dispatch from loading location and
reporting at receiving location is normal. In case of abnormal
delay, matter shall be investigated for finding the reasons.
(III) Seals on the TT carry the same no. as mentioned in the challan
and are intact.

DEPARTMENT 7
March 2014 7-17
(IV) CCOE approved make spark arrestor is welded to the exhaust

pipe and routed to front side of the truck towards driver side.
(V) 2 nos. BIS approved 10 Kg. DCP extinguishers having truck
registration number, date of checking / charging painted on
them are available in easily accessible / removable position.
The periodicity of checking shall be minimum once in a month.
(VI) Quick closing manifold valve with lever indicating close and
open status and locking arrangement with color-coding for the
liquid and vapour valves.
(VII) No visible dent on the tank body.
(VIII) All tyres are in roadworthy condition.
(IX) All junction boxes are properly sealed.
(X) There is no loose electrical wiring / terminal. Complete wiring
shall be double-pole with Glass fuse links of proper rating for
over current protection shall be provided. Electrical wiring
should be well insulated.
(XI) Truck is self-starting and batteries have been kept inside the
cabin.
(XII) Readily accessible Master switch with 300 Amp rating for
cutting off the supply from the battery is provided inside the
cabin.
(XIII) No leakage from any fittings or joints.
(XIV) Availability of all statutory valid licenses / certificates.
(b) The truck should be weighed on the Weigh Bridge and the
reading(Gross Wt.) should be recorded on the challan or any
relevant document and Drivers’ signature to be obtained on
weighment slip. Recorded Gross Wt. should be tallied with the Gross
Wt. mentioned on the loading invoice. In case of abnormal
variation , matter should be brought to be the knowledge of Plant
Manager and Transporter before start of decantation of such TT.
(c) No repairs shall be carried out on the truck while it is in the unloading
/ loading area. The crew should remain present throughout the
operation.
(d) Tank trucks should be unloaded only at the unloading points

provided for the purpose. The tank trucks should be properly
positioned at the unloading point earmarked for this. This is
extremely important not only from the viewpoint of the correct

DEPARTMENT 7
March 2014 7-18
gauging operation and complete sprinkler coverage, but also to

ensure proper and complete unloading.
(e) It should be determined that there is sufficient ullage in the receiving

storage vessel to receive the complete quantity.
(f) As soon as the tank truck is properly positioned at the unloading

point, the ignition switch other electrical circuits and battery cut off
switch in the truck should be switched off and the crew should
come out of the cabin and remain near the tank truck throughout
the operation to combat any emergency.
(g) Ignition keys of the Tank truck shall be handed over to the
competent person supervising unloading operations. The vehicle’s
hand brake system should be applied and chock-blocks fixed at the
front and rear wheels and vehicle kept in neutral mode.
(h) The fire extinguishers should be kept ready near the tank truck for
use in case of emergency.
(i) Earthing & bonding connections should be made properly at two

points i.e. chassis & tank.
(j) Before caps / plugs / blind flanges are removed from either liquid or
vapour connections on the tank truck, manually controlled valves
should be checked to determine that they are closed.
(k) Inspection to be made to ensure that there are no hazards present

and the unloading operation can be completed safely.
(l) Check the roto gauge , pressure gauge and temperature gauge
and record the readings .
(m) Liquid line and vapour line of the tank truck should be connected to
the respective hoses / unloading arms fixed to the unloading point,
taking due care for the correct connections. All flange connections
are to be made using only SS spiral wound metallic gaskets and
eight nos. properly sized studs. Bonding across the TT flange and
loading coupler/hoses to be ensured.

DEPARTMENT 7
March 2014 7-19
(n) After the vapour and liquid hoses / arms have been connected, the
first valves on the TLD manifold should be crack opened to check
for any leakage. If any leak appears, the valve should be
immediately closed and corrective measures should be taken.
(o) As soon as the connections are checked, valves of the storage

vessels, TLD header lines and TLD bays should be opened.. While
decanting through LPG Compressor, always ensure that the pressure
inside the tank truck is more than that of storage vessel before
opening the liquid valve of tank truck . The valves are opened slowly
to avoid closure of the Excess Flow Check Valve.
(p) Bay-wise Checklist points before start of TLD operation shall be

complied and checklist form as specified at Annexure-9 part 1 shall
be filled up and signed by TLD/TLF workman and TT driver
(q) Competent person must be present during the entire unloading

operation and respond immediately in the event of an emergency.
(r) Care should be taken to see that the pressure, within the delivery
vessel does not reach or exceed the set pressure of the relief valve.
(s) In order to ascertain that the liquid contents of the tank truck are
fully discharged, the rotogauge can be placed at ‘zero’ reading
and the bleeder valve opened. The vapour discharge in this
position is indicative of the complete discharge of the liquid.
Alternatively, it can also be checked from sight flow indicator at
unloading bay. Record the observation on the challan or relevant
document. When the transfer of the liquid is completed, the
compressor or pump should be shut-off, followed by immediately
closure of all liquid and vapour valves progressing from the tank
truck to receiving storage vessel.
(t) The remaining vapour in the bullet may be recovered by

connecting the vapour connection of the tank truck to the suction
of the compressor and discharge of the compressor may be
connected to the vapour inlet of receiving vessel.
(u) When the tank truck pressure is reduced to 1.5 to 2.0 kg/cm2 , stop
the compressor and close all the valves. Under no circumstances

DEPARTMENT 7
March 2014 7-20
pressure within the tank truck should be reduced below the

(v) Bay-wise Checklist points after completion of unloading operation

shall be complied and checklist form as specified at Annexure-9
part 2 shall be filled up and signed by TLD/TLF workman and TT driver
(w) Before disconnecting the hoses / unloading arms, the valves of the
tank truck should be checked for closure and the valves at the
receiving risers should likewise be re-checked.
(x) As soon as it has been determined that the shut-off valves at each
end of the hoses / arms are closed and the trapped LPG in the
hoses / unloading arms is vented out, the hoses / arms are to be
disconnected and placed at designated place.
(y) Caps and plugs must then be immediately fitted to the valves /
fittings on the tank truck and on free end of the hoses/arms.
(z) Before starting the tank truck engine for the removal from the bay,
the tank truck should be inspected by the competent person
supervising of the operation to check that the hoses / arms have
been disconnected, tank truck valves closed and plugged, bonding
cable wires disconnected and there is no concentration of vapour
around the vehicle.
(aa) With this operation completed, the choke blocks are removed and
the vehicle engine may be started for moving out the tank truck.
The empty tank truck should be weighed(Tare Wt.) and the reading
should be recorded on the challan or in the relevant document and
the net weight(Gross Wt.- Tare Wt.) should be calculated from this.
(bb) At the closure of operation at the shift end, unloading arms/hoses to

be kept at designated place and locked.
7.6.2.2 Checks Required to be Carried Out Before Issuing Loading Memo

(During the course of unloading operations)
(a) Height barrier provided as per specifications.


DEPARTMENT 7
March 2014 7-21
(b) Fuel tank is protected by means of stout guard and fuel tank cap is
locked.
(c) Paint of bullet is not peeling off.
7.6.2.3 Checks Required to be Carried Out on Random Basis

(Each truck to be checked at least once in a month)
a) Internals of fire extinguishers are in good condition.
b) TREM CARD and instructions booklet detailing instructions on

handling emergencies en-route are available.
c) Route map and training card for TT crew are available.
d) Valid CCOE license and authenticated copies of the drawings of

the tank truck are available.
e) Valid yearly certificate for SRV along with purging certificate and
Half Yearly Certificate for visual examination are available.
f) Hydraulic Test Certificate is available.
g) RTO permits and the RTO endorsement is available on the driving

license of the driver for hazardous goods..
h) RLW-ULW > Licensed capacity.
i) Hazchem sign, name of the contractor with address and telephone

Nos. displayed prominently at three places i.e. on either side and at
back side of the vessel.
j) Bullet has no sign of external corrosion.
k) Excess flow check valves are functioning. (The Excess flow checks
valves of tank trucks on liquid as well as on vapour service must be
checked by suddenly opening of the liquid / vapour valve after
connecting the hoses to the tank truck. EFCVs will close with ‘tick’
sound and on closing the tank truck’s Liquid / vapour valve
suddenly the EFCV will open and ‘tick’ sound will again be heard.

DEPARTMENT 7
March 2014 7-22
l) Fuel tank is locked and protected by steel guard.
m) First aid kit is available.
n) Liquid / vapour pipe lines are in single piece from excess flow
check valve to the discharge valves.
o) Safety fitting viz. safety valve, roto gauge, pressure gauge

and temperature gauge are adequately protected.
p) Operative fittings like roto gauge, pressure gauge and

temperature gauge are operational.
q) CCOE approved Emergency / Safety kit is available.
r) 4 Nos. caution sign boards with luminous paint for stopping

traffic in case of any emergency. Based on the nature of the
defects either all the deficiencies should be corrected at the
unloading location itself or the tanker should be allowed to get the
repairs done en-route and submit the details at loading location.
Note: Whenever a truck is taken for the first time for unloading in the
plant, the trucks should be subjected to all the checks mentioned at
Clauses Nos.7.6.2.1(a), 7.6.2.2 and 7.6.2.3. After full satisfaction that the
tank truck is complying with all the above points, then only loading
advice should be issued.
7.6.3 QUANTITY DETERMINATION
7.6.3.1 The contents of the tank truck should be verified by actual weighment.
The tank truck should be weighed prior to the unloading operation and
again after the completion of the unloading operation. The difference
represents the quantity unloaded. Proper records of the same should be
maintained. The quantity decanted shall be tallied with challan quantity
and incase of shortage beyond permissible limit, action as per transport
contract shall be taken.
7.6.4 UNLOADING THE TANK TRUCK USING PTO (Power Take-off) UNIT
7.6.4.1 This type of system is under use in Rural Marketing Vehicle (RMV) and in
Emergency Rescue Vehicle provided in some of the plants and in the
Auto LPG Bulk delivery vehicle (Bob Tail).

DEPARTMENT 7
March 2014 7-23
7.6.4.2 Some tank trucks may be equipped with pumps or compressors that may
be utilised to discharge / recover the contents of the tank trucks. This type
of arrangement may facilitate delivery of the product to the locations
(e.g. Industrial Customer, LPG retail outlet), which are not equipped with
the product transfer equipment.
7.6.4.3 Similar safety and operational precautions mentioned for unloading and
loading of tank trucks must be ensured in this operation also. Hence,
specific details are not being mentioned here. This may be read in
conjunction with unloading of tank trucks mentioned in Clauses Nos.7.6.2,
7.6.3 & 7.6.4.
7.6.4.4 The pump or compressor and tank truck engine should not be operated,
when the vapour is released in the vicinity of the tank truck. When the
tank truck is moved into position for unloading, the engine must be shut-
off and not re-activated until complete unloading operation takes place.
7.6.4.5 After checking all possible sources of leakage / vapour concentration in

the surrounding area, the tank truck engine may be started and the
pump or compressor engaged.
7.6.4.6 When the tank truck is empty, the pump or compressor should be
disengaged before the hoses are disconnected.
7.6.4.7 After the hoses are disconnected, time should be allowed for the
dissipation of the product, which may have escaped, before the
engine is re-started.
7.6.5 TANK TRUCK UNLOADING BY PUMP
7.6.5.1 The tank truck can be unloaded with the help of liquid pump, but it is
impossible to remove residual vapour from the tank truck if this system of
unloading is followed. Whether the pump performing the unloading
operation is permanently installed within the plant or is a part of the tank
truck unit, the generalized procedures described below should be
followed :

DEPARTMENT 7
March 2014 7-24
(a) Connect suction-side of the pump to tank truck liquid line and
delivery side of the pump to the liquid inlet line of the receiving
vessel.
(b) If pressure in the tank truck bullet is lower than the pressure in the
receiving storage vessel, equalise through the vapour connection .
If the tank truck pressure is higher than the pressure in the receiving
storage vessel equalise with the liquid stream.
(c) Start the pump.
(d) When unloading pump loses suction or vapour flow is observed in

‘sight-flow-glass’ discontinue pumping operation and close the
valves.
(e) Check through the tank truck roto gauge (by setting it to 0%
reading ) to ensure that the tank truck is empty.
(f) If the tank truck is not empty, determine cause for loss of suction on
unloading pump. Determine that excessive container pressure
does not exist. Allow sufficient time for ‘excess-flow-check--valve’
equalization, if the closure occurs. Determine that the bypass line is
operating as intended. If the suction can be re-established, open
the valves and continue unloading. If the tank truck cannot be
emptied, discontinue pumping, close the valves and investigate
causes for taking corrective measures. However, at lower liquid
levels in the tank trucks, some TTs can become empty before other
trucks and vapour may enter the pump causing “vapour lock”
thereby stopping the pumping
(g) LPG compressor is required for recovery of vapour from the tank
truck. In view of the inherent disadvantage of tank truck unloading
by pump, when compared to unloading by compressor, the above
method should not generally be followed , unless specific
circumstances necessitate it.
7.6.6 TANK TRUCK UNLOADING BY COMPRESSOR
7.6.6.1 Whether the compressor is installed as part of the storage plant facilities
or is installed on the tank truck, the following generalised procedure
could be followed :
-

DEPARTMENT 7
March 2014 7-25
a. Connect the suction side of the compressor to the vapour outlet of the
receiving vessel and the delivery side of the compressor to the
vapour line of the tank truck. Connect the liquid inlet line of receiving
vessel to the liquid line of the tank truck.
b. After having made necessary connections of hoses / unloading arms

as above and opened the valves, allow the tank truck pressure and
the storage vessel pressure to equalise. If the pressure within the tank
truck is lower than the pressure in the receiving storage vessel,
equalise through the vapour connection. If the tank truck pressure is
higher than the pressure in receiving storage vessel, equalise with
the liquid stream.
c. Start the compressor. The vapour will be sucked from the receiving
vessel and will be discharged into the vapour space of the tank truck
bullet creating a differential pressure, thereby pushing the liquid from
the tank truck to the receiving vessel.
d. Care must be exercised to see that the pressure created within the
tank truck does not approach or exceed the set pressure of relief
valve.
e. After all the liquid LPG has been decanted from the tank truck
bullet, the vapour remaining in the bullet may be recovered by
connecting the suction of the compressor to the vapour
connection of the tank truck bullet [the vapour valve is provided at
the bottom side of the bullet and the connecting pipe extends inside
the bullet up to the vapour space at the top) and discharge of the
compressor may be connected to the vapour inlet of receiving
storage vessel.
f. When the tank truck bullet pressure has been reduced to 1.5 to 2.0
kg/cm2, stop the compressor and close all valves.
g. Under no circumstances, the pressure within the tank truck bullet

should be reduced below the atmospheric pressure.
h. After ensuring that the shut-off valves are closed tightly and the
trapped LPG in hoses is vented out, disconnect the liquid and vapor
hoses/arms

DEPARTMENT 7
March 2014 7-26
7.7 LOADING PROCEDURES - GENERAL
7.7.1 Loading procedures are closely related to unloading procedures.

Therefore, the same basic precautions should be observed to ensure that
efficiency and safety are integral factors of each operation.
7.7.2 With the scope of loading procedures, two types of basic vehicles are
considered viz., tank wagon and tank truck. In each case, the vessel
being filled is capable of movement with the result the hose
connections used for transfer can be snapped if the vehicle moves
accidentally. It is, therefore, absolutely essential that during a transfer
operation these vehicles remain fixed.
7.7.3 The same basic safety requirements enumerated in Clause No. 7.4 and
Clauses Nos.7.4.5, 7.4.6, 7.4.7 and 7.4.8 should be observed, whenever
loading operations are undertaken .
7.7.4 The entire operation must be constantly supervised by a competent

person, who must remain in the immediate vicinity of the transfer
operation for the entire duration. The operators should remain as close
to the control devices as practicable at all times.
7.8 TANK WAGON LOADING OPERATIONS
7.8.1 GENERAL SAFETY PRECAUTIONS
7.8.1.1 Within the loading area there must not be any source of ignition (e.g.
smoking, naked flames, match box, cigarette lighter etc.).
7.8.1.2 At the sign of any leak the operation must be stopped immediately. Leaks
must be repaired promptly. If the leakage cannot be stopped, the
matter should be reported immediately to the Plant Manager for taking
corrective action / precautionary measures.
7.8.1.3 Before the start of loading operation, the tank wagons shall be visually
examined for the following :
(a) Periodic overhauling(POH) / Routine overhauling (ROH) and the

yearly examination of the Gaskets and ‘O' rings are not over due.

DEPARTMENT 7
March 2014 7-27
(b) There is no physical damage to the barrel and there is no sign of

leakage from the dome fittings.
(c) The surface is free from rust and deep pitting and the paint on the
barrel are not peeled off .
(d) It must be ensured that the liquid and vapour eduction valves,
sampling valve and magnetic gauging device are complete in all
respects and are in perfect working order and that there is no
evidence of leakage.
(e) There is no physical damage to the safety valve and the

thermo-well.
(f) When defective Wagons (Dip tube well, EFCV, leakages, etc), are
identified during loading operations or with prior intimation from
unloading locations, the details of all such wagons to be forwarded
to Railways with a request for joint inspection. Such wagons to be
loaded after clearance from Railways.
7.8.1.4 The tank wagons to be loaded shall not be located under or near any
electrical wire and wagons shall be suitably earthed before
commencement of loading.
7.8.1.5 Tank wagons found to be in any way defective shall not be loaded until
repairs are carried out by the Railways. Repairs involving hazards, should
not be allowed to be carried out in the plant premises.
7.8.1.6 Caution signs must be exhibited at a suitable distance away from tank
wagons on the approach end or both ends as applicable.
7.8.1.7 Jumping from the loading gantry to tank wagon or from one tank wagon
to other is extremely un-safe and should be prohibited. Rough handling
of tank wagons, whether loaded or empty within the plant should not
be permitted.
7.8.1.8 During placement on the siding, tank wagons should be aligned as close
as possible to the specific point for most convenient loading whether it
may be on an elevated loading gantry or ground-level loading
connection.

DEPARTMENT 7
March 2014 7-28
7.8.1.9 The use of open lights is prohibited. If the torches are required to be used,
they must be of flameproof type
7.8.1.10 The loading connections must be securely attached to the pipelines

before the eduction valves are opened.
7.8.1.11 Loading shall be done through the liquid eduction valve, which has pipe
leading to the bottom of the tank. The vapour eduction valve is
connected to the storage system of LPG plant. Good operating condition
of these valves should be ensured before commencement of loading
operation.
7.8.1.12 The maximum permitted filling level must not be exceeded

under any circumstances.
7.8.1.13 7.8.1.13 After completing loading operation and disconnection of

hoses / arms, it should be ensured that there are no leaks from the valves
/ plugs at the end of the hoses.
7.8.1.14 Tank wagons should be inspected thoroughly for the leaks before
issuing release memo.
7.8.1.15 Raise and secure gantry platforms (swing type) after completing the final
inspection wherever over-head gantry is provided .
7.8.1.16 Loaded tank wagons should be sealed and properly labeled giving
despatch particulars.
7.8.1.17 New tank wagon bullet or the bullets received after repairs / pneumatic
test must be purged before loading duly following purging procedures
(Annexure 10).
7.8.1.18 The Tare weight of the new tank wagon must be verified on a
weigh bridge and got corrected through local Railways, in case of any
variance with the marked tare weight.
7.8.2 LOADING OPERATIONS (Tank Wagon)
7.8.2.1 Sequence of operations for tank wagon loading is as follows :


DEPARTMENT 7
March 2014 7-29
a. Under any circumstances a tank wagon should not be loaded

with LPG having vapour pressure higher than designed working
pressure of the tank wagon.
b. It may be ensured that the tank wagon is placed close to the

loading point so that extension or stretching of hoses is not
required.
c. Tank wagon brakes should be set and caution sign boards are
i. to be placed at the tank wagon gantry.
(b) Tank wagon should be Inspected thoroughly to ensure that valves

and fittings are in satisfactory operating condition.
(c) Bonding cable is to be attached to the tank wagon.
(d) Liquid outlet line from the supplying vessel is to be connected to the
liquid line of tank wagon. It should be ensured that the vpour line of
tank wagon bullet is connected to vapour inlet line of the supplying
vessel (i.e. vapour return line or equalizing line).
(e) If a pump is used for loading, it must be ensured that bypass

arrangement is provided and is operative. Use of pump for loading
operations is more convenient compared to the use of
compressor.
(f) If a compressor is used, vapours from any other storage vessel in the
plant would be drawn and discharged into the supplying vessel.
In this case vapours from the tank wagon must be returned to the
storage system and in no case should be vented freely to the
atmosphere. The compressors may be started at this point.
(g) Valves on tank wagon and on loading points are to be opened

observing carefully for any indication of leakage, especially at the
hose connections. Tank wagon valve is to be closed to make sure
that it operates properly, thereafter it is re-opened. Loading must
be discontinued in the event of leakage. Thereafter, the leak must
be repaired promptly. Leaks beyond repairs must be reported to
the Plant Manager immediately.

DEPARTMENT 7
March 2014 7-30
(h) Determine final liquid level by referring to the density of the

product to be loaded and relevant tank wagon calibration chart.
(Refer Annexure No. 11 for details).
(i) After the last tank wagon is loaded, shut down the loading
pump (or compressor).
(j) Check final readings (liquid level) and then lower magnetic level
gauge to lock the position and secure
(k) Disconnect the loading hoses and plug or cap all connections
taking all possible measures to minimise venting of vapour to
atmosphere.
(l) Make sure that all valves in tank wagon bullet and unloading points
are shut tightly and all plugs are in place and gauging device is
locked. Inspect for leakage. Before shutting off the valve, it must be
ensured that thermal expansion arrangement by way of pop action
valve is provided and is operative on the section of pipelines
blocked with valves at both ends.
(m) Replace dome cover and seal
(n) Remove the bonding cable. Note that the bonding cable is fixed
before the operation starts and is disconnected after all the
operations on the tank wagon are over
(o) Place label on the tank wagon giving despatch particulars.
(p) Do not remove caution signs on the siding until all the tank wagons
on the siding are loaded, disconnected and ready for release
7.9 TANK TRUCK LOADING OPERATIONS

7.9.1 The competent person in charge of the operations shall check the
documents of the tank truck for valid loading advice and for any remark
from the unloading / receipt location regarding shortfalls in safety fittings.
If the tank truck does not comply with the shortcomings, the truck shall
not be taken for loading. The checks mentioned in Clause No. 7.6.2 for
the tank trucks for the unloading must be followed strictly for the loading

DEPARTMENT 7
March 2014 7-31
operation also. The following shall also be ensured before taking the truck
for loading :
a. The tank truck has a valid License and drawing duly approved by the
Chief Controller of Explosives. Apparent condition of the tank truck
before undertaking the loading operation should also be checked.
If there is any deviation, regarding the condition of the tank truck or its
safety fittings, the truck should not be taken for loading.
b. After truck has been moved to loading position, the engine must be
stopped and ignition and lights are switched off. Battery Cut-off switch
must be in “off” condition.
c. Crew must leave the truck cabin and handover the ignition keys to the
competent person supervising the operation. Crew should not re-enter
the cabin unless authorized by the competent person.
d. No electrical switch in the tank truck shall be turned on or off during

loading.
e. No mechanical repairs or adjustments shall be carried out on the truck

while in the loading area.
f. Only couplings suitable for LPG service shall be used for attaching
loading lines to the truck.
g. Hoses / arms suitable for LPG service should only be used.
h. When hoses/arms are not actually attached to the unit being loaded,
they should be properly secured to the hooks provided for the
purpose to prevent accidental run-over by a vehicle.
i. Trucks or other vehicles shall not be driven in the loading area when
there is heavy concentration of vapour in the atmosphere.
Explosimeter check should be made in such cases.
j. New tank truck or those received after repairs/ pneumatic test, must
be purged before loading, duly following purging procedures.
(Annexure 10).

DEPARTMENT 7
March 2014 7-32
k. Fire extinguishers should be kept stand-by before starting the

operation.
7.9.2 LOADING OPERATION (Tank Trucks)
Following Methodologies are used for Loading of LPG in Tank Trucks:
(a) Volume based
(I) With the help of ‘Roto Gauge’ : Filling through Roto gauge is
the basic method of Filling wherein exact quantity
determination (by weight) is not possible during the process of
filling. The maximum Roto gauge reading up to which TT can
be filled is different for different TTs. When tank truck is to be
filled using a ‘roto gauge’, percentage volume to be filled
should not be straight away set for the filling level determined,
but should be set around 50% level initially and thereafter 10%
higher i.e. 60%, 70% and 80% till final level is reached.. When
the level of LPG filled by volume reaches 5% below the pre-
determined level very close supervision is to be maintained to
ensure that no over filling takes place. Filling through this system
requires more control and close supervision as this system does
not have automatic control over the quantity to be filled. This
system also has the drawback that the TT filled may require
frequent corrections for under/over filling by weight.
(II) With the use of Positive Displacement(PD) meter: PD meter is

used for measuring the volume of the product flowing through
the pipeline. Whenever a truck is taken for loading, system
determines the quantity (weight) to be loaded in tank truck.
Normally for loading of LPG with help pf PD meter, on line
densitometer is also used, which keeps on recording the
density of the liquid flowing through the pipe. System, in turns
calculate the volume for the liquid to be filled and send signal
to the PD meter. In case, densitometer is not provided, fixed
density is considered for calculation of weight. Corrections in
the quantity filled may be required, since the equipment
primarily measures the volume. Vapor balancing line should
not be used for better accuracy.

DEPARTMENT 7
March 2014 7-33
(b) Weight based
(I) With the help of Weigh Bridge: In this system, every bay is
provided with a weighing bridge. Weight of LPG loaded is
available at any point of time during the loading. This ensures
accurate filling as far as net weight is concerned.
(II) With the use of Mass Flow Meter(MFM): Mass Flow Meter
directly measures the weight of the product flowing through it.
It measures the weight with greater accuracy with the help of
“Corriolis Principle”. Since MFMs can work accurately when a
single phase flow is maintained , it is recommended to provide
“Vapor Eliminator” before MFM. Loading through MFM is
possible by manually punching the quantity to be loaded
locally or through automated loading system with batch
controller and other facilities. This remote loading facility is
installed at places where no. of TTs loaded is quite high. In an
automated loading system, following features are available:
a. Master Data of all the TTs is pre-fed in the LRCS server.

b. All cards are configured in the system.
c. Card Readers are available at all points for communicating
the data stored in card to Central server through
communication network.
d. Each location i.e. Batch Controllers at Bays, Weigh bridge
Interface, Card readers communicate signals / data with
the central Server.
e. Monitoring of various parameters of loading incl. Flow rate
at each bay, queue at each bay, difference in MFM vs.
Weigh bridge readings can be done through Central Server
room at S&D, control room and TLF.
f. Each TT entering the plant for loading is provided a proximity
card which has got all details related to loading i.e. bay
number, Tare Wt., Gross Wt, LPG to be loaded etc.
g. TT has to show card at every stage of the loading process
e.g. entry to the licensed area, tare wt./ gross wt. Weighing,
TLF bay etc. Status of the TT is continuously available on a
very user friendly graphic screen. The flow rate at all bays
can be monitored. Bay wise details are shown with TT
number, Quantity to be filled, Quantity filled at the instant,

DEPARTMENT 7
March 2014 7-34
Flow rate etc. The system also shows the loading pump
being used, and status of ROVs etc.
h. Earthing to TT is controlled by means of earthing relay, which
does not allow loading to take place if it is not connected
and alarm is generated in control room.
This system provides a better control over the loading process and
requires minimal corrections.
While all the above methods are different and uses different equipment
to keep a control on the LPG to be loaded in the tanker, final invoice is
prepared on the basis on net weight loaded in the tanker, which is
determined by weighing the tanker before and after loading. All the
measuring equipment including the weigh bridge shall be regularly
calibrated and verified by local legal metrology department. Irrespective
of any method used for loading, following steps should be necessarily
followed while loading of tanker.
(a) TT has all statutory licenses and is fit for loading.
(b) After accepting the TT for loading, record tare weight of the TT after
proper placement of TT on the weigh bridge platform. The
positioning of the TT should be within the box painted on the weigh
bridge since positioning of TT at the edges increases probability of
error in weighment.
(c) The male coupling should be connected to the liquid / vapour

flange before entering the loading bay if unloading arm is used with
corresponding female coupler. In case unloading arm is provided
with flanged connection without dry-break coupler, the unloading
arm shall be directly connected to the tank truck flange. This
should be done using SS spiral wound metallic gaskets and
tightened with 8 nos. properly sized studs with bonding strip across
the connecting flanges. However, caution to be exercised while
connecting the mal coupling ensuring that TT valve remains in
closed condition.
(d) Position the vehicle in the loading area in the designated painted
box to facilitate proper connection of loading arms.

DEPARTMENT 7
March 2014 7-35
(e) Apply Hand brakes of the TT. Switch off the TT and apply Master cut
off Switch. The tank truck engine, lights, radio and all other electrical
equipments must also be switched off.
(f) Remove Fire extinguishers from the TT and position one on the front
and other on the rear side of TT.
(g) Apply wooden chokes on the front and rear wheels.
(h) Connect Earthing / Bonding cable on two points (one on tank shell
and other on chassis)
(i) Ignition keys shall be handed over to the person supervising the
loading operations for safe keeping in the box designated for this
purpose.
(j) Connecting to loading arms / hose: The connection to the loading

arms / hose must be made with utmost safety. Crack open the
valves on the loading point on the manifold and inspect the
loading hoses/arms and connections for leakage on the liquid
line. Repeat the same process for vapour line, if the same is
required to be connected. Under no circumstances loading should
begin until the system is leak-free.
(k) Vapour equalising line to be opened should only be opened after

the pressure inside the tank truck becomes more than the pressure
in the supplying storage vessel.
(l) As the filling operation progresses, the pressure within the tank truck
should be observed to ensure that it does not approach the ‘Start-
to-discharge pressure’ of pressure relief valve. The pressure relief
valve should not get actuated as a result of the filling operation.
(m) In case the tank truck pressure becomes excessive, the loading
operation should be stopped. Causes for excessive pressure build up
should then be investigated. Check the equalizing line, which may
have been blocked as a result of the closure of an ‘excess flow
check valve’ (on the tank truck vapour line). If this be the case,
valve on the vapour line of the tank truck must be closed to allow
the equalization of pressure across the excess flow check valve.
When re-establishing the transfer operation, care should be

DEPARTMENT 7
March 2014 7-36
exercised in opening the vapour equalizing valve slowly so that a

sudden surge does not cause closure again.
(n) In the actual filling operations ,when the liquid content is
approximately within 5% of the maximum safe filling level, the
operator should position himself so that he is in the control of the
shut-off valve and start to close the valve as the maximum filling
level approaches.
(o) As soon as the maximum filling level is reached, the valves on the
tank truck should be closed. Also, the valves on the loading point of
the bay closed. With the valves attached to hose ends closed, the
couplings on the liquid and vapour connections should be loosened
slightly, to gain assurance that the tank shut- off valves are tightly
closed. In case of automated systems, the cut off is automatic
through digital control valve (DCV) which in turn is controlled by two
nos. of solenoid valves and the control system.
(p) After tightness tests as above have been completed, the couplings
may be removed and the plugs and caps immediately replaced on
the tank truck bullet valves. Recheck tightness for any leakages.
(q) Using roto gauge, check reading on both (left and right) sides to
determine that the identical readings are obtained. In case the
readings are not identical, the mean value should be recorded.
However, it must be ensured that any of the readings does not
individually exceed the maximum safe filling volume.
(r) The roto gauge should also be checked against ‘fixed-liquid-level-

gauge’, which is comparatively more accurate and less prone to
variations.
(s) Before removing the chock blocks and authorizing movement of

the vehicle, the competent person should take a full round of the
unit to ensure that the hoses and bonding cable have been
disconnected and there is no unsafe concentration of vapor
around the tank truck and that the vehicle is in readiness for
movement.
(t) Remove the chock blocks and authorize the driver to remove the
vehicle from the loading area to weigh bridge.

DEPARTMENT 7
March 2014 7-37
(u) Tanker should be weighed (gross wt.) and it shall be ensured that it
has not exceeded the Registered Laden weight of the vehicle. New
weight(Gross Wt. – Tare Wt) shall be calculated and cross checked
against the licensed capacity of the vessel. In no case, net weight
shall be more than the licensed capacity.
After all the tank trucks are loaded, the pump should be stopped and all
valves should be close.
7.10 RECEIPT OF LPG THROUGH CROSS COUNTRY PIPELINES

7.10.1 GENERAL
7.10.1.1 Receiving the product in a plant by means of pipeline is the most

desirable method due to following reasons:
 It is most economical if the volumes handed is large.

 It is environment friendly since it reduces the rail/road movement
and thereby environment pollution.
 Reduces road/rail congestion and associated risk due to accident.
 Highly dependable since variables e.g. vehicle breakdown, road
jam, non availability of driver are eliminated.
7.10.1.2 The techniques and procedures, which may be necessary for the transfer
of LPG may vary widely since in one case the transfer line may be
extremely short merely passing through the fence from Refinery to the
bulk storage plant located immediately adjacent to the Refineries. In
some cases, the line may transverse many kilometers between Refineries
and Marketing plants conveniently located for the distribution purpose.
7.10.1.3 The quality and specification of the product may be determined by

sampling the storage vessel from which the product is to be dispatched .
7.10.1.4 It is essential to provide Mass Flow Meter(MFM) to measure the quantity

received in the Plant. MFM can be installed either in supplier’s or
receiver’s premises or both can have their independent meter based on
agreement between them. However, due care must be taken to have
similar measuring instruments i.e. both the metering instruments should
have the same principle of operation, same size and set of arrangements
like vapour eliminator etc. to obviate any discrepancy due to design
difference and difference in installation.

DEPARTMENT 7
March 2014 7-38
7.10.1.5 Dispatching location shall got all the requisite test done before supply of
the product. LPG passing all laboratory test shall only be pumped. Test
certificates of all batches shall be sent to receiving location at regular
intervals.
7.10.1.6 In case of cross-country pipelines, supply station having a control room is

established near the receiving location. In this event data pertaining to
tank level, pressure & temperature, status of ROVs on receipt line etc. in
receivers’ premises and flow rate, custody meter readings and
ROVs/MOVs on the supplier’s premises etc. shall be exchanged for better
control and safe operation. Guidelines stipulated in OISD Std 214 in this
need to be followed
7.10.1.7 Sufficient interlocks to be provided for stoppage of pumping/supply

operations in the event of high pressure, less/no flow, increase of level in
the receiving tank beyond permissible limit and other reasons which can
pose a threat to the safety of the pipeline or other facilities.
7.10.2 PREPARATION WITHIN THE PLANT
7.10.2.1 In order to ensure that there is sufficient capacity within the plant to
receive the pipeline shipment, receiving storage vessels should be
gauged by positive methods to ensure that sufficient capacity is
available for receiving the parcel and that maximum safe level should
not be exceeded.
7.10.2.2 Entire operation of receipt through Pipeline shall be supervised by a

competent person.
7.10.2.3 In most of the cases, the rate of transfer into the plant will be known and
the volume to be received will be pre-determined. Hence, a schedule
can be developed covering the entire transfer operation. Manifold
manipulation can be pre-determined to ensure that the storage
vessels, which are being filled, are monitored at appropriate intervals
and switching over from one storage vessel to another can be made
without any difficulty.
7.10.2.4 By preparing a programme to cover manifold manipulation within the

plant and subsequently adjusting the programme as the transfer

DEPARTMENT 7
March 2014 7-39
operation progresses, a system can be developed which may lead to

improved efficiency in subsequent transfers.
7.10.2.5 Ensure that no other activity except vapor balancing is being carried out
or planned from the same vessel during the receipt operation and
constant monitoring of gauges / reading is carried out by the competent
person.
7.10.2.6 Metering equipment must be in the satisfactory operating condition. If

the meter is used for primary accounting, it must be calibrated and
certified by the Weights & Measure’s Department.
7.10.2.7 In the event of utilising recording meters, which indicate volume,

temperature and pressure, their performance and reliability must be
determined in advance through meter provers. Proving of custody
transfer meter shall be carried out at agreed frequency and records to
be kept.
7.10.2.8 The quantity being received should be matched with the dispatching
location at a regular intervals of time. In case of any major deviation is
observed, dispatching point / location should be immediately informed
to stop the operation till corrective action is taken.
7.10.3 PRODUCT TRANSFER
7.10.3.1 Individual circumstances within the plant will pre-determine the

procedures that must be followed during the transfer operations.
However, regardless of the degree of automation, a competent person
must be available to monitor the overall progress of the transfer at
regular intervals. Gauge readings and observations, if any, must be
recorded in the logbook at regular intervals.
7.10.3.2 Due to the nature of a pipeline transfer, even though regulating means
are provided to ensure that the excessive pressures are not induced by
the incoming product, it is essential that the receiving storage vessels
are observed periodically to ensure that the pressures do not develop
which approach the ‘Start-to-discharge’ pressure setting of the pressure
relief valves of the receiving vessels.

DEPARTMENT 7
March 2014 7-40
7.10.4 COMPLETION OF PIPELINE OPERATION
7.10.4.1 At the completion of the transfer operation, the incoming control valves
should be closed. Charts, meter readings and other information that
may have been developed during the process should be noted or
secured. Inspection of the storage vessels where the product has been
received should be immediately completed. This should include
gauging of the contents, recording pressure, observing the product
temperature and making volumetric calculations to ensure that all the
vessels, which have been filled, are at appropriate level in relation to
maximum permissible level. Since, the working pressure during pipeline
transfer is generally higher than in case of decantation through TTs / TWs,
adequate time should be allowed for water draining and gauging of the
tank level.
7.11 TANKER UNLOADING - FOR MOVEMENT BY SEA

It is essential that the ship and terminal operators are familiar with the
basic characteristics of each other's facilities, aware of the precise
division of responsibilities and able to communicate effectively during the
time they are together involved in the joint operation of cargo handling.
7.11.1 COMMUNICATION
Reliable and effective communication, irrespective of whether it is

directly between the tanker and the terminal or indirectly via third party,
is a pre- requisite for safe and efficient cargo operation before the tanker
comes and during the period of cargo operation till the tanker departs.
Terminal communication should be compatible with tanker's system.
7.11.2 PRE-CARGO TRANSFER DISCUSSIONS
Before any cargo transfer operation is commenced, it is imperative that

the intended procedures are thoroughly discussed and a meeting held
between the responsible personnel from the tanker and the terminal. The
purpose of this meeting is primarily to make both sides fully conversant
with the characteristics of the tanker and shore cargo handling systems,
the envisaged operational and safety procedures and requirements and
the parameters to be adhered to during the transfer.

DEPARTMENT 7
March 2014 7-41
The contents of the meeting will depend on a wide variety of

circumstances but the following broad outlines form the basis of such
meetings :
(a) The names and roles of terminal and ship personnel who will be
responsible for cargo transfer operation may be noted.
(b) The terminal representatives shall check that pre-arrival

instructions to the ship on cargo, cargo disposition and cargo
conditioning are carried out. They shall also check that all
necessary inspection of tanker equipment is carried out
and tests are performed.
(c) Similarly, the officers of the tankers shall satisfy themselves that the
relevant Terminal equipment and inspection checks are carried out
satisfactorily.
(d) Terminal representatives and customs and/or independent

surveyors wherever necessary, will be informed of the cargo tank
data e.g. temperature, pressure, whether free of cargo, liquid
level or arrival dip, composition of tank vapour and quantity of
cargo on board.
7.11.3 PROCEDURE FOR DISCHARGE OF LPG TANKERS
7.11.3.1 The basic safety precautions mentioned in Clause No. 7.2 should be
followed fully for the transfer of LPG from tanker to vessels.
7.11.3.2 Before the arrival of the ship, the port clearance should be obtained and
other statutory formalities like customs should be completed.
7.11.3.3 On berthing of the ship and getting clearance from the customs, the
boarding officer should board the ship along with the surveyor for taking
joint ullage of the tanker and tallying with the quantity on board. In case
of shortage, protest is to be lodged with the Master of the ship.
7.11.3.4 Terminal tank levels are gauged and the quantity of the product arrived
at are recorded jointly with the independent surveyors.

DEPARTMENT 7
March 2014 7-42
7.11.3.5 Jetty lines cooling shall be done before transferring the product. During
line cooling and subsequent tanker discharge, communication with Jetty
control room and the boarding officer is maintained respectively.
7.11.3.6 A discharge plan shall be given to Master of the ship.
7.11.3.7 The marine unloading arms are connected to the tanker manifold.
7.11.3.8 Samples are taken from the ship tanks and sent to the lab. for analysis
before commencement of discharge.
7.11.3.9 Only on receiving the lab. clearance on the pre-discharge samples,

clearance should be given by the Officer –in –Charge of the terminal for
the commencement of discharge operation from the tanker.
7.11.3.10 The pumping rate and the number of pumps to be operated at any time
at the tanker end shall be controlled, based on the feed back from the
terminal on the pressures in the refrigerated tanks.
7.11.3.11 The pressure in the refrigerated tank during receipt is maintained by

removing the vapour through compressors. The compressed vapour is
then condensed in a condenser and pumped to the buffer tanks for the
storage at atmospheric temperature.
7.11.3.12 Hourly monitoring of the discharge figures should be reconciled at the

terminal and with the actual receipt.
7.11.3.13 Logging of all the events should be done in a log book and all
parameters should be recorded on hourly basis.
7.11.3.14 On completion of discharge the ship tanks should be gauged and the
quantity of product discharged should be arrived.
7.11.4 DISCONNECTION OF HOSE / UNLOADING ARM
On completion of the unloading operation, the tanker discharge pipeline

needs to be purged to push the liquid LPG to the receiving tank. Purging
may be done by LPG vapour, inert gas or water as per the design of the
system. However, before disconnecting hoses or unloading arms, it is to
be ensured that there is no liquid LPG left between the tanker main valve

DEPARTMENT 7
March 2014 7-43
and shore isolation valve. Product from this length of pipeline is to be

safely vented out.
7.11.5 CALCULATING THE QUANTITY OF LIQUID ON BOARD
Before commencement of tanker discharge operation, tank readings for

temperature, pressure, liquid level etc. are jointly agreed by the shore
and tank representatives. The corrections applied to assess the quantity
of cargo on board are :
Trim correction - to make allowance for the liquid level indicating devices
not centrally located.
(i) Shrinkage factor - for correction of volume at 15 deg.C.

(ii) Low sounding trim corrections to allow for the wedge shaped
volume.
Volume at 15 deg C. = Corrected Volume X VRF

Quantity at15 Deg. C = Volume at 15 Deg. C X Density at 15 Deg. C
(VRF is ascertained by ASTM-IP Table - 54).
7.12 TRANSFER BETWEEN STORAGE VESSELS

7.12.1 At bulk LPG plants, where there are number of storage vessels, there
may be a need for transfer of LPG from one storage vessel to another.
The procedures for transfer between the vessels are similar to those
described in Clauses Nos. 7.8 and 7.9.
7.12.2 All relevant safety precautions listed in Clause No. 7.2 should be
followed. Particular care must be exercised to ensure that the pressure
in the receiving vessel does not exceed the safe limits and that the
liquid level in the receiving vessel after completion of the transfer is not
above safe maximum level.
7.13 DRAINING OF WATER
7.13.1 It is not uncommon to find the presence of water in LPG vessels. The
water, in free form, being heavier than LPG will always settle at the
bottom of the vessels.

DEPARTMENT 7
March 2014 7-44
7.13.2 Because of the hazards that may be created as a result of presence of

water in LPG systems as detailed in Chapter No. 3, every effort should
be made to detect the presence of water and remove the same
form LPG systems as detailed in following Clauses:
7.13.2.1 Water in the Tank Wagon:

If the water level in the LPG tank wagon is above the bottom end of the
sampling tube it can be detected when the sample valve is opened.
The presence of the water can also be detected by opening the
bleeder valve on the unloading point (liquid connection), at initial
stage of unloading operation. It is, however, not practicable to assess the
quantity of water and also to drain it from a tank wagon as no drain
connection is provided to a tank wagon. Water detected in the tank
wagon should be transferred to the storage vessel along with liquid LPG.
No attempt should be made to drain water from the LPG tank wagon
directly.
7.13.2.2 Water in the Tank Truck
The presence of water in LPG tank truck can be detected by rotating the
roto-gauge to 0% reading & subsequently opening the bleed valve on
the on the roto-gauge before opening the unloading valve of the TT. If
water comes, the roto-gauge should be slowly rotated to higher reading
keeping the bleeder valve open till LPG start to come. At first sign of LPG,
the bleeder valve should be closed. The % water content should be
noted and recorded to take up further with the transporter/ Supply
location. Driver’s signature should be obtained on the declaration of
water quantity detected through the above process. However, as a
safety measure no attempt should be made to drain water from the
tank truck within the plant, but the same should be transferred to the
storage vessel along with liquid LPG.
7.13.2.3 Water in the Storage Vessel
As a routine, check for the presence of water in the storage vessel should
be made daily morning by opening the drain valve. However, if there
is no fresh receipt of the parcel into the vessel after the last draining,
subsequent checking and draining should be avoided till fresh receipt
of the parcel. This is done to minimise hazards that are associated with
water draining operation.

DEPARTMENT 7
March 2014 7-45
7.13.3 PRECAUTIONS FOR WATER DRAINING OPERATION
7.13.3.1 While draining water from the storage vessels, it must be ensured that
two valves are provided on the drain connection with a suitable distance
between them and an EFCV after the 1st valve (upstream valve).
7.13.3.2 It is important not to attempt removal of the entire quantity of water

soon, as considerable liquid LPG may escape in the process. The
draining operation should be monitored by observation of a water/LPG
interface at the drain outlet. At the first sign of appearance of LPG, the
operation must be stopped. If LPG escapes at the drain valve, ice may
form at the valve seating because of the sudden cooling caused by
the pressure drop across the valve. As a result of this, tight closure of the
valve would be prevented resulting in escape of uncontrolled vapour to
the atmosphere and thus causing a very serious hazard. This is the reason
why two valves are provided on the water drain pipeline. In the event
of ice crystal formation and blocking of the outer valve; the gas flow
can still be controlled through the unaffected inner valve.
7.13.3.3 The lock on the 1st valve nearer the vessel should be opened. The first
valve ( nearer to the vessel ) should be opened first and then closed.
After closing the first valve fully, the second valve (nearer to the drain
point) should be opened after opening the end blind flange. The
contents collected between the valve shall be drained and the second
valve shall be closed. The procedure shall be repeated in cycles till the
water is completely drained.
7.13.3.4 It should be ensured that the drain outlet is at a safe distance from the
vessel so that accidental ignition of any escaping vapour will not expose
the vessel to flame impingement.
7.13.3.5 The drained residue / muck should be washed immediately in water to

prevent chances of fire hazard due to the presence pyrophoric iron.
7.13.3.6 The draining operations should be continuously supervised by a

competent person. As soon as the draining is over, the drain valves
should be closed tightly in the sequence explained above and blind
flange/plug fixed at the end connection.

DEPARTMENT 7
March 2014 7-46
7.13.3.7 When not in use, both the drain valves should be kept in locked condition
and end of the pipe should be blinded or plugged.
7.13.3.8 Draining operation should be performed during the daylight hours only.
Draining shall be not be carried out in the event of lightening/thunder
storm.
7.13.3.9 Brief instructions for draining operation along with schematic diagram
should be displayed on a board near the storage area. The instructions
should be written in vernacular in addition to Hindi and English.
7.13.3.10 The records of water draining and quantity of water drained must be
entered in the gauge book.
7.14 ODOURISATION
7.14.1 LPG is an odourless gas, heavier than air. Any leakage developed from a
source of LPG can go undetected, thereby creating a grave safety
hazard. Therefore, if LPG is to be distributed as a utility gas to the
consumers, it shall be odourised by addition of a warning agent of such
characteristics that it is detectable by a distinct odour down to a
concentration in air of not over one fifth of the lower limit of flammability.
7.14.2 Ethyl mercaptan is commonly used as the odorant for LPG because of its
distinctive smell. The assessment of odour level and the amount of ethyl
mercaptan to be dosed are determined as per the guidelines given in
IS :1448 - 1968 (P : 75). Dosing of ethyl mercaptan to LPG to be carried out
at production source or import terminal before further dispatch. Normally
around 20 ppm of ethyl mercaptan is added
7.14.3 Mercaptan is generally received in sealed drums. The mercaptan should

be checked for quality and after receipt of confirmation from the lab.
on quality, this should be transferred to the mercaptan storage tank for
use in the process for dosing LPG. It should be ensured that the drums are
emptied fully. Partial unloading of Mercaptan should not be done.
7.14.4 Vapour pressure of ethyl mercaptan increases rather rapidly with the
temperature. It is, therefore, recommended that the drums containing
ethyl mercaptan be kept cool and away from direct exposure to
heat/sunlight before they are opened.

DEPARTMENT 7
March 2014 7-47
7.14.5 An useful device for transfer of ethyl mercaptan from a drum consists of a
dip pipe assembly equipped with tight bung or fittings. The dip pipe
should reach the bottom of the drum, if the drum is not kept tilted. An
inert gas is used to apply pressure inside the drum to force out mercaptan
through the dip pipe. The system shall have a suitable relief valve to avoid
accidental rupture of the drum due to high pressure built up. Alternately,
a suitable pump may be used for transferring ethyl mercaptan from a
drum into a dosing vessel.
7.14.6 Because of the odour of mecaptan, only hermetically sealed pumps shall
be used.
7.15 COMMISSIONING OF LPG STORAGE VESSELS / PIPELINES

7.15.1 COMMISSIONING PROCEDURES FOR LPG STORAGE VESSELS
Under mentioned steps are followed for commissioning LPG storage

vessels :
a. The following certificates should be obtained before commissioning

:
(I) Valid Storage license of Bulk LPG from CCOE and endorsement of
the same from the local concerned CCOE office.
(II) Permission for commissioning of new plant from Director(Marketing)
routed through concerned Regional Office and State Office.
(III) Availability of original test certificates from the third party inspection
agencies regarding radiography / stress relieving / hydrotesting etc
pertaining to storage vessels.
(IV) Availability of approved procedures containing the names of
officers and staff against each and every activity throughout the
period of commissioning by the Competent Authority / State LPG
Head.
b. Inspection of the vessels.
c. Equipment checks.
d. (Tightness test.
e. Removal of air.

DEPARTMENT 7
March 2014 7-48
7.15.2 CHECKLIST
7.15.2.1 Check list of operation/action involved for commissioning must always be

prepared for each start-up. Procedures already in existence should be
checked prior to each successive start-up to ensure that any change in
the equipment that might have been made are taken into account.
7.15.3 PRE-START CHECKS
(a) (a) Inspect the vessel to check that all foreign matters are
removed and that the interior of the vessel is cleaned.
(b) Check that all fittings, valves, ROVs including pressure relief valves,
duly tested, are installed.
(c) The drain line is provided with two valves with EFCV in between.
(d) Check that all the valves are working by opening and closing
them. Also check all the instruments / fittings on the vessels for
proper functioning.
(e) Boxing up of the manhole and other openings.
(f) Concerned project personal/safety personnel should be present

during the process of commissioning.
(g) Check the entire system for electrical continuity.
(h) (Ensure that all the electrical installations / equipment are of flame
proof. No loose wire connection is in this area.
(i) (Risk analysis and Hazop study are conducted and the
recommendations are implemented. Check for Fire proofing
recommendations).
(j) No hot work is carried out during the commissioning operation

and proper security checks at the main gate are enforced.
(k) Fire Hydrant system/Water sprinkler system is installed and

commissioned.

DEPARTMENT 7
March 2014 7-49
(l) Static water tanks are kept full.
(m) Fire fighting equipment is deployed as per the OISD 144 norms.
7.15.4 DISPLACING AIR WITH WATER
a. Close all the valves on all lines connected with the vessel.
b. Connect temporary water hose connection from the nearest fire

hydrant point to the Liquid inlet of the vessel.
c. Close the isolating valve provided below each of the ‘Pressure Relief
Valves”.
d. Vent the air from the nozzles available on the top of the vessel and
subsequently from the vapour line valve at ground level.
e. Open all the valves on the line connecting the hydrant to the
liquid inlet of the storage tank.
f. Start filling water from fire hydrant line by opening the hydrant
valve and gradually bring this valve to full open position.
g. Commission the pressure gauge and level gauge of the vessel,

by opening the control valves (wherever provided).
h. Keep a constant check on the water level in the vessel. When the
water starts overflowing through the bleeder valve of ‘fixed-tube-
level-gauge’ provided on the vessel top, displacer of the “SerVo
Gauge” should be brought to the top position and valve beneath it
shall be closed to avoid ingress of water in the gauge. Subsequently,
when water start coming through the vapour valve at the ground
level, shut-off the water flow to the vessel. After a time interval of
about 5/10 minutes, again pump water and allow to overflow.
Continue this process for few more minutes till the air pockets are
removed.
i. Close the vapour valve at the ground level and bleeder valve on
the ‘fixed-liquid-level -gauge’.
j. Check for leaks.


DEPARTMENT 7
March 2014 7-50
7.15.5 DISPLACING WATER WITH LPG VAPOUR
(a) (a) Before commencing displacement of water with LPG vapour,

assurance must be gained that the vessel is completely filled with
water to eliminate chances of air pockets and also that leaks
observed, if any, are rectified.
(b) Connect the vapour inlet of the vessel to the outlet of the LPG
compressor.
(c) Connect the vapour outlet of any LPG tank truck (or tank wagon
or nearby storage vessel) containing the LPG to the inlet of the
compressor.
(d) For new locations the vapour inlet of the vessel can be
connected directly to the vapour out let of the tank truck at TLD to
displace the water in the pipeline and in the vessel.
(e) Connect the drain valve of the vessel to any convenient line for
taking water from the vessel back to the drainage system of the
Plant through the sump.
(f) Ensure isolating valves for pressure relief valves on the receiving
vessel are open, secured with seals and locked in open position.
(g) Open valves on the vapour outlet of the tank truck (or tank
wagon or another Storage vessel) and vapour inlet of the
storage vessel and start the LPG compressor
(h) Start supply of LPG vapour to the storage vessel.

Simultaneously open the drain valve of the vessel gradually and
regulate draining rate in such a way that the positive pressure not
exceeding 1.5 kg / cm2(g is maintained in the storage vessel. When
water level goes below the safe filling height, make the “Servo
Gauge” operational by opening the isolation valve and releasing
the displacer to acquire its position or switching on the Radar
gauge/Rochester gauge.

DEPARTMENT 7
March 2014 7-51
(i) Maintain a constant watch on the pressure and level of the

water in the storage vessel. As water is displaced, the equivalent
volume is replaced by LPG vapour.
(j) Continue draining of water till LPG vapour just starts coming out of
the water draining line. After the traces of vapour are observed
form the drain line, close the drain valve and carry out the
water draining as per the water draining procedure mentioned
in Clause No. 7.13.3
(k) Close the water outlet drain valve immediately. At this stage
there will be some quantity of water left at the bottom of the
vessel.
(l) Receive some more vapour for raising the pressure in the
storage vessel to about 2 kg/cm2
(m) Close the vapour inlet of the vessel.
(n) The vessel is now not full of vapour but with small quantity of water
at the bottom.
7.15.6 FILLING VESSEL WITH LIQUID LPG
a. Check the vessel for any leak and rectify before receiving liquid
LPG.
b. Start receiving liquid LPG in the vessel gradually increasing the level.
Depending upon the temperature, pressure of 3 to 9 kg/cm2 (g) will
be attained.
c. Allow setting time of about one hour.
d. Drain any water present from the bottom of the vessel.
e. Shut-off valve if no further operations required.
f. Ensure that safety relief valves / thermal safety valve / pop action
valves are provided on the pipeline sections which remain blocked
with valves at both ends.

DEPARTMENT 7
March 2014 7-52
7.15.7 PURGING OF CONNECTED PIPELINES
(a) Pipelines connected to the storage vessel should also be purged of

air, following steps explained above.
(b) Vapour lines should be kept filled with vapour only.
(c) Liquid lines should be first filled with vapour, which should
thereafter be displaced with liquid LPG displacing the vapour
back into the vessel.
(d) (d)_ Vapour should not be released to the atmosphere, unless

approved venting / flaring arrangements are used.
(e) It is recommended to provide valves with blind flanges at the end

of Pipeline manifold to facilitate commissioning / decommissioning
of all product pipelines. After de-commissioning / commissioning, all
valves should be kept in closed condition and should be locked.
7.16 DE-COMMISSIONING OF LPG STORAGE VESSELS

7.16.1 The de-commissioning of a pressurised LPG storage vessel includes the
following steps :
(a) Pumping away liquid LPG with LPG vapour.
(b) Displacing the complete LPG vapour safely by over flowing the
vessel with water.
(c) Disconnecting the pipelines / fittings and fixing of blinds.
(d) Draining of water.
(e) Ventilating the vessel than opening for man entry.
(f) Checking for ‘gas-free’ condition.
7.16.2 Approved start-up procedures and detailed checklist must be provided

for each shutdown. Operating logbook must be maintained throughout

DEPARTMENT 7
March 2014 7-53
the period of shut down to ensure that all steps are carried out in the
correct sequence.
7.16.3 When an LPG storage vessel is opened, pyrophoric iron may be present in
the residues in the vessel. In the presence of the air, the pyrophoric iron
may get ignited if it becomes dry. Therefore, it must be kept wet until it is
removed and disposed off properly. If it catches fire inside the vessel,
considerable damage may occur to the steel shell of the vessel.
7.16.4 The procedures described below is for Horton Sphere. The shutdown
procedures for LPG storage bullet is the same in principle as for LPG
Horton Sphere.
7.16.5 The de-commissioning procedures should be read in conjunction with

commissioning procedures described in Clause No.7.15.
7.16.6 PROCEDURE FOR DE-COMMISSIONING
Procedures are to be followed for de-commissioning of vessels are

detailed below :
(a) Approval / vetting of procedures for de-commissioning of vessels

shall be obtained from the Competent Authority from the State
Office.
(b) Pump away as much liquid LPG as possible. (The high volatility of
liquid LPG makes it difficult to pump out when the liquid level
becomes very low). It should be ensured that during emptying out,
positive pressure is maintained within the sphere until pumping out
operation of Liquid LPG is completed.
(c) The float (wherever provided) will be at the bottom of the vessel,
having come down with the reducing level of liquid.
(d) Connect vapour outlet of the vessel to be de-commissioned with

the vapour inlet of the adjoining Storage vessel.
(e) Start filling of sphere with water (using the bottom flooded
connection). As the sphere is getting filled, residual liquid LPG will
float on the rising level of water. (The float if provided will come
upwards with the increasing level of water). At the same time

DEPARTMENT 7
March 2014 7-54
vapour from the vessel will get displaced into the vessel connected
for the purpose.
(f) Continue to fill the sphere completely with water, but slow down the
rate of entry of water nearer the topping up level.
(g) It is important to slow down the rate of entry of water at this stage to
ensure that the flow rate does not exceed the capacity of the
connecting line to the adjacent sphere. If the capacity of this line
for displacing the liquid is exceeded, the liquid LPG (floating on the
water) will be compressed at the top of the sphere under the
pressure relief valve, possibly resulting into the valve being blown off
with the associated hazard of liquid LPG being leaking to
atmosphere.
(h) Continue the flow of water into the sphere until a sample taken of
from the top of the sphere (e.g. drain point of Pressure gauge) gives
only water. This will confirm that all the LPG vapour is displaced
through the vapor line into the adjacent sphere.
(i) Stop and re-start, water pumping intermittently 3 to 4 times to

eliminate the possibility of vapour pockets.
(j) Close the valve on the vapour line to the adjacent sphere.
(k) Disconnect all the pipelines attached to the vessel and blank off the
connections while these are full of water.
(l) Start draining of water after having opened the vent at the top of
the sphere with a view to allow the volume of water being drained
of. This prevents creation of vacuum in the sphere. As a precaution,
vacuum gauge should be temporarily fitted at the top of the
spheres for the operation.
(m) Drain-out-water from the sphere avoiding flooding of the area

around the storage vessels.
(n) Remove the manhole cover to ventilate the sphere before man-
entry.

DEPARTMENT 7
March 2014 7-55
(o) Precautions should be taken to keep the interior of the sphere wet,
as pyrophoric iron may be present. These deposits, in the presence
of air, may ignite when they become dry.
(p) Man-entry for the work in the vessel should be allowed only after the
vessel has been checked and certified as ‘Gas Free’ by a
competent person and hot work permit is made for vessel entry.
7.17 TRANSPORTATION OF BULK LPG

7.17.1 GENERAL
(a) The term ‘transportation’ is used to include transportation by rail and

road only.
(b) Details of LPG tank wagons and LPG tank trucks are covered in
Chapter No. 6. Details of operations / precautions within the plant
are covered in earlier sections in this Chapter. This section deals
broadly with the transportation aspects outside the plant premises.
(c) Transportation of LPG in trucks is governed by ‘The Static and Mobile

Pressure Vessels (Unfired) Rules’ 1981’ and as such all relevant rules
and conditions of the license must be complied with.
7.17.2 TRANSPORTATION BY RAIL
(a) The movement of LPG tank wagon by Railways is done in a rake

form with 68 to 72 wagons in each rake.
(b) As per OISD guidelines not more than 600 MTs of LPG should be
unloaded / handled on a railway siding at the plant, at any given
time.
(c) Once the tank wagons are released from the plant and till such time
they are placed at the receiving end they are in the custody of
Railways and plant personnel have no direct role to play during
actual rail transportation.

DEPARTMENT 7
March 2014 7-56
7.17.3 TANSPORTATION BY ROAD
7.17.3.1 General
(a) Transportation by road is through transporter owned trucks only.
(b) Tank trucks used for LPG transportation must have a valid
transportation license issued by CCOE and must also comply with
the license conditions. The vehicle must also comply with RTO rules
and regulations.
(c) All inspection checks as detailed in Chapter Nos. 6 and 10

should be completed before the vehicle leaves the plant premises,
broadly ensuring that :
 There are no leaks.

 Vehicle is not over-filled.
 Vehicle is in road-worthy condition.
(d) Drivers for the tank trucks shall have their licensed endorsed for
carrying “Hazardous Goods” and shall be given training for safe
handling of the equipment and the compressed gas carried in the
vehicle before allowing them inside the plant for LPG transportation.
Tank Trucks carrying Auto LPG for unloading at Retail Outlets shall be
advised not to decant between hours of sunset and sunrise until and
unless permission for same is available from CCOE(PESO).
7.17.3.2 Safe Practices Enroute for Tank Trucks
(a) No, fire, artificial light, or article capable of causing fire or explosion
shall be taken or carried on any vehicle. This would also mean that
NO SMOKING is allowed within or around the tank truck.
(b) Every vehicle shall be constantly attended to by either the driver or

the helper who should be familiar with the hazards of LPG and
trained to handle emergencies.
(c) In the event of overnight stop enroute, nominated halting places as

per the route maps are to be followed.

DEPARTMENT 7
March 2014 7-57
(d) In an emergency, the driver may seek the co-operation of the local
police authorities in finding a suitable parking place for the vehicle.
(e) Whenever road or weather conditions are such that there is any
doubt with regard to the safe completion of the trip, the vehicle
may be parked safely or alternate safer route may be followed.
(f) It should be ensured that all the valves fixed on to the bullet
(whether full or empty); controlling liquid and vapour are closed and
properly secured to prevent tampering.
7.17.3.3 Parking During Transit
(a) An LPG tank truck, whether filled or empty, is to be parked at the

nominated halting points as specified in the route map.
(b) The vehicle should not be parked in a congested or hazardous

area.
(c) The vehicle should be parked off the street in uncongested areas at
least 50 feet away from any building.
(d) The Vehicle, except in an emergency, should not be left

unattended on any street, road or highway.
7.17.3.4 Parking of Vehicles in the Plant
(a) A specific location should be selected within the plant as a parking

place for each tank truck. The location should be selected
considering potential emergency conditions, which might develop
within the plant. The vehicle should be minimum 15 metres away
from any facility or equipment related to LPG handling when
parked.
(b) The tank truck should be parked minimum 15 metres away from the
buildings, storage - facilities and filling operations.
(c) Parking of TTs should be restricted to the capacity of TT Parking

Area(TTPA).

DEPARTMENT 7
March 2014 7-58
(d) One security guard should be positioned round the clock in TTPA for
supervision/control of movement of TTs.
(e) Nobody should be allowed to sleep in the TTPA except Drivers’ rest
room.
(f) Cooking of Food in the TTPA should not be allowed.
(g) The tank truck bullet’s liquid & vapour connections should be in
closed condition. In addition, liquid and vapour outlets should be
capped or plugged to provide a gas-tight seal and locked to
prevent tampering.
7.17.3.5 Garaging of Vehicles
(a) Vehicles should not be parked or garaged in any building unless the
building is specifically approved for such use.
(b) The precautions listed below should be followed when it is necessary

to garage LPG tank truck for service or repairs of the chassis or
engine, but excluding works.
(I) A primary shut-off valve shall be closed and liquid / vapour in

the pipeline vented to a safe location prior to moving the
vehicle into the building.
(II) The system should be inspected for leakage and in case any
leakage is found the same shall be repaired before the vehicle
is moved inside the building.
(III) The vehicle shall not be parked near a source of ignition or
within the path of hot air being blown from blower type heater.
(IV) Unless the product is removed from the bullet and pressure
reduced to atmospheric level the driver shall advise the
responsible parties in the garage of the nature of the cargo
contents and leave suitable instructions for safety.
7.17.3.6 Repairing of Vehicles
(a) Repair work shall not be performed on the bullet or primary shut-off
valves while the vehicle is in a garage unless the bullet is empty,
checked and certified ‘gas-free’ by a competent person.

DEPARTMENT 7
March 2014 7-59
(b) All repairs involving LPG systems attached to the tank trucks should
be performed preferably in the open area, well away from the
buildings and possible sources of ignition.
7.17.3.7 Emergencies in Transit
In the event of an accident on a highway, the driver should take the

following steps :
(i) Park the vehicle off the road, if possible. If on an incline, turn the
wheels towards a curb or bank and apply hand brake.
(ii) Shut-off engine and set the chock blocks on the real
i. wheels.
(iii) Place the fire extinguisher in easy-to-use position. Extinguish any
open flame in the area. Check the vehicle for damages. If there is a
leakage of LPG, stop all traffic and keep people away.
(iv) Enlist police help for this purpose, if readily available.
(v) Notify Police Authorities and the Plant Manager.
7.17.3.8 Action in the Event of Gas Leakage Without Fire
(a) Wherever possible, close the valve or cap fixed to the valve outlet
to stop gas flow. If this is not possible, possibility of moving the
vehicle to a safe place should be explored, provided this does not
expose the bullet, pipeline, or fittings to further damage and does
not endanger the public or property.
(b) Use all available means to disperse LPG vapours if the vehicle
cannot be removed. Evacuate the area and remove all sources of
ignition.
(c) In all cases where gas leakage cannot be stopped, seek the help of
Fire Brigade
7.17.3.9 Action in the Event of Gas Leakage With Fire
(a) Spray large quantities of water by jet or sprinklers over the bullet to
keep it cool. This will allow controlled burning of the gas without fear
of bullet rupture. However, every effort should be made to remove
the source of flame impingement by cutting off the gas supply.

DEPARTMENT 7
March 2014 7-60
(b) If sufficient water is not available, increased noise or flame will

indicate rising pressure within the bullet. At this stage take
immediate action to evacuate the surrounding area.
(c) Except in the case of flame impingement on the bullet, no attempt

should be made to extinguish the fire unless the leakage can be
promptly stopped or reduced to harmless proportions.
7.17.3.10 Overturned Vehicles
(a) Where the tank truck does not give rise to hazard (i.e. where
leakage is not experienced, or is of minor character, or can be
controlled), immediate action under the supervision and
specialist guidance of a competent person should be taken to
evacuate the contents and hoist the vehicle into an upright
position. Lifting gear should be positioned to avoid damage to
bullet fittings and over-stressing of any part of the bullet structure.
(b) (b) Where fire occurs from a small leakage not likely to cause
further hazards, the fire should be allowed to burn until
arrangements are ready to evacuate the bullet and place the
vehicle in an a up-right position.
(c) Where severe fire exists, its intensity or effect may be controlled by
copious volumes of water.
(d) In such a case, burning may continue for a considerable period,

depending on the quantity of LPG contained and the rate of
leakage. Action should be taken to evacuate the area for a
considerable distance.
.

DEPARTMENT 7
March 2014 7-61
DRAWING 18
PIPING ARRANGEMNT FOR LPG TANK WAGON UNLOADING


DEPARTMENT 7
March 2014 7-62
DRAWING 19
8
LPG CYLINDERS, RELATED EQUIPMENT

AND OPERATIONS
Ultimate objective of LPG Bottling Plant
Is to ensure that the cylinder, while
leaving the Plant, is 100% SAFE. Key
factors to achieve this are FILLING OF
CORRECT QUANTITY and STRICT ADHERENCE TO
ALL CHECKS FOR LEAKAGE


DEPARTMENT 8
PAGE No.
March 2014 LPG CYLINDERS, RELATED 8-1
EQUIPMENT & OPERATIONS
8.1 GENERAL
8.1.1 In this chapter the details of LPG Equipment like LPG cylinders, its fittings, SC
Valve, LOT Valve, Domestic Pressure Regulator and consumables like O
ring, PVC Seal and Safety Caps and other related operations are covered.
The description covers in brief the design / construction, utility and
operation of each unit.
8.1.2 Details of Statutory Testing (5/10 years testing) of cylinders as per IS16054
are covered in Chapter No. 9
8.1.3 Aspects of inspection, maintenance and hot repairs of cylinders are

covered in IS 13258
8.2 OIL INDUSTRY TECHNICAL COMMITTEE

In India multinational companies such as Burma Shell, Esso and Caltex
started marking LPG in mid fifties only. Those days bottling was confined to
refinery plants and marketing was limited to nearby areas only. LPG had a
steady growth till 1980-81. Subsequently there was a sudden spurt in
marketing due to increase in the availability of LPG.
In the initial few years , Oil Marketing Companies which include IOC, HPC
and BPC were sourcing equipments from manufacturers, who were almost
their ancillaries. As the popularity with acceptance of LPG as a fuel
zoomed, the requirement of equipment also grew geometrically.
As a consequence of a major fire in Shakurbasti LPG Plant, Ministry of

Petroleum & Natural Gas has set up a high level committee in May 1983
headed by Shri R. Vasudevan, the then Joint Secretary in the Deptt. of
Petroleum, to review all safety and operational procedures adopted in
LPG Bottling Plants, transportation of LPG and in the distribution of LPG
Cylinders. In line with the recommendations of the committee, the Oil
Industry Technical Committee (OITC) was constituted in 1983 for
formulating and implementing a series of regulatory measures to
standardize and upgrade the existing specifications of LPG Equipment to
ensure safer operations.

DEPARTMENT 8
PAGE No.
OITC is a body consisting of 3 members, one each from IOC, HPC and
BPC. OITC has been primarily constituted to deal with all technical matters
related to LPG equipment. BPC is the convenor of OITC.
The main activities of OITC are as under :
a) Advisory body on all technical matters with a view to ensure over all
quality and conformity to all the specifications in manufacturing of
LPG Equipment.
b) Technical assistance for procurement of LPG Equipment.
c) Liaise with BIS, CCOE etc from time to time on technical matters
related to LPG Equipment.
d) Monitor and upgrade the quality standard followed in manufacturing
of LPG Equipment.
e) Develop and enlistment of vendors for manufacturing of LPG
Equipment and consumables.
f) Technical development activities related to LPG Industry and liaison
with LERC.
Oil Industry Technical Audit Team ( OITAT) consisting of members from IOC,
HPC and BPC carries out technical audit of manufacturers of LPG
equipment ( i.e. Cylinder, Valve and Regulator) minimum once a year and
consumables ( e.g. Safety caps, PVC Seals and O rings) twice a year to
ascertain the quality of equipment/consumables being manufactured
and advise manufacturers to take corrective actions as required.
Inspection is carried out mainly in line with relevant BIS codes and Oil
company tender documents. The reports of inspection shared within Oil
Companies.
The cylinder manufacturer is suspended from production and despatch of

LPG Cylinders to LPG Plants on Oil Industry basis in case leak is observed
when filled first time with LPG in new LPG Cylinder and ascertained that first
fill leak is due to manufacturing defect. Similarly in case of other
equipment/consumables, depending upon seriousness on quality ,
manufacturers are suspended from production and despatch of
equipment to the LPG Plants on Oil industry basis.
On taking corrective actions by the manufacturer, the OITC recommends

revocation of suspension. Individual Oil Company obtains management’s
approval and revokes suspension.

DEPARTMENT 8
PAGE No.
8.3 LPG EQUIPMENT RESEARCH CENTRE (LERC) :

LERC is situated at Bengaluru and formed jointly by IOC, HPC and BPC in
1990 with an objective of setting up a full fledged Research Centre for
conducting research on LPG Equipment and related areas for enhancing
customer safety and improving quality. The centre is fully equipped with all
facilities for conducting various research projects on LPG Equipment ,
Consumables and its components and also for testing of LPG equipment &
Consumables for conformance to quality and identifying the causes of
failures of equipment.
LERC is headed by Chief Executive Officer from IOC. LERC is functioning

under the supervision of an Executive Committee (EC) consisting of EDs of
IOC,HPC,BPC, CEO-LERC, OITC Convenor, other Senior Oil Co. officials,
CCOE and representatives from BIS, PCRA, PETROFED, R&D-IOC. EC is
headed by ED(LPG) of IOC.
The overall policy of LERC is framed by the Governing Body consisting of

Directors (M) of IOC, HPC,BPC, Chairman of the EC/ED(LPG) of IOC,
Director (R&D) - IOC, Dir - IIP, ED–PCRA, DG- PETROFED, representative from
DSIR etc.
All expenses towards LERC are shared among the Industry members i.e.
IOC/HPC/BPC in the ratio of 2:1:1 and also officers are deputed in the ratio
of 2:1:1.
8.4 LPG CYLINDERS :
8.4.1 FEATURES
LPG in packed form is handled through cylinders specially designed for

the purpose. LPG cylinder provides storage in convenient size and
facilitates easy transportation at bottling plant, distributor’s premises and
customer’s premises. It Is also convenient for use by domestic and
commercial customers.

DEPARTMENT 8
PAGE No.
8.4.2 STANDARDS /CODES/REGULATIONS :
For the design / manufacture, filling, checking, handling repairs, etc., of

LPG cylinders, the rules and conditions of the “Gas Cylinder Rules, 2004”
MUST be complied with.
The Cylinders is manufactured as per IS 3196 (Part 1) for storage and

transportation of liquefied petroleum gases of nominal capacity
exceeding 5 litre upto and including 250 litre water capacity in welded low
carbon steel cylinders. The standard lays down the minimum requirements
for the material, design, manufacture, construction, tests and marking of
these cylinders.
The standard IS 3196 (Part 3) describes methods of test for welded low
carbon steel cylinders. This standard lays down various tests carried out in
the LPG Cylinder manufacturing unit and laboratory and details of
carrying out these tests.
As per Liquefied Petroleum Gas ( Regulation of Supply and Distribution )

Order, 2000 notified on 10.09.2009 by Ministry of Petroleum and Natural
Gas in the Gazette of India : Extraordinary , 5 kg & 14.2 kg LPG Cylinder will
be for domestic use and 5 kg, 19 kg, 35 kg and 47.5 kg LPG Cylinder will be
for non domestic use.
As per Liquefied Petroleum Gas (Regulation of Supply and Distribution )

Order, 2000 , no person shall supply or sell filled or empty cylinder, gas
cylinder valve and pressure regulator to any person other than a
Government Oil Company or a parallel marketer.
8.4.3 DESIGN DETAILS :
Design of LPG cylinders for domestic and NDNE use have been
standardised on Oil Industry basis. They are designed for maximum
working pressure of 1.66 MPa (16.87 kg/ cm2), which is the maximum
permissible vapor pressure for Propane-Butane mixture as per BIS
specification No. IS 4576 :1990 at the assessed temperature of 65C (149F).
The basic design details are as under :


DEPARTMENT 8
PAGE No.
Sl DESIGN PARAMETERS DETAILS

1 Design Code IS 3196 (Part 1) : 2006
2 Working pressure 1.66 Mpa (16.87 kgf/cm2)
3 Test Pressure 2.45 Mpa (25 kgf/cm2)
4 Working Temperature Ambient
5 Water Capacity for
a 5 kg cylinder 11.7 litres (variation limit + 5% / - 0%)
b 14.2 kg cylinder 33.3 litres (variation limit +3% / - 0%)
c 19 kg cylinder 44.5 litres (variation limit +3% / - 0%)
d 47.5 kg cylinder 111 litres (variation limit +3% / - 0%)
6 Inner diameter for
a 5 kg cylinder 270.0 mm (variation limit +1% / -0%)
b 14.2 kg cylinder 314.4 mm (variation limit +1% / -0%)
c 19 kg cylinder 330.1 mm (variation limit +1% / -0%)
d 47.5 kg cylinder 368.3 mm (variation limit +1% / -0%)
7 Total height for
a 5 kg Cylinder 370.0 mm (variation limit + 5 mm)
b 14.2 kg Cylinder 625.0 mm (variation limit + 5 mm)
c 19 kg Cylinder 725.0 mm (variation limit + 5 mm)
d 47.5 kg Cylinder 1270 mm (variation limit + 3%/-0%)
8 Steel used for LPG cylinder IS 6240 : 2008
shell shall conform to
9 Mechanical properties of (a) Tensile Strength : 350 to 450 Mpa
LPG Steel shall conform to (b) Yield Stress : 240 MPa (min)
(c) Percentage Elongation : 25 (min)
10 Minimum calculated 2.25 mm for 5 kg cylinder
thickness based on Steel 2.43 mm for 14.2 kg cylinder
Plate conforming to IS 6240 : 2.50 mm for 19 kg cylinder
2008 2.67 mm for dished end and 2.75 mm
for wall thickness for 47.5 kg
cylinder
11 Bung from hot forged steel IS 1875 :1992 or IS 2062 :1999
shall conform to
12 Foot ring material shall IS1079- Grade O : 1994 or IS 2062 :1999
conform to or IS 6240 : 2008
13 Valve protection Ring shall IS1239(Part1): 1990, 15 NB Black Steel
conform to Tube of low type for 5 kg,
medium type for 14.2 kg
and heavy type for 19 kg

DEPARTMENT 8
PAGE No.
and 16 NB Black steel tube

of heavy type for 47.5 kg
cylinder.
14 Zinc wire used for spraying IS12447:1993
zinc coating shall conform to
15 Zinc Chromate primer shall IS 2074 :1992
conform to
16 Synthetic enamel paint shall IS 2932 : 2003 of Signal Red Color
conform to ( Shade no. 537 of IS 5)
1kgf/sq. cm. = 98.0665 KPa = 0.0980665 MPa = 0.980665 bar
( Pa = Pascal)
8.4.4 CYLINDER CAPACITY
Cylinders with 33.3 litres water capacity are basically designed to

accommodate 15 kg of LPG normally marketed in India. However, the
capacity has been reduced to 14.2 kg due to high proportion of Propane,
which makes the product lighter, therefore, if filled to the capacity of 15 kg
would not leave sufficient vapour space ( about 15 to 20 %) as required
under statutory rules.
8.4.5 DRAWINGS :
For details of standardized LPG cylinder ,following drawings may be

referred :
I. For 5 kg LPG Cylinder for Domestic Use
a) LPG-ED/5 Sheet 1 of 4 : High RVP- LPG Cylinder of WC 11.7 Litres

b) LPG-ED/5 Sheet 2 of 4 : Screen Printing, SP and FR details
c) LPG-ED/5 Sheet 3 of 4 : Painting Details on 5 kg cylinder
d) LPG-ED/5 Sheet 4 of 4 : Safety Instructions & Screen Printing Details
II. For 5 kg LPG Cylinder for Non Domestic Use

b) LPG-ED/5 ND Sheet 2 of 4 : Screen Printing, SP and FR details for
Non Domestic use
c) LPG-ED/5 ND Sheet 3 of 4 : Painting Details on 5 kg cylinder for non
Domestic use

DEPARTMENT 8
PAGE No.
d) LPG-ED/5 Sheet 4 of 4 : Safety Instructions & Screen Printing Details
III. For 14.2 kg LPG Cylinder
a) LPG-ED/14.2 Sheet 1 of 4 : High RVP- LPG Cylinder of WC 33.3 Litres

b) LPG-ED/14.2 Sheet 2 of 4 : Screen Printing, SP and FR details
c) LPG-ED/14.2 Sheet 3 of 4 : Painting Details on 14.2 kg cylinder
d) LPG-ED/14.2 Sheet 4 of 4 : Safety Instructions & Screen Printing
Details
IV. For 19 kg LPG Cylinder

b) LPG-ED/19 Sheet 2 of 4 : Screen Printing, SP and FR details
c) LPG-ED/19 Sheet 3 of 4 : Painting Details on 19 kg cylinder
d) LPG-ED/19 & 47.5 Sheet 4 of 4 : Safety Instructions & Screen
Printing Details
V. For 47.5 kg LPG Cylinder
a) LPG-ED/47.5 Sheet 1 of 4 : High RVP- LPG Cylinder of WC 111 Litres

b) LPG-ED/47.5 Sheet 2 of 4 : Screen Printing, SP and FR details
c) LPG-ED/47.5 Sheet 3 of 4 : Painting Details on 47.5 kg cylinder
d) LPG-ED/19 & 47.5 Sheet 4 of 4 : Safety Instructions & Screen
Printing Details
8.4.6 MATERIAL FOR CONSTRUCTION :
LPG Cylinders are manufactured from Low carbon steel Hot rolled steel
plate sheet conforming to IS 6240 : 2008. The coil thickness and minimum
finished wall thickness of cylinders as per design calculation are as given
below :
Cylinder 5 kg 14.2 kg 19 kg 47.5 kg

Coil thickness 2.5 mm + 0.1 2.9 mm + 0.1 2.9 mm + 0.1 3.15 mm + 0.1
Wall thickness 2.25 mm 2.43 mm 2.5 mm 2.75 mm
Also LPG Cylinders are manufactured from newly introduced High Tensile
Strength Steel conforming to IS 15914 . The Steel Plate has thickness of

DEPARTMENT 8
PAGE No.
2.1± 0.1 mm, which will reduce the tare weight of cylinder by 20 to 25% as
compared to LPG Cylinders made of HR Steel conforming to IS 6240
8.4.7 BRIEF PROCESS OF MANUFACTURING
The LPG Cylinders are manufactured by the party who has BIS license and
PESO approval for manufacturing of LPG Cylinders of specific water
capacity.
LPG cylinders are manufactured as per Bureau of Indian Standards (BIS)

specification No. IS 3196 (Part 1) and tested as per IS 3196 (Part 3) and are
inspected , tested and certified by BIS officials at manufacturers premises.
Design calculations alongwith drawings of the Cylinder to be

manufactured are submitted by the cylinder manufacturer to CCOE,
PESO for approval. Before commencing the cylinder manufacturing, the
drawings of the cylinder are got approved from PESO and also BIS by the
manufacturer.
The following are the sequence of manufacturing process of LPG

Cylinders:
1. Circle cutting from HR Coil

2. Deep Drawing by hydraulic Press
3. Trimming of edges of halves after Deep Drawing for making equal
height
4. Washing, cleaning and drying of halves
5. Bung hole punching
6. Bung welding by MIG or SAW machine on top halves and joggling of
edges
7. Assembly of bottom and top halves and circumferential welding of
joint by MIG ( Metal Inert Gas) or SAW ( Submerged Arc Welding) and
buffing for welding.
8. Circumferential welding of two halves by MIG or SAW machine.
9. Foot ring welding at bottom portion and VP Ring assembly welding at
top portion of the cylinder.
10. Punching of Serial Number on one of the Stay Plates of Cylinder and
C Weld machine no. on the Foot ring as per the drawing.
11. Heat treatment or Normalisation of the cylinder in furnace.

DEPARTMENT 8
PAGE No.
12. Hydrostatic Test of cylinder at 25 kgf/cm² for a period not less than 30
seconds.
13. Removal of water and internal cleaning by vacuum pump
14. Grit blasting for surface preparation for metalizing
15. Metalising i.e. zinc coating of 40 µ (microns)
16. Primer painting by zinc chromate primer conforming to IS 2074
17. Final painting by Synthetic enamel paint conforming to IS 2932 of
Signal Red color (Shade No. 537 of IS 5). Both the layers of the Primer
and Finish paint shall have total thickness of minimum 30 microns.
18. Tapping of bung threads and checking by L1 and L9 gauges.
19. Internal Cleaning of cylinders by vacuum pump, drying, checking by
low voltage bulb and magnet.
20. Tare weighting of cylinder with SC Valve and Safety cap.
21. Punching of test date and tare weight on the cylinder on bung and
one of the Stay Plates. Also punching of Gross Weight on one of the
Stay Plates.
22. Screen printing of safety slogans and statutory warning on the
cylinder.
23. SC Valve fixing at torque of 145±15 lb-ft
24. Pneumatic test at 12 kgf/cm² by immersing cylinder with safety cap
fitted on SC Valve in water tank for a period not less than 60 seconds
for ensuring that no leakage from the body of the cylinder and bung
joint (valve pad).
25. Out of batch of 403 cylinders, one cylinder is taken for Acceptance
Test and two cylinders for burst Test as per IS 3196 (Part 3). Basis of
passing of samples, BIS issues Test Certificate for entire batch.
26. Record keeping for test reports of raw materials, stage wise
inspections during manufacturing, calibration of testing equipment
etc.
27. Packing and Despatch of new cylinders duly de-pressurized to LPG
Bottling Plant.
LPG cylinder manufacturer submits copy of BIS test certificates of

cylinders and SC Valves to PESO for obtaining approval from PESO
for filling the new cylinders supplied and thereafter PESO, Nagpur
issues filling permission.
8.4.8 PARTS OF LPG CYLINDER :
The following are the parts of LPG Cylinder :


DEPARTMENT 8
PAGE No.
i. Cylinder Shell ( Body)

ii. Bung
iii. Stay Plates
iv. Valve Protection Ring
v. Foot Ring
8.4.9 FITTINGS :
Only fitting which is directly mounted on LPG cylinder and forms an integral
part of the cylinder is the cylinder valve of Self-Closing (SC) type. Details of
a Self Closing type Valve is described in detail in Clause No. 8.5.
8.4.10 MARKING ON THE CYLINDERS :
Oil Industry has standardized the design of the domestic LPG cylinder. The
details of the markings standardized on Oil Industry basis pertain to the LPG
cylinder is given below
8.4.10.1 MARKING ON FOOT RING :
Foot ring is embossed with ‘INDANE’ mark on one side and with ‘IOC’ mark
on the other side. BIS allocates exclusive number to each manufacturer as
Marking License number, BIS Marking License No. in seven digits as CM/L-
xxxxxxx ( For example CM/L 1234567), which is embossed on the foot ring
with letters of 6 mm height. Also circumferential weld machine
identification number is punched on Foot ring. For details please refer
Sheet 1 of 4 of above drawing of LPG Cylinder
8.4.10.2 MARKING ON VERTICAL STAY PLATES
Following markings are embossed/punched on outer portion of the

vertical Stay Plates supporting the valve protection ring. For details please
refer Drawing No. LPG-ED/14.2 Sheet 1 of 4.
1 First vertical Stay Plate must have following markings :

a Manufacturer’s identification and Manufacturer’s monogram.
b Serial number of the cylinder ( in 6 digits) and source of steel

DEPARTMENT 8
PAGE No.
e.g. T for TISCO, S for SAIL, E for Essar, L for Lloyds, P for Ispat, SL
for Salem Steel, J for Jindal , B for Bhushan Steel etc.
c Tare Weight of the cylinder in kg.
d Maximum Gross Weight of the cylinder in kg.
2 Second vertical Stay Plate must have following markings :
a IS 3196 PART 1, LPG, BIS Logo and “SR” or “N” below BIS Logo.
(Letter “SR” or “N” , if the cylinder is stress relieved or normalized)
b Water capacity (WC) in litres.
c Maximum Working Pressure (WP) : 1.66 MPa.
d Test Pressure (TP) : 2.45 MPa.
3 Third vertical stay must have the following markings :
a Batch No.
b Test Date (Month and year of Hydrostatic Test ) i.e. for Jan 2013 as
01-13)
On the inner portion of the vertical stays, following details must be screen
printed :
Quarter [ i.e. A for 1st Quarter ( Jan to Mar) , B for 2nd Quarter ( Apr to Jun)
, C for 3rd Quarter ( Jul to Sept) & D for 4th Quarter ( Oct to Dec)] and
year of next due date ( in two digits) of statutory testing of cylinder will be
screen printed on inner side of the vertical Stay Plate having Batch No. &
Test Date.
( For example “A 23” for Statutory Testing is due in 1st Quarter of Year 2023)
Tare weight ( e.g. “15.5” ) will be screen printed on the inner side of the
other two vertical Stay Plates
8.4.10.3 MARKING ON THE BUNG :
On the top of the cylinder bung, details of (a) Cylinder Serial Number (in 6
digits), (b) Source of Steel, (c) Month & Year of Hydrostatic Test , (e) Tare
Weight of cylinder in kg and (f) Identification Mark of manufacturer are
stamped/punched.
8.4.10.4 SCREEN PRINTING ON BODY OF CYLINDER
Nett weight and Gross weight in kg of the cylinder in English.

Tare weight in kg at three places inside of the shroud portion.

DEPARTMENT 8
PAGE No.
The following details are screen printed on the body of the cylinders both
in Hindi and English.
For Domestic Cylinder : (a) Indane, (b) Check seal and weight on delivery,
(c) Switch off regulator when not in use & (d) Statutory warning : This
cylinder is for domestic use only, Non domestic use is strictly prohibited and
punishable.
For NDNE Cylinder : (a) Indane, (b) Check seal and weight on delivery
and (c) Switch off regulator when not in use.
8.4.11 PAINTING OF LPG CYLINDER
Good aesthetic look of an LPG cylinder definitely helps to improve the

image of the Corporation. To achieve this objective, the painting of the
LPG cylinders should be good without any scratch and thickness should be
minimum 70 µ (microns) as per specification. The paint coat thickness
can be measured with the help of an Elcometer (Paint Coat Thickness
Measuring Meter). Cylinders are sprayed with zinc of minimum 40 µ
(microns) followed by one coat of zinc chromate primer and one coat of
synthetic enamel paint conforming to IS 2932 of Signal Red color (Shade
No. 537 of IS 5) for domestic cylinder and Oxford Blue color (Shade No. 105
of IS 5) for NDNE cylinder as per the drawing. Both the layers of primer and
finish paint together should make a minimum thickness of 30 µ (microns).
8.4.11.1 The position of 3 vertical stay plates are fixed on the cylinder. The screen
printing on LPG Cylinder for safety instructions and other details is carried
out as per the standard drawing at earmarked locations on the cylinder
as shown in the drawing w.r.t. vertical stay plate for Batch Number & Test
Dates ( SP 1) so that all cylinders are look-alike irrespective of
manufacturer.
8.4.11.2 The thickness of the paint on the cylinder should be measured with the
help of digital type Elcometer in the same plain and without putting any
excess pressure on the Elcometer. In case reading is not taken in the same
plain or excess pressure is exerted on the Elcometer, the meter may not
give correct reading of the paint thickness. Therefore, necessary
precaution should be taken for proper measurement of the paint coat
thickness.

DEPARTMENT 8
PAGE No.
8.4.11.3 Procedure for measurement of coating of thickness as per IS 3196 (Part 1)

is given below :
8.4.11.4 Five gauge readings for each spot shall be taken moving the probe a short
distance for each new gauge reading within an approximate area of 2
cm x 2 cm. Discard any unusually high or low gauge reading that cannot
be repeated consistently. Take the average of the five guage readings as
a spot measurement.
8.4.11.5 Make five such spot measurements approximately evenly spaced over the
surface of the cylinder.
8.4.11.6 Each spot measurement shall not be below 80 percent of the specified
minimum thickness and average of the five spot measurements shall not
be below the specified thickness
8.4.12 MARKING FOR AGE PROFILE :
8.4.12.1 PESO has approved revised schedule of periodic inspection and testing of
L
Background
P ISI Spec for Lettering Year of Year of
G color Shade color manufacturing retesting
White 127 Black 2012 2022
Sea
c Green 217 Black 2013 2023
Dove
y Gray 694 Black 2014 2024
Air
l Craft Blue 108 White 2015 2025
Salmon
i Pink 443 Black 2016 2026
India
n Brown 415 White 2017 2027
d Blue
Satin 177 Black 2018 2028
e Green
Bus 299 White 2019 2029
r
Black 521 White 2020 2030
s
Yellow 355 Black 2021 2031
in use vide letter R.4(2)100/2007 dated 20.08.2007 as under:
a) First testing at an interval of 10 years from date of manufacturing and
b) Subsequent testing at an interval of 5 years.


DEPARTMENT 8
PAGE No.
This permission is applicable for the cylinders manufactured from the

second quarter of 2000 onwards. Color coding of inside portion of the
vertical stay plate for first statutory testing after 10 years from the
manufacturing date of the cylinder is as below. The colour gets repeated
every ten years i.e. colour of 2013: Sea Green - Shade 217 shall be
repeated for year 2023 ( 2013+10).
8.4.12.2 To facilitate segregation of the cylinders at the plant for statutory testing, a
uniform procedure is evolved by the Oil Industry. According to the
procedure, colour coding / marking is done on inside face of the vertical
Stay Plate (having Batch no. & Test Date at outer face ) of the valve
protection ring by screen printing the Quarter and Year of next due date
of Statutory Testing.
8.4.13 MARKING / IDENTIFICATION FOR OWNERSHIP
Since all the cylinders, which are in use by the Oil Industry are standardized
to the same specification, the Oil Industry has adopted the following
convention to facilitate identification of the ownership of the cylinders
8.4.13.1 DOMESTIC CYLINDER
a. IOC Cylinders : painted fully with Signal Red (Shade No. 537 of IS 5).
The foot ring is having 6 horizontal oval holes for air vent and 8 nos. 5
mm diameter holes at the bottom for draining of water.
b. BPC Cylinders : painted fully with Signal Red (Shade No. 537 of IS 5)
with Golden Yellow ( Shade No. 356 of IS 5) on shroud. The foot ring is
having 6 round holes for air vent and 8 nos. 5 mm dia holes at the
bottom for draining of water.
c. HPC Cylinders : painted fully with Signal Red (Shade No. 537 of IS 5)
with French Blue ( Shade No. 166 of IS 5) on shroud. The foot ring is
having 6 vertical oval holes for air vent and 8 nos. 5 mm dia holes at
the bottom for draining of water.

DEPARTMENT 8
PAGE No.
8.4.13.2 NDNE CYLINDER
a. IOC Cylinders : Painted fully with Oxford Blue ( Shade No. 105 of IS 5)
with Signal Red (Shade No. 537 of IS 5) on shroud . The foot-ring is
having 6 horizontal oval holes for air vent and 8 nos. 5 mm dia holes
at the bottom for draining of water for 5 kg cylinder and no drain
holes in case of 19 kg and 47.5 kg cylinders.
b. BPC Cylinders : Painted fully with Oxford Blue ( Shade No. 105 of IS 5)
with Golden Yellow ( Shade No. 356 of IS 5) on shroud. The foot ring is
having 6 round holes for air vent and 8 nos. 5 mm dia holes at the
bottom for draining of water for 5 kg cylinder and no drain holes in
case of 19 kg , 35 kg and 47.5 kg cylinders.
c. HPC Cylinders : Painted fully with Oxford Blue ( Shade No. 105 of IS 5 )
with French Blue ( Shade No. 166 of IS 5) on shroud. The foot ring is
having 6 vertical oval holes for air vent and 8 nos. 5 mm dia holes at
the bottom for draining of water for 5 kg and 19 kg cylinder and no
drain holes in case of 35 kg and 47.5 kg cylinders.
d. In addition to the above, in case of (a) 5 kg NDNE Cylinder, a red

band of Signal Red (Shade No. 537 of IS 5 ) of 75 mm width shall be
painted below circumferential weld joint on the body of the cylinder,
(b) a band of Signal Red (Shade No. 537 of IS 5) of 100 mm width
shall be painted below circumferential weld joint on the body of the
cylinder in case of 19 kg and at the centre of cylinder body of 47.5 kg
NDNE Cylinder
8.4.14 INSPECTION OF NEW CYLINDERS BY PLANT ON RECEIPT
8.4.14.1 On receipt of the new cylinders from the manufacturer, LPG Plant shall
carryout random quality check ( RQC ) of the cylinders as under :

DEPARTMENT 8
PAGE No.
Sr Type of Checking Quantity to be checked

a Tare weight & paint thickness 10% of consignment subject
b Marking on Cylinder, Bung, Stay to minimum of 25 cylinders
Plates and Foot-ring
c Visual Inspection & screen printing
d Valve Tightening torque 1% of consignment subject
to minimum of 3 cylinders
Apart from above there some other aspects of LPG cylinder quality which
are listed below. In case any discrepancy is observed, same shall be
reported to HO LPG Materials and LPG- Equipment Development, HO.

DEPARTMENT 8
PAGE No.
Other Rejection Critera for New LPG Cylinders
SR. CHECK POINT REJECTION CRITERIA

1 Visual Check for dents, cuts, digs, Cylinders to be rejected if the defects are
inspection bulge, wrinkles on the beyond the permissible limits as per IS-
cylinder. 15966 – Refillable welded steel cylinder for
Liquefied Petroleum Gas (LPG) Procedure
for checking before, during and after
filling.
Foot ring weld joint, VP ring Cylinders to be rejected.

weld joint broken.
Non- IOC foot ring Cylinder to be rejected after confirming
that it is a IOC cylinder with non-IOC foot
ring.
OMC cylinder Such cylinder to be returned to OMC after
confirming the Sr. nos. of the cylinders from
the test certificates produced by the
OMC.
Cylinder with parallel Parallel marketers valves have lesser collar
marketers valves dia ( 22 mm) than our SC valves ( 25.6
mm).
Cylinder having 2 stay The cylinder to be rejected.

plates with similar
markings.
Cylinders having same Sr. All cylinders to be tallied with the packing
nos. list. In case more than 1 cylinder with same
Sr. no are detected, all the cylinders to be
rejected.
Quality of painting / Signal red colour on band and shroud (in
stencilling. case of non domestic cylinder) and
stencilling quality and its positions to be
checked.
2 Inspection Weld joint on VP ring. Weld joint of VP ring should be positioned
Ring and on the designated stay plate (SP1) , and
stay plate the weld should be properly grounded.
assembly Weep hole on VP ring. Weep hole on the VP ring should be
plugged and positioned on the lower side.
Welding of assembly to the The welding should be done on both sides
body and stay plates to of the stay plates.
the VP ring.

DEPARTMENT 8
PAGE No.
Spacing between the stay The stay plates should be equi-spaced
plate during visual inspection.
Inclined stay plates. Check for the inclination of the stay plates.
Eccentricity of VP ring Eccentricity of VP ring with respect to the
Bung shall not be more than 3 mm.
3 Inspection of Eccentric welding of bung. The eccentricity of bung hole centre line
Bung with respect to centre line of body of the
cylinder shall not be more than one
percent of the nominal diameter of the
cylinder subject to a maximum of 2 mm.
4 Inspection of Drain / Vent holes Should be as per drawing.
foot ring Foot ring joint It should be positioned at centre of one of
the foot ring to body weld joints
Foot ring to body welds There are 6 welds of approx. 50 mm weld
length each and these welds should be
visually equi-spaced.
5 Marking Foot ring markings The markings should be checked for
details legibility, accuracy as per drawing.
Stay plate and bung (i) The markings on all the three stay
markings plates are different and should be in
accordance with the drawing
(ii) The monogram or the identification

mark of the manufacturer should be
present on the stay plate.
(iii) Double punching, legibility,

overpunching to be checked.
Sr. no and tare wt. of the (i) Sr. no and tare wt. is punched at two
cylinder places on the cylinder i.e., on the bung
and on the stay plates. Sr. no and tare wt.
on these two should match.
6. Inspection of Quality of welds (i) Check for undercuts, pin holes, weld
welds splatters etc. on the welds.
(ii) In case of C- welds check for the

waviness, offset of the weld bead and
misalignment of halves.
7. Tare weight To check the actual tare The maximum allowable variation in the
wt. of the cylinder with tare wt. after rounding off as per IS 2 is 50
punched / stencilled tare gms.
wt.

DEPARTMENT 8
PAGE No.
8. Internal Whether the cylinder has Cylinder should be without any air pressure.
pressure of been depressurised
cylinder
9. Valve Tightening torque of the The tightening torque range for fixing the
valve valves on cylinders is 145 ± 15 lb-ft.
Visual inspection of valves. (i) Markings on the valves
(ii) Presence of ‘O’ Ring, internals and
safety caps.
(iii) Damages to body of the valve,
cracks if any.
(iv) Presence of excessive foreign
material, dust inside the valve.
10. Water To check the actual water Water capacity to be checked by weight
capacity capacity of the cylinder method. Please note that for this the tare
wt. of the cylinder should be taken after
removing the valve. For 14.2 kg cylinder
water capacity = 33.3ltrs + 3% / - 0%
For 19 kg cylinder water capacity = 44.5 ltrs

+ 3% / - 0% If any cylinder fails in this then
the whole batch of Cylinders should be
segregated.
11 Overall To check the actual height The height shall be as under :
height of the cylinder 5 kg cylinder = 370±5 mm.
14.2 kg cylinder = 625±5 mm.
19 kg cylinder = 725±5 mm.
47.5 kg cylinder = 1270 mm.
If any cylinder fails in this then the whole
batch of Cylinders should be segregated
for checking.

DEPARTMENT 8
PAGE No.
8.4.15 PROCEDURE FOR SENDING NEW CYLINDERS TO LPG EQUIPMENT RESEARCH

CENTRE BANGALORE ( LERC) FOR TESTING :
Two cylinders of same batch of only one manufacturer per bottling plant
in one quarter ensuring that all the manufactures supplying cylinders to a
particular plant are covered in one complete year.
The format for sending cylinder is enclosed.
8.4.16 REPORT OF FIRST FILL LEAK / SUBSEQUENT FILL LEAK OF LPG CYLINDER :
During first filling of new cylinders, if any body leak cylinder is found, the
same shall be reported to HO (LPG-ED) so that suitable action is taken
against the manufacturer. The matter of first fill leak should be reported
within 24 hours.
8.4.16.1 PROCEDURE FOR REPORTING FIRST FILL (FF) LEAK OR SUBSEQUENT FILL LEAK
OF LPG CYLINDER :
In case of first fill leak of new cylinder or subsequent leak ( market return
cylinder during warrantee period), the following details duly signed by
Plant Manager shall be Intimated to HO LPG-ED :

DEPARTMENT 8
PAGE No.
REPORT OF FIRST FILL LEAK / SUBSEQUENT FILL LEAK OF LPG CYLINDER TO HO

(LPG-ED)
Sr. Description Particulars

1 Name of LPG Bottling
Plant
2 Name of Manufacturer
3 Address of Factory
4 Capacity of LPG Cylinder
(kg)
5 Consignment Note No. &
Date
6 Cylinders received on
(date)
7 First Fill leak observed Sr. No.:
from LPG Cylinder having Batch No.:
Test Date :
8 Subsequent Fill leak Sr. No.:
observed from LPG Batch No.:
Cylinder having Test Date :
9 Nature of leak
i Circumferential welding
ii Welding of Foot Ring
iii Bung welding
iv Welding joint of vertical
Stay Plates
v Any other defect
10 Whether Cylinder has
met with an accident
11 Whether the pin
hole/leak is due to
external impact on
cylinder
12 Observation of visual
inspection of the cylinder

DEPARTMENT 8
PAGE No.
The LPG from leaking cylinder shall be evacuated, the area from where
leak detected shall be marked with circle by permanent ink pen /painted
and cylinder is kept in safe custody under lock and key so that no body
tampers, steals and replaces with duplicate cylinder. The photographs of
the FF leak cylinder are taken including the leak portion, stay plate
marking etc.
HO (LPG-ED) will suspend the manufacturer for production and despatch

of new LPG Cylinders to LPG Bottling Plants on Oil Industry account with a
copy to PESO, BIS, BPC, HPC, LERC and concerned officials and advises
manufacturer to depute authorized representative for joint inspection of FF
leak cylinder with Plant officials.
BIS will be issued the stoppage marking of the cylinder to the

manufacturer.
The joint inspection with authorized representative shall be carried out by

Plant officials by filling FF Leak cylinder with LPG and joint inspection report
is signed and send to HO (LPG-ED) and handed over one copy to
manufacturer. The FF leak cylinder after degassing and without SC Valve is
handed over to the manufacturer for carrying out joint inspection with BIS
officials at their Cylinder manufacturing Plant.
The BIS officials will carry out joint inspection with manufacturer including
hydrostatic test and pneumatic test. After joint inspection , manufacturer
sends the FF Leak cylinder to LERC, Bangaluru for failure analysis and LERC
submits report to the HO (LPG-ED) and LPG Plant.
Basis of joint inspection with BIS officials, manufacturer identifies the root
cause of the defect and takes corrective measures to prevent re-
occurrence of the defect. Thereafter, BIS inspects the trial batch of the
cylinders and corrective measures taken by the manufacturer. On
satisfactory manufacturing and passing of the trial batch, BIS issues
resumption of stoppage of marking.
Basis of the above, Oil Industry Technical Committee (Consisting of officers

from IOC, BPC and HPC), recommends revocation of suspension for
production and despatch of LPG Cylinders on Oil Industry basis.

DEPARTMENT 8
PAGE No.
Basis of above, Individual Oil Company issues resumption of production

and despatch of LPG Cylinders advise to the manufacture after obtaining
approval of competent authority with a copy to PESO, BIS, CMD-BIS, HPC,
BPC and concerned officers.
8.4.17 RECOVERY FROM LPG CYLINDER MANUFACTURER
As per the Purchase Agreement with the manufacturer, the warranty

period of the cylinders is two years and if any body leak cylinders are
found during this two year period, the cost of the cylinder shall be
recovered from the manufacturer. Record of first fill leak and
subsequent leaks ( market return cylinder leak ) should be properly
maintained at the LPG Plant and record should be countersigned by the
Plant Manager/In charge
8.5 LPG CYLINDER VALVES

8.5.1 GENERAL
After fire accident at the LPG bottling plant, Shakurbasti, in the year 1983,
Government of India appointed Vasudevan Committee for detailed
investigation and submission of recommendations. Vasudevan
Committee’s recommendations are :
a) Setting of a system by Oil Companies for quality control of cylinders

/ valves / regulators.
b) Standardisation of LPG equipment
c) Collect, compile and analyse data on equipment failure to identify
failure due to quality of equipment.
d) Industry to maintain proper records of LPG equipment.
e) Rubber tubing to be covered by BIS specification
8.5.2 Government decided to adopt Kosan Technova design for valves and
both Kosan Technova (Denmark) and Sierra (Italy) designs for Pressure
Regulators (PRs) on 29.12.1983.
8.5.3 BRIEF HISTORY ABOUT DEVELOPMENT
The technology for LPG valves was imported by IOC on behalf of the Oil
Industry from Kosan Technova, Denmark. The technology is for 25.6 mm

DEPARTMENT 8
PAGE No.
collar diameter and valve is called as Self Closing type valves (SC Valves).
Technology for SC valves was adopted by the Oil Industry in 1985 after its
implementation as per the requirement of Indian condition. SC Valves are
being used by the Oil Industry in India since then. Presently, there is only
one type of cylinder valves in circulation for the use on IOC cylinders as
well as cylinders of Other Marketing Companies (OMC).
8.5.4 TECHNOLOGY TRANSFER TO SC VALVE MANUFACTURER :
The Kosan technology of SC Valves is being transferred by IOCL on behalf

of Oil Industry by charging Technology Transfer fees to manufacturers who
are interested to manufacture SC Valves and having license for SC Valve
of collar size 22 mm and approval of CCOE and qualifies in the tender.
After satisfactory implementation of technology and obtaining

amendment of License from BIS for SC Valve of collar size 25.6 mm and
approval of CCOE for manufacture of SC Valve of color size of 25.6 mm
and recommendations of OITC members after joint inspection of
manufacturing unit and successful implementation of technology , trial
order is placed on the manufacturer by one of the PSU Oil Companies
and on successful execution of trial order and passing of samples at LERC
in various tests , manufacturer is enlisted for supply of SC Valves to Oil
Industry and LPG Cylinder manufacturers by OITC ( Oil Industry Technical
Committee)
For industrial customers having very high LPG requirement, 47.5 Kg

cylinders with LOT ( Liquid Off Take) valves are now in use. The details of
LOT valve is covered under Clause 8.6.
8.5.5 FUNCTION OF SC VALVE :
8.5.5.1 The function of the valve is to provide gas-tight seal in closed position and
to prevent the contents leaking from the cylinders and in open position to
allow operation such as filling, discharge, evacuation, venting, etc. in a
controlled manner
8.5.5.2 The term ‘Self Closing’ is derived from its design as it remains closed unless
a pressure regulator (PR) or other suitable device is used for opening it. In
the case of accidental removal of the PR or the Filling Gun or any other
device, the valve automatically gets closed, thereby preventing any likely

DEPARTMENT 8
PAGE No.
accident that may otherwise take place due to large scale leakage of
LPG from the cylinder. This aspect makes this valve safer when compared
to other types of valves.
8.5.6 IS STANDARD :
Bureau of Indian Standards formulated Standards for the “Valve fittings for
use with Liquefied Petroleum Gas (LPG) cylinders of more than 5 litres
water capacity as per IS 8737:1995
8.5.7 DESIGN PRESSURE
Basically, the valve should withstand the working pressure of the cylinder to
which it is fitted. SC Valves are designed for a working pressure of 1.66
MPa ( 16.87 kgf/cm2) at 65 °C.
8.5.8 CONSTRUCTION OF SC VALVE :
While the collar dimension of the valve is standardised as 25.6 + 0.1/-0.0

mm (to suit fixing on to the cylinder and connection for PR), the internal
design details are also standardised with the result the valves are having
same design and specification among the Oil Industry all over India.
This valve is standardised on Oil Industry basis and all cylinders are
provided with these type of valves.
The body of SC Valve is made of brass . Valve body is forged from wrought
or extruded sections. The valve inlet have a taper of 1 in 16 on diameter
and thread size ¾” – NGT of ANSI/CGA V-1-1987 “Compressed gas cylinder
valve outlet and inlet connection, ANSI”.
The valve with threaded outlet connection have parallel left hand
external threads conforming to SI threads with a pitch of 1.814 mm and
thread angle of 60°.

DEPARTMENT 8
PAGE No.
8.5.9 PARTS OF SC VALVE :
There are total 10 components of SC Valve :
1. Body 6. Spring
2. O ring 7. Spindle Guide
3. Upper Spindle 8. Adjusting Screw
4. Gasket 9. Safety Cap
5. Lower Spindle 10. Thread Cap
8.5.10 DRAWING :
Please refer drawing SC Valve.
8.5.11 MATERIAL OF CONSTRUCTION
8.5.11.1 The metallic valve housing is forged from the wrought or extruded sections
of brass alloy mainly of copper and zinc to meet the requirement of
physical properties as appended below
i. Tensile strength : 392 N/ mm2 ( 40 kgf/mm2) (min.)

ii. Percentage elongation : 18% (min.).
iii. Izod impact strength : 21.5 N.m (2.2 kg.m) (min.)
8.5.11.2 The materials of construction of the component parts of the valves are
selected so as to ensure that they are unaffected by the chemical,
thermal and cyclic stress influences that will be encountered in normal use.
8.5.12 BRIEF PROCESS OF MANUFACTURING OF SC VALVE :
The SC Valve is made out of brass rod meeting the IS 8737 specification.
The following is the sequence of manufacturing process :
a. Brass rod of 25 mm dia is cut to the length of 55 mm.

b. Heated at 700 to 800° C
c. Forging of Billet
d. Trimming
e. Shot blasting or Chromotisation

DEPARTMENT 8
PAGE No.
f. Stamping on 6 hexagonal sides for IS no. & BIS Logo, Batch, Qtr &
year of manufacture, BIS License no., Manufacturer’s monogram, Oil
Co’s name, WP.
g. Outlet Operation on PMT Index machine or CNC m/c or Multi Spindle
m/c.
h. Inlet Operation on PMT Index machine or CNC m/c or Multi Spindle
m/c.
i. Threading on inlet dia by Special Wagener die head drilling m/c.
j. Ultrasonic cleaning of valve body
k. Sub-assembly fitting ( Spindle with gaskets, spindle guide, spring,
adjustment screw)
l. Air cleaning of assembled SC Valve.
8.5.13 TESTS DURING MANUFACTURING OF SC VALVES :
The following tests are carried out by the manufacturer as per IS 8737 and
“Scheme of Testing and Inspection for Certification of Valve fittings for use
with Liquefied Petroleum Gas (LPG) Cylinders of more than 5 litre water
capacity according to IS 8737” :
i. Hydrostatic test of valve body on sample basis before assembly at

25 kgf/cm².
ii. Each assembled SC Valve will be tested as under :

a. Tightness of Joint packing ( in valve outlet) and valve spindle (
Pressure of 1000 mm water column from outlet)
b. Tightness of valve spindle and valve housing ( Pressure of 17
kgf/cm² with valve spindle in closed position ).
c. Tightness of joint packing and housing ( Pressure of 17 kgf/cm²
with valve spindle in open position from inlet ).
d. Testing by torque wrench for torque at 5 kg-cm for adjusting screw.
iii. Cycle Test of one sample out of 20000 valves of same type is
being carried out. The valve shall perform satisfactorily at not less
than 5000 cycles of opening and closing operations with valve
inlet connected to an air supply of not less than 7 kgf/cm². After
the cycle test , the valve shall be subjected to the Pneumatic Test.

DEPARTMENT 8
PAGE No.
8.5.14 MARKING ON SC VALVE :
SC Valve fitted to the LPG cylinder MUST have the following markings on
the six hexagonal sides :
(i) Flat 1 : IS 8737 & ISI Logo.

(ii) Flat 2 : Batch No., Quarter & Year of manufacture.
(iii) Flat 3 : BIS License number for manufacturing of SC Valve
(iv) Flat 4 : Manufacturer’s Monogram
(v) Flat 5 : Oil Company’s name
(vi) Flat 6 : Working Pressure (WP) in MPa.
8.5.15 INSPECTION OF SC VALVES BY PLANT ON RECEIPT :
The following visual inspection of SC Valves shall be carried out by the

Plant on receipt from the manufacturer :
Sr Description Samples
a Check marking on hexagonal of 0.1% of consignment subject to
Valves w.r.t. approved drawing minimum 10 Nos.
b Visual Inspection of valve 0.1% of consignment subject to

minimum 10 Nos.
c Marking on body, cover and 0.2% of consignment subject to
Marking Plate minimum 10 Nos.
d Checking of documents Manufacturers Test Report and
BIS certificate.
8.5.16 NORMS FOR SENDING NEW SC VALVES TO LPG EQUIPMENT RESEARCH

CENTRE BANGALORE ( LERC) FOR TESTING :
Four SC Valves of same batch of only one manufacturer per bottling

plant in one quarter ensuring that all the manufactures supplying SC
Valves to a particular plant are covered in one complete year.
The format for sending SC Valve is enclosed.


DEPARTMENT 8
PAGE No.
8.5.17 CAUSES OF LEAKAGE :
The leakage in the case of this type of valve can occur as under :
(a) With the valve in closed position and valve outlet open :
(i) Leakage can occur through the valve outlet indicating

that the valve seat is defective.
(ii) The leakage through the valve seat can occur in case the dirt / rust
particles prevent the proper seal. Slight opening and re-closing of
the valve may stop the leak.
(iii) In case the valve seat is damaged / defective, the valve needs
replacement.
(iv) Escape of vapour to the atmosphere due to leakage through the
valve seat can be prevented to some extent by closing the valve
outlet with a safety cap. This should, however, be adopted purely as
a temporary measure till such time the contents are safely
evacuated.
(b) With valve in open position and outlet closed :
As described earlier, the valve seat in this type of valve remains closed
unless external pressure is applied. Therefore, to keep the valve seat open
there will be a need for special type of adaptor called as ‘Dummy
pressure regulator’ (Dummy PR). In this case the leakage can occur
through the connection between the valve outlet and the special adaptor
(Dummy PR) indicating that the sealing ‘O’ ring is absent or defective. This
will necessitate replacement of the ‘O’ ring.
8.5.18 REPLACE MENT OF DEFECTIVE SC VALVES BY MANUFACTURER :
The manufacture shall replace manufacturing defective SC Valves

generated in plants with new SC Valves within warrantee period of 2
years and in case same is not replaced by the respective manufacturers
within 2 months period from the date of intimation by the Plant, then same
should be reported to LPG Materials Deptt. However, under no
circumstances the defective SC Valves shall be returned to the
manufacturers. The defective SC Valves shall be deshaped by the Plant .

DEPARTMENT 8
PAGE No.
8.5.19 VALVE PROTECTION SYSTEM
Valve bodies are made of brass alloy and can get damaged, if it is hit
against any object. This may develop leak of LPG creating serious
hazards. To prevent this, protection for the valve is provided by means of
valve protection (VP) ring assembly on the top of the cylinder.
8.5.20 ULTRASONIC VALVE CLEANING EQUIPMENT
Each and every valve housing after machining are being cleaned by the
valve manufacturers with Ultrasonic Cleaning Equipment to remove any
oil, grease, chips from the valve housing before assembly. The solution
used in Ultrasonic Cleaning Equipment is Trichloroethylene. In this system,
there are three chambers. The first chamber contains liquid
trichloroethylene which vibrates at ultrasonic frequency. The second
chamber is of liquid trichloroethylene without any frequency and the third
chamber is a vapour chamber.
8.5.21 DEFECTS OBSERVED IN VALVES DUE TO HANDLING :
The some of the following defects may be noticed during handling of

valves :
a. Damage to inlet thread.

b. Damage to body.
c. Valve spindle getting stuck.
d. Valve spindle spring becomes solid.
e. Valve spindle broken.
f. Valve spindle bent.
g. Valve internals come out.
h. Damage to outlet of valve.
i. Wearing of collar of valve.
j. Joint packing of valve spindle damaged.
8.5.22 REPAIRING OF SC VALVE :
Repairing of SC Valve or changing of internal parts is not permitted by BIS

and PESO. In other words, SC Valve is not repairable and same shall be
discarded / deshaped if threads are worn out or jammed or is leaking from
the gasket.

DEPARTMENT 8
PAGE No.
8.6 LIQUID OFF TAKE (LOT) VALVE

8.6.1 FUNCTION
In an LPG Cylinder, LPG exists in dual phase under equilibrium i.e. Vapour
phase and Liquid phase. The Liquid Off Take (LOT) Valve is to facilitate the
off take of liquid LPG from the Commercial cylinders of higher capacity to
meet the heavy BTU loads found in industrial uses and enable the user to
withdraw the full quantity of LPG from the cylinde
8.6.2 STANDARD / SPECIFICATION :
Presently, IS Specification for LOT Valve is under preparation. However,

imported LOT Valves conform to EN: ISO 15995 : 2006.
The LOT Valve can be either of following make approved by PESO and
tested by third party inspection agency like M/s Bureau Veritas (BV) , M/s
Lloyds Register of shipping , M/s Det Norske Veritas (DNV) etc :
a) Model No. D-V6-CH 15 of SCG, Thailand make or

b) Model No. 9107K8A of Rego, ECII,USA make or
c) Kosan Industries, Surat or Any other Equivalent Model and Make duly
approved by Petroleum and Explosives Safety Organisation (PESO),
Nagpur (India) .
8.6.3 DESIGN DETAILS :
Item Detail Specification

Inlet (Cylinder/tank) connection ¾” 14 NGT, taper 1 in 16 thread of
ANSI/CSA/CGA Standard V-1-
1987.
Outlet Connection 1-1/4” – 5 ACME 2 G-H / CGA 790 V-1
Built in Safety Relief Valve Set Pressure 20 kg/cm2
Fitted with Excess Flow Check Valve Closing at approx 3 Kg/Minute of Butane
HDPE Tube Length 44” (1100mm) material HDPE
Test Pressure 19 Kg/cm2
Relief Valve Flow Capacity 6 m3 / minute (approx)
Filling Rate Minimum 20 LPM (approx)

DEPARTMENT 8
PAGE No.
8.6.4 DRAWING :
The drawing for LOT Valve is enclosed.
8.6.5 MATERIAL OF CONSTRUCTION :
The LOT valve body is made of brass , have external threading to match
with the existing internal bung thread on cylinder i.e. ¾” 14 NGT. The valve
body is forged from wrought or extruded sections.
8.6.6 PARTS OF LOT VALVE :
a. The hand wheel is provided to regulate the flow rate of liquid LPG.
b. A Pressure Relief Valve is provided near the outlet & integral part of
LOT Valve
c. Excess Flow Check Valve (EFCV) is provided at bottom inlet side of
the valve at the top of liquid withdrawal tube. The EFCV will close
automatically if the flow exceeds the pre set flow rating.
d. The LOT valve is provided with a tube which, on screwing of valve
on cylinder, shall go up to the bottom of the cylinder. This will
facilitate direct removal of liquid from cylinder.
e. LOT Cap with Nylon string.
8.6.7 MARKING ON LOT VALVES :
LOT Valve fitted to the LPG cylinder MUST have the following markings :
a. Manufacturer’s identification mark.

b. Batch No., Month / Quarter & Year of manufacture.
c. Test Pressure, SRV Set pressure, SRV Flow rate
d. CCOE approval no.
e. Opening and closing mark on hand wheel
8.6.8 TESTS DURING MANUFACTURING OF LOT VALVE :
a. Internal and external leakage test

b. Hydrostatic leakage test

DEPARTMENT 8
PAGE No.
c. SRV Test for pop up & reset at 19 kg/cm² whenever cylinder pressure
drops, rest and relieving (declared) capacity
d. EFCV closing flow ( 7.5 lpm LPG max) and residual leak ( 500 cc/min
max)
e. Closing /Opening Torque
f. Filling Rate 20 litres /minute at 12 to 15 kg/cm²
8.6.9 INSPECTION OF NEW LOT VALVES BY PLANT ON RECEIPT :
The following visual inspection of LOT Valves shall be carried out by the
Plant on receipt from the manufacturer :
a Check marking as per approved 0.1% of consignment subject to
drawing minimum 10 Nos.
b Visual Inspection 0.1% of consignment subject to

minimum 10 Nos.
c Marking on body, cover and 0.2% of consignment subject to
Marking Plate minimum 10 Nos.
d Checking of documents Manufacturers Test Report and
Third party inspection’s test
report or BIS certificate.
8.6.10 PERFORMANCE GUARANTEE :
LOT Valve & Its components are guaranteed by vendor against defective
material, design and workmanship as per warrantee period from date of
delivery for Indian vendors and from date of boarding for foreign vendors.
In case any defects develop within warrantee period the same shall be
replaced or the goods shall be replaced free of charge. All expenses
incurred including those on transportation shall be borne by the
manufacturer.

DEPARTMENT 8
PAGE No.
8.6.11 METHOD OF FIXING OF LOT VALVE :
The valve shall be fixed on the cylinder with applying specified torque of
176 to 200 Nm max, with fixture & torque wrenches only. It is
recommended to install a filter/strainer at the filling site (before the filling
adopter) to prevent any dirt from entering the cylinder. An approximate
10 mm cutting of the tube is recommended so the tube will not be bent on
the bottom and the gas will not get blocked.
8.6.12 TROUBLE SHOOTING CHART :
Sr. Observation Likely causes Action recommended

1 In the Cylinder a. Refer Drawing A. The part # 4 Check the NRV
Bank is the NRV commonly installed orientation and
installation, in manifolds. This is one way change if wrongly
product is not valve permitting flow in only installed.
coming out thru one direction. This could be
some of the installed with wrong direction.
cylinders b. The hand wheel of the LOT Wait for a few minutes
valve may have been until the internal EFCV
opened too fast and this may resets itself . Then try
have caused activation of opening the valve
the internal excess flow valve very slowly.
which shuts off the supply
c. The outlet adopter , refer Replace the outlet
drawing A, Part # 2 ,may not adopter with OEM
be of the correct supplied adaptor and
specification. It should be try out.
noted that the outlet of LOT
Valve has a Self closing
feature. The outlet adopter
has a Plunger which pushes a
Pin in the outlet of LOT Valve
to make the valve open.
If the outlet adopter is of local

make, its Plunger may not
have adequate travel to fully
push the Pin of SC Valve, thus
keeping the valve closed.
d. Some foreign matter or If steps at “a”,”b”, and
sludge lying at the bottom of “c” above do not

DEPARTMENT 8
PAGE No.
Sr. Observation Likely causes Action recommended
the cylinder may have work out, segregate
travelled up thru the tube the cylinder.
and lodged in the excess flow
valve, thus clogging the valve Replace the LOT
passage. Valve.
2 In some of the The LOT Valve is supplied with extra Replace with new LOT
cylinders fitted long tube. It has to be cut by the valve and ensure the
with LOT valves, user as per the cylinder depth. The tube is having proper
complete length of the withdrawal tube may length as per cylinder
evacuation have been over cut by the user. depth.
does not take
place and
some gas is left
over.
3 When LOT The withdrawal tube may have got Segregate these
Valve is opened detached from the valve assembly. cylinders and replace
only gas comes the valve.
out.
4 Replacement Do not try to replace
of any part of any part of LOT Valve.
LOT Valve The manufacturer shall
be consulted for
remedial measures.
8.7 LPG PRESSURE REGULATORS
8.7.1 GENERAL :
8.7.1.1 Prior to 1991-92, IOC and HPC were procuring Pressure Regulators (PRs) as
per the technology imported by IOC from Kosan Technova, Denmark
whereas BPC finalised technology from Sierra, Italy and had been
procuring PRs of Sierra design right from the beginning. As per Kosan
Technova design the PR is having three position knob i.e. on / off /
detach.
8.7.1.2 Subsequently IOC and HPC decided to switch over to Sierra Design for
procurement of PRs during 1991-92 due to obvious advantage of two
position knob i.e. on / off. The locking of Sierra design PR is independent of
on / off position of the knob. In this PR the engagement of inlet of PR with
outlet of SC valve is done by five steel balls held by a circular ring called a
bush. After engaging the regulator to the valve outlet, the regulator gets

DEPARTMENT 8
PAGE No.
locked by pushing the bush downwards. It will be difficult to disengage the

regulator from the valve outlet without pushing the bush upwards and this
is possible only when regulator knob is in off position
8.7.1.3 Procurement of Sierra design PRs for IOC and HPC actually started from
the third quarter of 1994 after reviewing various dimensions, tolerances
and other design aspects of Sierra design PRs by the Oil Industry.
8.7.2 PRESSURE REGULATOR (PR) of SIERRA DESIGN
It has a vertical inlet without any threads. It sits on the outlet of SC valve
and is mechanically locked to the valve with the help of a circular ring
called ‘bush’. The valve is opened / closed by a lever mechanism
operated by a 2 position knob. After placing the PR on the outlet of the
valve, the bush is lifted upwards and locking of the PR with the valve is
ensured by pushing the bush downwards. By turning the PR knob or
spindle, it presses down the valve pin keeping the valve seat in open
position. The design of the PR is such that the valve seat will not be opened
unless the regulator is properly kept in locked position on the valve outlet.
The gas tightness of the connection, joining the valve and the PR, is
achieved with the help of secondary sealing ring made of synthetic rubber
(Base polymer NBR, CAN content or FKM ) provided on the inlet of PR and
is called tight joint of PR.
At the time of making PR connections, it must be ensured that the ‘O’ ring
is present at the outlet of the valve for primary sealing between SC Valve
outlet and PR inlet.
For disconnection, PR knob should be in off position. Then only the bush
can be pushed upwards to disengage the PR from the valve.
Compared to Kosan Technova design PR, Sierra design PR is considered to

be safer because of simplicity of the locking mechanism independent of
regulator knob.
Based on its method of connection, this PR is also commonly known as

‘Click-on’ type regulator.

DEPARTMENT 8
PAGE No.
8.7.2.1 TECHNOLOGY TRANSFER FOR PRESSURE REGULATOR :
The Sierra technology of PRs is being transferred by BPCL by charging

fees to interested manufacturers who are interested to manufacture PR
and having license for PR of inlet size 22 mm and approval of CCOE and
qualifies in the tender. After satisfactory implementation of technology
and obtaining amendment of License from BIS for PR of inlet size 25.6 mm
and approval of CCOE for manufacture of PR of inlet size of 25.6 mm ,
trial order is placed on the manufacturer and on successful execution of
trial order, manufacturer is enlisted for supply of PRs to Oil Industry by OITC (
Oil Industry Technical Committee).
8.7.2.2 FUNCTION :
The pressure in a LPG cylinder will depend on the composition of LPG and
will vary with the temperature within the cylinder. Usually it is considerably
higher than that required for the consuming appliances. To enable to
reduce the pressure within the cylinder to the operating pressure of the
consuming appliances, a Pressure Regulator is required.
8.7.2.3 PR is an important and highly sensitive piece of equipment. Its main

functions are as under :
a. To regulate LPG in vapour phase from maximum inlet pressure of

16.87 kgf/cm2 in the cylinder to a nominal outlet pressure of 30 gf/cm2
(300 mm of water column) for domestic installation of LPG cylinders.
b. To maintain a constant outlet pressure as above, under varying rates

of gas flow within its rated capacity of 500 litres / hour of vapour at the
outlet.
The PR consists of a gas tight casing with inlet and outlet passages and
divided into two chambers by a flexible diaphragm. The diaphragm is
connected to jet in the vapour inlet connection, by means of a lever
mechanism which closes the jet whenever the diaphragm is lifted. An
adjustable compression spring is mounted above the diaphragm and
applies a downward pressure which tends to open the jet. A vent hole in
the upper casing connects the chamber above the diaphragm to the
atmosphere. The vapour from the cylinder flows into the lower chamber
of the PR and it tends to lift the diaphragm against the spring pressure and

DEPARTMENT 8
PAGE No.
thus closes the set. When the vapour in lower chamber is used, the
pressure under the diaphragm tends to fall, thereby opening the jet. In
practice, the diaphragm constantly fluctuates for regulating the
flow/pressure , thus state of balance exists and delivery pressure is held
within narrow limits.
8.7.2.4 IS STANDARD :
The PRs currently manufactured for use in domestic installations are

manufactured as per BIS specification no. “ IS 9798 for Low Pressure
Regulators for use with Liquefied Petroleum Gas (LPG) mixtures –
Specification”.
8.7.2.5 DESIGN PRESSURE :
The domestic and commercial appliances normally operate at a gas

pressure of 30 gf/cm2.
8.7.2.6 DRAWING :
Please refer drawing for PR attached with this manual
8.7.2.7 MATERIAL OF CONSTRUCTION :
Body and Cover : Zinc Alloys by pressure die casting

Diaphragm : Synthetic Rubber
Valve Pad Material : Synthetic Rubber
8.7.2.8 COMPONENTS OF PRESSURE REGULATOR :
There are total 28 components of DPR which are as under :
Sr Component Sr Component
1 Plastic Cap for Bush 16 Filter
2 Spacing Collar 17 Lever
3 Bush 18 Lever Pin
4 Clamping Balls – 5 nos. 19 Rubber Disc ( Lever Pad)
5 Tight Joint 20 Diaphragm Plate

DEPARTMENT 8
PAGE No.
Sr Component Sr Component
6 Spring for Bush 21 Diaphragm
7 Washer 22 Connecting Fork
8 Operating Tap with Spindle 23 Load Spring
9/10 O - rings 2 nos. for Operating 24 Regulating Knob
Tap Spindle
11 Retaining Pin 25 Marking Plate
12 Working Rod 26 Plastic Cap for outlet nozzle
13 O - ring for working rod 27 Bottom Cover ( Body)
14 Spring for Working Rod 28 Upper Cover
15 Bush for Working Rod
8.7.2.9 BRIEF PROCESS OF MANUFACTURING OF DPR :
1. Die Casting : Zinc Alloy (Zamac 5) is used for making body and cover
by die casting method by use of hot chamber die casting machine
and dies of body and cover.
2. Trimming : Extra flashes in body and cover castings are removed.
3. 5 hole drilling and reaming
4. Stub hole drilling
5. Retaining pin hole drilling
6. 6 hole( rivet ) hole drilling
7. Orifice hole drilling
8. Final filling and visual checking
9. O ring seat reaming
10. Passivation/degreasing and vibrating fro burr removing : 7 tank
process.
11. Preheating at 60 to 80° C for moisture removing in electrical oven
12. Powder coating and Baking at 180 to 190° C in electrical oven
13. Visual Checking
14. Orifice reaming
15. Lever sub-assembly and Lever fitting by 2 Ton hydro-pneumatic Press
16. Filter fitting
17. Cover fitting and riveting by 15 Ton hydro-pneumatic Press
18. Load spring and nut fitting
19. First soundness testing at 1500 mm WC
20. Operating Tap Spindle (OTS) sub-assembly and OTS fitting
21. Bush fitting

DEPARTMENT 8
PAGE No.
22. 5 ball fitting

23. Collar fitting
24. Working rod and bushing fitting
25. Tight joint fitting
26. First Performance Checking : At 0.5 kg/cm² , Pressure flow should be
225 to 240 mm WC. At 17 kg/cm2, lock up at 450 mm WC, 10% and
100% Flow outlet Pressure maximum 360 mm WC and 400 mm WC
respectively.
27. First Pneumatic Checking at 17 kg/cm²
28. Marking plate fitting
29. Batch number punching
30. Serial Number punching
31. Final Performance
32. Final Pneumatic
33. Final Soundness
34. Visual inspection and Packing and despatch to LPG Plants
8.7.2.10 MARKING ON PRESSURE REGULATOR :
A PR shall be clearly marked with the following details :
a. Manufacturer’s name or trade mark.

b. Maximum rated capacity in m3 / hour of LPG.
c. BIS License Number i.e CM/L-xxxxxxx of manufacturer
d. BIS Logo with IS 9798 :1995
e. Owner’s name (i.e. PROPERTY OF INDIANOIL CORPORATION LTD.),
f. Six character Batch no. First two character are Alphabets in Capital
followed by 4 numeric character. The first two digit indicate Month
and other two digit indicate Year of manufacture. Example AB0413.
g. Seven Character Serial Number. First digit is a Alphabet in capital
followed by six numeric characters (use of O,U,V are avoided).
Example A1234567.
8.7.2.11 TESTS DURING MANUFACTURING OF PRESSURE REGULATOR :
The DPR undergoes stringent quality controls at the time of manufacturing.

Following Type Tests on DPR are being carried out as per IS specification
and Technology Implementation report :

DEPARTMENT 8
PAGE No.
1. 1 kg ball drop test 10. Tight Joint Leak Test

2. Hydrostatic Test 11. Working Rod O ring Leak Test
3. 65° C High Temperature 12. Clearance & Opening Travel
Test Check
F4. -20° C Low Temperature 13. Body Low Pressure Test
o Test
l 5. Pull out Test of Diaphragm 14. Body High Pressure Test
l 6. Clamping Test of 15. Minimum wall Thickness Check at
o Diaphragm ( a) Nozzle section , (b) Knob section
w and (c) Orifice section
i 7. Cycle Test 16. Paint Adhesion Check
n8. Salt Spray Test 17. 2 kg Fitting Test of DPR
g9. Cover Riveting Pull out Test
Tests on DPR are being carried out as per IS specification and Technology
Implementation report :
1. 100% inspection of fitment dimension

2. Orifice reaming height check
3. Soundness Test of parts subject to full cylinder pressure : Pneumatic
Pr at 17 kgf/cm² at inlet connection for 30 to 60 seconds and
pneumatic back pressure at 150 gf/cm² to the outlet connection .
4. Annular gap and stub folding gauging
5. Pneumatic Test for leak tightness at 150 gf/cm² at outlet connection
for 30 seconds.
6. Hydraulic Test : For leak tight of parts subject to full cylinder pressure
at 25 kgf/cm² at inlet connection for 120 seconds.
7. Performance Test
8. Bush movement Check
9. Final checking of soundness, Pneumatic and Performance after
Serial number punching.
10. Chatter Test
8.7.3 INSPECTION OF PR BY PLANT ON RECEIPT
The following visual inspection of DPR shall be carried out by the Plant on
receipt from the manufacturer :

DEPARTMENT 8
PAGE No.
a Check marking as per approved 0.2% of consignment subject to
drawing minimum 10 Nos.
b Visual Inspection 0.2% of consignment

c Weight of DPR Min 10 nos. ( Weight to be
minimum 405 gm)
d Internal Diameter for fitment to 0.2% of consignment subject to
valve minimum 10 Nos.
8.7.4 NORMS FOR SENDING NEW PRs TO LERC FOR TESTING
Norms for sending PR to LERC is as below :
Three PRs of same batch of only one manufacturer per bottling plant in
one quarter ensuring that all manufactures supplying PRs to particular
plant are covered in one complete year.
Under no circumstances, defective DPR be returned to the manufacturer.

In case, defective DPRs within warranty period are not replaced by the
respective manufacturers, within two months from the date of intimation
by plant, information on the same, should be reported to HO LPG Ops
materials.
8.7.5 FAULTS AND REPAIRS OF PR :
The principle causes of failure of a regulator are worn or damaged

diaphragm and valve seat and mechanical stiffness in the lever
mechanism due to dirt and corrosion. No repairs are to be carried out and
PR to be deshaped.
8.7.6 CAUSES OF PRESSURE REGULATOR FREEZING :
PRs may become frozen if water is present in LPG. Water may enter into
the system due to hydrostatic testing of vessels, cylinders, pipelines etc. or
due to breathing-in of empty cylinders if valves are left open.
LPG, both in the liquid and the vapour phase, absorbs moisture readily until
saturation point is reached. Any water present in the LPG cylinder is likely

DEPARTMENT 8
PAGE No.
to freeze due to fall in temperature on account of expansion of vapour

through the regulator valve.
8.7.7 DEFECTS DUE TO HANDLING :
a) Damage to the body.

b) Damage to the cover.
c) Breaking of operating knob or bush.
d) Breaking of nozzle.
e) Damage to the sign plate.
f) Damage to the pin.
8.7.8 REPLACE MENT OF DEFECTIVE DPR BY MANUFACTURER :
The manufacture shall replace manufacturing defective Pressure

Regulator returned by LPG Distributors with new PRs within warrantee
period of 2 years and in case same is not replaced by the respective
manufacturers within 2 months period from the date of intimation by the
Plant, then same should be reported to LPG Materials Deptt. However,
under no circumstances the defective PRs shall be returned to the
manufacturers. The defective PRs shall be deshaped by the Plant .
8.7.9 MULTI FUNCTION REGULATOR :
8.7.9.1 GENERAL :
The Multi Function Regulator have four additional features in built in the
design, over & above the basic features in normal DPR.
8.7.9.2 SALIENT FEATURES OF MFR :
a. 100% Excess Flow Shut off :
MFR is provided with inbuilt mechanism to shut off the flow of LPG, in case
of failure of tube connecting MFR outlet to the Gas stove. The mechanism
meet following working requirements:
a) It auto-actuates at minimum flow rate of 120% of the rated

capacity of 500 l/hr of LPG vapour. Shutting off does not require
any human intervention for its operation.

DEPARTMENT 8
PAGE No.
b) Under normal usage and gas flow condition, the excess flow
shut off feature does not activate.
c) The excess flow mechanism is not be for one time use. Once
the mechanism is operated, it is possible to reset the
mechanism after taking corrective action & ensuring safety by
the operator. The resetting process is simple and easy to
operate without requiring any tools or tackles.
b. Child Lock Mechanism :
The MFR is provided with mechanism to have restriction on normal rotation

of the operating knob to ‘ON’ position. The mechanism is such that to turn
on the MFR, along with the normal turning of the operating knob,
additional action is also required to be done by the operator
simultaneously.
The mechanism is aimed to restrict accidental turning ‘ON’ of MFR by a

child. The mechanism will not impose any restriction while switching off the
gas flow.
c. Low Level Indicator :
MFR is provided with an analogues display which helps the user to monitor
the level of the LPG in the cylinder. The display have indication for various
situations like ‘LOW GAS’ & ‘REFILL’ by the way of different colours zones.
This will help the user to decide for the refill of cylinder well in advance. The
display can be also electronic which gives alarm in case the Gas is Low.
d. Leak Detection Mechanism :
It is possible to use this low level indicator to check for the minor leakages
in the gas tube/hose and from the joints.
8.7.9.3 IS SPECIFICATION :
The MFR is manufactured in accordance with IS 9798 , however, IS

specification is not covering the above additional features and therefore,

DEPARTMENT 8
PAGE No.
PESO has accorded approval for introducing MFR duly approved by third
party inspection agency like TUV on pilot basis.
8.8 SAFETY CAP :

8.8.1 FUNCTION :
Valve outlet is fitted with Safety Cap to avoid damage to internals of the
LPG valve and also to arrest the entry of dust particles and dirt inside the
valve assembly. Safety cap should be put on to the valve at all times
except for filling of the cylinder at the Plant and usage of the cylinder at
the customer’s premises.
If the safety cap is not fitted on to the valve by means of SS spring, valve
may get damaged due to entry of dust particles or dirt into the valve
spindle joint packing and may cause leakage of LPG through the valve.
Hence, the safety cap is also considered as a protection for the leakage
of the valve. This is an important component for valve protection as well
as stopping leakage in case of emergency.
8.8.2 DRAWING :
Please refer drawing no. LPG-ED/SCAP Rev 2 for Safety Cap.
8.8.3 SPECIFICATION :
Safety cap is manufactured out of Dupont Delrin 500P /900P/1700P/901S or

CELCON M90/M270 or KOCETAL virgin material or equivalent or better
material .
Safety cap shall be milkfish white in colour. Average weight of cap with
spring and nylon/PPMF string shall be 9.18 + 0.5 grams. Average weight of
cap without spring and nylon/PPMF string shall be minimum 7.5 grams. It is
tested for pneumatic pressure of 17 kgf/ cm².
The Plant shall check all critical dimensions of safety caps by gauges etc .
Plant shall keep weighing scale with proper least count duly calibrated
for checking the quality of safety cap on receipt. Immediately on receipt
of Safety Cap, Plant shall weigh 25 nos of safety cap for every lot of
25000 nos. of safety caps received and shall maintain record of the same.

DEPARTMENT 8
PAGE No.
Also check fitment of safety cap on the SC Valves for easy fixing and
removal.
If in the physical test, it is found that the samples are not meeting the
requirements viz. average weights, fitment on the SC Valves, critical
dimensions etc. the supplier shall be informed for joint inspection and
once it is established that the caps are not meeting the requirement for
average weights, fitment on the SC Valves, critical dimensions etc. then
the entire supplies/ lot should be rejected.
8.8.4 MARKING ON SAFETY CAP :
Marking for the following on Safety Caps shall be as given in the drawing
a. “INDANE” on Top face

b. “RD158178” on the Top face below “INDANE”
c. Arrow mark towards string
d. Manufacturers identification mark on the top face
e. Mould number inside portion of safety cap.
f. Quarter of manufacture on Top face at LHS.
g. Year of manufacture on Top face at RHS.
8.8.5 ENLISTED PARTIES FOR PROCUREMENT :
The Safety Caps are to be procured from the OITC (Oil Industry Technical
Committee) enlisted manufacturers only.
8.8.6 INVENTORY OF SAFETY CAPS BY LPG PLANT :
Plants shall keep minimum two months inventory of Safety Caps.
8.8.7 NORMS FOR SENDING SAMPLES OF SAFETY CAPS TO LERC FOR TESTING :
Plant immediately on receipt of safety caps, shall send at least 10 safety

caps to LERC for every lot of 25000 nos. & equal number of samples from
all the moulds to be sent. LERC shall test the samples as per relevant
specifications of safety cap and submit the test report within 15 days from
the date of receipt of samples by LERC.

DEPARTMENT 8
PAGE No.
Plant on receipt of report shall decide about utilization of Safety Caps. If

the Safety Caps are rejected, Plant shall deform the Safety Cap and
hand over to the supplier as per the Purchase order conditions.
The format for sending samples of Safety Caps to LERC is enclosed.
8.9 “O” RINGS FOR SC VALVE :
8.9.1 FUNCTION
The O - ring is provided on the outlet of SC Valve for primary sealing of DPR
inlet with SC Valve outlet. Thus there will not be any leakage from the
regulator when regulator is kept in “ON” position. If any leakage is
observed from the O - ring, then O - ring shall be replaced with new O ring.
8.9.2 DRAWING :
Refer drawing no. LPG-ED/O-RING for O – ring.
O - ring is manufactured from Nitrile Butadine Rubber ( NBR) or Flouro

Karbon Elastomer (FKM) developed by LPG Equipment Research Centre.
150 mm x 150 mm rubber compound slab from which O- rings are

manufactured are to be received with each consignment from the
manufacturer by the Bottling Plant along with Test Report. Immediately on
receipt of O rings, Plant shall carryout visual inspection of O - rings. The O-
rings should be free from fins, moulding defects, porosity, pits and foreign
particles and shall have non tacky surface and free from casting coat.
8.9.4 MARKING ON O RING :
Marking for the following on the inner side of O ring shall be as given in the
drawing :
a. Cavity/Pin number
b. Manufacturers identification mark
c. Half year and Year of manufacture.

DEPARTMENT 8
PAGE No.
8.9.5 ENLISTED PARTIES FOR PROCUREMENT OF O RINGS :
The O - rings are to be procured from OITC (Oil Industry Technical

8.9.6 INVENTORY OF O RINGS BY LPG PLANT :
Plants shall keep minimum two months inventory of O - rings.
8.9.7 NORMS FOR SENDING SAMPLES OF O RINGS TO LERC FOR TESTING :
Immediately on receipt of O rings from the manufacturer, plant shall send

within a day, 10 samples if O ring receipt is =/< 50000 Nos or 20 samples if O
ring receipt is > 50000 nos. Equal number of samples from all the cavities to
be sent to LERC along with rubber compound slab of 150 mm x 150 mm
size to LERC by fastest mode of transport preferably by courier .
LERC shall test the samples and submit the test report within 15 days from
the date of receipt of samples by LERC. Plant on receipt of report shall
decide about utilization of O rings. If the O rings are rejected, Plant shall
deform the O ring and hand over to the supplier.
8.10 PVC HEAT SHRINKABLE SEAL FOR SEALING OF FILLED LPG

CYLINDER :
8.10.1 FUNCTION :
PVC Heat Shrinkable seal is being used for sealing of safety cap provided
on filled LPG Cylinder to prevent any theft of LPG from the cylinder by
unscrupulous person or delivery boys. The PVC Seal is placed on the safety
cap and with steam, the PVC seal shrinks and is tight fitted on the safety
caps, thus it is difficult to remove the PVC seal without breakage due to its
shrinkable properties.
8.10.2 DRAWING :
Refer drawing no. LPG-ED/PVC Seal for PVC Seal.


DEPARTMENT 8
PAGE No.
The thickness of PVC Seal shall be 0.08± 0.010 mm. Height shall be 42 mm
with 9 mm collar. The color of PVC Seal shall be metallic white with
markings as shown in the drawing.
The shrinkage lengthwise shall be between 12% to 15% and shrinkage

widthwise shall be between 35% to 45% at 100 to 110°C.
Plant shall keep weighing scale with proper least count duly calibrated
for checking the quantity of PVC Seal on receipt. 1000 pieces of PVC Seal
weigh 700 grams (min) Immediately on receipt of PVC Seal, Plant shall
carryout dimensional checks and average thickness of PVC Seal and
average thickness of PVC Seal should not be less than 0.08 mm.
Perforations of 4 mm size with gap of 1.5 mm between consecutive
perforations shall be checked.
If in the physical test, it is found that the samples are not meeting the
requirements viz. average weights, dimensions etc the manufacturer shall
be informed for joint inspection and once it is established that the PVC
Seals are not meeting the requirement for average weights, dimensions
etc. then the entire supplies/ lot should be rejected.
8.10.4 MARKING ON PVC SEAL :
Marking for the following on PVC Seal shall be as given in the drawing :
I. “Indane” logo on both the sides

II. “IndianOil” emblem on both the sides
III. Plant Name on one side
IV. Manufacturers identification mark
V. Perforations shall be 4 mm size with gap of 1.5 mm between
consecutive perforations.
8.10.5 ENLISTED PARTIES FOR PROCUREMENT :
The PVC Seals are to be procured from the OITC (Oil Industry Technical

DEPARTMENT 8
PAGE No.
8.10.6 INVENTORY OF PVC SEALS BY PLANT :
Plants shall keep minimum two months inventory of PVC Seals.
8.10.7 NORMS FOR SENDING SAMPLES OF PVC SEALS TO LERC FOR TESTING :
Immediately on receipt of PVC Seals from the manufacturer, Plant shall

send within a day, 10 samples if PVC Seal receipt is =/< 25000 Nos. or 20
samples if PVC Seals receipt is > 50000 nos. to LERC by fastest mode of
transport preferably by courier .
LERC shall test the samples and submit the test report within 15 days from
the date of receipt of samples by LERC. Plant on receipt of report shall
decide about utilization of PVC Seals. If the PVC Seals are rejected, Plant
shall deform the PVC Seals and hand over to the manufacturer.
8.11 FACILITIES/EQUIPMENT RELATED TO LPG CYLINDER FILLING AND

ALLIED OPERATIONS
8.11.1 GENERAL
. LPG bottling plants and related equipment vary considerably in layout

and size depending upon the number, size and capacities (e.g. 14.2/19kg
etc) of cylinders to be filled and the limitations of the site.]
Apart from safety considerations, market demand and related capacity

are the major consideration for the design of bottling plants.
8.11.1.1 The size of bottling plants is standardized as below.
Sl. Carousel No. of Shifts CAPACITY

(TMTPA)
1 1 X 6 / UFM 1 8
2 1 X 12 pt 1/2 15/30
3 1 X 18 pt 1/2 23/45
4 2 X 18 pt 1/2 45/90
5 1 X 24 pt 1/2 30/60
6 2 X 24 pt 1/2 60/120

DEPARTMENT 8
PAGE No.
7 3 X 24 pt 1/2 90/180
8 4 X 24 pt 1/2 120/240
8.11.1.2 OISD 169 OISD 144 LPG BOTTLING PLANTS:
Bottling plants having a bulk inventory not exceeding 100 MT of LPG with
minimum two storage vessels and also bottling a total quantity not
exceeding 20 MT of LPG per shift of 8 hrs are falling under OISD 169. The
addendum provided vide Section 5 as approved in the 26th Safety
Council Meeting held on 25th July,2008 of OISD 169 lays down the
additional minimum safety requirements on design, layout, storage,
loading / unloading, operation at LPG installations having Bulk Storage (a)
exceeding 100 MT but limited to 300 MT for aboveground storage and also
for (b) 450 MT in mounded or in combination of aboveground and
mounded storage of LPG with total bottling quantity not exceeding 35 MT
per shift. of 8 hrs.
For all the plants where either storage or bottling capacity is higher than
the above limits, OISD Std.144 shall be applicable.
8.11.1.3 From the safety point of view, separate covered sheds, with a minimum
distance of 15 metres between the sheds are planned for the following
activities :
a. Storage of empty cylinders, evacuation, and purging operations.

b. Filling operations.
c. Storage of filled cylinders.
d. Cold repair activities such as change of defective valves & bung leak
repairs.
However the facilities are combined to Two / Three sheds as per the latest
design, but cold repair shed is always segregated 15 metres away from the
main filling operation. Valve changing unit without evacuation can be
provided in filling shed itself. For OISD-169 bottling plants all the activities
are covered under single shed only.
8.11.1.4 In the area within the plant, where cylinder handling is done, mastic
covering is provided on the columns (up to 1.5 metres height) and the
entire shed flooring. It minimizes the cylinder damage and also prevents
sparking, in the case of accidental fall of cylinders.

DEPARTMENT 8
PAGE No.
8.11.1.5 The movement of cylinders within the plant should, as far as practicable,
be handled through conveyor system. For manual handling of cylinders,
wherever unavoidable, cylinder trolleys should be used for the safe
handling of the cylinders.
8.11.1.6 Essential facilities / equipment required for various operations related to

LPG cylinders are described below. It may, however, be noted that the
details pertaining to a typical equipment may vary significantly with the
make and model of each equipment. Within the scope of Manual it is not
possible to cover the details of various makes / models. Therefore,
reference should be made to the manufacturer’s catalogues and
installation / operating instructions for details.
8.11.2 CONVEYOR SYSTEM
8.11.2.1 Function
The function of a conveyor system, in bottling plants, is to convey and

distribute the cylinders mechanically, thereby reducing the manual
handling and faster movement of cylinders to the various on-line facilities.
Power operated chain conveyers are widely used in the filling plants due to
the following advantages :
(a) Power operated chain type conveyors are found to be most

suitable for the size and type of cylinders, that are being handled
at IOC’s filling plants. The special shape and surface of the chain
permit LPG cylinders to accumulate anywhere on the conveyor.
Thus, LPG cylinders may be retained for different working operations
while the chain moves uninterrupted.
(b) The chain can run at different velocities on different sections when
provided with suitable drive units, giving considerable flexibility to
adopt to different working requirements.
(c) All the on-line equipment with wide range of special

purpose utilities can be incorporated in the system.

DEPARTMENT 8
PAGE No.
8.11.2.2 CONTROL OF CYLINDER MOVEMENT ON THE CONVEYORS - COMPONENTS
a. Pusher / Shifter / Shunter : It is intended for automatic diversion of

LPG cylinders to the required direction and conveyor sections. The
same are operated pneumatically actuated by pneumatic/Electro
pneumatic signals.
b. Pneumatic-cylinder-stop-device : It can be placed at desired

locations on the chain conveyor and is intended for stopping,
retaining or releasing LPG cylinders at designed intervals. The same
are operated pneumatically actuated by pneumatic / Electro
pneumatic signals.
c. Diverter/Converger : It is intended for diverting movement

of cylinders to different conveyer sections by means of pneumatic
device.
d. Stopper : This is a pneumatic device to stop the movement of

cylinders by manual or automatic actuation.
8.11.2.3 TELESCOPIC CONVEYORS
These are intended to convey LPG cylinders from chain conveyor to stake
trucks and vice-versa. It consists of a stationary and a movable section. The
movable section can be extended for 6 metre and is supported by the
steel rollers in the stationary section. It comprised of chain conveyors with 2
parallel chains, which are common for both the stationary and the
movable sections. Two drive units with necessary gears and transmission
elements are built into the stationary section, one for the conveyor chains
and the other for the extension and retraction of the movable section. Two
actuators are placed on the movable section of the telescopic conveyor,
one for start and stop and reversing of the chain conveyor; and the other
for extension and retraction of the movable section. For safety reasons, the
movable section of the telescopic conveyor is provided with automatic
stop-device as well as a safety stop-device, which at the slightest touch,
instantaneously stops both the conveyor chains and the movable section.

DEPARTMENT 8
PAGE No.
8.11.2.4 DRIVING UNITS
(a) The chain conveyors are driven by the drive units. Drive unit consists
of worm reduction gear box coupled to flame proof electric motors.
Transmission of power is made by the transmission chain from the
sprocket of the gear box (or directly through the sprocket assembly
of planetary gear box) to the sprocket of conveyer drive section.
(b) The number and specific dimensions of the driving units are adopted
based on the anticipated load and the desired velocity of
conveyance. The driving units are provided with tensioning device for
the conveyor chain. Soap water trays are provided at suitable
locations on the system, where the chain gets cleaned and
efficiently lubricated during its continuous passage through the
solution.
8.11.3 PRE-FILLING FACILITIES
8.11.3.1 The following facilities are provided prior to the filling of cylinders :
(a) Purging unit : The unit consists of Vacuum pump with gauge and a
manifold with sets of adopters for removal of air from the new
empty cylinders and filling of LPG vapor .into these cylinders. The
unit is installed and operated on line and designed for automatic &
semiautomatic operations. To ensure removal of air up to 0.35
kg/cm2 (absolute )/ (-)494 mm of Hg (g)/(-)0.65 kg/cm2 (g), pressure
based purging cut-off has been provided.
(b) Cylinder washing / Drying unit : This unit is installed on line for the
cylinder washing and subsequent drying of empty Cylinders prior to
filling. The unit consists of continuous water rinsing section with rinsing
nozzles and water tank with filter, centrifugal pump & air blower.
(c) On line check facilities for market return cylinders. The facilities
consist of check weighing scale along to check the weight of
defectives returned by the distributors.
(d) VP Ring/Stay Plate/Foot Ring Straightener: The cylinders segregated

on account of bent VP Ring/Stay Plate / footring but without break

DEPARTMENT 8
PAGE No.
in welding, should be repaired at this machine before being sent to

carousel for filling.
(e) Weighing arrangement for new cylinders : A weighing scale is

provided to check and verify the tare weight of the new, statutory
tested and hot repaired cylinders. Minimum 10% of the cylinders
received should be checked at random for the correctness of the
tare weight. The paint thickness (70 microns) should also be verified
at random by using Elcometer to check whether the minimum
thickness of the paint is maintained as per specification, for ST tested
cylinder.
8.11.4 LPG CYLINDER FILLING FACILITIES
8.11.4.1 FILLING MACHINES-General
Filling machine can be used as a stationary unit or mounted on a

Carousel for filling of cylinders as under :
(a) Filling of LPG cylinders is done on gross weighment principle.
(b) Weighing machine forms a primary part of filling machine along with
mechanism for filling liquid LPG.
For the safety of filling operation, filling machine (carousel / unit filling
machine) should be electrically interlocked with the vapor extractor system
i.e. without operating the vapor extraction system , filling operation cannot
be commenced.
8.11.4.2 FILLING METHOD- GROSS WEIGHT SYSTEM
Gross weight system is adopted for filling operation in all plants. In this
case, the machine is provided with individual adjustments for ‘Tare-Weight’
and ‘Net-Weight’. Once the weight of the product to be filled is pre-set as
‘Net-weight” which remains constant, the only adjustment required is that
of ‘Tare-Weight’. Once the set ‘Gross-Weight’ (arithmetical sum of pre-set
‘Net-Weight’ and the ‘Tare-Weight’ set) is reached, the product flow is cut-
off automatically. So the accuracy of the filling relates to the accuracy of
‘Tare-Weight Marking’ on the cylinders and the tare weight set on the

DEPARTMENT 8
PAGE No.
machine. It is, therefore, essential that the ‘Tare-Weight’ marked on the

cylinders is accurate and legible.
8.11.4.3 TYPES OF FILLING MACHINES
(a) Filling carousel - General
The filling carousel is intended for filling of large number of LPG

cylinders at major / mini bottling plants. It consists of a carousel
frame with running wheel and corresponding running rail, a central
column for gas and air and hydraulic driving unit, which by means of
anti-static V-Belts / Tyre rotates the carousel frame around the
central column. The speed of the driving unit is variable so that the
rotation of the carousel can be adjusted to various filling times and
capacities.
From the central column, gas and air are distributed through
distributing pipes to circular pipes behind the filling machines and
through gas-stop valves and anti-static hoses. A filling machine can
thus be shut-off for repairs without affecting the operation on the
other machines. The LPG liquid line from the pump house is provided
with a by-pass arrangement with DP (Differential Pressure) Valve
near the carousal. The DP valve is a spring loaded valve, which
automatically allows the flow of LPG through a by-pass line,
whenever LPG pressure in the pipeline exceeds the set limit..
The filling pressure shall not exceed max. working pressure of the
cylinder i.e. 16.9 Kgf/sq cm at 65 Degree centigrade.
While selecting the size of the carousel (6/12/18/24 machine

capacity) not only the immediate requirement but also future
requirement of filling capacity is considered. The carousel frame
chosen can then be equipped with a number of filling machines
covering the present demand. Further, machines can subsequently
be augmented as and when the demand increases.
The filling carousel is provided with equipment for automatic

introduction and also ejection of cylinders. Using automatic
Introduction and ejection units, smooth transfer of cylinders, to and
from the carousel to conveyer is achieved.

DEPARTMENT 8
PAGE No.
b) Types of Carousels
Carousel may be either Mechanical or Electronic type as

under :
Mechanical Carousel : The Carousel Platform consists of illing

machines (mechanical scale base supported on knife
edges) with self aligning running wheels located on running circular
rail. LPG & Compressed air are distributed through a central
column and filling is done through automatic/ self de-coupling
filing heads. The filling operation is controlled pneumatically in
respect to the tare weight of the cylinder set to the individual
machine manually by rotating the knob on the graduated dial.
However, all mechanical carousels have been converted to
Electronic Carousels.
Filling Operation in Carousel : The empty cylinders are introduced

continuously to the rotating filling machines of carousel by the
Introduction unit. The tare weight of the cylinder is set on the filling
machine and filling commences with automatic/ manual lowering
and clamping of the filling head. The filling continues during the
rotation of the carousel and cuts off once the overall weight of
cylinder reaches the gross weight. The filling head gets detached
automatically from the cylinder valve and ejected out of the
carousel to the conveyor by ejection unit.
Electronic Carousel : The Carousel Platform consists of electronic

filling machines with load cells supported on a base frame with self
aligning running wheels located on running circular rail. LPG,
Compressed air and electricity are distributed through a central
column and filling is done through automatic / self de-coupling filing
heads. The filling operation is controlled by pre-programmed
software.
The tare weight of the cylinder from the individual filling machine is
automatically transferred to check scale for verification. The data
from carousal and check scale is used for generation of on-line MIS
by means of a PC installed in the control room. Also the fault

DEPARTMENT 8
PAGE No.
diagnosis of the system as well as filling quality can be assessed on

line through this PC. The tare weight input to the filling machines of
carousel is done through centrally located cylinder tare weight
punching station and the data gets transferred automatically. If
required, manual punching of tare wt. can also be done at
individual filling machines
c) Stationary Filling Machine: These filling machines operate in

stationary position installed on the conveyor system. The system
consists of mechanical / electronic weighing scale with LPG filling
arrangements. The principle of filling is gross weight system where the
filling is cut off automatically once the total weight of the cylinder
reaches the gross weight (Cylinder weight +Liquid net weight).
Stationary filling machines are installed in sets, on line, for achieving
higher output. Also centralized tare weight punching facility is
adopted through PC in Stationary electronic filling system.
For higher output of filling, pre-filling facilities are installed in tandem

before the filling machine. The empty cylinders are pre-filled to some
quantity during the waiting time before final filling in the filing
machines. Stationary filling machine is also used for filling of 47.5 kg
cylinders and 5 Kg Cylinders
8.11.5 POST FILLING FACILITIES
8.11.5.1 ON LINE CHECK SCALES
The function of the equipment is to check the correctness of the quantity

filled in the LPG cylinder on filling machines. Check scales consist of
weighing scale suitably modified for the operation. The least count of the
scale should not be more than 10 grams. They are installed on line on the
conveyor section to check the correctness of the weight of the filled
cylinders on a continuous basis after they come out of filling machines.
The check scale consists of electronic weighing scale with load cell
and digital display and the net weight (14.2 Kg, 19 Kg etc) is tared or fixed
and the check scale shows only the variation in weight of the cylinder and
cylinders with weight variation higher than the preset values are
automatically rejected into a different loop.

DEPARTMENT 8
PAGE No.
In majority of the Plants, the check-scale is integrated with carousel and

the tare weight of the cylinders is automatically transferred to check scale.
The check-scale gets the input tare weight data from tare punching
station and compares the actual weight of the cylinders with tare weight
as received from punching station plus net weight of the cylinder and If
found within range, it allows the cylinder on main stream else it transfers
the cylinder on the correction loop.
In some of the Plants, stand alone check scales are still available. In this
type of check scale, tare weight of the cylinder is punched by an operator
as it approaches the check scale. Check scale after comparison
automatically accepts or rejects the cylinder as the case may be.
The scales of capacity 1200cyls/hr, 1400 cylinders/hr, 1600 cylinders /hr are
available and are provided with anti jam sensors to stop the operation in
case of accumulation of cylinders down the stream or on the rejection
conveyor.
Maximum permissible errors in deficiency against the declared weight

should be within +75 gm & -75 gm ( +/- 1.5% ) incase of 5 Kg cylinders & +/-
150 gm incase of 14.2 Kg cylinders, in accordance with the Legal
Metrology (Packaged Commodities) Rules 2011. However, as per our
Corporation norms maximum acceptable variation in net weight for 14.2
Kg Cylinders is + 200 gm and -100 gm. However, it must be borne in mind
that as per Legal Metrology Rules, the average net weight of cylinders in a
lot should be equal to or greater than the declared net weight.
8.11.5.2 WEIGHT CORRECTION UNIT
Over filled / under filled cylinders rejected from the check scale are
manually corrected at this unit. The unit consists of weighing scale and one
filling head (common for filling and evacuation) with a stopper, lifting
mechanism, tilting mechanism for evacuating excess quantity of over filled
cylinders. The under filled cylinders are corrected by topping up with the
required quantity and the overfilled cylinders are evacuated to the net
quantity by tilting the cylinder on the frame of the machine. The system
operates on the same gross weight method similar to the filling, where the
operation cuts off once the total weight of cylinder reaches the gross
weight of cylinder.

DEPARTMENT 8
PAGE No.
The cylinders after correction are checked again in the check scale for the
correct net weight.
8.11.5.3 AUTOMATIC WEIGHT REDUCTION UNIT
At many of the plant, since the rejection from electronic carousal is very
low, Automatic Weight Reduction Unit has been provided in place of
Integrated Weight Correction Unit. The cylinders rejected from check scale
are fed to this machine, wherein 3 to 4 Kg of gas is removed (by
evacuating the gas for a fixed time from all the cylinders. These cylinders
are then sent back to the carousal for refilling.
8.11.5.4 COMPACT VALVE TESTER (CVT)
The CVT is used for checking the ‘O’ ring condition and the valve leak. CVT
is designed to detect the leakage of 0.5 gm per hour and above. It
consists of a detecting head with a central air capillary connected to the
top chamber filled with kerosene. When the head is connected to the
cylinder valve, it clamps the valve and probe air is supplied around valve
‘O’ ring . For any damage in the ‘O’ ring, the air passes through the ‘O’ ring
to the top chamber through air capillary. Bubbles in the kerosene chamber
shall indicate the damaged “O” ring or the valve leak. If the bubble
continues to persist, when the probe air is cut off, it indicates the valve leak
and if not, defective ‘O’ ring. The working of CVT should be verified by
using CVT verifier. Now a days, CVT is being used only at RQC loop at most
of the Plants.
8.11.5.5 AUTOMATIC ELECTRONIC ‘O’ RING LEAK DETECTORS
The unit consists of testing head with auto centering and cylinder
clamping/lifting facility. When the cylinder enters the unit, the cylinder is
clamped and lifted simultaneously .The testing head lowers and is
clamped to the cylinder valve, probe air is supplied around Valve “O” ring
. For any damage in the “O” ring, the air passes through the central
capillary and taken to the pressure transmitter. The pressure transmitter
produces an electrical signal (4-20 milliamps) proportionate to the
quantum of air leak. As per the preset values set in the PLC panel, the
cylinder will be sorted out according to the magnitude of the electrical
signal. The cylinder valve with defective ‘O’ ring shall be rejected
automatically by a pusher to the rejection conveyer. The on line MIS is also
generated as the unit is integrated to the PC.

DEPARTMENT 8
PAGE No.
The detector has the capacity to check 1200 to 2200 cylinders /hr with
single/ double head. The unit is totally automated and does not require
manning.
8.11.5.6 AUTOMATIC ELECTRONIC VALVE LEAK AND BUNG LEAK DETECTOR
The unit consists of single / multi sensing head with auto centering &lifting
facility. The equipment is also provided with a gas analyzer and a control
panel. When the cylinder enters the unit, the cylinder is lifted and centered
automatically. The sensing head is automatically lowered covering and
sealing the valve and bung portion of the cylinder. Clean air is supplied to
the sealed cavity of the sensor head. In case of a leaky cylinder, mixture of
air and LPG is formed within the sealed cavity of sensor head. This mixture
of air and LPG from the sensor head cavity is transferred through a tube to
the gas analyzer, which intern actuates the control panel to give a signal
for auto rejection of the cylinder.
The gas analyzer is calibrated to detect leakage of LPG of 0.5 gm/hr or

more. The detector has the capacity to check 1200 to 2200cylinders per
hour. The on-line MIS also is generated as the unit is integrated to the PC.
The unit is totally automated one and does not require manning. The
cylinders segregated from this unit are either valve leak or bung leak. These
segregated cylinders are sent for valve change after evacuation. OK
valves fitted on Bung leak cylinders can later be retrieved through valve
retrieval machine/system.
8.11.5.7 AUTOMATIC VALVE TESTING MACHINE
Automatic valve testing machine is an on-line automatic valve leak and

damaged ‘O’ ring testing equipment. The cylinder detected for the valve
leak / ‘O’ ring damage is also rejected by this equipment automatically to
either a common rejection loop conveyer or separate loop conveyors for
valve leak and O-ring leak cylinders.
Operation : The cylinder enters into the unit on the conveyor and is
automatically positioned under the testing head. The testing head lowers
on to the cylinder valve and test starts as soon as head is engaged to the
cylinder valve fully. Incase there is no leakage the head lifts off after pre-set
time and cylinder is released for further operation. Incase of leak either

DEPARTMENT 8
PAGE No.
from the valve seat or damaged valve ‘O’ ring the head lifts up. For any
leakage, the air/LPG vapor passes through the central capillary and taken
to the pressure transmitter. The pressure transmitter produces an electrical
signal (4-20 milliamps) proportionate to the quantum of leak. As per the
preset values set in the PLC panel, the cylinder will be sorted out according
to the magnitude of the electrical signal and pusher of the unit ejects the
cylinder to the rejection conveyer loop for further identification of the type
of leakage and necessary operation there of.
8.11.5.8 SAFETY CAP MALLETING UNIT
This unit consists of pneumatically operated PVC head and it taps on the
top of the safety cap placed on the valve. This unit is installed before the in
line bath to ensure that capping of the cylinder is done before entering
into water bath.
8.11.5.9 IN-LINE WATER BATH
The filled cylinders are passed through the in-line water bath, dipped up to
the bung level to determine the leakage from the bung and the body. The
facility consists of a water bath made of sheet metal having chain
conveyer for the movement of cylinders inside the bath.
Periodical painting of the interior surface of the water bath with white paint
or cleaning of the white tiles, provision of sufficient lighting arrangement
and periodical changing of water are required to ensure that it is kept
clean for easy detection of the leaks.
8.11.5.10 HOT AIR SEALING:
The cylinder sealing is done by means of PVC seal using hot air. The PVC
seals are placed on the safety caps over which hot air or steam jet is
forced on. The PVC seals shrink and effectively cover the safety cap as a
seal. Portable hot air sealing unit may be provided at plants, in addition to
fixed hot air sealing unit to ensure 100% sealing of sound filled cylinders
before dispatch.

DEPARTMENT 8
PAGE No.
8.11.5.11 RQC (RANDOM QUALITY CONTROL) FACILITY:
The unit consists of on-line check scale and a CVT, installed after the
sealing unit .Filled cylinders ready for dispatch (Minimum 0.5% of saleable
cylinders filled in a shift production ) are checked at random in intervals of
one hour during the shift production. The cylinders after having subjected
to all pre-filling and post filling quality checks, carried out earlier during the
filing operation, including sealing of safety caps are drawn from the
conveyor for the RQC check. The quality of cylinders shall be analyzed for
further corrective action. In any case, the rejection should not exceed
2.25% of the total cylinders checked during RQC.
8.11.5.12 EVACUATION UNITS:
The unit is used for emptying of contents from the LPG cylinders. The
contents are emptied out when cylinder is found leaky, defective or over
filled.
(a) The unit comprises the following.
(i) On line cylinder holding rack with evacuation adapters and anti-
static LPG hoses, having pneumatically operated inverting
mechanism for evacuating the cylinders in inverted position. The
evacuation adopters in the racks are in turn connected to the
evacuation vessels through pipe line manifold. A special adapter is
required for evacuating pin defective cylinders
(ii) Two numbers of evacuation vessels connected to the evacuation

rack storage vessel and LPG compressor through separate manifolds
of liquid and vapor. Two numbers of four way valves are used in this
manifold for LPG liquid and vapor transfer operation. The vessels are
provided with pressure gauge, level indicator, safety valves,high level
alarm etc.
(iii) Storage vessel is connected to the evacuation vessels through

pipeline manifold of four way valve for liquid LPG transfer
.
(iv) As a safety measure, No attempts to be made to drain water from
water filled cylinders received from markets. Such cylinders shall be
evacuated using evacuation unit. LPG with water from evacuation

DEPARTMENT 8
PAGE No.
vessel to be transferred to storage vessel. Water draining to be done

from the concerned storage vessel before taking delivery from the
vessel. Proper records are to be maintained for water filled cylinders
along with distributor and transporter name. Such evacuated
cylinders should be purged before taking them for filling with LPG.
Drain line provided in evacuation vessel should be used for draining

water only during cleaning and hydro testing of
evacuation vessel.
(v) High level alarm switch shall be provided in evacuation vessel and to
be set at 85% with audio-visual alarm and arrangement for change
over of vessels.
(b) LPG compressor for Evacuation:
The suction and discharge side of the compressor is connected to

either of the evacuation vessel through pipeline manifold with a
four way valve, for vapor transfer and pressurization.
(c) Working procedure
The cylinders enter into the rack of the unit in batches depending on
the number of heads on the rack are clamped with evacuation
adopters to the pipe line system either automatically or manually.
The rack gets / is inverted by pneumatic arrangement for
evacuating cylinders. By means of vapor transfer and compression
by the compressor low pressure is created in one vessel & higher
pressure in the other. The vessel at the lower pressure gets
connected to the cylinders at the evacuation rack through the four
way valve and thereby LPG flows to the vessel from the connected
cylinders under evacuation. The vessel at higher pressure gets
connected to storage vessel through the four way valve and there
by product from evacuation vessel is transferred to the storage
vessel due to pressure difference.
Once the receipt vessel from cylinders is filled up to maximum 85%,

configuration of the four way valves is changed either manually or
automatically so that earlier receipt vessel from the cylinder is

DEPARTMENT 8
PAGE No.
connected to storage vessel and delivery vessel shall become the

receipt vessel for evacuated product.
The cylinders are evacuated of their product up to a pressure of 2 to

2.5 Kg/sq cm and then remaining vapor is then flared off by cold
flare arrangement connected to the unit to de-pressurize the
cylinders.
A sight flow indicator is fitted on to the outlet LPG pipeline from the
rack to observe the flow of LPG and ensure emptying of LPG liquid
from the cylinders before de-pressurization.
8.11.5.13 VALVE SCREWING-UNSCREWING MACHINES
(a) Function
The machine consists of a mild steel frame support with a

pneumatically operated cylinder clamp and vertically movable
valve clamping head coupled to a driving unit. The driving unit
consists of air motor or electric motor which drives the head key
through a reduction gear and transmission shaft. By changing the
direction of the rotation of the motor, valve screwing or unscrewing is
achieved. 20 Kgf-,m. +/- 2 Kg.m. torque is applied through the
transmission shaft for tightening the valve. The torque is controlled
automatically either by pneumatic device or electronic logic
controller.
(b) Working Procedure
Before carrying out valve change operation, depressurization of

evacuated cylinder, to be done, using suitable adopters, attached
with suitable cold flare line. The LPG cylinder is placed on the
machine and is clamped by pneumatic actuator. The valve-
clamping head, fixed to the transmission shaft, is then fitted on to the
valve, which is unscrewed by operating the actuator.
After ensuring fitness of the bung thread of the cylinder, valves are
fixed on to the bung with suitable thread sealant. Teflon tapes are
generally used as the thread sealant. Valve should be fitted on
cylinder by using minimum 2 rounds of un-sintered polytetra fluro

DEPARTMENT 8
PAGE No.
ethylene (PTFE) tape of 3/4" (width) , 40 micron thickness conforming

to IS:14643:1999 at the specified torque. . The valves should be
tightened to the desired torque by fixing the clamping head and
operating the actuator or screwing operation. An inter-locking
device in the machine shall ensure that the “On-and-Off-screwing”
can only be started when the LPG cylinder is properly clamped. The
tightness of the valve should be checked by using a torque wrench,
at the beginning of the shift operation and thereafter every two
hours and records for the same to be maintained. For bung leak
cylinders, the cylinder is to be fitted with a new valve with suitable
jointing compound (Teflon tape). If the repaired cylinder, is found
leaking from the bung in the same cycle, cylinder should be
scrapped after evacuation and degassing.
8.11.5.14 VALVE CHANGING UNIT WITHOUT EVACUATION
This unit changes the defective valve with a new valve without evacuation
of LPG liquid from the cylinder. The unit consists of a welded frame with
centering device, a head covering valve and bung, internal shaft (driven
by hydraulic jack to go up and down) to screw and unscrew driven by a
hydraulic motor, hydraulic power station with explosion proof motor and
pneumatic control cabinet.
Operation : The cylinder is properly positioned on the machine by the

operator, the head lowers and holds the cylinder valve. The unscrewing
shaft automatically unscrews the valve and rises up with the valve and at
the same time the dampener seals the head section. The operator
replaces the defective valve with the new valve. The shaft with the new
valve lowers automatically and the flap dampener opens and then the
valve is screwed. The volume of LPG vapour released through cold flaring
during the operation is negligible. Cylinders, after valve change, in the
valve change without evacuation unit, are to be checked for weight and
leak, before dispatch.
The tightness of the valve should be checked by using a torque wrench, at

the beginning of the shift operation and thereafter every two hours and
records for the same to be maintained.

DEPARTMENT 8
PAGE No.
8.11.5.15 DE-GASSING UNIT
A separate shed as per OISD-144 shall be provided for carrying out

degassing of defective cylinders, in case of new plant. The degassing unit
consists of suitable rack arrangement with tilting provision to hold the
cylinders and adopters for filling water with water filling arrangement.
Operation : The unserviceable cylinder shall be evacuated, de-pressurised

and the cylinder valve shall be removed prior to de-gassing. The cylinder
shall be filled fully with water and allowed to over flow and there after shall
be emptied out by inverting the rack. Not more than 6 cylinders are to be
de-gassed at a time. De-gassed cylinders may be checked with
explosimeter for the gas, if any. For degassing operation carried out if any
in the plant, approval from CCOE is to be obtained, It should be ensured
that vapor extraction system is available near the degassing facility and
water drain from the cylinder filling area, where it enters the outside
drainage system is provided with vapor seals as per OISD 144.
8.11.5.16 HYDRAULIC PRESS (DESHAPING UNIT)
All cylinders declared as unserviceable are required to be de-shaped,

after de gassing & pressing, before disposing off the same as scrap. For this
purpose, a hydraulic press is provided which can de-shape the cylinders
by pressing one or more cylinders simultaneously depending upon the type
and size of the machine. The machine works on hydraulic principle and has
minimum capacity of 300/350 MT. The pressing of the cylinders should not
be done through the vertical axis.
8.12 OPERATIONS - LPG CYLINDERS
Primary and Secondary operations at bottling plants are described in the

following paragraphs.. The sequence of primary operations described
below pertains to filling operation in LPG bottling plants

DEPARTMENT 8
PAGE No.
8.12.1 SEQUENCE OF PRIMARY OPERATIONS
8.12.1.1 RECEIPT OF CYLINDERS
(a) Incoming cylinders fall into following categories:
i. New cylinders from the manufactures.

ii. Cylinders in circulation from the distributors (empty, under-filled,
defective).
iii. Cylinders received from the statutory testing plants, duly
tested.
iv. Hot repaired cylinders received from the approved repairers.
(b) All cylinders received should be verified against valid

documents and the actual receipt should be tallied with the details
on the relevant documents and the shortages or any other
shortcomings should be endorsed and certified on the body of the
document.
(c) All new cylinders received should be supported by test

certificates issued by BIS inspecting officers
(d) The defective returns from the distributors may be classified in two
categories as under :
i. Return through the same truck : The defective cylinders identified

by the distributor after unloading (Under filled / over filled / Bung
leak / Body leak) are returned in the same truck to the plant with
the required documentation as specified in the back of the
invoice. For such cylinders the seals should be intact and the
condition of the seals should be recorded.
ii. Subsequent defective returns : Subsequent defective returns such

as valve leak and ’O’ ring defect which are checked after
breaking the seals are certified by the Field Officers or Area
Manager. For effecting credit to defective cylinders, less than 13
kg weight, certification from Area Manager is required

DEPARTMENT 8
PAGE No.
8.12.1.2 VISUAL INSPECTION/SEGREGATION – I
On line detailed visual inspection shall be carried out during

receipt/unloading of cylinders at Plant
(a) Based on visual inspection, cylinders should be segregated as

under :
i. Cylinders due for statutory testing (to be sent to statutory testing

plant).
ii. Under-filled cylinders received from the distributors, duly
tagged.( for further correction)
iii. Leaky / defective cylinders received from the distributors duly
tagged ( For further operation)
iv. Spurious cylinders (for investigation/scrapping).
v. Cylinders found unfit for filling (beyond repairs) on visual
inspection (e.g. heavily rusted or heavily dented etc. for de-
shaping and disposal as scrap).
vi. Cylinders found defective, but repairable such as
 Cylinders having damaged valve spindle

 Cylinders having broken / bent foot rings / valve
protection rings (to be segregated for cold / hot
repairs depending upon the condition and those found
unfit after close examination, are rejected as unservicable).
vii. Cylinders owned by Other Marketing Companies (OMC),
wrongly mixed with IOC’s cylinders (to be segregated for
exchanging with OMC).
viii. Empty cylinders fit for filling. (To be allowed for filling).
ix. Cylinders to be checked physically for presence of O ring. New O
ring to be provided, if O ring is missing in cylinders.
(b) Rejection criteria guidelines for physical and material defects on the
cylinder are given in Table 1 to Table 3 as per IS 15966:2013.

DEPARTMENT 8
PAGE No.
(c) Under-filled cylinders received from the distributors should be

weighed to verify the extent of the under-filling. It should be ensured
that the cylinders are having seals intact on the safety caps when
received and shall be corrected at the correction unit.
(d) Reasons for leaky/defective cylinders received from the distributors

should be verified from the tag attached to the cylinder. These
cylinders should be corrected.
(e) (Extra care should be exercised to check for spurious cylinders and
efforts be made to identify the source of receipt. Spurious cylinders
must be segregated for scrapping.
(f) New cylinders or cylinders received from statutory testing plants or

hot repair plants or any cylinder which has undergone pneumatic
test must be purged as per Purging Procedure.
(g) Cylinders due for statutory testing / hot repairs MUST not be taken up
for filling but sent to testing plant.
(h) Cylinders without proper markings or without serial number should

not be taken up for filling and should be declared as spurious.
(i) Cylinders of OMCs, unless specifically sent for filling, should not be
taken up for filling but segregated for exchange with the concerned
marketing company.
(j) At the time of visual inspection during unloading, check should be

made for shortage of safety caps. Shortage of safety caps, if any,
should be recorded and acknowledged by the driver for deduction
from the transportation bill.

DEPARTMENT 8
PAGE No.
Table 1 Physical Defects In the Cylinder Wall
S/No. Defects Description Rejection Limit
1 Bulge Visible swelling of the cylinder Rejection in all cases

2 Dent Depression in the cylinder that has a) Depth of dent is greater
neither penetrated nor removed than 1/10th of the mean
the metal and its width at any diameter of the dent
point is greater than 2 percent of OR
external cylinder diameter b) Mean diameter of the
dent is greater than one-
quarter of the diameter of
cylinder OR
c) Dent on or adjacent to
weld
3 Cut or Sharp impression where metal has 75mm or more in length or
intersection been removed or redistributed when the depth of cut is
such that the undamaged
(remaining) wall thickness is
less than the minimum
calculated wall thickness
4 Intersecting cut Point of intersection of two or more Rejection in all cases
or gouge cuts or gouge
5 Dent containing Depression in the cylinder within When the size of dent or cut
cut which there is cut or gouge or gouge exceeds the
dimension for rejection as an
individual defect
6 Crack A split or rift in the cylinder shell Rejection in all cases
7 Lamination Layering of the material within the Rejection in all cases
cylinder wall appearing as a
discontinuity, crack. Lap or bulge
at the surface
8 Dig A sharp depression where the 75mm or more in length and
surface material has been 4mm or more in width
penetrated

DEPARTMENT 8
PAGE No.
Table 2 Corrosion Defects In the Cylinder Wall
1 Isolated Pitting of metal occurring in Depth of penetration of any

corrosion pits isolated areas at a concentration pit exceeds 0.4mm1)
not greater than 1pit / 500mm2 of
surface area
2 Area corrosion Reduction in wall thickness over an Depth of penetration of any
area not exceeding 20 pit exceeds 0.4mm1)
percent of the cylinder surface
including the ends (top and
bottom)
3 General Reduction in wall thickness over an Rejection in all the cases
corrosion area exceeding 20 percent of the
cylinder surface
4 Line corrosion Series of pits or corroded cavities of
a) Total length of corrosion in
limited width along the length or any direction exceeds 50
around corrosion circumference percent of the
circumference of the
cylinder
b) Depth of penetration
exceeds 0.4mm1)
c) Depth of corrosion cannot
be measured
5 Crevice Crevice corrosion occurs in the When the depth of
corrosion area of the intersection of the foot penetration exceeds 0.4mm
ring or stay plate with the cylinder or when the depth of
corrosion cannot be
measured1)
Cylinder shall be rejected in case the observed thickness of the damaged remaining wall in
the affected portion is less than the minimum calculated wall thickness

DEPARTMENT 8
PAGE No.
Table 3 Other Defects

(Clause 5)
1 Depressed bung Damage to the bung which alters Rejection in all cases
the profile of the cylinder
Arc or torch Burning of the cylinder base metal , Rejection in all cases
burns a hardened heat affected zone ,
the addition of extraneous weld
metal, or removal of metal by
scarfing or catering
Fire damage Excessive general or localised Rejection in all cases
heating of the cylinder usually
indicated by: a)
Charring or burning of paint1)
b) Fire damage of the metal
c) Distortion of the cylinder
d) Melting of metallic valve parts
-
e) Melting of safety cap
1) In case of superficial charring of paint cylinder may be accepted.
BIS code “IS 15966:2013 – Refillable Welded steel Cylinder for LPG-
Procedure for checking before, during and after filling” shall also be
referred.
8.12.1.3 PREPARING CYLINDERS FOR FILLING
(a) The cylinders are passed through online washing and drying unit for
washing.
(b) Safety cap of the cylinder is removed only after the cylinder passes
through the washing and drying unit as the entry of the water inside
may damage the internals of the valve. It must be ensured that
cylinder is introduced to the filling machine only after removal of
safety cap.
8.12.1.4 TARE WEIGHT MARKING
(a) Wherever the tare weight stenciling is not legible on the cylinder
shoulder, tare weight is marked with a chalk on the cylinder shoulder

DEPARTMENT 8
PAGE No.
after checking the punched tare weight marking on the cylinder

stay.
(b) For accuracy of filling, the marking of correct and accurate tare
weight on the cylinder body is essential. To verify the accuracy of
the cylinder tare weight the new cylinders received at the plant
should be checked for their tare weights marked / stenciled on the
cylinder. In case discrepancies are observed in a particular lot, the
lot should be kept segregated and the matter should be reported to
the HO LPG Department.(Materials) for arranging inspection /
corrective action by the concerned cylinder manufacturers.
8.12.1.5 FILLING OPERATION
Filling of cylinders are under taken either on Carousel or on Unit Filling

Machine (UFM)
(i) Cylinder is introduced in the carousel or unit filling machine.

(ii) Filling head is fixed either manually or automatically on to the
valve.
(iii) Tare weight of the cylinder is set on the machine/punched through
tare weight punching station or alternately through camera readers
(iv) Filling Commences
(v) Auto detachment of filling head takes place after completing
Filling
(vi) Cylinder ejected out automatically from the carousel/ UFM
.
8.12.1.6 CHECK WEIGHING-POST FILLING OPERATION / INSPECTION
(a) All filled cylinders coming out of the carousel are weighed for
ensuring 100% check weighing.
(b) Check-scale in use should be certified by the Department legal

Metrology. Further accuracy of the check scale should be checked
by using standard weights at the beginning of the shift and at
intervals of two hours during the shift operation and records should
be maintained for the above.

DEPARTMENT 8
PAGE No.
(c) In case of change in composition of LPG to be filled in the cylinders,

the correct weight of the product that can be safely filled should be
worked out.
(d) Over-filling, if not detected, subjects the cylinders to very high

pressure (Due to Increase in the ambient temperature, the liquid in
the cylinder will expand and high pressure developed may at times
lead to bursting of the cylinders): The danger point reaches when
the liquid expands to occupy fully the volumetric capacity of the
cylinder leaving no vapour space. Once this point is reached there
will be a pressure rise inside the cylinder at the rate of 14 to 15
kg/cm2 for every degree increase in temperature.
(e) Over-filled cylinders must be sent for immediate correction of excess

quantity.
(f) Filling machines on the carousal in the plant are serially numbered.
Accuracy of each electronic filling machine should be checked at
the check scale at the beginning of each shift and subsequently
every four hours during the shift operation and recorded..
Alternatively, print out of filling machine accuracy to be taken from
control room PC for review and corrective action, However, if data
logging is not provided/working the format has to be maintained
manually for corrective action. This process helps to detect any
filling machine giving incorrect quantity and necessary corrective
action is taken from time to time to adjust the machine for giving
correct quantity.
(g) A daily record should be maintained for under filled and over filled
cylinders generated in each operating shift.
8.12.1.7 SEGREGATION – I
Cylinders rejected at check-weighing scale are segregated for removal of

excess gas / topping up as the case may be.

DEPARTMENT 8
PAGE No.
8.12.1.8 SEGREGATION- II
Segregation is carried out for the following categories of leaks.
a. ‘O’ ring damage is identified at AVTS / “O” Ring leak detector .For
the defective ‘O’rings identified, “O” rings are replaced with new
ones by “O” ring fixing tool and further subjected to test by AVTS.
b. Leak through valve seats is identified at AVTS and Valve Leak

cylinders are sent for replacement of valves.
c. Leakage through bung joints is identified at inline water bath / leak
detectors. Cylinders having leaks through bung joints are
segregated and sent for valve change .
d. Leakage from the cylinder body, either from the parent metal or
from the weld joints is identified at water bath and such cylinders
are sent for evacuation.
e. Daily shift wise record of leaky cylinders generated should be
maintained.
f. Suitable tags / markers should be used to identify different
categories of leaky cylinders.
g. Valve defective cylinders should be capped with safety
caps until they are evacuated.
h. Body leak and bung leak cylinders should be evacuated on priority
at the earliest.
i. Stock of leaky cylinders at the end of the shift should be
maintained nil.
8.12.1.9 SEALING AND DESPATCH OF CYLINDERS
The sound filled cylinders, passed through all quality control checks, are
then sealed at the sealing unit. As per Packaged Commodity Rules 1977,
Retail Selling Price (RSP) and Month & Year of Packaging to be mentioned
on all Non - Domestic cylinder. At this stage the cylinders are ready for
dispatch.
(I) The cylinders can be directly loaded to the stake trucks.

(II) If no stake-truck is available, the cylinders can be stacked in the
area earmarked for the purpose of storing filled cylinders.

DEPARTMENT 8
PAGE No.
8.12.2 SECONDARY OPERATIONS
8.12.2.1 PURGING
Cylinders falling into any of the following categories require purging :
(I) New cylinders received from the manufacturers.

(II) Cylinders received from statutory testing plant after testing.
(III) Cylinders received from the repairers after hot repairs.
(I) Any other cylinders that may be suspected to contain air.
Purging of cylinders is undertaken to purge air from the cylinders. If the air is
not removed from the cylinders, LPG being heavier will settle down at the
bottom of the cylinder and the air will remain at the top. During the initial
operation of the pressure regulator, only air will be released from the
cylinder and the burner will not get ignited. There is every possibility that the
consumer under the false impression may keep the regulator and burner in
open position, thereby allowing LPG to spread in the surrounding area
which may result into fire accident when get ignited.
The air is sucked from the cylinder by means of a vacuum pump and the
pressure inside the cylinder comes down below the atmospheric pressure
0.35 kg /cm2 absolute= (-)0.65 kg/cm2(g)) . The cylinder then immediately
filled with LPG vapour to bring it back to at least atmospheric pressure (i.e.
a pressure of 1.035 kg / cm2). In this process, the entire cylinder space is
occupied with LPG vapour.
8.12.2.2 STATUATORY TESTING / HOT REPAIR : (For details refer Chapter No. 9)
Cylinders segregated for statutory testing and hot repairs should be sent to
the testing plant. Record of cylinders sent to the testing plant should be
maintained.
8.12.2.3 DISPOSAL OF CYLINDERS WITH BODY LEAK
(a) Body leak cylinders segregated at any stage of primary operations

can be classified as under :
 Leaking through the weld joint.
 Leaking through the parent metal of cylinder body.

DEPARTMENT 8
PAGE No.
In both the cases the cylinders must be evacuated immediately.
(b) Leaky spot should be circled using paint for easier Identification
subsequently
(c) In case of a body leak during the first filling of new cylinders, it should
be segregated and the matter be referred to HO LPG Department
(Materials) for further action. Such cylinders should be scrapped only
after the investigation is over.
(d) In case of cylinders in circulation, if the body leak is observed

through the parent metal, such cylinders should be segregated for
detailed inspection and scrapping.
(e) Cylinders leaking through the welded joints should be segregated

and scrapped.
(f) All the leaky cylinders must be evacuated before the close of
working hours.
(g) Detailed record of cylinders having body leaks should be maintained

for each shift.
8.12.2.4 DISPOSAL OF CYLINDERS WITH OTHER DEFECTS
(a) Cylinders with other defects like, foot-ring (bent/broken), valve

protection ring (bent / broken), body damage ( dent / cut / pitting)
etc., should be segregated for cold / hot repairs depending upon the
condition.
(b) Shift wise record of the defective cylinders should be maintained.
8.12.2.5 REJECTION
(a) Detailed record of all the cylinders rejected should be maintained in

a register form or in the PC.
(b) Following minimum details must be available :


DEPARTMENT 8
PAGE No.
 Serial No.
 Date rejected.
 Manufacturer’s Code / Name.
 Date of Manufacture.
 Reasons for Rejection.
8.12.2.6 EVACUATION :
1. Evacuation procedure will depend on the type of equipment provided.

Therefore, the Manufacturer’s manual should be referred for operating
instructions.
2. Cylinders profusely leaking and over-filled cylinders should get

preference for evacuation over other cylinders.
3. Category-wise record of total number of cylinders evacuated during

each shift should be maintained.
4. Evacuation of over-filled and leaky cylinders must be completed before

end of the working hours. However, if any defective valve leak cylinders
are left at the day end, they should be capped.
8.12.2.7 COLD REPAIR OF CYLINDERS
The valve leak and bung leak cylinders are repaired as under :
a. Cold Repair of Valve leak cylinders : The valve is replaced on screw/

unscrew machine at cold repair shed or valve change without
evacuation machine at Filling Shed .
The valve is tightened upto a torque of 20 Kgf-m +/- 2 Kgf-m by the

valve screw / unscrew machine where the specified torque limit is
adjusted either by pneumatic control or by electronic control.
The torque limit (20 Kg-M. +/- 2Kg-M.) set on screw / unscrew machine
should be verified by using a torque wrench at the beginning of the shift
and every two hours thereafter.

DEPARTMENT 8
PAGE No.
The cylinders identified for the bung thread defects should be

segregated, recorded and further declared as scrap.
b. Cold Repair of Bung leak cylinder : For bung leak cylinders, the cylinder
is to be fitted with a new valve with suitable jointing compound (Teflon
tape). If the repaired cylinder, is found leaking from the bung in the
same cycle, cylinder should be scrapped after evacuation and
degassing.
8.12.2.8 CYLINDER VALVE RETRIEVAL
Impregnation of foreign materials / dust on the valve seat shall lead to

leakage from the valve. Valve retrieval operation is carried out with the
objective of cleaning /clearing such foreign materials. The defective valves
taken out from the cylinders are subjected to cleaning in an Ultrasonic
Valve Cleaning Equipment / LERC developed Valve Retrieval Machine
followed by testing them on a test bench with air pressure of 7 Kg/sq cm.
and using CVT.
8.12.2.9 DE-GASSING OF CYLINDERS
If the cylinders are identified as unserviceable during the operation, the

same should be degassed. The unserviceable cylinders shall be evacuated
and de-pressurised and the valves are removed from the cylinders after
de-gassing. The concerned cylinder shall be filled fully with water and
allowed to overflow and thereafter shall be emptied out by inverting the
cylinders. More than six cylinders should not be de-gassed at time.
8.12.2.10 DE-SHAPING / DISPOSAL OF SCRAP CYLINDERS:
Cylinders identified as unserviceable are de-gassed after removal of the

valves. The said cylinders then should be certified by an authorized
committee as scrap . The cylinders declared as scrap are de-shaped by
using a hydraulic press. Details of the cylinders with reasons for scrapping
are to be recorded prior to de-shaping and markings on the stays and the
foot rings are to be de-faced or ground off. Cylinder wise record should be
maintained for the cylinders de-shaped. The de-shaped cylinders shall be
disposed off as scrap .

DEPARTMENT 8
PAGE No.
8.12.2.11 CONDEMNING OF CYLINDERS
Any cylinder which fails to pass periodic examination or test or which loses
in its tare weight by over 5 per cent or which for any other defect is found
to be unsafe for use , shall not be filled with any compressed gas and shall
be destroyed by flattening it as a whole or after being cut into pieces in
such a manner that the pieces cannot again be joined together by
welding or otherwise to form a cylinder, under intimation to the owner of
the cylinder, as specified in IS:8198. History sheets or records of such
cylinders shall be closed and records maintained. Reports of the details of
such closed history cards or records shall be sent to the Chief Controller, in
writing, on the 1st of January, April, July and October every year.
8.12.2.12 DE-SHAPING/ DISPOSAL OF SCRAP VALVES & PRESSURE REGULATORS:
Valves and pressure regulators identified as unserviceable are stored in lots.

The said equipment should be certified by an authorized committee as
scrap. The threaded portions of the valves declared as scrap are then de-
shaped by suitable hammer. The nozzle of the pressure regulator should be
de shaped by using a suitable hammer. Records should be maintained for
the valves and the pressure regulators de-shaped as scrap.
8.12.3 HANDLING AND STORAGE OF CYLINDERS
8.12.3.1 HANDLING
a) Handling and storage of LPG cylinders, whether empty or full, are

covered under the Gas Cylinder Rules 2004 and its subsequent
amendments . Therefore, all applicable rules and regulation MUST be
complied with. The following may be noted.
Competent person to be in-charge of operations - Every person

holding or acting under a license granted under these rules, shall,
whenever cylinders are filled, loaded, unloaded, examined or tested,
depute a competent and experienced person to be present and to
conduct any of the said operations in accordance with provisions of
these rules and the name, qualification and experience of such
personnel deputed in each shift shall be furnished to the Chief
Controller or Controller for considering filling permission round the
clock.

DEPARTMENT 8
PAGE No.
Owner’s record:-The owner of a cylinder shall keep for the life of each
cylinder, a record containing the following information regarding each
cylinder, namely:-
i. Cylinder manufacturer’s name and the rotation number;

ii. The specification number to which the cylinder is
manufactured;
iii. The original hydrostatic test or hydrostatic stretch
iv. Cylinder manufacturer’s test and inspection certificates;
v. Number and date of letter of approval granted by the Chief
Controller.
b) Under the statutory rules referred to above, separate license for the
plant is required for filling and storage of LPG cylinders.
c) The cylinder life is considerably enhanced if the cylinders are handled

properly as described in subsequent clauses.
d) Improper handling of cylinders not only reduces the life of the cylinders
but also creates safety hazards.
8.12.3.1.1 GENERAL GUIDELINES FOR HANDLING
a. Filled cylinders must be handled in the vertical position at all stages of

operations and handling.
b. Cylinders must be handled with due care at all times, avoiding

damage to the cylinders and the cylinder valves fixed on to it.
c. Belly rolling of cylinders either filled or empty is strictly prohibited.
d. No attempt should be made to heat the cylinders for normal operation.
e. The safety cap should not be removed from the cylinder valve until the
cylinder is taken up for filling or any other operation. The same should
be refitted as soon as the operation is over. Safety cap should be fitted
while the cylinders are passed through the washing unit.
f. Tests for suspected leaks must never be made with naked flame.

DEPARTMENT 8
PAGE No.
g. For all practical purposes, empty cylinders must receive same care and
attention as given to filled cylinders while handling.
h. Manual handling of the cylinder should be minimised as far as

practicable. To achieve this, a proper conveyor layout should be
designed and installed in the plant so that most of the operations
pertaining to cylinders (from receipt to delivery) are carried out with
the cylinders on the conveyor. However, if not possible to move the
cylinders on the conveyor, portable trolleys should be used.
i. Cylinders shall never be thrown from a height even though sufficient

padding on the floor is available.
8.12.3.1.2 HANDLING DURING LOADING AND UNLOADING OPERATIONS
a. General
i. Cylinders must be loaded/unloaded without dropping them or

subjecting them to any shock
ii. Telescopic conveyors should be used for this purpose, wherever

provided.
iii. The operations can be carried out after sun set hours also with
adequate Illumination and with the approval from CCOE.
b. Loading Operations – Filled / empty cylinders
i. At the time of loading, precautions should be taken as detailed

earlier.
ii. Filled cylinders must be stacked in vertical position in stake trucks.
iii. Stacking of cylinders in truck in vertical position should be maximum
3 high ensuring that the maximum height and overall gross weight of
the truck does not exceed the Registered Laden Weight (RLW) fixed
by Regional Transport Officer (RTO) or any other local road
restrictions en route.
iv. Empty cylinders in a stake truck can be loaded vertically maximum
3 high or horizontally 5 high max. (new cylinders only) ensuring that
the overall height of the loaded truck and the total gross weight do

DEPARTMENT 8
PAGE No.
not exceed the RLW fixed by R.T.O. and other local road restrictions
en route.
v. Cylinders must not be subjected to rough handling.
c. Unloading operations – filled / empty cylinders
i. Cylinders should be handled in such a way, avoiding dropping or

subjecting them to shocks or rolling inside the truck or on the
ground.
ii. Visual checks should be made to detect:

 spurious cylinders.
 damaged cylinders.
 missing items, such as safety caps.
8.12.3.2 STORAGE OF CYLINDERS
8.12.3.2.1 General Guidelines for Storage of cylinders :
a) Valves of all cylinders stored in the plant should be capped with

safety caps.
b) LPG cylinders should be stored in a covered shed or a godown, duly

licensed by CCOE in earmarked cylinder stacks.
c) The storage area should be cool, dry, well ventilated, covered and
away from any potential source of heat. The area should also be
easily accessible
d) The quantity of empty serviceable cylinders and filled cylinders stored

in the sheds at any point of time should not exceed the designed
capacity of the area of the shed as per the license condition of
CCOE. In particular, inventory of the filled cylinders MUST not exceed
the licensed capacity for the plant issued by CCOE under any
circumstances.
e) There should be different storage areas (stack marks) earmarked for

different categories of cylinders such as :

DEPARTMENT 8
PAGE No.
i. Filled cylinders :
 Filled Cylinders ready for despatch.

 Over-filled/Under-filled cylinders awaiting correction.
 Cylinders with valve leak / bung leak / body leak.
ii. Empty Cylinders :
 Serviceable cylinders.
 Segregated for statutory testing.
 Segregated for hot repairs
 Defective empty cylinders awaiting cold repairs.
 Defective/spurious cylinders for scrapping.
 New cylinders.
 ST repaired / HR returned cylinders
f) All the filled cylinders MUST be stacked vertically with the exception
of body leak cylinders which may be temporarily laid horizontally.
However, this should not be done in the case of cylinders having
leakage through bungs or valves. These cylinders are to kept
vertically since the escape of LPG will be of vapour and not the
liquid as leakage of liquid LPG is more hazardous compared to
vapour leakage as explained earlier. Such cylinders, however, must
be evacuated on priority.
g) For the cylinders segregated as scrap, the valves should be removed

after degassing and returned to Stores.
h) For the reason of stability during storage, cylinders whether filled or

empty should be stacked only two highs. Empty cylinders with valve
removed or in open position should not be kept in the storage, with
out a suitable plug, as the moisture/dirt will get accumulated inside
the cylinders and render them hazardous. Besides, life span of the
cylinders will get reduced as a result of possible rusting of the interior
wall by direct exposure to the atmosphere.
i) In case removal of valve is essential for longer periods, the bung hole
must be covered with a suitable plug taking all precautions to ensure
that the internal threads of the bung are not damaged ,due to
corrosion.

DEPARTMENT 8
PAGE No.
j) Basically the cylinder storage should be such that each cylinder is

easily accessible at all times so that any leaky cylinder can be
detected easily and speedily removed from the stack for corrective
action. To achieve this, the stack should comprise of small lots of 4
rows with 25 cylinders in each row in two highs. Minimum access
pathway of one metre wide must be maintained on both sides of the
4 rows and 2 meters after every 5 such lots. After each length of 25
cylinders there must be a passage of 2 meters. The stack areas must
be properly marked/painted on the flooring. In addition two metres
clear distance should be maintained from edges of the shed, edges
of conveyer and from the equipment.
k) Each stack should be clearly marked with sign boards indicating

the type of cylinders in the stack.
8.12.3.2.2 STORAGE OF FILLED CYLINDERS (sound)
The filled cylinders should be stored at the plant in filled cylinder storage
shed in lots only in two highs as mentioned earlier.
8.12.3.2.3 STORAGE OF DEFECTIVE FILLED CYLINDERS
a. Leaky cylinders
i. Cylinders with body leak, bung leak and valve leak fall into this
category. Cylinders should be properly identified with a marker
indicating the type of leak.
ii. Contents from all leaky cylinders should be evacuated at the earliest
giving preference to those which are leaking profusely.
iii. For unavoidable reasons, if leaky cylinders are required to be stored on

the floor, they must be stored on nominated area and stack in single
tier.
iv. No leaky cylinder should be left in leaky condition at the end of the
working hours.

DEPARTMENT 8
PAGE No.
b. Defective filled cylinders without leakage
i. Cylinders with damaged foot ring, damaged stay or valve

protection ring, and heavy dent, cut or corrosion fall in this category.
ii. Such cylinders should be stacked in the same manner as filled sound
cylinders described above, with the exception that the stack should
be limited to a single tier.
iii. The contents from the cylinder should be evacuated at the earliest.
Efforts to be made to rectify the stay bend/foot ring/VP ring

damaged cylinder through stay bend/Foot ring/VP ring rectification
unit so as to reduce the cylinders due for HR and to improve the
quality. Cylinders which cannot be repaired as above at Plant,
should be sent for hot repair and if irrepairable, these cylinders should
be degassed and scrapped recording the nature of defects.
8.12.3.2.4 STORAGE OF EMPTY CYLINDERS (sound)
(a) New cylinders
i. The new cylinders can be stacked vertically in 4 rows of 25 cylinders

each in 2 highs.
ii. The new cylinders may be stored in open in a stack of 200 cylinders of
5 high (horizontally), If specified area (concrete yard) is provided in
the layout for the purpose. If no yard is available, suitable drainage
should be provided on the bottom row, to avoid stagnation of rain
water and corrosion to the cylinders. However it is advised not to
store the new cylinders in open area for a longer period and the
cylinders should be consumed on ‘FIRST IN FIRST OUT’ basis.
iii. Passage between each stack, whether stored in the covered shed or
in the open, should be left as per the standard stack arrangement,
already mentioned above.

DEPARTMENT 8
PAGE No.
(b) Serviceable Empty Cylinders
i. All the serviceable empty cylinders should be stored in the covered

shed and only in the demarcated areas. Storing in the open area is
NOT allowed.
ii. These should be stored vertically only as per standard stack

arrangement given above. The stacking should be maximum 2 high.
8.12.3.2.5 STORAGE FOR STATUTORY TESTING (Cold / Hot repairs)
Empty cylinders segregated for statutory testing should be stored in a

similar way as serviceable cylinders in circulation described above.
Adequate space in the covered shed should be provided for this purpose
and the stack should be properly identified with a sign board.
8.12.3.2.6 STORAGE OF EMPTY CYLINDERS AWAITING REPAIRS (Cold / Hot

repairs)
(a) Each cylinder should be properly marked and tagged to indicate

the nature of defect.
(b) The cylinders due for hot repairs should be stacked in demarcated
area as per standard stack arrangement and sign board should be
displayed.
8.12.3.2.7 STORAGE OF CYLINDERS IDENTIFIED FOR SCRAPPING
(a) The valve should be removed from the cylinders identified as scrap
and the cylinders should be made gas-free immediately thereafter
and before stacking.
(b) Once the cylinders are made gas free, they can be stored in open
in horizontal stacks as in the case of new empty cylinders as
described above.

DEPARTMENT 8
PAGE No.
8.12.4 TRANSPORTATION OF LPG CYLINDERS
8.12.4.1 GENERAL
(a) There are basically two modes of inland transportation :
(i) By rail through covered box wagons.
(ii) By road through stake trucks.
Transportation of the empty as well as the filled cylinders in general and

between the plant and the distributors in particular should be done
through road only. Rail transport is resorted to only on selective basis in the
following case :
i) Movement of new cylinders from the Manufacturers to the plant.

ii) Transportation of the filled cylinders should not be done by rail as it
involves serious fire hazards
iii) Transportation of all LPG cylinders is governed by the Gas Cylinder
Rules 2004, therefore, all relevant rules MUST be complied with.
8.12.4.2 BASIC REQUIREMENTS OF TRUCKS
The stake truck deployed for transportation of LPG cylinders, whether filled
or empty, should meet with the following requirements :
a. Trucks should have suitable carrying capacity as per RTO guidelines, as

per IOC’s requirement.
b. The truck cage should be strongly constructed and should be

maintained in good condition. The sides and back of the truck should
be of adequate height to ensure that the cylinders do not project out.
c. The truck should be caged with locking arrangement.
d. Exhaust pipe should be re-routed towards the front driver side and
should be welded with a spark arrestor of CCOE approved quality
make and design.

DEPARTMENT 8
PAGE No.
e. Batteries should not be positioned outside the cabin.
f. The floor of the truck should be wooden in construction, provided with

adequate number of breather holes.
g. Floor of the truck body should not contain protruded nails or any other
objects which can cause a spark or damage to the cylinders
h. Every truck should carry minimum two numbers of 10 kg DCP type fire
extinguishers of BIS approved quality.
i. Master cut off switch should be provided in the cabin of the truck in a
easily accessible position.
j. No loose electrical wiring should be allowed.
k. Diesel tank should be adequately guarded by metal frames and the

tank cap should be kept in locked condition.
l. The driver should possess valid license with RTO’s endorsement /

permission for driving hazardous goods vehicle.
m. Cylinder shall be adequately secured to prevent their falling off the

vehicle and being subject to rough handling/ excessive shocks or Local
stress
n. The LPG cylinders shall always be transported and kept in the up-right
position and shall be so placed that these cannot be knocked over
8.12.4.3 PRECAUTIONS WHILE LOADING
(a) The loading operation should be supervised.
(b) The truck unloading should be done meeting all safety

requirements.
(c) The truck MUST be parked minimum 15 metre away from the filled or
empty cylinder shed within the plant.
(d) After the truck is properly positioned, the engine should be put off
and ignition key is removed. The lights and electrical switches should

DEPARTMENT 8
PAGE No.
be switched off by isolating the power through master cut off switch.
The truck should be positioned in gear & hand brakes should be
applied
(e) Fire extinguishers should be positioned on the ground near the truck
for ready access of operation in case of emergency. Driver should be
available all along the loading operations.
(f) While loading filled cylinders, it should be ensured that
i. The cylinder is in apparent good condition and reasonably clean.

ii. Safety caps are fixed on cylinder valves and properly sealed.
iii. Neck labels are fixed on to the cylinders, as per Gas Cylinder Rules
2004. Neck lables shall include the following details . Name of
gas and name & address of person who filled the gas; A
warning shall be attached to the cylinder as below. Do not
change the color of this cylinder, This cylinder not to be filled with
any other gas, No flammable material should be kept in the
vicinity of the cylinder or in the same room, where this cylinder is
kept, No oil or similar lubricant should be used, on the valves or
other fittings of this cylinder, Please look for the next date of test
and if this date is over, do not accept the cylinders for filling.
(g) Cylinders must not be thrown, dropped or dragged or rolled
(h) All filled cylinders should be stacked vertically. The stacking of

cylinders should be compact to prevent slipping, shifting and falling
of cylinders. The cylinder stack should be properly secured to prevent
rolling or shifting during transit.
(i) The cylinders, whether filled or empty, should not project above or
beyond the sides or ends of cage of the truck.
(j) After loading is over, check should be made for the leakage of the
gas with the help of Explosimeter and the truck should be released
after endorsing on the challan as ‘NIL leakage observed’. In case of
any suspected leakage, the leaky cylinders should be segregated
and replaced with sound cylinders.
(k) The cylinder stacks should be secured with wooden crossbars so as to

prevent movement or falling of cylinders during transit.

DEPARTMENT 8
PAGE No.
(l) Loading of cylinders should be done with the help of Telescopic

conveyors, wherever provided.
8.12.4.4 PRECAUTIONS DURING TRANSIT
(a) No person, other than the driver and the helper, should travel in the
truck.
(b) ‘SMOKING’, and ‘COOKING’ of food etc, MUST NOT be done in and
around the truck. No person should ride over the cylinders.
(c) The speed limit of vehicles should not exceed 40 kms. per hour. If a
lower limit of speed is enforced by Road Transport Authority or any
other Government body, the same MUST be observed.
(d) The truck should not be parked in congested area during transit.
(e) Other goods should not be carried in the truck along with LPG
cylinders.
(f) The truck should be constantly attended by at least 2 persons, one of

which should know driving and should have a valid driving license.
The truck crew should have basic knowledge of :
(g) Fire hazards involved in LPG cylinder handling / transportation.
(h) Handling associated emergencies.
(i) Minimum 2 Nos. of 10 kg. BIS approved DCP type fire extinguishers
should be carried in a truck in an easily accessible position (one on
either side).
(j) Fire, artificial light, or any item capable of producing fire or explosion
MUST not be taken or carried in the truck.
(k) In the event of overnight stop en route prior arrangement shall be

made for safe parking of the truck. In an emergency, the driver may
seek co-operation of local Police Authorities in finding a suitable
parking place for the truck.

DEPARTMENT 8
PAGE No.
(l) Whenever roads or weather conditions are such that there is any
doubt with regard to the safe completion of the trip, the vehicle may
be parked safely or alternate safer route may be followed.
(m) In case of an accident during transit, applicable safety precautions

as described in Chapter No.7 should be followed.
8.12.4.5 PRECAUTIONS DURING UNLOADING
a. The truck MUST be parked minimum 15 meters away from the edge of
filled or empty cylinder shed.
b. After the truck is properly positioned, the engine should be put off
and ignition key removed. The lights and electrical switches should
be switched off by isolating the power through the master switch. The
truck should be positioned in gear and hand brakes should be
applied.
c. The cylinders must not be thrown, dragged, dropped or rolled along

the floor. Wherever telescopic conveyors are provided the same
should be used for unloading operations.
d. In case the filled cylinders are received at the plant from other
locations, visual inspection should be made to ensure that the
cylinders received are apparently in good condition. Wherever safety
caps are to found to be missing, quantity of short receipt of safety
caps should be recorded in the relevant challan.
e. In case of unloading of filled cylinders (defective return from the

distributors), the cylinders should be taken for immediate evacuation.
f. In case of unloading of empty cylinders at the plant, visual inspection

should be made as detailed in Chapter No.10 and the cylinders
suitably segregated into various categories as described therein.
During the visual inspection, particular attention should be paid to :
i. Identification of spurious OMC and dented cylinders

ii. Shortage of safety caps.

DEPARTMENT 8
PAGE No.
8.12.4.6 LEAKY CYLINDERS
(a) In case any cylinder develops leak during transit, the vehicle should
be promptly taken to an isolated open place away from the sources
of ignition. Leaky cylinders should be identified and segregated.
(b) Attempt should be made to stop the leak, if possible.
8.13 OTHER OPERATIONS
a. Safe operation of equipment is essential, in view of the safety of

operating personnel and health of the equipment.
b. Special attention is required in maintaining the flame proof condition

of electrical equipment and systems.
c. Earthing of electrical equipment and bonding of equipment should

be ensured and maintained in proper condition .
d. Protective clothing and personal safety equipment should be used as

per the need of operation.
e. Good housekeeping plays a major role in safe & quality operation of

the plant. Accordingly, habits and practices for good housekeeping
has to be cultivated. Good housekeeping also contributes in
improving working environment.
f. Regular grass cutting should be done and dry vegetation should be

cleared from the plant area.
g. Standard maintenance schedules should be formed and followed for

plant equipment.
h. Competence and job knowledge should be enhanced by

proper training and refresher courses from time to time to all
officers, employees and contract laborers.
9
STATUTORY TESTING OF LPG CYLINDERS

Taking into account the fact that an LPG
Cylinder stays longest at the consumer’s
Premises; who by and large does not have
Adequate knowledge of safe handling of LPG
in emergencies; it is very essential to
ensure that the cylinder is tested at specified
interval to gain assurance for the continued
safe usage.


DEPARTMENT 9
PAGE No.
March 2014 STATUTORY TESTING OF LPG 9-1
CYLINDERS
9.1 GENERAL
9.1.1 As described earlier LPG cylinders are manufactured as per IS: 3196 (Part-I)
2006 The new cylinders are inspected and tested by BIS officials and a
certificate of fitness is issued by them. Based on the certificate, approval is
given by the Chief Controller of Explosives, Nagpur or his authorised
representative for the use of the cylinders for LPG. As a part of the test by
BIS officials, hydrostatic tests and pneumatic tests are conducted on each
cylinder and the data of hydrostatic testing is punched on one of the stay
plates. I.e., Month and year of testing called as test dates.
9.1.2 Under the Gas Cylinder Rules 2004, after a new cylinder is initially tested at
the manufacturer’s plant, it is required to be re-tested periodically to
ascertain the fitness for further service. The period of re-test as per latest
norms is 10 years from the date of manufacture of cylinders for the
cylinders manufactured from 2nd quarter 2000 onwards and subsequently
every five years as per the approval given by CCOE vide reference No.
R.4(2) 100/2007 dated 20.08.07
9.1.3 The test for re-qualification primarily include the following as per IS 16054 :
(a) Visual inspection of cylinder body, both internally and externally; for
dents, cuts, corrosion etc.
(b) Hydrostatic test after the inspection of cylinders as per IS: 13258 at a
pressure of 2.45 MPa ( 25 Kgf/cm2) an interval of 30 seconds, after the
desired pressure is attained and the external surface is fully dried.
Observation time is minimum 30 seconds.
(c) Pneumatic test, after refitting the valve, with a pressure of 1.180 MPa
(12 Kgf/cm2 ) for an interval of 60 seconds.
9.1.3.1 For the sake of convenience, other related activities such as re-painting of
the cylinders, attending to cold repairs etc. are also carried out at the
Statutory Testing Plant.
9.1.4 The cylinders found unfit for service during the visual inspection or
hydrostatic test are rejected for scrapping. Such rejected cylinders at ST
tester are to be returned to plant for inspection and certification by

DEPARTMENT 9
PAGE No.
CYLINDERS
committee as required. Scrapped cylinders are required to be de-

shaped by pressing in a hydraulic press before the disposal.
9.1.5 As segregation of the cylinders for statutory testing is done at the Bottling
plants, the testing plants are also planned in the close proximity to
minimise the expenses on transportation and also to have fast turn-round
of the cylinders.
9.1.6 The Statutory Testing Plant require the Chief Controller of Explosives’
license. The approval from the Chief Controller of Explosives is necessary
for de-gassing of cylinders and running of the plant. Further, the operation
at the plant shall be supervised by a competent person whose bio-data
such as name, qualification and experience should be sent to the Chief
Controller of Explosives for record. Qualifications must be in line with the
provisions of Gas Cylinder Rules, 2004 and future amendments
9.1.7 The Statutory Testing operation at the Plant must be done in accordance
with the Gas Cylinder Rules, 2004 and all requirements mentioned therein
must be complied with. Also New IS code for Statutory Testing of LPG
Cylinders for Periodic Inspection and Testing – Welded Low Carbon Steel
Cylinders exceeding 5 Litre water capacity for Liquefied Petroleum Gas
(LPG) – Code of Practice is under consideration of BIS. Same shall be
referred after its publication
9.1.8 As the cylinders which are stored and handled at the testing plant
contain LPG vapour, all rules pertaining to and all precautions applicable
to the licensed premises must be observed.
9.1.9 One set of Gas Cylinder Rules 2004 , BIS code in the form of Manual for
Testing of LPG cylinders in circulation, and all BIS standards referred to in
these two publications MUST be available in the testing plant.
9.1.10 Following Documents are to be maintained by Re-Testing Agency with

current amendments
The Gas Cylinders Rules, 2004

IS2:1960 Rules for rounding off numerical values (revised)
IS2074:1992 Ready mixed paint, air drying, red oxide zinc chrome,
priming –Specification (second revision)

DEPARTMENT 9
PAGE No.
CYLINDERS
IS2932:2003 Enamel, synthetic, exterior: (a) Undercoating (b) Finishing –

Specification (third revision)
IS3196 (Part1): 2006. Welded low carbon steel gas cylinder exceeding 5
litre water capacity for low pressure liquefiable
gases: Part 1 Cylinders for liquefied petroleum gases
(LPG) – Specification (fifth revision)
IS7241:1981 Glossary terms used in gas cylinder technology (revision)
IS8737:1995 Valve fittings for use with liquefied petroleum gas (LPG)
cylinders more than 5 litre water capacity – Specification
(first revision)
IS9121:2005 Inspection gauges for checking Type 1 (size 2) taper
threads of as cylinder valves, taper 1 in 16 – Specification
IS13258:2013 Welded Low carbon steel cylinders exceeding 5 litre
water capacity for low pressure liquefiable gases – Code
of practive for inspection and reconditioning of used LPG
cylinders
9.2 COLOUR CODE FOR AGE PROFILE

9.2.1 GENERAL
(a) Although the dates of initial test and subsequent re-test are
punched on the third stay plate of the cylinder, segregation of the
cylinders for statutory testing based on the punched markings is not
only cumbersome but also a time consuming process. A system for
colour coding of the cylinders to indicate the age profile has,
therefore, been developed on Oil Industry basis. The system is
described in detail in Clause No. 9.2.3.
(b) As per Gas Cylinder Rules 2004, the following two conditions are
mandatory :
(i) Quarter and year of initial testing must be stamped on every

cylinder.
(ii) Quarter and year of next testing should also be indicated on
every cylinder.
9.2.2 Procedures are standardized on Industry basis :
There is only one category of cylinder in use by the Oil Companies, i.e., one
with protected ring supported by three vertical stays.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.2.3 CYLINDERS WITH PROTECTING RINGS
(a) In the case of these cylinders, immediately after re-testing, the

quarter and year shall be punched on the outside surface of one of
the third stay plate.
(i) Each quarter will be distinguished as under:
 January to March by letter ‘A’.

 April to June by letter ‘B’.
 July to September by letter ‘C’
 October to December by letter ‘D’.
(ii) The year of test would be identified by the last two digits of the
year. For example, figure 09 would represent the year 2009.
(iii) If a cylinder has been tested in the month of July 2009,
the punched marking shall be ‘C-09’ based on the above
guidelines.
(b) In order to indicate the next quarter of the testing, inside surface of
one of the vertical stay plates shall be painted with the appropriate
colour scheme as detailed in Clause No.9.2.4 and the next quarter
and the year of testing due are stenciled with the appropriate
colour scheme on the painted background. For example, if a
cylinder is tested in ‘C-09’, the marking on the inside of the stay will
be ‘C-14’.
(c) The manufacturers should mention the date of manufacture /

testing on the outside of the third stay plate giving rest of the space
of this stay blank for further stamping of testing dates. The outer side
surface of the other two stays will be utilised for indicating other
statutory details . i.e. Sl. No, W.P. T.P., etc.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.2.4 COLOUR CODING
(a) The following color coding of cylinders is to be followed.
Background color IS spec Lettering color Year of Year of

manufacturing retesting
White 127 Black 2012 2022
Sea Green 217 Black 2013 2023
Dove Grey 694 Black 2014 2024
Air Craft Blue 108 White 2015 2025
Salmon Pink 443 Black 2016 2026
India Brown 415 White 2017 2027
Satin Blue 177 Black 2018 2028
Bus Green 299 White 2019 2029
Black 521 White 2020 2030
Yellow 355 Black 2021 2031
However, for cylinders coming for 2nd testing, five year periodicity is
to be maintained and color change has to be done according to
the 10 year color scheme given above.
For example :
For cylinders coming for 2nd retesting in year 2013, the color scheme
for retesting for year 2018 is to be adopted.
(b) The height of the lettering shall be of 25 mm for quarter and year
of next due date.
The above colour scheme shall be followed by the Statutory Testing

Plants and Hot Repairer Plants
9.2.5 The above colour coding scheme shall also be followed by the Oil
Industry in respect of cylinders in circulation due for next testing.
9.2.6 It is essential that the periodic visual inspection of marking, painting and
stamping on the cylinders is undertaken at the bottling plants to ensure
that these are legible at all times.
9.2.7 Since the stamping and marking are done at the time of re-testing, the
next due date of hydrostatic test can be easily established.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.2.8 Statutory testing plants to stencill the next date for re-testing on the vertical
stays of the cylinders with proper colour coding as above and as such the
next date of re-testing can be easily found out from the colour coding
and marking.
9.3 EQUIPMENT / FACILITIES

9.3.1 GENERAL
a. Facilities / equipment at the plant should confirm to the

requirements of Explosives Department as listed in the Gas Cylinder
Rules,2004
b. All electrical installations in the plant should be as per area

classification.
9.3.2 The basic facilities provided in the Statutory Testing Plant are given below :
(a) Covered shed, well ventilated at ground level, for the storage for
cylinders due for testing and for carrying out the testing operation.
(b) Sufficient open area to store the cylinders already tested, cylinders
discarded for scrapping and cylinders already de-shaped for
disposal.
(c) Fire fighting facilities covering the covered shed and the open area.
(d) Water storage facility for hydrostatic test and Pneumatic test
9.3.3 The basic equipment required at the Statutory Testing Plant is given
below, which also incorporates facilities required as per Schedule IV of
Gas Cylinders Rules 2004 :
a. Adequate cylinder handling equipment/ facility
b. Washing/ cleaning facility for external cleaning of the cylinders.


DEPARTMENT 9
PAGE No.
CYLINDERS
c. Non-destructive testing facility like ultrasonic flaw detection, acoustic

emission techniques, etc. for detection of stress corrosion cracks
developed during service.
d. Water jets for internal cleaning of the cylinders.
e. Valve on-off screwing facility.
f. Boroscope, Extra low voltage lamps to permit internal viewing of the

cylinders and other lamps for close examination of external surfaces.
g. Hydrostatic test apparatus comprising pressurizing equipment, pressure

gauge and volumetric measuring equipment in accordance with IS-
5844 - Hydrostatic stretch testing of compressed gas cylinders. The
apparatus shall be equipped with at least two 15cm dia (min) working
pressure gauges.
h. Drying equipment for internal surface of the cylinder which would

comprise of a vacuum pump with dry air facilities.
i. Air compressor of adequate capacity for pneumatic test at a pressure

of 12 kgf/cm2 .
j. Weighing scale with least count of 5/10 gms. for weighing tare weight
of the cylinders together with the standard test weights stamped by
Weights and Measures Department
k. Hand trolleys for manual handling of cylinders.
l. Dead weight pressure gauge tester of appropriate pressure range or a

master pressure gauge of minimum 15 cm. diameter covering the
pressure range of 0 to 3 MPa.
m. Miscellaneous equipment such as straight edges, templates, tools,

gauges, equipment for marking / stamping and stenciling.
n. Adequate cylinder draining facility.
o. Torque wrenches, minimum three numbers of range of 0-200 lb. ft.


DEPARTMENT 9
PAGE No.
CYLINDERS
p. L1 & L9 gauges as per IS-9121 for bung/ valve pad thread inspection.
q. Explosimeter / Gas leak tester.
r. Magnet for removal of any metallic particle from cylinder.
s. Wire brushes for cleaning external surfaces before painting.
t. Painting booth for primer coat and finish coat painting of the cylinder.
u. Elco-meter for checking the paint thickness.
9.4 SEQUENCE OF OPERATION

(a) Receipt of cylinders.
(b) De-pressurisation.
(c) Recording details (like Sl. No., Test Dates, Tare weight, Manufacturer’s
name.
(d) Valve removal.
(e) De-gassing.
(f) External surface cleaning.
(g) Internal cleaning and internal inspection.
(h) Visual inspection of external surface and bung threads by L-1 and L-9
plug gauges.
(i) Tare weight checking.
(j) Hydrostatic testing.
(k) Internal cleaning and checking.
(l) Primer coating.
(m) Signal red painting.
(n) Punching of new test date and repairer’s identification mark.
(o) Tare weight checking.
(p) Colour code painting to indicate the ownership of cylinders,
stenciling of new tare weight, net weight and next test date.
(q) Tapping the bung thread, cleaning the same by brass wire brush & ¾
NGT threads and checking the bung threads with L-1 & L-9 plug
gauges.
(r) Valve fixing.
(s) Pneumatic test.
(t) Certification and despatches.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.4.1 RECEIPT OF CYLINDERS
(a) Cylinders are received from :
(i) Associated filling plant.

(ii) Other filling Plants.
(b) The cylinders received at the plant should be supported by proper

accounting documents and should be checked against the
particulars given therein.
(c) The cylinders received for statutory testing, must be stored in a
covered shed, if they are not in ‘gas-free’ condition at the time of
receipt.
9.4.2 VERIFICATION OF AGE PROFILE
(a) Before the cylinders are taken for statutory testing, the last test date
punched on the cylinder stay plates should be verified. The cylinder
should be taken for re-test only when it is due as per statutory
regulations or if the re-test is required for any other specific purpose.
(b) At this stage, the serial number of the cylinders, date of last test
and the name of the cylinder manufacturers should be checked
and recorded.
9.5 SEGGREGATION
9.5.1 All the markings of each cylinder shall be scrutinised to establish that it
complies with the requirements of IS: 3196-Part I revised 2006 and with any
other statutory requirement applying to its use. The cylinders having lost its
identity with respect to its original manufacturers, serial number, date of
manufacture and the relevant code of manufacture shall be branded
and declared unserviceable.
9.5.2 The cylinders found acceptable as per Clause No. 9.9.4 of this chapter
shall be segregated separately for hot repairs.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.6 PREPARATION
9.6.1 Removal of Valves
9.6.2 All the cylinders shall be de-pressurised to the atmospheric pressure. The
contents shall be released in a safe manner through a high rise vent that
should be 1.5 m from the eve of the shed
9.6.3 At a time not more than 5 cylinders shall be de-pressurised. The gas shall
be cold flared by using a suitable adopter connected to a header. The
gas so collected in the headers shall be finally vented through a piping
above the roof level.
9.6.4 The adopter used for the purpose should not press the valve spindle
beyond 2.5 mm.
9.6.5 The valves shall be removed carefully after ensuring complete de-
pressurisation. While removing the valves, a suitable adopter and proper
fixture shall be used to ensure that valves, bung threads & cylinders are not
damaged. Preferably the Cylinders shall be kept vertical at the time of
valve removal.
9.7 DEGASSING OF CYLINDERS

9.7.1 Work on LPG cylinders shall not be carried out in the enclosed space prior
to degassing.
9.7.2 Degassing should be carried out in CCOE approved site. Cylinders shall
be degassed by purging the same by inert gas, steam or by filling water till
it overflows. The water shall be retained in the cylinders for not less than
one hour to ensure that entire vapour or gas remaining in the cylinder
comes out. After emptying out the water, the cylinders shall be kept in
inverted position and be tapped gently by non-metallic hammer to
remove dust, rust or any loose remnants in the cylinders.
In Cylinder, Pyrophoric substance is present. When pyrophoric substances

come in contact with air, they react with the oxygen generating heat
which would ignite a flammable mixture and may cause an accident.
Major source of pyrophoric substance is iron sulphide. Pyrophoric iron
sulphide is a corrosive product that may form on the wall of the cylinder.

DEPARTMENT 9
PAGE No.
CYLINDERS
Pyrophoric material should be kept wet till buried in the pit and pit is
covered with earth. Pit for disposal of this sludge should be located
sufficiently away from hydrocarbon area so that the plant / Equipment is
not in danger at any time
9.7.3 After degassing, the inside of the cylinders shall be checked by an

Explosimeter to ensure that the cylinders are gas-freed and shall again be
taken up for de-gassing till it completely gas freed.
9.8 EXTERNAL CLEANING

9.8.1 Each Cylinder shall have the external surface thoroughly cleaned by
caustic soda, solution, non-ferrous wire brush and water jet. Care shall be
taken to ensure that the body of cylinder and metalizing is not damaged.
9.8.2 While cleaning the surface of cylinder by caustic soda solution or water jet
the bung of cylinder should be closed by suitable plastic / rubber cap to
prevent the entry of foreign material, solution into the cylinder.
9.8.3 Any suitable method of surface cleaning other than the methods as
mentioned in Clause Nos. 9.8.1 and 9.8.2 may be used as agreed upon
between the owner of cylinder and testing station.
9.9 EXTERNAL AND INTERNAL INPSECTION
9.9.1 External Inspection
9.9.1.1 The entire surface shall be inspected by a competent person for,
a) dents, cuts, gouges, bulges cracks, laminations or punctures, bottom

shell thickness, foot ring bottom clearance applying the criteria for
rejection given in Table 1.
b) corrosion, giving special attention to areas where water can be

trapped, at the base of the cylinder, the junction between the body
and the footring, the junction between the body and valve guard or
shroud, applying the criteria for rejection given in Table 2.

DEPARTMENT 9
PAGE No.
CYLINDERS
c) Other defects (for example, depressed bung or fire damage), applying

the criteria for rejection given in Table 3.
d) integrity of all permanent attachments for example, VP ring and

footring.
Any cylinder rejected by the competent person shall be segregated for

repair or shall be rendered unserviceable. The reasons for repair or
declaring the cylinders as unserviceable shall be recorded along with the
cylinder details, for example Sl. No., Name of manufacturer and Year of
manufacturing
Cylinders with damaged foot ring, valve protection ring, which cannot be
cold repaired and require/can be hot repaired, to be sent for hot
repairs.,
9.9.1.2 For checking the internal surface of the cylinders, a low voltage lamp of
suitable intensity shall be used.
9.9.1.3 Before carrying out the internal inspection of the cylinders, the inside
portion of the cylinders shall be properly cleaned by using vacuum pump,
compressed / hot air and magnetic bar to remove any foreign particles
and traces of water inside the cylinders.
9.9.1.4 Cylinders having damaged non-pressure parts such as valve protection

(VP) rings, foot rings etc., however, acceptable as per Clause No. 9.9.1 of
this chapter may be segregated for hot repairs.

DEPARTMENT 9
PAGE No.
CYLINDERS
Table 1 Physical Defects In the Cylinder Wall
Sl. Defects Description Rejection Criteria

(2) . (3) (4)
(1)
i) Bulge Visible swelling of the cylinder Rejection in all cases
ii) Dent Depression in the cylinder that a) Depth of dent is greater than 1/10th
has neither penetrated nor of the mean diameter of the dent OR
removed the metal and its b) Mean diameter of the dent is greater
width at any point is greater than one-quarter of the diameter of
than 2 percent of external cylinder OR
cylinder diameter c) Dent on or adjacent to weld
iii) Cut or Sharp impression where metal 75mm or more in length or when the
intersection has been removed or depth of cut is such that the
redistributed undamaged (remaining) wall thickness
is less than the minimum calculated
wall thickness
iv) Intersecting Point of intersection of two or Rejection in all cases
cut more cuts
v) Dent Depression in the cylinder When the size of dent or cut exceeds
containing within which there is cut the dimension for rejection as an
cut individual defect
vi) Crack A split or rift in the cylinder shell Rejection in all cases
vii) Lamination Layering of the material within Rejection in all cases

the cylinder wall appearing as
a discontinuity, crack. Lap or
bulge at the surface
viii Dig A sharp depression where the 75mm or more in length and 4mm or
) surface material has been more in width
penetrated
ix) Bottom shell Thickness of the bottom of the Less than minimum calculated wall
thickness cylinder surface thickness.1)
x) Footring Clearance of the body bottom a) Less than 8mm for cylinders of water
bottom from the ground. capacity upto 34 litre
clearance b) Less that 15mm for cylinders of water
capacity exceeding 34 litre and upto
50 litre
c) Less than 25mm for cylinders of water
capacity exceeding 50 litre.

DEPARTMENT 9
PAGE No.
CYLINDERS
Table 2 Corrosion Defects In the Cylinder Wall

.
(2) (3) (4)
(1)
i) Isolated Pitting of metal occurring in Depth of penetration of any pit
corrosion isolated areas at a concentration exceeds 0.4mm1)
pits not greater than 1pit / 500mm2 of
surface area
ii) Area Reduction in wall thickness over Depth of penetration of any pit
corrosion an area not exceeding 20 exceeds 0.4mm1)
including the ends (top and
bottom)
iii) General Reduction in wall thickness over Rejection in all the cases
corrosion an area exceeding 20
iv) Line Series of pits or corroded cavities a) Total length of corrosion in any
corrosion of limited width along the length direction exceeds 50 percent of the
or around corrosion circumference of the cylinder
circumference b) Depth of penetration exceeds
0.4mm1)
c) Depth of corrosion cannot be
measured
v) Cervice Cervice corrosion occurs in the When the depth of penetration
corrosion area of the intersection of the foot exceeds 0.4mm or when the depth of
ring or stay plate with the cylinder corrosion cannot be measured1)
1) Cylinders shall be rejected in case the observed thickness of the undamaged remaining
wall in the affected portion is less than the minimum calculated wall thickness.

DEPARTMENT 9
PAGE No.
CYLINDERS
Table 3 Other Defects

.
(1) (2) (3) (4)
i) Depressed bung Damage to the bung which Rejection in all cases
alters the profile of the
cylinder
ii) Arc or torch Burning of the cylinder base Rejection in all cases
burns metal , a hardened heat
affected zone , the addition
of extraneous weld metal,
or removal of metal by
scarfing or cratering
iii) Fire damage Excessive general or Rejection in all cases
localised heating of the
cylinder usually indicated
by: a)
Charring or burning of
paint1)
b) Fire damage of the metal
c) Distortion of the cylinder
d) Melting of metallic valve
parts -
e) Melting of safety cap
1) In case of superficial charring of paint cylinder may be accepted by
inspecting officer.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.9.2 Internal Cleaning and Inspection
9.9.2.1 Internal cleaning
Cylinder shall be first cleaned from inside by using vacuum pump. After
internal cleaning, magnetic bar shall be used to remove any ferrous
particle sticking at the bottom of the cylinder surface
9.9.2.2 Internal inspection
The inside of the cylinder shall be visually inspected with appropriate

internal illumination using low voltage lamp. Cylinder showing sign of
internal corrosion shall be evaluated further in accordance with Table 2. If
mechanical cleaning is required, care shall be taken to avoid damaging
the cylinder wall. Cylinders shall be re-inspected after cleaning
9.10 VALVE PAD (BUNG) THREAD INSPECTION

9.10.1 The threads of the valve pad (bung) of each cylinder shall be checked
by L-1 & L-9 plug gauges as per IS-9121 (Code for inspection gauges for
checking of taper threads of gas cylinders) . The valve pad threads shall
be properly cleaned by soft wire brush and ¾” 14 NGT thread cleaning
tap before checking.
9.10.2 The cylinders which are having the valve pad threads worn out, not
meeting their respective thread gauges, broken at any point and rough
surface on the threads not meeting the requirements of IS-9121 shall be
rejected.
9.11 TARE WEIGHT CHECKING

9.11.1 After degassing and thorough external and internal cleaning, the cylinders
shall be checked for tare weight.
9.11.2 Any cylinder having loss of weight by more than 5% of original tare weight
shall be branded and declared as unserviceable.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.12 HYDROSTATIC TEST
9.12.1 PREPARATION OF CYLINDERS
The external surface of the cylinder shall be clean and completely dry so
that any leak can be detected during the test.
9.12.2 TEST EQUIPMENTS
All pipe work, flexible tubing, valves, fittings and other components forming
the pressure system of the test equipment shall be designed to withstand a
pressure of 1.5 times the maximum test pressure of cylinder to be tested.
The design and the installation of the equipment and the cylinders
connected to it shall ensure that no air is trapped in the system.
Equipment shall be either rotary type or invertible type to facilitate

examination of complete surface of the cylinder. Equipment shall be
provided with isolation valve to isolate the system once the test pressure is
reached.
Dedicated pressure gauges for each cylinder to read the cylinder test
pressure in accordance to relevant Indian standard shall be provided. In
addition to this 2 number of main gauges shall also be provided on the
inlet line of the equipment after the isolation valve.
The gauges shall be calibrated for accuracy against a master gauge at

regular interval of minimum once in a month. The master gauge shall be
recalibrated in accordance with Gas Cylinder Rules, 2004 i.e. once in
every 3 months. The records for checking the calibration shall be
maintained.
A device shall be fitted in the test equipment to ensure that no cylinder is

subjected to pressure in excess of its test pressure by more than 1 kgf/cm2

DEPARTMENT 9
PAGE No.
CYLINDERS
9.12.3 PROCEDURE
The cylinder shall be tested at the test pressure of 2.45 MPa ( 25 kgf/cm2).
Before applying pressure, the external surface of the cylinder shall be in

such a condition that any leak can be detected. Cylinder shall be
positioned so the welds are visible during the test.
During test the pressure shall be increased gradually till the required test
pressure is reached. Then the cylinder shall be isolated from the pumping
system and the pressure shall be retained for a period of not less than 30
seconds. During the test, the cylinder shall be gently tapped with wooden/
nylon hammer near the weld joints.
The cylinder shall be thoroughly examined externally for any leak. Any
reduction in pressure noticed during this retention period or leakage,
visible bulge of deformation, sweating on cylinder body shall be treated as
a case of failure in the test.
In case of a leakage in the pressure system, it shall be corrected and the

cylinder re-tested.
9.12.4 INTERNAL CLEANING AND DRYING
Subsequent to hydraulic proof pressure test, water inside the cylinder shall
be completely removed. The internal surface shall be completely dried by
dry compressed air and vacuum pump. Internal cleaning and drying shall
be checked by low voltage lamp.
9.12.5 The fixtures installed for hydrostatic test shall have covered shed with
adequate illumination.
9.13 PAINTING
9.13.1 PRIMER COATING
a) Cylinder(s) found acceptable in all the tests prescribed above shall

be taken for painting with primer coating. Before applying the

DEPARTMENT 9
PAGE No.
CYLINDERS
primer coat, it should be ensured that the external surface of

cylinders is properly cleaned of dirt, dust and loose remnants of the
previous paint so that a uniform coating is obtained. The bung
threads should be closed by a plastic/rubber cap to prevent the
entry of paint into the cylinders.
b) The Zinc Chromate primer conforming to IS: 2074-1992 shall be used

and shall be of brushing consistency and suitable for spraying. It is
desirable that the primer is certified by BIS for its conformity with IS:
2074-1992. The colour of the primer should be of red oxide
9.13.2 FINAL COATING
(a) After the cylinder(s) are coated with primer, the cylinder(s) shall be left
in the air for drying. The drying time shall be as per paint
manufacturer’s/supplier’s recommendations.
(b) The signal red paint shall be based on super synthetic enamel
conforming to IS: 2932-1991 having the colour category No.23(2) Signal
Red as per IS: 2932-1991 which is also shade no. 537 of IS: 5-1991.
(c) The paint shall be of brushing consistency and suitable for application
by spraying. It is desirable that the paint is certified by BIS for its
conformity with IS: 2932-1991.
(d) Painting of 19.0 kg, 5.0 Kg & 47.5 kg Cylinders is to be carried out as per
latest guideline issued by HO.
9.14 GENERAL REQUIREMENTS FOR PAINTING

9.14.1 Both the primer coating with zinc chromate primer and the final coating
with super synthetic enamel paint of signal red colour for 14.2 kg
cylinders & as specified for other type of cylinders shall be applied on the
external surface of cylinders by using a suitable pneumatic spraying gun in
a fabricated painting booth provided with water curtain, draft and
rotating arrangement for cylinders(s).
9.14.2 While applying the primer coating and final painting, care should be
taken to ensure that the shadow zones such as surfaces under foot ring,
VP ring etc. are properly covered with paint.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.14.3 Metallic coating of 40 microns is provided on each cylinder. Over the

above metallic coat thickness of minimum 30 micron of Zinc Chromate
primer and finish paint shall be applied on each cylinders .Minimum
thickness of primer and paint should be 15 microns each.
9.14.4 Sufficient drying time should be provided after finish coat of enamel
painting.
9.14.5 For better results, it is desirable that both the primer and the enamel paint
are obtained from the same source.
9.15 TARE WEIGHING

9.15.1 The tare weighing shall be carried out including the weight of the valve
and safety cap.
9.15.2 The weighing scale used shall have a least count of not more than 10 gms.
and the value of tare weight may be rounded off to the nearest 100 gms.
as per IS: 2-1990. The weighing scale shall be of suitable weighing
capacity.
9.16 MARKING / PUNCHING

9.16.1 After satisfactory completion of inspection and testing, each cylinder,
which is found acceptable, shall be marked with the following details on
the third vertical stay of the cylinder :
(a) The identification mark of the testing unit as registered with Chief
Controller of Explosives, Nagpur.
(b) The new test date retaining the previous test dates
(c) New tare weight of cylinder according to 9.16 and gross weight in,
kg, shall be punched on the cylinder stay plate while retaining the
old tare weight and gross weight. Details for punching are given in
Appendix-I.
(d) Loss in tare weight, if observed under 9.11. (within 5 percent of
original tare weight ) shall be punched at the footring. For example, if
the loss in tare weight is 200 gram, it shall be punched as LTW 200

DEPARTMENT 9
PAGE No.
CYLINDERS
The next periodic inspection date and tare weight shall be stenciled on the
cylinder as per the agreement between the IOC and the re-testing
agency.
Above details are punched on the stay as shown in the drawing

enclosed.
9.17 STENCILLING
9.17.1 The cylinders, which are marked, shall be taken for stenciling of tare
weight, net. weight and next due date for testing. The colour coding for
stenciling of the next test date due shall be followed as detailed in
Clause No. 9.2.4
9.17.2 Size and the colour of stenciling and location on the cylinder shall be as
per instructions issued by IOCL.
9.18 VALVE FIXING

9.18.1 Each valve shall be fitted with a suitable torque wrench or pneumatic
device at a torque of 145+15 ft.lbs (20 +/-2 Kgf-m). using teflon tape
approved by the Oil Industry to ensure perfect sealing between the valve
and the bung joint. A suitable adopter shall be used to prevent any
damage to the valve during the valve fixing operation.
9.18.2 Before the valve fixing operation, the valve pad (bung) threads shall be
cleaned by using ¾”–14 NGT cleaning tap and wire brush. Subsequently
the same shall be checked as per Clause No. 9.10 of this chapter.
9.18.3 Before fixing the valve, inside of the cylinder shall be dried out by the
compressed air. Foreign particles etc., if any, shall be removed by a bar
magnet and checked by a low voltage lamp. The cylinders after
hydrostatic test, may be internally dried using nitrogen, not at a
temperature exceeding 300 deg c and retaining a positive pressure of 2 to
3 bar, effectively preventing internal corrosion.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.19 PNEUMATIC TEST

9.19.1 GENERAL
Each cylinder after it has been dried and fitted with valve shall be tested
for leakage by subjecting to air pressure of not less than 1.18 MPa
(12kgf/cm2) for period of not less than 1 minute .
9.19.2 TEST EQUIPMENT
All pipe work, flexible tubing, valves, fittings and other components forming
the pressure system of the test equipment shall be designed to withstand a
pressure of 1.5 times of the pneumatic test pressure. Proper illumination
and draining arrangement of soiled water and filling of clean water in
pneumatic tank shall be provided .
Equipment shall have facility to fully immerse the cylinder in water during
the test by use of suitable pneumatic fixture. Equipment shall facilitate
rotation of cylinder manually during the test.
Air drier (refrigeration type) of suitable capacity and capable of

achieving dew point required for removal of water traces shall be
provided in the line to remove moisture from the air before it enters the
cylinder.
Pressure gauge of suitable capacity shall be provided at the air filling point
to check the pressure of air in the cylinder prior to starting the test.
9.19.3 PROCEDURE
Cylinder shall be filled with dry air up to the pressure of 12 kgf/cm2. After
that the cylinder shall be isolated from the pressure source. The cylinder
shall be immersed in water for a period of not less than 1 minute.
The cylinder shall show no leakage from the body of cylinder and the joint
between valve and bung. The test is to be carried out after fixing the
safety cap on the valve.

DEPARTMENT 9
PAGE No.
CYLINDERS
Any cylinder that fails the test shall be inspected for leakage cause. In
case the leakage is due to improper tightening of valve, same shall be
corrected and cylinder shall be rechecked.
Otherwise the cylinder shall be rendered unserviceable.
After testing, air shall be removed by press opening the valve using suitable
adaptor.
No cylinder shall be stored with air pressure inside.
9.20 CALIBRATION :
Calibration of equipment shall be carried out at periods not exceeding
the following :
(a) Working pressure gauge – 1 month

(b) Master pressure gauge – 6 months
(c) Weighing equipment – Checked by test weight daily when in
service
(d) Test weights – As per Weights & Measures requirement.
9.21 HANDLING OF REJECTED CYLINDERS

9.21.1 RE-CONDITIONING
Cylinders segregated during the visual inspection shall be returned to the

Corporation (IOC) for re-conditioning .
9.21.2 DE-SHAPING
Cylinder rendered unserviceable at any stage during periodic inspection

procedure shall be marked prominently with paint showing the reasons of
rejection and returned to the Corporation for proper de-shaping or shall
be returned after de-shaping as per the agreement between the
Corporation and the re-testing agency. Complete record of such cylinders
shall be maintained.

DEPARTMENT 9
PAGE No.
CYLINDERS
9.21.3 All the rejected cylinders shall be marked prominently with the paint
showing the reasons of rejection. Following codes shall be used.:
Sl. REASONS FOR REJECTION CODES

1 Visual inspection rejection VI-R
2 Marking unidentified MU-R
3 HST Testing HST-R
4 Pneumatic Testing PT-R
5 Tare Weight loss TW-R
6 Bung Thread Rejection BT-R
7 Hot Repair HR
9.22 RECORD KEEPING & CERTIFICATION

9.22.1 Records shall be maintained for all the tests and inspections carried out
at the statutory testing plant and copies are made available to Statutory
Authorities, if required. A certificate with respect to the fitness of the
cylinders shall be issued as per Appendix No. II and records of LPG
cylinders rejected and recommended for hot repairs are to be kept safely
in a format as per Appendix No. V.
9.22.1 PROCEDURE FOR RECORD KEEPING
9.22.1.1 Since the cylinders received at the Statutory Testing Plants will be
different serial numbers of different manufacturers, recording and
handling of cylinders should be done with proper care to ensure
systematic and batch-wise movement of cylinders so that there is no mix
up resulting into escape of few operations. Following methods are
suggested for handling and recording of cylinders :
(a) On receipt of cylinders, a batch of 150 or 200 cylinders (Max. 400),

preferably of one day’s production, is to be formed.
(b) The details of cylinders are to be recorded in a format known as

‘ROUTE CARD’ as given in Appendix No. IV. This format is to be
printed on a thicker card, as this will move along with the batch
and shall be handled at the shop floor. The important stages where
recordings are to be made are given in the Route Card. On
completion of operation / inspection, the concerned inspecting

DEPARTMENT 9
PAGE No.
CYLINDERS
staff shall sign the card with date and forward the same to the next
stage.
By following this procedure, it may be noted that the recordings of

Serial number of cylinders, Test Dates, Name of Manufacturer at all
the intermediary stages are avoided.
(c) The allotment of batch number is linked with the year and month of
testing e.g. 01 A-XX which indicates 01 as the year of testing (2001),
A for the month of January, B for the month of February etc. and XX
is the control number for the month as 01,02,03,…. . This procedure
provides necessary assistance in monitoring the control on the
production as well as for easy access to a particular cylinder, if any
information is required at a later date.
(d) The LPG cylinders, which are accepted, are recorded in a format
as per Appendix No. III. The various reasons for rejection shall be
coded as given in Route Card and marked on the back of
Appendix No. V.

DEPARTMENT 9
PAGE No.
CYLINDERS
APPENDIX No. I
DETAILS OF MARKING ON STAY PLATE
B-1 TEST DATE AND IDENTIFICATION MARK
Batch No.
Old Test Date
Test Dates
XXX XXYY
NOTE : 1. XXX - IDENTIFICATION MARK OF TESTING STATION

2. XYY - MONTH AND YEAR OF RE-TEST DATE
B-2 TARE WEIGHT AND GROSS WEIGHT

a) Tare Wt. Old New
b) Gross Wt. Old New

DEPARTMENT 9
PAGE No.
CYLINDERS
APPENDIX No. II
NAME AND ADDRESS OF TESTING STATION

CERTIFICATE ON PERIODIC TESTING OF LPG CYLINDERS
Certificate No.:_______________________
Date:_______________
This is to certify that LPG cylinders having normal water capacity_______ litres
as per Appendix No. III belonging to IOC have been found acceptable in visual
inspection as per IS : 13258 – 2013 and Hydrostatic Test at 2.45 Mpa ( 25.0
Kg/cm2). Pressure as per IS: 3196 (Part I) 2006. These cylinders are fitted with
self closing (SC) type valves as per IS: 8737 – 1995 of type I threads (3/4”- 14
NGT of ANSI/CGA V-I-1987).
Batch No.: Batch Size:
No. of Cylinders accepted :
No. of cylinders rejected :
Duration of testing : From To
.
The cylinders rejected / recommended for hot repairs are furnished in
Appendix No. V
Certifying Authority

DEPARTMENT 9
PAGE No.
CYLINDERS
APPENDIX No. III

NAME AND ADDRESS OF TESTING STATION,
LIST OF LPG CYLINDERS ACCEPTED
Owner of Cylinders INDIAN OIL CORPORATION LIMITED
Certificate No: Cylinder S.NO

Date :
Sl. Cylinder Name of Tare Tare Date of Test Date

S.NON manufacturer weight weight Mfr.
o (Original (Observed Old New
. and
punched
now)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Signature ,
Stamp of ST
tester

DEPARTMENT 9
PAGE No.
CYLINDERS
APPENDIX - IV
ROUTE CARD
Name Of Cylinders Testing Station
Owner Of LPG Cylinders – IOC Batch No_______________
Batch Size _________________________Date ________________
Control No. 1 2 ….
Sr.No of Cylinder
Name Manufacturers
Date Manufacturer (i.e. first Test Date )
Previous Test Date
Internal & External Inspection
Internal Inspection (OK/ Rej. )
External Inspection (OK/ Rej.)
External Inspection RT/HR/Rej.
Tare Weight Check OK/Rej.
Hydrostatic Test at 2.45 MPa (25.00kg/cm2
OK/Rej.)
Original Tare weight
New Tare weight
Bung Threads rechecked OK/Rej.
Final Inspection Of Marking ,
Painting Stenciling ,
Any Other defects Accepted /Not Accepted
Remarks if any
Name & Signature of Inspecting official ______________________________
Date of Completion _______________________
* RT - Accepted for re-testing, R- Repair, Rej.- Rejected.

The code used shall be as given below:
Bulge – E1 Burn - E2
Dent - E3, Dig-E4,
Cut - E5, Pit - E6,
Line corrosion -E7, General corrosion -E8,
Bung thread damaged-E9, Loss in tare wt – E10
Identity lost -E11, Bottom clearnace less than limits: E12
Wall thickness less than limits- E 13 Internal defect cannot be assessed –I1,

DEPARTMENT 9
PAGE No.
CYLINDERS
Remarks : Allotment of batch no is to be linked with the year and month of testing e.g.O5A-XX
which indicates 05 as the year of testing A for the month January , B for the month of February
etc. and XX is the control number for the month as 1,2,3Remarks : Allotment of batch no is to
be linked with the year and month of testing e.g.O5A-XX which indicates 05 as the year of
testing A for the month January , B for the month of February etc. and XX is the control
number for the month as 1,2,3

DEPARTMENT 9
PAGE No.
CYLINDERS
APPENDIX -V
Name Of Testing Station :
Hot repair
Certificate No. :
Date :
List of cylinders rejected/recommended for Hot repair
Sr. Cyl.No Manufacturer Date of Reason for failure

N Name Manufacture Visu Min Tare Bung HST Mark Hot
o Thickness
a W T unidenti repair
l t h fied
. r
l e
o a
s d
s s
10
INSPECTION AND MAINTENANCE
The objective of an ‘Inspection and

Maintenance Programme’ within the
LPG Plant is to establish uninterrupted,
efficient and SAFE operations.


DEPARTMENT 10
PAGE No.
March 2014 INSPECTION & 10-1
MAINTENANCE
10.1 INTRODUCTION
10.1.1 When an equipment is purchased, maintenance of the same is also

purchased because the machines are composed of various
components or parts; having different life & wear out rates depending
upon the design, operating condition, workmanship etc. The machines
are designed on some parameters to perform a function and to keep
the machine performing in the same fashion on same parameters,
maintenance is undertaken. Maintenance is a partial replacement of
the system and it is monitored by carrying out periodic inspection of the
equipment. The objective is to ensure that the system is reliable for
achieving the desired productivity & safe operation.
10.1.2 The serviceability and safety of the LPG plant equipment, especially in
the long term, are affected by the standard of maintenance
undertaken. Complete information, through manufacturer’s operating
and maintenance manuals / service booklets should be available
about each type of machine and equipment in the plant. The
recommendations therein must be incorporated in the plant
maintenance schedules to ensure that the equipment is always in
good working condition and will not give unpleasant surprises when
you least expect of them. Typical schedules are available in OISD 144,
under Chapter no 9 and task list attached ( pl. click attachment of
acrobat reader )
10.1.3 Each plant should work out a similar schedule of maintenance based
on the make and type of equipment installed and also the operating
conditions and specific needs for each plant. e.g. Plant operation in
single shift would need a different schedule than the plant running in
two shifts. Depending upon the plant’s size, one or more officers should
be assigned specific jobs for inspection and maintenance.
10.1.4 To avoid rush indents and chances of plant shutdown for want of
sufficient spare parts, maximum and minimum stock levels for the spares
should be worked out and maintained. The need for adequate
inventory level of spares is all the more important, in case of spares
which are to be imported as the lead time for the procurement of such
items would be higher than that for indigenous spares.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.1.5 Maintenance scheduling, monitoring of maintenance activities,

inventory management and documentation must be carried out with
the help of PM and MM modules of SAP at all Plants.
10.1.6 Training on maintenance activities must be a continuous affair in order

to develop required competence for effective maintenance. The
maintenance officers must be well versed with the Operations &
Maintenance ( O&M )manual of the equipment, OISD norms and other
statutory norms related to maintenance and inspection and must keep
himself/herself updated on any changes in the norms that may take
place.
10.1.7 Wherever necessary, personal protective equipment must be used as

detailed in OISD Std. 155 Parts I & II. Manufacturers’ recommended tools
and tackles must be used for maintenance of the equipment.
10.1.8 Remember, nothing could be more pleasing than to have an accident-

free and breakdown-free record at the plant, and one way to achieve
this is to work out and Implement a regular Inspection and maintenance
programme.
10.2 OBJECTIVE
10.2.1 The objective of an Inspection and Maintenance Programme for an
LPG plant is to ensure uninterrupted, efficient and safe operation.
10.2.2 All equipment log books must be religiously filled to record all
performance and inspection parameters. Log books must be
maintained in standard format
10.2.3 The shift log / activity should contain a specific column detailing any
abnormal working of the plant equipment and breakdowns, observed
during the shift. The above data shall be analyzed and used for
effective maintenance management.
10.2.4 A well-planned and implemented maintenance programme will result

in higher productivity due to elimination of breakdowns.
10.2.5 The elimination of safety hazard is an integral part of the inspection and
maintenance. As such safety is not treated as an isolated subject within
this section.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.3 TYPES OF MAINTENANCE

10.3.1 ESSENTIAL CARE
Essential Care (EC) includes preventing failure from occurring, with tasks
such as detailed cleaning, lubrication, alignment, balancing, operating
procedures, adjustments, and installation procedures.
10.3.2 Predictive Maintenance ( PdM) or Condition monitoring (CM)
Condition monitoring (CM) is all inspections from simple subjective look,

listen, feel, smell inspections done by operators to objective vibration
analysis, oil sampling, ultrasonic leak detection, pressure checks, current
readings, etc .
Standard predictive maintenance techniques available for stationary

equipment shall be employed for ensuring timely detection & correction
of associated maintenance problems.
The critical / major equipment, which requires predictive maintenance,

shall be identified by the plant and a suitable predictive maintenance
schedule prepared, implemented and records maintained.
Criticality of all equipments at plant should be defined. Frequency of

vibration monitoring readings shall depend upon degree of criticality of
equipment. For super-critical equipment vibration monitoring shall be
undertaken at most frequent interval.
Following major equipments shall be covered under predictive

maintenance for vibration monitoring:
LPG Pumps
Air / LPG Compressors
Vapor Extraction Unit
Fire Engines / Jockey Pump
DG Sets
Any other as assessed by the Plant

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.3.3 PREVENTIVE OR FIXED TIME MAINTENANCE
Preventive maintenance is the system of maintenance whereby

specified checks are carried out on the equipment at periodic intervals,
the frequency of which is determined based on OISD standards,
manufacturers’ recommendations and experience gained by the plant.
These checks are done daily, weekly, fortnightly, monthly, quarterly, half
yearly and annually. Maintenance module of SAP to be updated in line
with OISD and manufacturer’s recommendations and shall be used to
aid the maintenance activities. It is recommended that details of all
Statutory licenses/Test Certificates of the Plants are updated in SAP PM
Module
10.3.4 BREAKDOWN MAINTENANCE
This is forced maintenance carried out when the equipment breaks

down. Breakdown of equipment is not desirable as it not only hampers
the production but may also result in unsafe situation. The cost
associated with the breakdown of equipment can be very high. All
efforts shall be made by the plant to avoid breakdown of any
equipment. Breakdown of the equipment and maintenance cost
should be logged in SAP PM module so that the same can reflect in the
history card of the equipment along with the preventive maintenance
history. This shall be helpful in ascertaining maintenance cost of the
equipment and decision making while considering replacement.
10.3.5 SHUTDOWN MAINTENANCE
Total plant shut down is generally not required as most of the

maintenance work can be done during the weekly off days.
Equipment can be categorized in two broad groups :
(a) Equipment having standby units.

(b) Online equipment without standby.
Shutdown may be unavoidable in the following cases :
(a) Repair / modification of equipments with no stand-by.

(b) Taking new installed equipment into service.

DEPARTMENT 10
PAGE No.
MAINTENANCE
Following procedure would be adopted at the time of taking a planned

shutdown:
When the plant shut down is planned, opportunity must be utilized for
undertaking maximum number of critical maintenance activities
simultaneously. A road map / PERT chart shall to be drawn in advance.
Approval of competent authority shall be taken. Alternate supply plan
would be drawn to feed the markets attached with the Plant
undertaking a shutdown. Before proceeding for actual shutdown, it
shall be ensured that all spares and equipments, tools and tackles,
maintenance/service personnel etc. are in place. Control and
Monitoring of all activities as per the PERT Chart drawn shall be
undertaken at micro level.
10.4 PERFORMANCE MONITORING SYSTEM

All equipment is designed to give a certain desired output with a given
set of input conditions.
A performance Monitoring system should be in place to measure:

– Operating input parameters eg. Pressure, temperature, voltage etc
– Output Conditions eg. Pressure, temperature, voltage, current etc
– Health of equipment through vibration monitoring/thickness
measurement/Oil sample monitoring/Visual checks
Corrective action has to be initiated if Performance parameter is found

to be deteriorating,.
It is very important to have all parameters measuring system like

pressure gauges, temperature gauges, level gauges, trip switches,
relays etc. to be regularly calibrated with standards and calibration
status & set pressure to be conspicuously displayed on the equipment.
Maintenance In-charge shall carry out M&I audit on bi-monthly as per

the M&I ( maintenance & Inspection ) Index format attached with this
file for self assessment and corrective action. In case of any Updation
of the format the same shall be applicable.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.5 SYSTEM INTEGRITY & WORK PERMIT SYSTEM

10.5.1 Safety should be uppermost in mind whenever any maintenance job is
undertaken at the plant. No equipment should be removed from a
pressurised system without written permission of the Plant Manager.
The Plant Manager, before permitting maintenance of equipment

installed in a ‘pressurised system’ such as pump, compressor, vessel,
valve, etc. must ensure that :
(a) The system is de-pressurised.

(b) The system is made ‘gas-free’
(c) Whenever man entry is required, the vessel is checked with the
help of an Explosimeter at different levels and certified as ‘gas-
free’. Oxygen availability must be ensured through proper means.
(d) All necessary safety-systems, fire-protection systems, are in
operating condition.
(e) Required manpower and competent persons for supervision are
available.
(f) After the equipment is removed, openings in the system, if any,
should be properly plugged/blanked-off.
(g) Re-installation of the equipment should again be done with the
written permission from the Plant Manager, taking due
precautions.
(h) Whenever air gets into the system on account of maintenance
work, proper purging should be done before re-commissioning.
10.5.2 Maintenance & inspection work should be carried out only with valid
work permits. Hot work / cold work / Height Permit / Electrical work
permits must be issued by the Plant Manager before commencement
of the job. Work permit system for hot work and cold work shall be in line
with OISD Std.105 and Electrical work permit system shall be as per OISD
Std.137. For Height permit, guidelines as detailed in the permit and OISD
Std 192 shall be complied. The Work Permit must be available at the
work site throughout the course of the job. Closing of the work permits
and proper record keeping must be ensured on completion of the job.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.6 PREPARATION FOR MAINTENANCE
10.6.1 MANUALS
The importance of retaining the manufacturers’ manual for specific

equipment cannot be over emphasized. In many instances, there are
disassembly and assembly techniques, which must be carefully
followed. Likewise, information relating to fits, adjustments and torque
loads must be available in order to properly maintain the equipment.
It may be worthwhile to have two sets of the manuals so that

maintenance personnel can use one, while the other can be placed in
the plant library for proper custody and reference.
10.6.2 MAINTENANCE EQUIPMENT, TOOLS & TACKLES
In addition to conventional hand tools, usage of any special tools &

tackles as per the instruction manual should also be ensured wherever
applicable. While using tools precautions should be taken to avoid
sparks.
10.6.3 FACILITIES
Prior to taking up the maintenance works, availability of adequate

facilities in terms of skilled manpower, tools, spare parts etc. shall be
ensured.
Where the facilities / equipment at the plant are of special nature such
maintenance / repair jobs must be assigned to the specialists in the field
and the equipment should be re-installed in service after proper
checking and third party inspection.
10.7 DOCUMENTATION
10.7.1 Equipment maintenance records should clearly indicate the details of

actual Inspection / maintenance performed vis-à-vis the schedule,
spares used and other costs incurred.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.7.2 Formats and logbooks maintained at the plant may be utilized to

develop data which, when evaluated, can lead to corrective measures
in procedures and techniques. This type of data can be useful for the
scheduling of both inspection and maintenance.
10.7.3 Equipment Data and History cards shall be maintained in SAP PM

Module for all equipment including static equipment such as LPG
storage vessels, water storage tanks, etc. Equipment data shall be
updated in SAP PM Module under Class Characteristics Field under the
Functional Location.
10.7.4 A print out of the history card shall be taken out quarterly from SAP and
kept under custody of the maintenance In-charge..
10.7.5 Formats as per relevant OISD/Statutory standards and Corporation

guidelines shall be used for maintenance of these documents. Various
in-house formats standardized for log books and testing records &
certificates is attached with this file.
10.7.6 Plant facility data base maintained at marketing division intranet shall
be kept updated at all times.
10.8 STANDARDS/GUIDELINES/RECOMMENDED PRACTICES

10.8.1 OIL INDUSTRY SAFETY DIRECTORATE (OISD) is a Govt. body working since
1986 under MOP & NG, New Delhi. It has constituted a number of
functional committees comprising of experts nominated from the OIL
industry to draw up standard and guidance on various subjects for
overall improvement & up gradation.
OISD standards lay down the minimum safety requirements on design/

layout/ operation/ inspection/maintenance/fire protection and safety
facilities/statutory rules & regulations/ emergency planning etc. related
to LPG/ other Petroleum installations.
Some of the relevant OISD Standards, Guidelines and Recommended

Practices on LPG Plant Operations, Maintenance and Inspection are
given below.

DEPARTMENT 10
PAGE No.
MAINTENANCE
OISD STD Description
OISD STD144 Design, layout, storage, loading / unloading,

operation, inspection & maintenance, fire
protection, emergency planning and safety
audit systems of LPG Installations
OISD GDN 169 Layout, design & Fire protection System for small
LPG Bottling Plants
OISD STD 150 Design & Safety requirement for LPG Mounded
Storage Facility
OISD STD 105 Work Permit System
OISD STD154 Safety aspects in functional training
OISD-STD-112 Safe handling of air hydrocarbon mixtures and

pyrophoric substances
OISD-STD-113 Classification of Area for electrical installations

at Hydrocarbon processing and handling
facilities
OISD-STD-119 Inspection of Pumps
OISD-STD-120 Inspection of Compressors
OISD-STD-128 Inspection of unfired pressure vessels
OISD-STD-128 Inspection of Storage tanks

OISD-STD-130 Inspection pipes, valves and fittings
OISD-STD-137 Inspection of electrical equipment
OISD-GDN-145 Guidelines on Internal Safety Audits (Procedures

and Checklist)

DEPARTMENT 10
PAGE No.
MAINTENANCE
OISD-STD-159 LPG Tank Trucks - Requirements of Safety on

Design/Fabrication and Fittings.
OISD-STD-160 Protection to fittings mounted on existing LPG

tank trucks
OISD-STD-161 LPG Tank Truck Incidents : Rescue & Relief

Operations
OISD-STD-162 Safety in installation and maintenance of LPG

Cylinders Manifold
OISD-STD-110 Recommended Practices on Static Electricity

OISD-STD-132 Inspection of pressure relieving devices
OISD-STD-127 Selection, Operation & maintenance of Diesel
engines
OISD-STD-135 Inspection of loading and unloading hoses for
petroleum product
OISD-STD-145 Guidelines for Internal Safety Audit

OISD-STD-155 Part-1 PPE ( Non- Respiratory equipment
OISD-STD-155 Part-II PPE (Respiratory equipment
OISD STD-164 Fire Proofing of Steel Supporting Structures in Oil
& Gas Industry
OISD GDN- 180 Lightning Protection
OISD GDN- 192 Safety practices during Construction
OISD GDN- 203 Operation, maintenance and Inspection of
Hoisting Equipment
OISD RP 126 Specific practices for installation and
Maintenance of Rotary Equipment
OISD STD 214 (Section Cross Country Pipelines ( Interface between
12) pipeline operator and consumer terminal
10.8.2 Due to continual review and changes in Operations and maintenance

practices at plants due to new Products, methodologies, concepts etc,
to improve the existing systems the existing guidelines, standards , norms
etc. are also continuously revised or new ones are formed. Such
revisions and new guidelines are communicated to the Plants through
various Circulars which are uploaded on LPG intranet site. Plant

DEPARTMENT 10
PAGE No.
MAINTENANCE
personnel must go through these new/revised circulars/standards/Rules

etc. to ensure their timely implemenation,
10.9 INSPECTION AND MAINTENANCE OF BULK STORAGE AND

PRODUCT TRANSFER FACILITIES
10.9.1 A checklist for routine inspection is to be developed by each plant as

per relevant OISD Standards, manufacturers’ recommendations and
local requirements.
10.9.2 The inspection should perceive any conditions, which might in any way
reduce the safety standard of the operation.
10.9.3 Remote Operated Valves (ROV) should be inspected daily for proper
operation and response time. High Level Alarm (HLA) should be
checked daily for audio-visual alarm through test button & once in six
months for proper functioning by filling up the LPG vessel under
controlled conditions. HLA should be set to actuate at 85% volume
liquid level & interlocked with the liquid ROV of the vessel i.e. in case of
actuation of HLA when liquid level reaches 85% volume, the ROV on the
liquid line of the vessel must close preventing further entry of liquid LPG
into the vessel. While carrying out the above check, fixed tube level
gauge should be continuously checked thereby ensuring that vessel
never gets overfilled even if HLA is not working properly. HLA of storage
vessels should be kept in operating conditions always.
10.9.4 Gauging devices should be inspected to detect any leakage in their

fitment. Servo gauges are having provision to check the repeatability of
the reading by way of putting the float on the hoist position and then
observing whether the float returns to the same level when put on
normal position.
10.9.5 Provision of Filter, Regulator & Lubricator units close to the transmitter
and ensuring proper functioning of the same will aid in smooth
functioning of the Differential Pressure (DP) gauges. Draining of water
from the impulse line of DP gauges, zero setting and comparing the
reading with servo gauge must be done daily to ensure proper
functioning of these gauges.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.9.6 DETAILED EXTERNAL INSPECTION AND MAINTENANCE
(a) Storage vessels should be examined externally evaluating the

painted surface with particular attention paid to supports, saddles,
valve recess or areas that may be subjected to rust and corrosion.
For details on Inspection & Maintenance of storage vessels, OISD
Std.128 may be referred.
Vessels should be maintained with a well painted exterior surface;

free of rust or corrosion. In maintaining the vessels, the painting
operations should be undertaken before serious rust or corrosion
develops. Rust or corrosion is highly undesirable on LPG vessels,
since not only does the initial action reduce the wall thickness of the
vessels to a certain degree but also subsequent operations
necessary to remove the rust and corrosion such as grit blasting can
further diminish the wall thickness. Specifications of the paint to be
used & its application etc., shall be as per the Painting Manual with
latest amendments
During the statutory testing of the vessels, all the gauging devices,
Valves &ROVS installed in the vessels shall be overhauled. Displacer
of servo gauge has to be checked once in six months for any
possible sludge or dust deposit. Measuring wire of servo gauge also
has to be inspected for corrosion, twist or any other damage and
dirt on wire drum at least once in a year.
Condition of the bearings needs to be checked once a year.

Thorough cleaning of rack and pinion and float of Rochester gauge
has to be carried out when the storage vessel is de-commissioned.
Float should also be checked for any puncture.
(b) Safety Relief Valves must be carefully examined by ensuring that

the body of the inspecting person, particularly his face is kept well
away from the discharge end of the device. The interior of the
safety valve should be clear of any foreign materials, which may
interfere with its proper functioning. A mirror (preferably convex)
should be used during daylight hours instead of torch during the
inspection for better visibility. Drain-hole, if available on the body,

DEPARTMENT 10
PAGE No.
MAINTENANCE
should be open and clear. Vent stacks and protective rain cap also
should be inspected for any abnormalities.
(c) Shut-off valves or Control valves should be checked for possible

leakage.
(d) Non-return valve (NRV) should be tested for proper functioning

during the periodical hydrostatic testing of the pipelines.
(e) Excess flow check valves (EFCV) can be tested by closing a shut off
valve immediately down-stream of the excess flow check valve
and then venting a section of pipeline downstream of the shut off
device and connecting the line to the vent. Thereafter, the shut-off
valve can be opened rapidly causing closure of the excess flow
check valve.
(f) Strainers or Filters should be inspected for leakage or choking
(g) Temperature Gauges integral with the containers should be inspected

to determine whether they are working properly. Temperature Gauges
used in the wells should be checked against standard thermometer.
(h) Flexible Hoses should be inspected for dimensional check,

cracks, tear, puncture, abrasion, kinks, bulges or any other damage
on hose surface, cracks on coupling, irregularities in the end assembly
and electrical continuity. Hydrostatic test for the hose and pneumatic
test for the end connections also should be carried out periodically.
Detailed procedures, periodicity of testing etc. shall be as per our
Corporation guidelines.
Hoses in stock should be preserved against weathering and should

be subjected to test procedures as mentioned above prior to use.
Detailed inspection and testing procedure for LPG hoses are
covered under Clause No. 10.18
(i) Unloading arms used for tank lorry decantation should be inspected
regularly to check for leakages, free rotation of swivel joints & proper
lubrication. Balancing arrangement of the (un)loading arm is to be
checked daily for free movement and it should settle at a height equal

DEPARTMENT 10
PAGE No.
MAINTENANCE
to the level of TT valves. OEM guidelines for periodic maintenance are

to be carried out.
Ultrasonic thickness test of the arms is to be carried for each

segment of the arms near the joints and at mid-section at 3, 6 & 9
O’clock position and these segments are to be clearly identified on
the Arms with alphabets A,B,C etc. All arms are also required to be
prominently identified with Tag Numbers. Kindly note that the Tag
Nos. of the Arms should not change even if the arm is shifted to
another bay so that proper history can be maintained and
deterioration in thickness, if any, can be monitored for corrective
action.
The above tests are also required to be carried out on all Spool
Pieces which are used for connection with the unloading/loading
arms and TTs and records to be maintained separately for the same.
Each such spool piece are also required to be tagged with
identification mark which should not be changed during its service
life.
Hydrotest pressure shall be carried out at 30 kgf/cm2 for 30 minutes

along with the couplings, where provided.
(j) Pipeline systems should be inspected by tracing each individual line

fittings particularly for any indication of rust or corrosion. The
inspection should also focus on detection of leakages, if any, with
particular emphasis being placed on any screwed connections or
flanged joints.
Maintaining LPG, air and water pipe lines free of corrosion, erosion,
fouling, cracks, leakages etc. is of utmost importance for healthy
working of the plant. Special attention should be given to the ends
of thread connections and to smaller size of the pipelines since rust
and corrosion in these areas can lead to rapid failure. All the
underground pipelines should be properly coated, wrapped and
protected from the environment. While applying wrapping coating,
it is to be ensured that the wrapping and coating are extended up
to the horizontal portion of the pipelines. At no place the pipelines
without wrapping and coating should touch vegetation, soil or
humid areas. Colour coding used for the purpose of pipeline

DEPARTMENT 10
PAGE No.
MAINTENANCE
identification should be perpetuated during the repainting

operation.
It is to be ensured that the fasteners used for flange joints are studs
of low alloy steel and in no case carbon steel bolts are used.
Fasteners of proper size and specification preferably as per
A193/A194 should be used.
For Inspection & testing procedures, schedules, safe procedures to

be followed during pressure testing, etc., LPG M&I Circular no. 06
dated 20.08.2014 shall be referred. Updated pipeline engineering /
isometric drawings as well as P & I Diagrams should be available in
the plant. Records of Inspection shall be maintained in the plant for
assessment of health of pipelines both aboveground &
underground.
In essence, the inspection should cover each and every piece of

equipment within the plant with special emphasis on equipment
where leakage can occur. The exterior surface of each item should
be examined for rust, corrosion or signs of deterioration. All
equipment whether main/standby should be operated on regular
basis so that performance can be ascertained.
10.10 INSPECTION AND TESTS OF PRESSURE VESSELS THROUGH DIS-

ASSEMBLY
10.10.1 Inspection and Maintenance of LPG Pressure Vessels should be done
once in five years in accordance with Static & Mobile Pressure Vessels
(Unfired) Rules. 1981. OISD Std. 128 also deals with Inspection & testing of
unfired pressure vessels.
It must be noted that disassembly of pressurized systems is a specialized

job and should be carried out by speacilist. Re-assembly should be
performed after thorough inspection and issue of fitness certificate by a
third party inspection agency. While re-assembling the vessel, all gaskets
and studs attached to the vessel should be changed. After 5 year
testing of storage vessels, fitness certificate is to be received from
CCOE approved third party, who witnessed the 5 year testing and
CCOE informed regarding commissioning of the vessel. However, in
case of any repairs/modifications to storage vessels, prior approval

DEPARTMENT 10
PAGE No.
MAINTENANCE
before carrying out the repairs/modifications from CCOE is required .

Approval from CCOE is required before commissioning storage vessels in
case of repairs/modifications. 5 year testing of storage vessels shall be
planned well in advance so as to complete the same before the vessel
is due for testing. Storage vessels , Which are due for testing, shall not be
used unless specifically approved by CCOE.
10.10.2 All fittings attached to or contained within the vessel should be

inspected and replacement / repair carried out when the vessel is
decommissioned.
10.10.3 In case complete internal and external inspection with hydrostatic re-
test is required, the vessel must be emptied, the internal pressure
reduced to atmospheric and residual vapor dispersed safely by filling
the vessel with water.
10.10.4 Any fitting that is likely to be damaged by the hydrostatic pressure must
be removed and the opening is properly closed prior to carrying out the
hydrostatic test.
10.10.5 In case the vessel entry is required for the purpose of inspection, special
precautions as applicable must be observed. Statutory regulations,
wherever applicable, for such operation must be strictly adhered to.
Given below is a generalized outline of the procedures :
(a) All the work pertaining to a storage vessel should be carried

out under the strict supervision of a competent person who should
be present during the entire operation.
(b) The vessel must be positively isolated from rest of the plant pipeline
system. This should be accomplished by the removal of valves,
fittings, or pipelines with appropriate plugs blanks fixed to the open
ends. The vessel should then be purged of LPG.
(c) Before entering into the vessel, availability of sufficient oxygen must
be ensured by checking the same with oxygen meter prior to
vessel entry. The concentration of gas must also be measured by
an Explosimeter. The measurements should be made immediately
below the manhole and then at the mid point of the vessel and at
the bottom of the vessel. Only after repeated readings are taken

DEPARTMENT 10
PAGE No.
MAINTENANCE
at intervals of a few minutes, which show the concentration of gas

below 10% of the lower flammable limit, may a person be allowed
to enter into the vessel. The concentration of gas should again be
measured at the bottom of the vessel.
(d) From the time the workmen enter into the vessel till they leave the
vessel, a person on watch duty must be posted at the manhole.
The person on watch duty must keep in constant touch with the
men within and be aware of their activities at all times.
(e) Earthing connections of the vessel should not be disconnected

even after the vessel is empty.
(f) When any person is inside the vessel, the person on watch duty
outside the vessel must have means of communication to call
people for assistance, if required. In case the need arises for the
person on watch duty to enter into the vessel in an emergent
situation, he must secure a replacement for his position. The
person on watch duty must at all times have a flameproof torch, a
fresh air breathing apparatus, a lifting belt and a safety line.
10.10.6 Considering the inspection of a vessel in which man-entry is not required

after the initial pressure has been reduced to atmospheric level, the
valves and other fittings, if removed, must be replaced with tested
valves and fittings or openings to be closed by other means. If the
internal inspection is required, through whatever openings are
available, the vessel should be purged of LPG and lighting of approved
make used within the vessel for inspection purposes. The interior of the
vessel should be cleaned free of any foreign materials before being
returned to service.
10.10.7 Documentation of inspection procedures should be made as per the

Static & Mobile Pressure Vessel ( Unfired ) Rules, 1981 and also a
detailed log of the procedures, operation and the persons involved
should be kept for the plant record.
10.10.8 Pressure relief valves may be removed after de-pressurization. If

required, they can be exchanged (with valve of same rating) or re-

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MAINTENANCE
conditioned and tested. Reconditioning of the removed valves may

be done at a convenient place and time.
Multi-port Pressure Relief Valves are so constructed that the valves may
be selectively removed and replaced, while the vessel is pressurized. It
permits the selective removal, testing and possible reconditioning of
individual valves on the valve assembly by rotation.
Reference should be made to the manufacturer’s manual for removal,

setting and replacement procedures. OISD Std. 132- Inspection of
Pressure Relieving Devices shall be referred.
Whenever testing of the safety relief valves is done to determine the

initial “Start-To-Discharge” pressure setting, a suitable testing device
must be employed so that regulated air or inert gas supply can be
applied to the inlet of the valve with a water seal of approx. 100mm
applied to the outlet. A pressure gauge must be attached to the inlet
of the valve to determine the pressure at which bubbles first appear
through the water seal at the outlet. Care must be exercised to ensure
that the operator’s face is not exposed to the discharge of the safety
relief valve, as violent discharge or “Pop” may be the first indication of
leakage. In addition to this test, the valve should be inspected to
determine that the guides and outlet end are in condition so that full
travel or lift is possible. The range of pressure gauge used for testing
should be twice that of the SRV test pressure. The two SRVs installed on
each LPG storage vessel shall be set at two different set pressures as per
OISD Std.144. Also all SRVs are to be tested for re-set pressure and
recorded
10.10.9 Valves attached to or installed within the vessel should be removed for
cleaning, inspection and testing. This includes excess flow check valves
& non-return valves. It is recommended that disassembly of any of these
valves should not be undertaken unless the original manufacturer’s test
and maintenance instructions are available.
10.10.10 Equipment such as pumps, compressors, etc., can be isolated from the
storage facilities and inspection performed independently of vessel
inspection. If inspection by disassembly is to be performed with the
equipment installed on site, precautions must be taken to ensure

DEPARTMENT 10
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positive isolation of the device from the pipeline system.
All aboveground pipelines used for LPG should undergo hydrostatic test
for a minimum of once in 6 years. Underground pipelines for LPG should
be hydraulically tested every year. Sections of the pipeline system
should be isolated for convenience of testing. A test pressure of 125% of
maximum allowable working pressure of the pipeline should be applied
for a period of at least 30 minutes without indication of leakage.
Thickness survey of pipeline should be undertaken once in three years
and the readings must be compared with last reading and designed
thickness. If during the trend analysis, appreciable thickness loss has
been observed, frequency of survey shall suitably be enhanced.
Provisions of OISD Standard; OISD-STD-130 and section 9.5.3 of OISD Std.

144 on inspection of above ground and underground pipelines shall be
followed
10.10.11 Pressure testing, water should be drained off from all lines and blown
before being returned to service. Flanges disconnected during the
testing procedures should be refitted with new gaskets and studs.
10.11 MOUNDED STORAGE VESSEL
10.11.1 Mounded vessels are distinct from other above ground pressuyre vessels
in that Pressure Vessels are fully contained within a mound except man-
ways and dome for nozzles on each vessel that protrude from the top of
the mound and in some Plants provided in a nozzle box enclosure and
the vessel is protected from corrosion through Cathodic Protection
system ( CP System )
10.11.2 All the regular testes as per Statutory norms and OISD Std. 128 and as
stated above, the vessels are also required to be tested for the Health
of CP System and settlement of the vessel. Following are the schedules
for inspection of mounded storage vessel including the CP system:
a. Weekly- CP Parameters at TRU

b. Quarterly- CP parameters at JBs at site
c. Half Yearly - Settlement reading of the Vessel
d. 5 yearly- NDT of weld joints- radiography/WMPT/DPT/
Ultrasonic flaw detection and UT

DEPARTMENT 10
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e. 10 yearly- Hydrotest of vessel
Settlement reading of the vessel is to be taken along the longitudinal

axis of the vessel to assess the overall settlement of the vessel as well as
to establish relative settlement of the vessel along the longitudinal axis.
All procedures and documentation of for inspection and maintenance
of mounded pressure vessel shall be governed by SMPV (Unfired) Rule,
1981 and its subsequent amendments, if any, OISD Std.128 and OISD
Std. 150
10.11.3 CATHODIC PROTECTION SYSTEM
Cathodic Protection (CP) System has been provided for Mounded

Storage vessels at the LPG Plants as the secondary protection against
corrosion while paint coat on the vessels act as the primary protection.
Though CP system is an effective means to prevent corrosion in the

vessel where bare metal of vessel gets exposed to environment due to
damage to paint coat, its operating parameters need to be closely
monitored on regular basis to ensure its effective functioning. Any
deterioration in the operating parameters may lead to corrosion of
vessel if timely corrective action is not taken.
To strengthen the monitoring of the CP system the following aspects

need to be followed:
One must go through the O&M ( Operations & Maintenance ) manual

of OEM and OISD Std 150 and acquaint himself/herself on the various
O&M ( Operation & maintenance ) aspects of the CP system
Plants having Mounded Vessel must have Cu-CuSO4 Half Cell (Portable
Reference Cell) for taking Vessel to Soil Potential at 12 O’clock Position
on the vessel mound where-in a PVC sleeve is provided for the same. In
case provision is not made the same is to be provided.
The polarization cells (also called Kirk Cells) through which earthing
connection of the vessels are routed to the earth pit, shall be checked
quarterly for replenishing of the liquid levels (OISD 150 -9.2 a (iv)). It
should not be allowed to go below the low level mark. Add water to
bring the solution to high level. If regular replenishment is required

DEPARTMENT 10
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change solution (30% KOH Solution) every year. Brief write-up on

Polarization Cell is enclosed. Electronic device has now been
developed in in lieu of Polarization cells with KOH solution.
Given below are two CP system monitoring formats to be maintained as

CP Log Book in the room housing the TR Unit. These are formats-
LPG/OPS/046 and LPG/OPS/047. It is to be ensured that parameters are
monitored and recorded as per the details given in the format..
One must ensure that the intended protected vessel and fittings is
effectively insulated from the unprotected side through prper
insulation/monolithic joints to prevent any leakage of CP current into
the unprotected portion.

DEPARTMENT 10
PAGE No.
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LPG/OPS/046
LPG BOTTLING PLANT, ___________________
WEEKLY DATA COLLECTION REPORT
Date : Time :
Parameters to be noted on the Transformer Rectifier Unit

Mode of Operation (Tick AUTO AVCC MAN
mark relevant Box)
AC Voltage Volts AC Current Amps

DC Voltage Volts DC Current Amps
Voltage Selector Switch position
Current Selector Switch position
Reference Voltage (PSP) in V ON Potential OFF potential
Ref. Electrode of Bullet No. 1 V V
Check Alarms & Indications (tick whichever is applicable)
Mains ON ON OF Reference 1 ON OF
Lowest
F F
Under Protection ON OF Reference 2 ON OF
Lowest
F F
Over Protection ON OF Reference 3 ON OF
Lowest
F F
Over Current ON OF Reference 1 Fail ON OF
F F
Unit in Auto Mode ON OF Reference 2 Fail ON OF
F F
Unit in AVCC Mode ON OF Reference 3 Fail ON OF
F F
All Reference Fail ON OF
F

DEPARTMENT 10
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MAINTENANCE
LPG/OPS/047
LPG BOTTLING PLANT, _____________________
QUARTERLY DATA COLLECTION REPORT
Date : Time :
Parameters to be noted on the Junction Boxes near the Mound:
1. At Reference Cell JB
Reference Voltage Bullet No : 1 Bullet No : 2 Bullet No : 3
(PSP) ON OFF ON OFF ON OFF
Ref. Electrode No: 1 V V V V V V
2. At Anode JB
Check Bullet No: 1 Bullet No: 2 Bullet No: 3

Current/
Voltage
Loop-1 mV A mV A mV A
Testing of Monolithic Joints (Quarterly basis) by using a external portable ref

cell
Check ON/OFF Bullet No: 1 Bullet No: 2 Bullet No: 3
Potential mV

DEPARTMENT 10
PAGE No.
MAINTENANCE
ON OFF ON OFF ON OFF

Liquid Line Protected
Liquid Line Un-
Protected
Vapour Line Protected
Vapour Line Un-
Protected
Any Other Line
Protected
Any Other Line
Protected
Use Portable reference cell inside the mound for Testing Protected side
Use Portable reference cell outside the mound for Testing Un-Protected side
Off Potential to be noted instantaneously after switching off DC output from TR unit
10.12 PAINTING OF EQUIPMENT

Proper painting of equipment is essential for appearance, safety and
protection of the equipment from environment. The exterior surface of the
pumps, compressors, strainers, manifolds, etc. should be maintained to
ensure long service life, ease of inspection and elimination of fire hazards.
Equipment, which may be removed from the system for periodic
disassembly and maintenance, should be thoroughly cleaned and painted
before being re-installed in the system. In this way, cleaning and painting
can usually be much more efficiently accomplished. For specifications of
painting and application methods, painting manual may be referred along
with all subsequent amendments/Circulars.
10.13 LPG PUMPS
10.13.1 The preventive maintenance schedule shall be prepared by the plant

on the basis of OISD standards, OEM recommendations and local
requirements, if any. The pumps used for LPG service are generally
centrifugal pumps of single stage or multistage having double
mechanical seals in each gland. In few locations, vane type positive
displacement pumps are also used. The pumps should be inspected for
leakage and parameters such as discharge pressure, suction pressure &
motor load current shall be observed during the operation of the pump.

DEPARTMENT 10
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Condition of mechanical seals, earthing, flame proofing of motor gland,

etc., also need to be checked during the routine inspection of the
pumps. Condition of bearings can be assessed by observing the sound
and temperature during the operation of the pump. Vibration probes
and temperature guns can be used to know the vibration level and
temperature of the bearing casing at a plant
.
10.13.2 Vibrations occur in a pump mainly due to loose foundation bolts,

defective bearings, bent shafts, and mis-alignment besides several
other reasons. In case of any abrupt increase in vibration / noise levels,
corrective action will have to be initiated immediately.
10.13.3 Proper functioning of the alarm & trip devices for cavitation protection (
Pressure switch on discharge pipeline shall trip the pump in case
discharge pressure falls below set pressure during cavitation), low level
of seal coolant, seal failure alarm should be checked for proper
functioning for protection of pump and mechanical seal and prevent
any unsafe condition on account of malfunctioning of these protection
devices.. An annunciation panel with audio-visual indication for the
various alarm/trip conditions should be provided.
10.13.4 When minor repairs are to be carried out, it may be possible at times to
repair the pump installed in the system. In this case it is absolutely
essential that the valves connected to the pump are closed and
preferably locked before starting repairs. The pump must be vented of
any LPG before starting the work. Work permit system must be adhered
to carry out the repairs. After minor repairs are completed, the pump
should be carefully tested after work permit clearance to determine
that it is operating satisfactorily before being returned to normal service.
10.13.5 If the unit is removed from the system before repairs, an alternate pump
should be used and the connecting pipelines should be fitted with the
blind flanges until the pump is returned to the system.
10.13.6 Due to the relatively close fittings involved in the LPG pumps, the parts
of the entire assembly must be kept clean and free of dust, dirt or other
foreign materials when repairs are undertaken.

DEPARTMENT 10
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10.13.7 Gaskets, packing, fasteners and lubricants specifically recommended

by the manufacturers only should be used, while carrying out the
repairs to pumps.
10.13.8 Testing of an LPG pump may be accomplished by testing the pump

under flow conditions after making sure that adequate supply of LPG is
available to the suction and then imposing specific back pressure on
the pump. Quantity of LPG pumped can be ascertained by means of
the liquid level gauging at the vessel and based on the quantity
measured, specific flow rates can be determined. This information can
be compared with the manufacturer’s specifications to determine the
relative efficiency of the unit. It is essential that the pump be operated
at the speed recommended by the manufacturer.
10.13.9 For further details on Inspection and maintenance of pumps OISD

Std. 119 may be referred.
10.14 LPG VAPOUR COMPRESSORS
10.14.1 The preventive maintenance schedule shall be prepared by the plant

requirements, if any.
LPG compressors used in the bottling plants are generally of

reciprocating type and the following procedures are to be adopted for
inspection and maintenance:
(a) Compressors should be inspected for leakage of both product

and lubricant and parameters such as discharge pressure, suction
pressure & motor load current shall be observed during the
operation of the compressor.
(b) Vibrations occur in compressors mainly due to loose foundation

bolts, defective bearings and mis-alignment between pulleys,
besides several other reasons. In case of any abrupt increase in
vibration / noise levels, corrective action should be taken
immediately

DEPARTMENT 10
PAGE No.
MAINTENANCE
(c) Proper functioning of the alarm, alarm indication & trip devices
such as low suction pressure, high discharge pressure &
temperature, low lube oil pressure, high liquid level in the suction
volume bottle should be ensured for safe and efficient operation
of the compressors.. Audiovisual annunciation of the compressor
control panel for indicating the trips should be functional.
(d) When minor repairs are to be carried out, it may be possible at

times to perform the repairs with the compressor installed in the
system. In this case, it is absolutely essential that the valves
connected to the compressor are closed and preferably locked
before repairs are started. The compressor must be vented of any
LPG before the work is started. After repairs are completed, the
compressor should be carefully tested to determine that it is
operating satisfactorily and trip devices are functional before
being returned to normal service.
(e) Proper flow of cooling water for the compressor cylinder jacket
cooling as well as cooling for stuffing box shall be ensured. Safety
valve provided at the compressor discharge shall be tested and
serviced as per the frequency prescribed. Test date and test
pressure must be dispyed on the SRV. SRV shall be sealed in set
condition.
(f) Compressors may be tested by determining the pressure

differential, which can be created by the unit when it is operated
at the speed specified by the manufacturer. A pre-requisite to this
test is pipeline of adequate size to eliminate line restrictions.
For further details on inspection and maintenance of compressors OISD

Std. 120 may be referred
.
10.15 VESSEL VALVES AND ACCESSORIES

10.15.1 Gate valves, globe valves, non-return valves, excess flow check valves,
remote operated valves and ball valves are used for LPG service. For
safety reasons, it is always advisable to use two valves in series. Valves of
minimum class 300 lbs. rating are to be used in LPG service. Accessories
used include flanges, blinds, gaskets, pressure relief valves & studs.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.15.2 Wearing parts of the valves that need replacement are resilient seat
disc and sealing elements. Resilient materials used for sealing elements
and seat discs are in most cases compounded specifically to resist the
action of LPG. Therefore, the original equipment manufacturer’s
recommended spare parts towards replacement only should be used.
Such spare parts should be available in the plant prior to taking up the
valves for repairs.
10.15.3 Valve body thickness measurements shall be done for the valves
without dismantling for assessment of their health by using ultrasonic
thickness tester. However, thorough internal examination of the valve
seats & internals can be done only after dismantling the valves, which
may be done during the period of partial / total shut down
maintenance.
10.15.4 For detailed procedures for inspection and testing of valves and
accessories, OISD Std. 130 can be referred.
10.15.5 Other than replacement of seat discs & springs, no other repairs shall be
carried out in the safety relief valves. Safety relief valves shall be
subjected to inspection & testing once in a year.. During the visual
inspection of the safety valves after dismantling, flange condition for
pitting, roughening, decrease in width of seating surface and springs for
evidence of bending, cracking and corrosion shall be checked. For
detailed procedures for inspection and testing of safety valves and
accessories OISD Std. 132 may be referred.
10.15.6 Excess flow check valves should not be repaired but replaced, if found
defective.
10.15.7 DIFFERENTIAL PRESSURE VALVES, STRAINERS, LINE VALVES, SIGHT

FLOW,INDICATORS, BULKHEAD FITTINGS, etc.
10.15.7.1 Sufficient stock of spare parts towards replacement as recommended

by the manufacturers is to be carried in stock at the plant
10.15.7.2 While repairing or removing any of these items, the pipeline system in
which they are located must be shut off and equipment vented safely
before any repairs are undertaken.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.15.7.3 Differential Pressure valves normally have a diaphragm made up of

rubber & spring. While repairing, diaphragms & springs supplied by the
original equipment manufacturer shall only be used as replacement
parts.
10.15.7.4 Strainers usually require nothing more than periodic cleaning as a

maintenance operation. Care should be taken to ensure that the
screen fits properly within the strainer before re-assembly. While taking
out the strainers for cleaning, adequate precautions for immersing
strainer screen in the water & spraying of water on to the strainer interior
should be done so that action of pyrophoric iron does not create any
unsafe situations.
10.15.7.5 Line valves usually require replacement of stem seals of resilient seats in
case of wear outs. Only those materials that are specifically resistant to
the action of LPG should be used for replacement.
10.15.7.6 Sight Flow Indicators utilize a transparent material with strength of

properties not found in other materials that may appear to be similar.
Therefore, only sight flow glasses recommended by the manufacturer
should be used.
10.15.8 PIPELINES
10.15.8.1 Provision of OISD 130 and 9.5.3 of OISD-144 shall be applicable

inspection and testing of pipelines While repairing pipelines the
objective should be to make the installation with minimum number of
joints. Joints may create possibility for leaks and may also cause
restrictions to the flow.
10.15.8.2 Usage of pipe clamps or compression type couplings for arresting the
leakages from LPG pipelines should be restricted to extreme
emergencies and should be removed and leaky / corroded sections of
the pipelines replaced at the earliest.
10.15.8.3 NDT tests like Dye Penetration Test (DP), wet magnetic particle
inspection test (WMPI), Hydrotest etc. as per code of practice shall be
carried out before re-commissioning., Hydrotest shall be carried out at
125% of the design pressure of the pipeline.

DEPARTMENT 10
PAGE No.
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10.16 LPG TANK WAGONS: INSPECTION & MAINTENANCE
10.16.1 Whenever an LPG tank wagon is received at the plant, visual

inspection shall be carried out to determine that the tank wagon bullet is
leak free. In case minor leakage is observed and if the product can be
safety dissipated in the immediate area, every effort should be made to
immediately unload the tank wagon. All precautions should be taken to
see that the area surrounding the tank wagon is kept free of all possible
sources of ignition.
10.16.2 If the inspection reveals the leakage of a greater magnitude, full

emergency precautions should be observed, while unloading the tank
wagon.
10.16.3 Complete periodic Inspection and re-qualification of tank wagons are to

be performed by the Railways in accordance with the requirements of the
design code.
10.16.4 Within the dome of a tank wagon the following items are provided and
should be Inspected to determine that they are leak-free
(a) Liquid Eduction Valve should be tested to determine that it

does not leak when it is closed. A plug or closure device should be
installed at the outlet. If the liquid level is relatively low in the tank
wagon, the presence of the eduction tube or pipe extending from
the valve to the bottom of the tank wagon can be tested by
crack opening the valve. If the discharge of liquid is noticed, the
tube is in place. If not, the tube has become displaced. The
excess flow check valve immediately beneath the liquid eduction
valve may be tested by connecting the outlet of the valve to the
vent and then rapidly opening the valve. If the bullet is pressurised,
the excess flow check valve should close as the rapid opening is
caused.
(b) The Vapour Valve should be tested for gas tight seal in the shut-off
position. A plug should be available at the outlet connection. The
excess flow check valve attached to the vapour valve may be
tested by connecting the outlet of the vapour valve to the vent
system and then rapidly opening the valve. This action should

DEPARTMENT 10
PAGE No.
MAINTENANCE
cause automatic closure of the excess flow check valve provided

the bullet is pressurised.
(c) Pressure Relief Valve is inspected to determine that the vent outlet
is free and clear. This operation should be performed without
exposing the inspector’s face to the end of the valve. A mirror may
be used for this purpose.
(d) Magnetic level gauge may be inspected for free movement of the
graduated tube within the opening of the gauge and holding of
the tube at the liquid level due to magnetic coupling.
(e) Sampling Valve should be tested for any leakage while in closed
condition. Rapid opening of the sampling valve, when the outlet is
connected to a vent, should lead to closure of the excess flow
check valve on the sampling-line inside the bullet. The sampling
valve may be further tested, if the liquid level within the tank
wagon is relatively low, by opening the valve slightly. If liquid
appears, the sampling line is intact. If not, it has become
disconnected or broken and would therefore needs replacement.
(f) Thermo well can be leak tested, by removing the sealing cap and
filling the well with a suitable anti-freeze solution. By observing the
surface of the liquid within the tube, it will be evident if a leak
exists. In no case water should be used for such a test.
(g) Shut-Off valve: in case leak is observed in shut-off valves, an effort

should be made to close the valves by applying normal pressure
on the handle. If the leak does not stop, plug shall be fitted to the
valve outlet and the valve opened slightly. This may remove
foreign matter on the valve seat, if present. The valve should then
be closed by hand pressure and the plug loosened carefully to
allow for the discharge of the trapped LPG. If the leak persists, the
plug should be used to close the valve outlet after unloading
operation is completed.
The valve should be suitably marked as “DEFECTIVE” and the same

be mentioned in the tank wagon release memo. Information
should be passed on to dispatching location also in writing. In case
leakage is observed around the valve stem, the packing nut may

DEPARTMENT 10
PAGE No.
MAINTENANCE
be tightened to eliminate the same. If leakage is observed at the

base flange the hold down bolts in the flange should be tightened
to eliminate the same.
(h) Pressure Relief valve: Discharge from a pressure relief valve could
either be due to leakage from the valve seat or the valve has
performed its intended function. In case of former, the wagon
should be unloaded after taking due precautions and Railways be
informed through tank wagon release memo. If the valve opens
due to increase in the pressure in the vessel, the reasons for the
same shall be investigated and immediate corrective action be
taken.
(i) Gauges: If the leakage is observed above the cap of the plug
of the thermo well, the connection should be tightened. If the
leakage cannot be stopped, the cap or plug should not be
removed since it is possible that the same will result in liquid
discharge. If the leakage cannot be eliminated, adequate safety
precautions should be observed until the wagon is emptied out
and depressurised for subsequent removal of the tube, by railway
authorities, for repair/replacement
Railways carry out repairs of the tank wagons. However, any defect
noticed by the plant in the tank wagons shall be intimated to railways
for corrective action.
10.17 INSPECTION OF LPG TANK TRUCKS
10.17.1 INSPECTION OF VEHICLE
10.17.1.1 It should be ensured that the vehicle complies with RTO and
CCOE’s regulations and has valid permits / certificates such as
load permit, registration, insurance, tax payment, fitness certificate,
etc.
10.17.1.2 Prior to the utilization of a vehicle, inspection should be carried out to

determine that it is in satisfactory condition and is capable of
completing the assigned trip safely.

DEPARTMENT 10
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10.17.2 INSPECTION OF TANK TRUCK BULLET
10.17.2.1 Prior to the utilization of tank truck, an inspection should be performed

as per OISD 144 Annexure- 7-I to determine that :
(a) Tank truck has valid CCOE’s license for transportation.

(b) The bullet and its fittings are apparently in good condition. There are
no signs of damage or corrosion and loose wirings are not present.
(c) The vehicle is in sound running condition.
(d) In the case of new tank truck returning after repairs /
pneumatic test, it should be ensured that it is purged before filling
LPG. Purging /Hydrotest certificate as the case may be, must be
checked
(e) Spark arrestor approved by CCOE is available and welded to the
exhaust.
(f) Master cut off switch is available.
(g) TT is fitted with ABS as per norms
(h) Bullet design shall be as per the the CCOE approved fabrication
drawing copy of which shall be available with the TT.
10.17.2.2 The following fittings in the tank truck also need to be inspected :
(a) Safety Relief Valve: Vents must be clear and free.

(b) Roto gauge: The gauge should be functional and the dial or
scale must be legible. Also the rotation of the roto gauge tube
should be smooth and free from obstructions. Rotogauge plate
should not be loose rotatable
(c) Liquid & Vapour line connections: Check valve spindle for any
jamming.
(d) Excess flow check valve : Truck must be fitted with Excess flow
check valve ( EFCV) between the shut-off valve and tank. In a
recent order PESO has mandated for provision of internal valve
with EFCV during SRV test/Hydrotest of the vessel ( whichever is
earlier with effect from 01.01.2014. This shall replace the stand
alone EFCV protruding out of the vessel and which gets
subjected to shearing –off during accidents.

DEPARTMENT 10
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10.18 INSPECTION AND MAINTENANCE OF LPG HOSES
10.18.1 GENERAL
10.18.1.1 LPG hoses in India are manufactured as per IS 9573. Imported LPG hoses
conform to BS 4089, section 2 of which is superseded by BS EN 1762.
LPG hoses being of flexible nature constitute a weak link in the
pressurised system. Therefore, due importance must be attached to its
proper inspection, maintenance and care while handling.
10.18.1.2 LPG hoses should be subjected to a brief visual examination to check

for any apparent signs of failure or weakness whenever they are put into
use. In case of slightest doubt, the hose should be subjected to tests
described in subsequent clauses given below, before continuing its use.
OISD Std. 135 Part-B should be referred for guidance on the
manufacture of LPG hoses.
10.18.2 PERIODIC INSPECTION AND TESTING OF LPG HOSES
10.18.2.1 Each hose should be tested minimum once in four months as detailed in
subsequent clauses. Those hoses that are found unsuitable for LPG
service shall be disposed off. A metal tag of non-ferrous material should
be attached to each hose so that the serial number, date of
commissioning and date of testing could be conveniently punched.
10.18.2.2 The date of last test should be checked while using the hose and it
should be sent for testing if a period of four months lapses after the last
test. If a hose fails any of the tests detailed below, an attempt should
not be made to cut away the defective portion and re-use the balance
length, but the entire hose length should be discarded from LPG service.
Due care must be exercised while using, handling or storing LPG hoses
as per guidelines given in subsequent clause.
10.18.2.3 VISUAL INSPECTION
(a) The hose should be laid out as straight as possible to

avoid kinking during examination. The hose should be
examined closely for cuts, abrasions, soft spot, bulges and other
defects; with the internal pressure reduced to atmospheric.

DEPARTMENT 10
PAGE No.
MAINTENANCE
(b) Hoses having cuts in the coverings that have damaged or

exposed reinforcement fabric should be discarded.
(c) Small cuts and nicks in the outer cover should not be generally
a cause for hose replacement, unless the rubber involved is
loose or the reinforcement is exposed.
(d) The area adjacent to the end fitting up to a distance of

minimum 50 cm from the fitting should be carefully examined
by pressing the hose with the thumb to detect any soft spots or
bulges. Hoses having such weaknesses should be removed
from LPG service immediately.
(e) Hose should be removed from LPG service immediately, if

blisters or loose outer cover is observed on inspection.
(f) Each coupling should be inspected for slippage that may

be noticed by misalignment of the coupling on the hose end
and / or scored or exposed areas where slippage has occurred.
In case of any evidence of slippage, the hose shall be removed
from LPG service.
(g) A hose subjected to unusual abuse such as kinking or

flattening by a vehicle shall be removed from LPG service.
(h) The hoses that pass all the above visual inspection
tests shall then be subjected to hydrostatic, pneumatic
and electrical continuity tests as described below;
hoses failing any of these tests must be discarded for LPG
service
10.18.2.4 HYDROSTATIC TEST
(a) The test should be carried out at minimum once in every four
months. Hydro Test pressure is 25 kg/cm2 for a period of 5 minutes.
(b) Original length of the hose as recorded in the hose history card/data
card should be noted

DEPARTMENT 10
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(c) Hydraulic pressure using water should be developed using a hand-

operated hydraulic pump.
(d) The end of the hose should be closed by a blank flange, plug
or cap fitted with a bleed valve. At the other end, the delivery
side of the hydraulic pump should be connected.
(e) Before applying the pressure through the pump, the hose must be
completely filled with water taking precautions to ensure that the air
is completely removed from the hose, using the bleed valve.
(f) With the hose completely filled with water, pressure should be
gradually increased at the rate of 0.1 to 0.7 kg/cm2 (g) per
second using the hydraulic pump. The pressure gauge used for
testing should be calibrated and its range should preferably be
twice that of test pressure.
(g) The test pressure applied should be maintained for a period of 5

minutes and the hose critically inspected for any sign of deformation
and any noise such as ‘pops’ or ‘snaps’. The hose should be rejected
from LPG service if any leak or deformation is observed.
(h) After releasing pressure and draining water, the straight length of the
hose should once again be measured and recorded from one end
to the other. In case a variation in length is more than 5% when
compared to the original length (without pressure) the hose should
be discarded from LPG service.
(i) LPG hoses shall be discarded after 3 years of service irrespective of

test result or earlier in case the hose fails during the test on any
account. Plant must make advance planning to replenish the stock
of hoses to ensure the availability of hoses meeting these criteria.
(j) After the hydrostatic test is over, water content should be fully
drained and the hose interior thoroughly dried before putting to re-
use.
(k) The interior of the hose should be inspected visually to check that the
liner is intact and there is no foreign material present.

DEPARTMENT 10
PAGE No.
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10.18.2.5 PNEUMATIC TEST
The hose should be tested with air pressure of 3.5 kg/cm2 (g) with the
hose end plugged and submerged in water. The pressure should be
maintained for a period of minimum 10 minutes. The test should be
carried out minimum once in four months.
10.18.2.6 ELECTRICAL CONTINUITY TEST : Minimum once in four months the

hose should be tested for electrical continuity. The electrical resistance
measured over the entire length of the hose, complete with its
connections, shall not exceed 0.75 ohms per metre length of the hose.
The test should be done after completion of hydrostatic and pneumatic
test.
10.18.3 HOSE CARE
(a) The hose should be laid down straight on solid supports when not
in use.
(b) The hoses should be covered to protect them from sun light. Cool,
dark and dry storage space is preferred.
(c) Before returning the hose to storage after use, it should be
completely drained.
(d) The new hoses from the store should be used on ‘First-In-First Out’
basis.
(e) Care should be exercised to ensure that people does not step over
the hoses. Likewise, vehicles should not be allowed to be driven
over the hoses.
(f) Care should be exercised to avoid twisting and kinking while
handling.
(g) Hoses should not be lifted from a single point with the ends
hanging down. While lifting the hose it should be supported
at least by two slings located near the ends.
(h) Hoses should not be allowed to lie in a pool of oil or other
liquid that may affect the rubber compound.
(i) Care should be exercised to ensure that the valves are not
operated with a sudden jerk to avoid sudden increase or
decrease of pressure in the hose. Closing / opening of the valves
should be done in a gradual manner.
(j) Hoses should not be allowed to touch any hot surface.

DEPARTMENT 10
PAGE No.
MAINTENANCE
(k) Means should be provided to prevent ingress of moisture

during storage and transportation..
(l) Whenever LPG is retained in the hose under pressure, suitable
arrangements for thermal expansion must be provided.
10.19 INSPECTION AND MAINTENANCE OF CYLINDER FILLING

MACHINES
10.19.1 GENERAL :
Filling systems can be broadly classified as Carousels and Unit filling

machines. Each of these types of filling systems is available in
mechanical & electronic versions. Inspection & maintenance of the
filling systems will depend upon the type of filling machines and the
procedures are covered under the heads “Daily procedures &
Complete Inspection”. Operating personnel shall be conversant with
the daily procedures so that optimum output of highest quality can be
derived from the filling machines.
The daily procedure primarily covers observations to determine that

operations are being conducted in accordance with pre-determined
standards and that the carousel speed can be adjusted commensurate
with the type and size of cylinder being handled. In general, it should
aim to ensure that the efficiency is being maintained. Observations
relating to basic safety should also form a part of daily checks. This
would primarily include exercising control over the accuracy of the
filling operation, the immediate elimination of any leakage of product
within the system and constant surveillance to ensure that the safety
precautions are being observed. Earthing and bonding integrity of the
frame, filling machine, filling guns shall be maintained at all time.
Complete Inspection and maintenance of filling machines, central

column, electrical and instrumentation system shall be carried out as
per the preventive maintenance schedule of the plant. This should
include checking of the carousel rail levels, knife-edges/ load cells,
central column, drive unit, flexible hoses, introduction and ejection
devices, clamping arms, table etc.
Critical and long lead spares should be available at all times to ensure
maximum utility and efficiency and minimum downtime in case of any

DEPARTMENT 10
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MAINTENANCE
unforeseen breakdown.. In the case of Electronic filling machines,

condition of glands, sensors, flame-proof integrity, proper terminations,
etc., shall also be checked periodically. The preventive maintenance
schedule shall be prepared by the plant on the basis of OISD standards,
OEM recommendations and local requirements, if any. One has to keep
in mind that variation in weight may not necessarily be indicative of
inaccuracy in the scales but may be caused due to variation in the
filling pressure or re-positioning/replacement of a filling hose.
As all Plants are now provided with Electronic carousel it is very essential
to have proper electrical supply and earthing system. Each carousel
must have dedicated earth pit with no other equipment earthing
connected to the pit. The potential difference between the earth and
neutral should not be greater than 0.5 volts ( 0 Volts would be ideal ).
It is also essential that all critical spares are procured through OEM for
healthy upkeep and efficient performance of the equipment on
sustained basis.
10.19.2 INSPECTION & MAINTENANCE OF CHECK SCALES

Check scales available in the bottling plants are of mechanical &
electronic types. Proper inspection & maintenance of check scales are of
utmost importance from the point of view of the quality of cylinders as well
as safety. Preventive maintenance schedule for each plant shall be
prepared on the basis of OISD standards, OEM recommendations and
local requirements, if any. It is essential that calibration of the equipment is
maintained at all times. For this purpose the check scales must be
calibrated with Standard weight and records for the same shall be
maintained.
.
10.19.3 INSPECTION AND MAINTENANCE OF WATER TEST BATH
The following shall be checked for water test baths:
a. The interior of the water bath should be painted white and the
bright finish should be maintained by regular cleaning and
painting.
b. Specified minimum water level must be maintained throughout
the operation. At the same time, filling of water beyond

DEPARTMENT 10
PAGE No.
MAINTENANCE
maximum specified level should be avoided to prevent the over

flow.
c. As and when the water gets dirty, it should be replaced with clean
water.
d. Light fitting provided above the test bath should be adjusted for
proper illumination in the leak detection area of test bath.
e. It must be ensured that guide rails are properly adjusted to ensure
that the water level is below the SC Valve top and above the
bung
10.20 INSPECTION OF VALVE LEAK / O - RING LEAK CHECKING

EQUIPMENT
10.20.1 Valve leak & O-ring leak is checked by using Compact Valve Tester (CVT),
Automatic Valve Testing System (AVTS) or Electronic Gas Detector. In some
Plants it is called GD-PD ( Gas detector- Pressure detector. Segregation of
Valve Leak & O-ring leak has to be done manually in a CVT. In some Plants
AVTS segregates all leaks irrespective of whether the leak is O-Ring leak or
Valve leak. Secondary stage segregation has to be further carried out
between O-ring & valve leaks and in some Plants, there are two rejection
loop downstream of the AVTS and depending upon the detection of O-
Ring defect (OD) or Valve leak defect (VD), cylinders are rejected into
respective loops for further processing/correction. Yet in some Plants, we
have GD to detect valve defect with a downstream rejection loop and
sound cylinders then proceed to PD for O-Ring defect6 heck with a
rejection loop in the downstream. Electronic valve leak detector employs
Infrared sensor or pressure sensor for detection of valve leaks. Infrared
sensor can also detect bung leak
10.20.2 Preventive maintenance schedule for each plant shall be prepared on the
basis of OISD standards, OEM recommendations and Corporation
guidelines.
Calibrate Electronic Leak detector with the calibrator. Check for valve
leak rejection at 0.5 gm/hr leakage as well as for no rejection at lower
level, say 0.3 gm/hr
10.21 ANCILLARY EQUIPMENT FOR LPG CYLINDER FILLING


DEPARTMENT 10
PAGE No.
MAINTENANCE
10.21.1 CHAIN CONVEYOR SYSTEM
10.21.1.1 The transmission sprocket must be properly aligned with the chain
conveyor sprocket.
10.21.1.2 Chain conveyors should be well lubricated with the soap solution. It is
essential to prepare soap solution as per recommended specification.
Proper mixing of soap solution only will ensure proper lubrication and
washing of dust / foreign materials from the chains and channels which
reduce wear and tear and enhance the life of chain and conveyor
channel
10.21.1.3 Conveyor chain length shall be checked and adjusted by removing or

adding chain links such that the tensioner acts on the chain sufficiently
dipping in soap water and the chain does not touch the bottom of the
soap tray. The counter weight, idler sprocket and drive sprocket should
be checked for its wear and tear. A loose plumber block may obstruct
free movement of chain and may affect alignment of the complete
drive system. It is essential to emphasise here that a well-maintained
conveyor system is a road to productivity. Spillage of soap water from
the conveyor system shall be avoided.
10.21.1.4 Telescopic loading and unloading conveyors should be checked for its
free forward and backward movement. The drive rollers should be
checked for wear and tear and if observed entire set must be replaced
instead of individual ones. Wherever tyre is used for traction, tyre
pressure should be checked regularly. Controls for the boom movement
and chain ON-OFF should be checked for proper functioning.
It must be ensured that housekeeping around the drive units are proper
with easy accessibility. Oil and water spillage around the foundation
tend to weaken the foundation and the foundation bolts then loosen up
and vibration in the machine starts leading to misalignment and
premature failure. Oil seal quality of gear box is critical for leak free
operation of the drive unit. It is preferable to purchase the same from
OEM. Coupling guards should be designed such that it can be
conveniently removed to facilitate inspection

DEPARTMENT 10
PAGE No.
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10.21.2 CYLINDER WASHING UNIT
10.21.2.1 Water level in the service water tank should be checked whether the
same is adequate. Water pump shall be checked for the development
of pressure and should be kept well maintained with proper coupling
guards, no gland leakage or corrosion.. Choked nozzles are to be
inspected and cleaned whenever necessary. Water in the water tank is
to be replaced after every shift or earlier depending on the condition of
the water. There should not be any water spillage / splashing outside
the unit and corrective action be taken, if required. Entry and exit
flappers to arrest water splash outside, shall be well maintained and
replaced regularly depending on their wear and tear.
10.21.3 CYLINDER DRYING UNIT
This unit is checked for any abnormal noise and the nozzles are checked
for choking and correct, wherever necessary.
10.21.4 PURGING UNIT
Vacuum pump shall be checked for proper functioning. OEM

recommendation for Operation and Maintenance ( O&M) as given in
the equipment O&M manual must be followed. Filter Regulator
Lubricator (FRL) is also to be checked. Bonding and earthing integrity of
purging adapters/guns. Hoses, machines must be ensured. Vacuum &
LPG cut-off switches are to checked for proper functioning. Cut-off
shall be based on vacuum and not timer.
It must be ensured that proper vacuum is created inside the cylinder ( -
0.65 kg/cm2 (g) ) and not just in the connecting pipe. To establish this a
proper SC valve adapter connected with a vacuum gauge is
recommended for random checking. A separate hose fitted with Proper
adapter ( for SC/L.O.T Valve ) for purging 47.5 kg LPG cylinders for
vacuum and LPG filling shall be provided at Plants with 47.5 Kg bottling
facility for purging new /tested 47.5 kg Cylinders received at the Plant.
10.21.5 WEIGHT CORRECTION UNIT
The check scale of this unit should be checked at the beginning of the
shift and then every two hours. The records of the same must be
maintained thereof. The FRL should be checked for pressure regulation

DEPARTMENT 10
PAGE No.
MAINTENANCE
and oil carryover. The check scale should be checked at various loads
with standard weights. The corrected cylinder should be counter
checked with post filling check scale. The pneumatics and electronic
interlocks should be checked for operation. It is worth mentioning here
that correcting overfilled or underweight cylinders is a repair work and
accurate working of this scale will enhance the productivity of the plant.
At some of the plants Weight Reduction Unit has been installed in place
of weight correction unit. In weight reduction unit, it is to be ensured
that some amount of product is taken out from each of the cylinders.
The proper functioning of pneumatics is to be checked for operation.
However, installation of Weight reduction unit should avoided due to
the fact that introduction of part filled (heavier cylinders) into the
carousel increases the wear and tera of the carousel table and also
reduces productivity when compared to Weight Correction Unit.
10.21.6 AUTOMATIC SAFETY CAP FIXING UNIT.
The unit should be checked for its proper operation. Centring and
Lubrication of the pneumatic parts should be ensured.
10.21.7 HOT AIR SEALING UNIT
10.21.7.1 In most of the plants, fixed type and portable hot air sealing has been
provided where PVC seals are used. Flame-proofness of such system
should be maintained. Thermostat cut-off should be tested periodically.
Whenever one of the two thermo couple is removed for maintenance,
it must be ensured that the thermo-well is plugged to prevent any
accidental leakage of hot air into the control panel in case of any
puncture of thermo-well. In no case should one tinker with electronics
that would jeopardize the FLP characteristics of the equipment. Thermal
insulation of the heated parts and surfaces should be well maintained
to prevent any hot burn injury. Pnematics and centering should be well
maintained for smooth operations.
10.21.8 EVACUATION UNIT
10.21.8.1 Preventive maintenance schedule for each plant shall be prepared on

the basis of OISD standards, OEM recommendations and local

DEPARTMENT 10
PAGE No.
MAINTENANCE
requirements, if any. Some of important checks for its operation and

interlocks. Are as follows:
a. The LPG hoses used should be periodically inspected and tested as

per the guidelines.
b. The liquid level gauge fitted in the evacuation tanks should be
functional at all times.
c. Safety Relief Valve should be tested every year. If any leakage is
observed, the same should be immediately arrested and the
defective parts replaced.
d. The wall thickness of the LPG vessel should be inspected periodically
and records maintained as per the State Factory Rules.
e. The vessel should be hydrostatically tested once in two/four years or
as required by the statutory regulations.
f. Removal of four-way valve should be undertaken after completely
de-pressurising the tank and water flushing. The tank should be put
in service after purging.
g. HLA shall be checked for its proper functioning through simulation
for audio visual indication in the annunciation panel.
h. Proper provision for evacuating pin defective cylinders shall be
made through proper breaking evacuation adapter. The adapter
must be check for its leak tightness and smooth movement of the
spindle.
i. Depressurizing system for depressurizing the cylinders after
evacuation must be check for its proper functioning.
j. Evacuation tilting stand for evacuation of 47.5 Kg LPG cylinders
must be checked for proper guards and rotational controls and
locks etc.
10.21.8.2 The sight flow indicator, NRV, excess flow check valve, pneumatically
actuated valves should be checked for operation. It is very essential to
maintain earthing and bonding of evacuation guns and the unit as a
whole. The unit should not be operated at all, if there is any break in
bonding within equipment. All pipes, fittings, flanges, studs and nuts shall
be of standard ratings.
10.21.8.3 At some of the plants, Auto Evacuation Unit has been installed along
with auto changeover system in the evacuation bullets. Proper
functioning of auto changeover system should be ensured as its failure
may lead to abnormal high level of product in evacuation tank. High-

DEPARTMENT 10
PAGE No.
MAINTENANCE
level alarm installed in Evacuation vessels shall be checked for its proper
working. Hoses of the auto evacuation unit shall also be tested at the
interval given above and records shall be maintained.
10.21.9 DE-PRESSURISING UNIT
The hoses should be thoroughly checked. The guns should be free of any
leakage. The unit should be properly earthed. Vent pipe shall be 1.5 m
above the eve of shed and the mouth shall be effectively earthed
10.21.10 VALVE CHANGING MACHINE
Check gearbox for the correct oil level, if gearbox is filled with
lubricating oil. Centering of the socket should be periodically checked
to avoid any damage to the valves. The pneumatic valves should be
lubricated at all times. The torque cut-off should be checked
periodically (at the beginning of shift and thereafter every two hours)
with a torque wrench and if any variation is observed, the same should
be corrected by adjusting the control unit. Flameproof fittings and the
glands should be checked for their integrity. PM schedule as per task list
should be adhered to.
Nowadays, Valve Change Machine without evacuation (VCWE) is being

provided at the Plants. It is very essential and critical to adopt the
procedures as laid out in equipment manual for their Operation and
maintenance to ensure safe operation of the equipment.. No interlocks
should be bypassed under any circumstances. Centering table shall be
well maintained. The machine must not be operated in case of any
abnormality is observed.
10.21.11 RANDOM QUALITY CONTROL (RQC) UNIT
10.21.11.1 The check scale should be checked with the standard weights at the
beginning of the shift and prior to carrying out RQC. A trained person
should calibrate the scale before it is offered for annual stamping to
Weights and Measures inspector. Pneumatic circuits and lifting table
shall be checked for proper functioning.
10.21.11.2 The CVT should be calibrated periodically. Checking and calibration of

CVT has been covered earlier in the chapter.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.21.12 DE-GASSING UNIT
10.21.12.1 The unit should be checked for proper operation. The pump and motor
should be checked for abnormal vibrations. The water used for de-
gassing should be changed periodically. The FRL should be checked for
proper functioning. The gear should be greased. The universal joint
should be checked for any leakage. Earthing of the unit should be
checked regularly
10.22 WEIGH BRIDGE
10.22.1 The weigh bridge should be checked and stamped once in a year by
Legal Metrology department and shall be internally calibrated on quarterly
basis or earlier case of abnormal variation in the weights is observed.
Calibration records shall be maintained at the Plant. The standard weights
should be kept around the platform and uniformity of reading should be
observed. The weigh bridge should be stamped annually by the Weights &
Measures Inspector. The earthing of the weigh bridge should be inspected
regularly. User interface unit should be checked for proper connections
and functioning of display, keyboard, etc. Printer attached to the unit
should be serviced periodically.
10.22.2 It is mandatory to keep standard weights for calibration of weigh bridge

as per Weights and Measurements Act. Weigh bridges must be calibrated
quarterly through at least 25% standard weights of the weigh bridge
capacity over the full range by checking incremental increases by keeping
loaded /empty trucks on the weigh bridge. Records shall be maintained for
such calibrations. Refer IS 1436:1991
10.23 AIR COMPRESSORS

10.23.1 The preventive maintenance schedule shall be prepared by the plant on
the basis of OISD standards, OEM recommendations and local
requirements, if any. The Compressors should be daily checked for lube oil
level, lube oil pressure, discharge pressure, discharge temperature and
flow of cooling water. Various trips such as high discharge pressure, low
lube oil pressure, cooling water flow, high discharge temperature and
overload should be periodically checked for functioning. Audiovisual
annunciation system should be in good working condition. At plants,

DEPARTMENT 10
PAGE No.
MAINTENANCE
compressors are run by Electric motor through belt drive. It is

recommended to replace all belts at time, whenever replacement of any
belt is required. It is a healthy practice to start and stop the compressors in
no-load condition. The air compressor should be interlocked with cooling
water pump. Plants having standby compressors must ensure that they are
alternatively run.
Plant are now being provided with air cooled Screw Air Compressors
with VFD ( Variable frequency drive). As these compressors are
lubricated, care must be taken for regular inspection of oil filters for
leakage, clogging etc. to prevent excessive oil carry over to the Air
driers. OEM recommendation as given in the O&M manual of the
equipment must be followed for preventive maintenance.
10.23.2 Any overheating of the reciprocating compressor may be due to

malfunctioning of inlet or outlet valves. Whenever the inlet or outlet valves
are taken for servicing it must be ensured that the channels after servicing
are re-positioned at the same port on seat plate from where it originally
was removed.
10.23.3 Efficiency of the compressor can be determined by “pump-off” test. Air

receiver shall be completely drained and its outlet closed. Compressor
shall be started and the time taken to attain the predetermined pressure
say 6 kg/cm2 (g) is noted. This, when compared with the time noted
immediately after thorough overhauling, gives an indication of the overall
efficiency of the compressor. The pump-off test can be used as one of the
test to ascertain whether the next overhauling is due.
10.23.4 Air Leakage should be bare minimum in the pneumatic system. Efforts
should be made to peg down the overall leakage in the system to 10%. The
overall leakage can be calculated by conducting a test during off day
when none of the equipment is running. Compressor shall be run after
keeping all the equipment idle with the supply of air on. The ratio of
loading time of the compressor to total loading and unloading time
represented as a percentage is leakage in the system. If this percentage is
more than 10 %, the individual equipment may be isolated to study the
improvement in leakage. Exact leakage area identified should be taken
for maintenance.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.24 AIR DRIER
The preventive maintenance schedule shall be prepared by the plant

requirements, if any. Various types of air driers such as absorption type,
heating type and refrigeration type are available. Regular water
draining shall be ensured. The differential pressure around the drier
should not be more than the recommended value. A high differential
pressure is an indication of deterioration of the desiccant and filters and
a low differential pressure is an indication of non-performance of the
drier. The filters and desiccant shall be replaced as per manufacturer’s
recommendation or earlier based on the performance. All the gauges
should be checked and calibrated once in six months. It is advisable to
have an online hygrometer for continuous monitoring of the dryness of
air. Dew point test is also required to be carried out at a regular interval.
10.25 FILTER, REGULATOR & LUBRICATOR

These should be daily checked for accumulation of water and dirt and
drained. Only recommended oils should be used in FRLs. It is essential to
regulate oil flow in lubricator as per the requirement of lubrication in
pneumatic components. Periodically, these should be serviced for good
performance. In case the desired performance is not achieved, FRL
should be replaced. Proper functioning of the pressure gauge should
be ensured.
10.26 OFFICE AND OTHER EQUIPMENTS

Equipment like PCs and accessories, Fax machines, photocopiers, water
coolers, deep freezer, refrigerators, air conditioners, etc., should
preferably be maintained through original equipment manufacturers or
reputed service agencies only.
10.27 SAFETY AND FIRE PROTECTION EQUIPMENT

LPG bottling plant stores large quantities of highly inflammable product
that pose safety risk to the plant and the surrounding environment.
Therefore, it is very much essential that elaborate in-built fire protection

DEPARTMENT 10
PAGE No.
MAINTENANCE
systems are installed at the plant. Preventive measures in the form of

maintaining safe inter-distances between the facilities, use of
flameproof / intrinsically safe electrical equipment, gas monitoring
system, controlled access to licensed area, etc., are taken to minimise
the risk.
.
All LPG storage vessels, cylinder sheds, pump and compressor houses,
tank truck decanting bays and tank wagon Gantries situated inside the
licensed area shall be fully covered by the fire protection facilities in
particular by a medium velocity water sprinkler system.
The fire fighting system in the plant consists of fire water system and fire
extinguishers.
10.28 FIRE WATER SYSTEM
10.28.1 FIRE WATER STORAGE TANKS
Firewater tank must be kept in a well-maintained condition at all times.

Inspection should cover the following:
a. The tank should be checked for any rusting, sinking, bulge etc.
b. The roof of the tank must be checked for clear gooseneck and
availability of SS wire mesh at the opening.
c. The gauging device must be free.
d. It should be ensured that the annular plate at the bottom of the
tank is clear of any water, deposits or concrete.
e. Full thickness of annular plate must be exposed with outward slope
of the tank pad from the bottom of annular plate.
f. There should not be any gap between the annular plate and the
pad.
g. The tank must be earthed at two places.
External inspections (visual and ultrasonic thickness tester) should be

carried out once in 3 years and internal inspection and cleaning once
in 5 years. Where the atmosphere is corrosive, the external inspection
should be done once in 2 years. If the measurement of the wall with
ultrasonic thickness tester indicates a high corrosion, internal inspection
shall be carried out frequently. The wall thickness measurement shall be

DEPARTMENT 10
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MAINTENANCE
done near the weld joints. OISD Std. 129 shall be referred for inspection
of the fire water storage tanks
10.28.2 FIRE WATER RESERVOIR
The Fire water reservoir / tank (ground level) should be cleaned once in
six months or as and when needed so that there shall not be any foreign
particles / fungus / vegetation in the reservoir. It should be checked for
leakages in the reservoir.
10.28.3 FIRE ENGINES AND PUMPS

requirements Fire engines and pumps shall be started and checked
daily. Battery electrolyte specific gravity and condition of the terminals
must be checked. Twice a week each engine should be run at least for
30 minutes. Lube oil pressure, RPM, coolant circulation, coolant
temperature, inlet and discharge pressure must be recorded. Protective
devices such as low lube oil pressure and high coolant temperature
alarms shall be checked for proper functioning and annunciation in the
panel.
The diesel tank of the fire engines should be kept full at all times .The
capacity of diesel tank shall be for running fire engine minimum 6 hours.
The diesel tanks of Fire Engines and also DG sets shall be away from the
exhaust to avoid possible fire. There should not be any leakage of diesel
or water anywhere. The diesel tank breather should be checked for any
possibility of choking and kept clean at all times.
A preventive maintenance schedule must be developed for the fire

engines and pump as per the manufacturer’s recommendations and
OISD Std. 144
10.28.4 JOCKEY PUMP

requirements. Operation of the jockey pumps shall be checked
periodically. Frequent starting / stopping of the jockey pumps indicates

DEPARTMENT 10
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MAINTENANCE
that there are water leaks in the water system. Alignment of motor with
pump, condition of starter contactors and availability of coupling guards
should be checked regularly.
10.28.5 TESTING OF FIRE ENGINES AND JOCKEY PUMPS
The operation of the jockey pumps and fire engines are automatic. This
automation is achieved by the pressure switches that sense drop in the
line pressure. The set pressure of each engine and Jockey Pump should
be verified by gradually reducing the line pressure through draining. Set
point of pressure switches should be adjusted, if necessary.
10.28.6 STRAINER
The strainer of the pump inlet and inlet of deluge valves must be
inspected and cleaned once in a quarter.
10.28.7 SECURITY AIR COMPRESSOR
Security Air Compressor operation shall be checked periodically.

Frequent operation of security air compressor indicates that there are air
leaks in the system. The schedule for preventive maintenance shall be
drawn out and followed for the compressor. The water must be drained
from the receiver periodically. The receiver and safety valve must be
tested as per Factories Act. Overhauling of the compressor shall be
carried out as per the manufacturer’s recommendations.
The belts of the compressors must be checked for proper tension. The
compressor must develop the required pressure recommended for
Deluge Valve system and stop thereafter.
10.28.8 FIRE WATER NETWORK
10.28.8.1 The ring main shall be kept pressurised and pressure at the farthest point
should be minimum 7kg/cm2 (g).
10.28.8.2 Sufficient clearance should be provided between the above ground

pipeline and the earth. The pipeline should rest on pedestals with point
contact. The same can be achieved by providing a rod as pipeline rest.
Pipelines must be inspected for leaks, defects, damages and corrosion.

DEPARTMENT 10
PAGE No.
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The pipeline should be inspected for proper rest on the supports and
should not hang over the supports. The damaged supports, if any,
should be immediately repaired to avoid any stress on the pipeline. The
underground pipeline must be wrapped for corrosion protection. The
water in the pipeline must be flushed at least once in a fortnight to
prevent corrosion due to bacterial action. The thickness test of the
above ground lines must be done once in a year.
10.28.8.3 All the valves on the ring main / hydrants / monitors shall be checked for
leaks / operation and lubricated once in a month. All the valves,
hydrants, monitors, sprinkler nozzles should be numbered for easy
identification and maintenance. The sprinkler nozzles should be
checked for free flow, spread and discharge.
10.28.8.4 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 the system in total. The sprinkler system in the
sheds shall be tested for correct remote operation once in a quarter by
closing the outlet of the deluge valves. The strainers provided in the fire
water sprinkler system shall be cleaned once in a quarter and records
maintained.
10.28.9 FIRE HOSE AND HOSE BOX
Fire hoses should be periodically inspected for any leakage and other
damages. 25 % of the total hydrant hoses required should be kept as
spare. Hose boxes should be installed at each hydrant point. Each hose
box should have two numbers of hoses and one branch pipe nozzle. The
hose box should be well maintained and numbered. The hose should be
dried completely after use before it is rolled back for placement in hose
box. The new hoses should be checked periodically for fitness.
10.28.10 INTERLOCK SHUTDOWN SYSTEM
Interlock shutdown system should be checked once in a month for its

operation and fidelity for complying with the installed scheme. The
pressurised air should be drained of any condensate water periodically.
The system should be checked by draining air for automatic operation
of deluge valves, power trip, operation of siren and closure of ROVs. The

DEPARTMENT 10
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ILSD system must be activated on actuation of Deluge Valve either from

QB breakage, local air release or through remote control panel.
10.29 FIRE EXTINGUISHERS
10.29.1 DRY CHEMICAL POWDER (DCP) FIRE EXTINGUISHER
The fire extinguishers must be positioned in the plant as per OISD

Standard 144. These must be checked once in a quarter as per HS&E
manual. It must be hydro-tested once in three years. External Visual
inspection shall be carried out monthly
10.29.2 CO2 FIRE EXTINGUISHER
CO2 fire extinguishers should be checked for the weight of carbon

dioxide. If the loss is more than 10% of the net weight, the same must be
sent for refilling. Over filled CO2 cartridges must be rejected
immediately.
10.29.3 OISD standard 142 –Inspection of Fire Fighting Inspection and

Equipment provides inspection guidelines for inspecting all type of fire
extinguishers .
10.30 GAS MONITORING SYSTEM
10.30.1 The sensors must be free of dust, moisture or cobwebs. The sensors
should be calibrated once in a quarter. Day to day record of sensors
activated should be reviewed and necessary corrective action must be
taken.
10.30.2 Calibration and testing must be carried out in line with OISD Std. 144.
Calibration of sensors must be carried out quarterly through test gas and
monthly for audio visual indication at control panel by activating the
sensors by releasing LPG at the sensors in controlled manner. Records
shall be maintained for calibration and testing.

DEPARTMENT 10
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10.31 FIRE ALARM

Hand siren should be checked for its proper functioning once in a
month. The bearing must be greased for smooth operation.
Electric siren must be operated once in a month for its proper operation.
The sound should be heard at a distance of one km. from the periphery of
the plant. In case sound is not heard, the siren should be repaired or
replaced.
Manual call points must be tested once in a month for its proper
functioning.
10.32 COMMUNICATION SYSTEM

Communication system like Telephone, Intercom, PA Paging and
Walkie-Talkie instruments should be checked daily to ensure its proper
functioning. Wherever required, help of experts should be taken to
maintain them.
10.33 VAPOUR EXTRACTION UNIT

The vapor extraction unit should be interlocked with the carousel / filling
system input conveyor. It should be ensured that the carousel / filling
system input conveyor starts only after the start of the vapor extraction unit.
The working of the vapor extraction unit, i.e., suction at its inlet should be
checked daily. Mesh provided at the suction points should be cleaned of
dust, muck and foreign materials.
Unbalancing and misalignment are two major sources of problems in the

blower. Extra care for proper alignment and balancing of blower drum
must be taken.
The NRV on the blowers discharge of the two blowers including standby
should be properly checked for its functioning to ensure that during
running of one blower , it should not take atmospheric suction from the
discharge of standby blower, reducing effective suction of the blowers
the floor ducts.

DEPARTMENT 10
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10.34 ACCESSORIES AND PERSONNEL PROTECTIVE EQUIPMENT

Frequent visual inspections are required to keep these items in sound
condition. Manufacture’s recommendation for the storage and shelf life
should be religiously followed. Self-contained breathing apparatus
cylinders should be filled through genuine manufacturers. It will be
advisable to get its gauging device checked once in a year or as advised
by the manufacturer.
After use, Personal Protective Equipment should be cleaned, disinfected
and restored to its nominated place.
Rubber hand gloves for electrical purpose should be checked half

yearly or as advised by the manufacturer. In case proper testing facilities
are not available, the rubber hand gloves should be replaced. Test
certificates of the same should be retained at all times.
Explosimeter should be calibrated once in a year through authorized

representative of the manufacturer.
Fire or smoke detectors should be checked periodically to establish its

proper working.
For more details on Personal Protective equipment, OISD Std. 155 Parts I
& II may be followed.
10.35 INSPECTION AND MAINTENANCE OF ELECTRICAL EQUIPMENT

10.35.1 Electricity constitutes one of the major sources of ignition for fire
accidents and explosions in the bottling plants. Besides the equipment
damage and property loss, electrical hazards also include injuries and
fatalities due to electrical shocks. Timely inspection and preventive
maintenance of the electrical equipment and its connected systems
will go a long way in ensuring safer operation of the electrical
installations. A well-maintained electrical system pays rich dividends by
way of lower operating cost and higher reliability.
10.35.2 Detailed procedures and checklists for various electrical equipment are
available in OISD Std. 137 and also covered to some extent in OISD
Std.144 section 9. Plants must also comply with the requirements of IE

DEPARTMENT 10
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Rules 1956 and its subsequent amendments. Any specific inspection

recommended by the manufacturers is also to be incorporated in SAP
PM module and followed. Some of the important inspection and
maintenance checks are furnished in this section. Electrical work permit
in line with OISD Std. 137 must be obtained from the Plant Manager prior
to commencement of any electrical job. Isolation of the equipment
from the power source must be done and caution board be displayed
prior to taking up the work.
10.35.3 DOUBLE POLE ( DP) STRUCTURE
Double pole is the first point where HT line is connected to the plant
electrical system. In some of the plants, the double pole structure is
located outside the plant periphery. Area surrounding the double pole
structure should be maintained free of dry vegetation and easily
accessible. Frequent checks should be carried out to see that the dipole
earthing of the dipole structure and the fence provided is proper. The
Gang Operated switch should also be earthed and Operating handle
must be properly insulated. Drop Out ( DO )fuses should be used instead
of exposed wire. Only authorised entry should be permitted.
10.35.4 HIGH TENSION (HT) BREAKER
HT breaker and panel are generally of minimum oil circuit type (MOCB)
or vacuum circuit type (VCB). General cleanliness, proper weather
protection, dust and vermin-proofness, availability of control supply,
accessibility for maintenance and operation, functioning of meters,
indication lamps and correctness of relay settings, etc., are to be
checked on a regular basis. Tripping circuit of the HT breaker shall be
regularly checked through simulation from the Relays/contacts
connected to the breaker. MOCB should be observed for oil leakages.
Dielectric strength of the oil should be tested periodically for MOCB.

Condition of earthing connection, measurement of insulation and
resistance, condition of contacts, clearances, etc., and calibration of
relays are also to be checked on a regular basis.
Overhauling of the high-tension breaker should be carried out as per the

manufacturer’s recommendations.

DEPARTMENT 10
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10.35.5 TRANSFORMER
Daily checks shall be carried out for oil leakage, oil level, and condition
of silica gel, oil and winding temperatures and general cleanliness of the
transformer. In case the transformer is of the outdoor type its fence
should be earthed. There should not be any vegetation in and around
the fence.
Weekly checks for transformer includes ensuring proper operation of

annunciation system, checking condition of cable and sealing, terminal
boxes, etc.
Dielectric strength and acidity of oil samples shall be tested every year
and filtration of oil should be carried out in case the dielectric value is
lesser than the permissible value. Bucoltz relay, oil and winding
temperature alarm and trips should be tested once in a year.
Insulating mats as per IS: 15652: 2006 should be provided.
10.35.6 SWITCH BOARD & PANEL
Regular inspection for switchboard & panel includes checking for

general cleanliness, weather protection, dust and vermin-proofness,
availability of control supply and ventilation system.
Accessibility for the maintenance and operation, functioning of meters

and indication lamps, condition of earthing shall be checked once in a
month.
Checks for tightness of all bolts, cable connections, terminals, etc.,

condition of contacts, clearance with live parts, checking and
calibration of relays, etc., are to be carried out once in a year.
Each panel shall be provided with HRC type fuses of recommended

rating only. A single line diagram of the electrical system shall be
displayed prominently in the substation indicating fuse rating & relay
settings.

DEPARTMENT 10
PAGE No.
MAINTENANCE
In the panel room as well insulating mats as per IS:15652: 2006 should be
provided.
10.35.7 AIR CIRCUIT BREAKER
Inspection for air circuit breaker consists of checking for rack in out
mechanism, operation of safety shutters, protection, control, Interlock
circuits, breaker closing and opening time. Tripping circuit of the HT
breaker shall be regularly checked through simulation from the
Relays/contacts connected to the breaker.
10.35.8 RELAYS
Secondary injection test for protective relays should be carried out once
in a year. It is also suggested to carry out primary injection test for over
load relays of major equipment. After relays are calibrated and put
back in the system, a simulation check for the tripping circuit should be
carried out by manually triggering the relay
10.35.9 DIESEL GENERATING SETS
Diesel Generating Set should be started daily and the parameters like oil
pressure, coolant temperature, frequency and output voltage be
checked. Daily checks should be carried out for the diesel engines for
ascertaining the coolant level in the radiator, engine oil level, fuel level
in the tank and condition of batteries. Water and sediment should be
drained off daily from the fuel tank. Functioning of protective devices,
such as high coolant temperature and low lube oil pressure trip devices
shall be checked once a week. B checks and C checks should also form
part of Plant Preventive Maintenance Schedule.
The equipment shall be checked for any abnormal noise and increase in
the temperature. Earthing connection shall be checked periodically.
Alignment of the engine to the alternator and insulation resistance shall
be checked half-yearly.
Proper functioning of the protective devices such as over voltage, over

load and earth fault relays shall also be checked periodically.

DEPARTMENT 10
PAGE No.
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10.35.10 MOTORS
Inspection of the motors should be for general cleanliness, surface

overheating, excessive vibration, abnormal noise, external damages,
load current, terminal connections and lubrication. Provision of guards
above the moving parts should also be checked. Insulation resistance,
winding resistance, earth resistance and continuity and functioning of
overload relay also need to be checked. Each motor should have two
independent earthing connected to the grid.
10.35.11 CABLES
Connection of the cables shall be made through proper lugs. Lugs of

proper size should be crimped. All cable should be protected from the
damage due to falling of objects. No sharp edges or hot surfaces shall
come in contact with the cables. Cables running on the pillars /
structures should be properly clamped. Cable trays should be used.
Cables should be properly identified by means of tags. Cable route
markers should be displayed prominently. Special care shall be
exercised while carrying the excavation in areas where cables are
passing underneath. Cables running in trenches shall be segregated
with proper spacing. Cable Insulation test is to be conducted every
year. Cables are to be rejected incase the insulation is found to be less
than 1 mega ohm.
10.35.12 OTHER FLAME PROOF EQUIPMENT AND FITTINGS
Flameproof junction boxes, power distribution boards, push buttons and

other FLP fittings should be primarily checked for completeness of bolts /
allen screws, glands and their tightness. There should not be any
unplugged openings. Flame path should be well maintained without
any corrosion. These shall be inspected for cleanliness, external
damages, and proper supports and earthing. Availability of properly
sized double compression glands should be ensured in the Licensed /
battery area. Presence of dust, moisture and rust should be checked.
Joint Flanges should be slightly greased while re-fixing after repairs or
inspection.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.35.13 EARTHING AND BONDING
All the earthing pits should be interconnected to form a grid. Double

earthing should be provided to each motor. Light fixtures, all structures,
lighting towers, vessels, and pipelines should also be earthed. Availability
of proper earthing should be checked for the tank wagon loading /
unloading gantry, tank lorry decantation / filling sheds loading /
unloading arms and flexible hoses.
All flange joints in the pipelines should be first bonded. The pipeline
system should be earthed at least at two points preferably towards the
ends.
Similarly different sections of the conveyors & rail tracks within the gantry
should be bonded and connected to earth grid at minimum two places.
The area wherein the earth connection is provided should be free of
paint & rust.
Visual inspection for external damages to earth conductors and earth

electrodes and corrosion effects and tightness of the connections
should be checked periodically. Only galvanized / cadmium plated
bolts should be used to connect the earth strip with the electrodes.
Earthing resistance of individual electrodes and that of the grid shall be
measured using a three point Earth Tester once in dry and once in wet
weather. Continuity between the equipment and the earth grid should
also be measured. The resistance value of an earthing system to general
mass of the earth should not exceed 4 ohms for electrical systems and
metallic structures, 7 ohms for storage tanks, 1 ohm for main earth grid
and bonding connections and 2 ohms for each electrode to the
general mass of the earth. Earthing guidelines issued in year 2001 and
any subsequent amendment can be referred for design of earthing
system
10.35.14 LIGHTNING PROTECTION
Lightning arrestors shall be checked for external damages and proper

connection to the earth pit. Earth strip connecting lightning arrestors to
the earth pit should be supported through the insulators in order to avoid
the strip coming in direct contact with the structure being protected.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.35.15 BATTERIES, BATTERY CHARGER & UNINTERRUPTED POWER SUPPLIES (UPS)
General cleanliness, specific gravity & level of electrolyte for the cells,
condition of terminals, blockage of the vent plugs & cracks on the
containers shall be checked in the batteries. Application of petroleum
jelly on terminals helps in avoiding sulphate formation on the terminals.
Record of specific gravity of each cell of all batteries must be kept to
know the health of batteries.
Battery chargers shall be checked for general cleanliness, condition of

contactors & switches, float voltage & charging current, operation of
charger changeover circuits, over heating & tightness of connections.
HRC fuses of recommended rating only shall be used.
Inspection of UPS shall be done for general cleanliness of printed circuit

boards, running of cooling fans, accumulation of dust & dirt on
contactors and tightness of the connections. The UPS should either have
in-built surge suppressor or it should be externally provided. Back up time
of the UPS shall be checked periodically by switching off the input
power and giving non-critical loads. The UPS should not be used for the
purpose other than it is intended for.
10.36 INSPECTION OF BUILDINGS, ROADS & STRUCTURES
10.36.1 Major areas to be inspected in the buildings are mastic flooring of filling
/ filled cylinder / cold repair sheds, structure columns and flooring of the
other sheds, concreted surfaces around the LPG storage vessels,
compound walls, concreted area around the weigh bridge etc.
Inspection of these facilities can be done by visual checks. In the pump
house, the floor should not have water or oil accumulated on it. The
buildings should not have cobwebs and should have pleasing
appearance. Mastic flooring provided on the shed floors and
fireproofing on the columns should not have cracks etc. Top of the
sheds should not have openings / leakages. Rainwater accumulation at
the open areas in the plant should be prevented by providing proper
drainage. Drains in the plant should be kept free of muck / mud at all
times.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.36.2 The open space within the licensed area should not have grass /
vegetation growth which affects the pipelines laid thereon. Presence of
dry grass should be avoided at all times, since the same provides fuel for
fire. Scrap accumulation within the operating areas should be avoided,
since it can affect the operation during emergencies. Facilities that are
redundant must be dismantled and area be cleared.
10.36.3 Administrative building should not have seepage / leakage due to

rainwater. Sewage line should always remain clean. Buildings should be
free of pests. Proper ventilation should be ensured in the buildings
including canteen & stores. Maintenance of cleanliness in the canteen
including wash area goes a long way in healthy working of the
personnel. All toilets in the plant must remain clean all times. LPG
cylinder bank provided near the canteen should have good ground
level ventilation. Adequate precautions should be taken to see that the
rodents do not find access to the LPG cylinder bank area.
10.36.4 Garden, lawns, if provided, should be well maintained and over

watering of these should be avoided. Proper maintenance of green belt
area need not be overemphasised.
10.36.5 Roads and other asphalted surfaces should have proper slope to avoid
accumulation of water. Vegetation growth should not be allowed on
both sides of the roads. Potholes should be repaired immediately so as
to avoid further damage. Road should not be used as places for
preparation of materials for concreting.
10.36.6 Structures of the towers should not be allowed to corrode and rust.
Visual inspection checks for verticality of tall structures and thickness of
steel members should be done on a routine basis. Growth of grass and
vegetation around the structures should not be allowed.
10.36.7 Timely painting of all buildings & structures after proper surface
preparation will go a long way giving good appearance and ensuring
longer life.

DEPARTMENT 10
PAGE No.
MAINTENANCE
10.37 INSPECTION AND MAINTENANCE OF PRESSURE GAUGES,

PRESSURE SWITCHES, TEMPERATURE GAUGES AND
TEMPERATURE TRIPS
10.37.1 PRESSURE SWITCHES, TEMPERATURE TRIPS mounted on rotary equipment
shall calibrated once in a quarter. The pressure gauges and
temperature gauges shall be checked for zero once in a month and
calibrated once in six months. Availability of dampeners and isolation
valves between the pressure gauges and the pipelines shall also be
ensured. Pressure switches, Temperature gauges, Temperature switches,
Level switches & other trips and alarms in the plant have to be tested
and calibrated once in six months.
10.37.2 Inspection and maintenance of level gauges used in the LPG storage
vessels have been covered under Product transfer facilities.
10.38 REFRIGERATED LPG IMPORT TERMINAL
10.38.1 These terminals are akin to a process Plant with Distributed Control
System (DCS), having heater exchangers, condensers and Steam
boilers, DM Plant, refrigerated LPG Storage tanks storing
Propane/Butane at their boiling point etc. M&I of such plant I not
covered in this manual. M&I shall be carried out as per the various
codes and standards applicable to the various facility at the Plant.
11
MEASUREMENT AND STOCK CONTROL
INACCURATE MEASUREMENT AND CALCULATIONS INEVITABLY LEAD TO ‘FICTITIOUS’

LOSSES / GAINS. SUCH LOSSES/GAINS CAN CONCEAL REAL LOSSES/ GAINS AND
LEAD TO MIS-APPROPRIATION OR CARELESS AND INCORRECT OPERATIONS.
THEREFORE, FOLLOW CORRECT MEASUREMENT AND CCOUNTING SYSTEMS TO KEEP
TRACK OF REAL LOSSES/GAINS WITH A VIEW TO CONTROL THEM BY TAKING
APPROPRIATE CORRECTIVE ACTION TIMELY.


DEPARTMENT 11
PAGE No.
March 2014 MEASUREMENT & STOCK 11-1
CONTROL
11.1 GENERAL
11.1.1 Losses/gains and control of stock are inter-related. haphazard control of

quantities held in the plant and/or inaccurate measurement and
calculations inevitably lead to ‘apparent’ (i.e. Book-Keeping)
losses/gains. Apparent losses/gains can conceal real losses/gains thus
leading to misappropriation, if it remains unchecked and/or develops
careless approach in making analysis/accepting incorrect operations.
The control on stock loss is essential as it eats away the profit and causes
direct loss to the organization. Therefore, it is important to note all the
factors contributing to apparent losses/gains so that factors causing real
loss are not allowed to swell by way of controlling losses/gains through
the receipt, losses/gains and through the bottling, unwarranted leak,
venting etc.
11.1.2 To achieve better control over the product stock and loss control within
the plant, it must be ensured that only competent persons measure,
calculate and record all the stocks carefully, accurately and in
conformity with the standard procedures. It must also be ensured that
proper security arrangements and operating practices given in the
previous chapters of the manual are enforced in the plant to keep the
real losses/gains to the barest minimum.
11.2 STOCK LEVELS
11.2.1 LPG bulk and packed stock levels should be maintained within the
limitation of available safe storage capacity, which in turn should be
related to the estimated market demand and forecast for supplies. In no
case the stock levels should be in excess of the CCOE licensed
capacity.
11.2.2 The Plant Manager should ensure that sufficient stock of the product
and cylinders are available to cover the expected sales and stock-
transfer.

DEPARTMENT 11
PAGE No.
CONTROL
11.3 BULK STOCK CONTROL

11.3.1 General guidelines for the bulk stock control are as under :
Bulk stock records should be maintained at the plant in “Gauge BooK”

(Bulk Stock Ledger) and should be compiled daily before start of the
day’s activity. Gauge book, shall be serially numbered in each page.
Storage vessel dip and bulk LPG quantity in MT, as per physical
measurement, to be updated in the gauge book before start of the
day’s activity. Gauge book is to be filled and signed by the shift officer
nominated by the Location In Charge. Gauge book to be
countersigned by the Location In Charge on daily basis. The same
gauge book readings shall be updated too in SAP on daily basis . It
may be possible in future for direct posting of levels/quantity in SAP from
the gauge through an interface. Also the concept of maintaining
gauge book in SAP and printing the same from SAP is being worked
upon and same shall be implemented upon approval.
The sample format for Gauge Book is given in the Annexure No.12
(a) Entries should be made for each storage vessel.
(b) Stock held in bulk vehicles reported at the parking area of the
plant awaiting delivery/collection should be recorded in the Daily
Activity Report.
(c) Certified Pipeline stocks should be recorded and are not

subjected to change, until and unless modification of the
pipeline is carried out. Pipeline quantity is to be certified by a
team consisting of Site-in-charge, representatives from
LPG(Engineering) and LPG(Operations) and a representative from
Finance department nominated by the State Office. The pipeline
quantity thus certified shall be updated in SAP. For cross country
Pipe lines,
(d) Any apparent/real losses/gains revealed/observed should be

reported on daily basis by carrying out critical analysis.
(e) Plant Manager should periodically cross check that the gauge
book readings and data uploaded in SAP/ AC2A are the same

DEPARTMENT 11
PAGE No.
CONTROL
11.3.2 The maximum quantity of the product which may be stored in each
vessel should be worked out and entered in the vessel’s calibration
tables and stock control records. The maximum safe storage level must
not be exceeded (in practice. This is achieved by filling the vessel only
by setting of ‘High Level Alarm’ which is normally set at 85% of water
capacity of the vessel.
11.3.3 The Plant Manager should analyse stock loss/gain and take necessary
corrective actions. In case of any abnormal stock loss/gain, the same
shall be intimated to state office by the Location In Charge..The
analysis of stock loss/gain data will enable the Plant Manager to ensure
the following:
(a) The replenishment plans are geared to existing stocks,

estimated thruput and economic operation.
(b) The stock levels are neither excessive nor inadequate.
(c) Orderly and timely action regarding surpluses or

requirements for additional storage.
(d) Efficient planning of maintenance of storage vessels, testing etc.
(e) Physical calibration of the storage vessels should be re-

verified after statutory testing.
(f) Source-wise, model-wise stock gain/loss for analysis
(g) Identifying tank behaviour pattern
(h) Verification of accuracy of the weigh bridge by standard

weights and adopting set position of the tank trucks of
different sizes for weighment. Record of accuracy of the
weigh bridge checked should be maintained on quarterly
basis or as and when abnormality is observed. Accuracy of
weighbridge shall be checked by placing standard weights
equivalent to at least 25% of the capacity of weighbridge.
Accuracy shall be verified over the full range by placing
empty/full trucks and verifying incremental increase and

DEPARTMENT 11
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decrease in display by adding/removing the standard weights

respectively.
(i) As a safety measure and to have uniformity in the stock

accounting, product in evacuation vessels should be transferred
to the storage vessel at the end of each day before taking the
closing gauge readings for the day.
(j) LPG bulk receipt through tank wagons should be checked by

recording dip and using tank wagon chart and releasing tank
wagons at vapor pressure as brought out in the earlier chapter of
the manual for tank truck and tank wagon. Calibration charts for
the tank wagons are given in the Annexure No. 11.
11.3.4 In case of malfunctioning of level gauges of storage vessels- the

following corrective actions are to be ensured.
As per OISD Std 144, LPG storage vessels shall be provided with 2 level
measuring gauges for monitoring the stocks in vessels. Both the level
gauges are expected to be in working condition and in case one level
gauge fails, stock monitoring is to be done through other level gauges.
However, if both level gauges do not function, to reiterate the

prevailing guidelines the vessel should be operated at 70% of book
stock only to avoid any safely hazards due to overfilling beyond 85%
level. The norm is to be implemented despite the availability of High
Level alarm or Fixed tube level gauge.
Following guidelines regarding storage vessels operation and stock

accounting are advised, regarding the subject.
a. Both the level gauges of storage vessels should be in operating

condition. Periodically readings of both level gauges should be
compared for accuracy. One level gauge should be declared as
the custody transfer gauge and the other shall be the check
gauge. Daily readings to be recorded in the gauge book from the
custody transfer gauge only. Only in case of faulty custody transfer
gauge, reading from Check gauge to be recorded in gauge book
with the remark that custody transfer gauge is faulty and reading
are recorded from the Check gauge.

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b. In case any level gauge malfunction, action for rectification

should be initiated immediately and completed with a time bound
action plan. Proper records/History card in this regard to be
maintained at plant.
c. In case both the level gauges malfunction for a period, then that
particular vessel should be operated at 70% of level of book stock.
d. The functioning of the high level alarm of each vessel should be
checked periodically and same should be interlocked with the
ROV on liquid line.
e. Close stock monitoring should be done in case of gauge failure of
any vessel. Such vessels also should be emptied out (till suction
failure of LPG pump) once in a while to understand the stock loss
position Abnormal losses, if any, should be investigated
immediately.
11.4 PACKED STOCK CONTROL

11.4.1 Packed LPG stock control differs from the bulk stock control because it is
concerned not only with the product but also with the cylinders which
are returnable. Cylinders represent a considerable capital investment
and therefore, strict control of the numbers in use and the prevention of
losses/gains are essential.
11.4.2 The Plant Manager should ensure that sufficient stocks of serviceable
empty and filled cylinders are available at the plant to cover the
anticipated sales, deliveries and stock transfers. These stocks should be
related to the available cylinder filling capacity, number of cylinders,
packed trucks and the efficient operation of the plant. As a general
guideline, empty cylinders to cover 4 hours bottling and filled cylinders
equivalent to 2 hours bottling should be kept in stock. However, stock
of filled cylinders should be limited to the licensed capacity .
11.4.3 New cylinders (before purging) procured for enrolment should be kept
on a strong cement concrete floor (not covered) and replenishment
against the depleted stock should be made good from time to time.
Planning should be made to avoid aging of new cylinders in the open
storage. Unserviceable cylinders found in the receipt of empties should
be evacuated, de-gassed and kept in the open space for inspection /
certification by the competent authority for scrapping. Disposal of the
scrap should be done quickly to avoid accumulation. Buffer stock of

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cylinders held to meet the seasonal peak demand should be as far as

practicable kept as empty.
11.4.4 Report of physical stocks of cylinders giving the following details should
be maintained on daily basis. Category of 14.2 ,19.0, 5.0 and 47.5 Kg.
inventory of cylinders . oil company wise should be maintained
separately. Daily Physical inventory of all cylinders are to undertaken by
Security in the night shift and submitted for review to Plant Manager.
Monthly Physical inventory is to be done jointly by Security personnel,
one Officer nominated by Plant Manager and Finance Officer and
certified by each of them at the end of the inventory.
(a) Opening stock of each type of filled cylinders

(b) Empty stock of each type of cylinders.
(c) No. of each type of cylinders filled during the day.
(d) No. of cylinders awaiting cold repairs.
(e) No. of cylinders awaiting re-testing and hot repairs.
(f) No. of cylinders awaiting scrapping.
(g) No. of cylinders scrapped, but awaiting disposal.
(h) No. of empty cylinders filled at the plant.
(i) (No. of filled cylinders received from other sources
(j) (No. of empty cylinders received (source-wise including new
from the manufacturers, re-tested ,repaired from the
repairers etc.).
(k) No. of filled cylinders dispatched.
(l) (No. of empty cylinders dispatched (for statutory testing, hot
repairs etc.)
(m) Closing stock of filled cylinders.
(n) Closing stock of empty cylinders.
(o) Closing stock of defective cylinders.
(Note : The cylinder stock should be based on the physical count.)
11.4.5 Further detailed instructions on accounting of LPG cylinders are

covered in the guidelines Issued by the Finance Department and should
be followed fully.
11.4.6 Accurate and up-to-date record of cylinders of different types and sizes
should be maintained at the plant

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11.5 LOSS CONTROL

11.5.1 The Plant Manager is responsible for LPG loss control both within the
plant and during the delivery operations carried out directly ex plant. To
control this, detailed analysis of the market return of the cylinders is to
be carried out and corrective action is taken to arrest the loss. Quality
control of bottled cylinders is to be carried out to avoid losses/gains.
Other areas by which losses/gains can be controlled are as under:
(a) Receipt of market return cylinders:
(i) Same load return: As per Corporation policy, credit should

be given to the distributors as per the detailed guidelines
given by HO LPG Department from time to time. In the case
of broken seals, debits are to be raised on the transporters as
per policy.
(ii) Subsequent load return: Defective cylinders duly certified /

approved by the Area Office are returned to the plant along
with Form No.SL-27 giving details of the defects and quantity.
Credits are normally given as per the policy guidelines. In
case there is any abnormal variation between the certified
stock and the actual receipt, cylinders are to be segregated
for joint inspection by the Area Office and the plant and
decision is to be taken regarding giving of credit for the
disputed number of cylinders
(b) Detailed calculation is enclosed for 14.2 Kg. cylinders for purging
vide Annexure No.13. Around 200 gm per cylinder should be
considered as purging quantity. While doing statutory testing (ST)/
hot repairs (HR)/ scrapping, the cylinders are de-gassed. All the
new, ST completed and HR completed cylinders are to be
purged with LPG,
(c) While carrying out 5 year testing of storage vessels, utmost efforts
to be made to recover LPG vapor, by vapor compressor and
venting of vapor to be as minimum as possible. For calculation of
stock loss, in carrying out 5 year testing of storage vessels, due to
venting of vapor, vapor pressure of 2.0 kg/cm2 be taken for 15%
of the vessel volume.

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11.5.2 LPG, unlike other general petroleum products, is always contained

(stored and transported) in a sealed system and evaporation, breathing
and gauging losses / gains do not occur. It is therefore, possible to
prevent almost all LPG losses / gains by carrying out operations
efficiently and in accordance with approved / correct procedures. For
virtual elimination of product losses / gains, Plant Manager must ensure
the following:
(a) All personnel engaged in the LPG operation should know :
 the product characteristics.

 the correct procedures for handling LPG
 their responsibility for preventing the losses /
gains.
(b) The right equipment is provided for each function and it is

used, installed and maintained properly and efficiently.
(c) Sound procedures are established for measuring, calculating

and recording the inventory of product and cylinders and their
movement.
(d) All instruments are provided for each function and it is used,
installed and maintained properly and efficiently.
(e) To keep the knowledge alive and useful in day to day working,
the Plant Manager should share the knowledge by conducting
meetings and carrying out quiz tests from time to time.
11.5.3 As is prevalent in other petroleum products, losses / gains of LPG fall into
two categories :
(a) Real or actual or physical losses / gains (e.g. leakage,

pilferage, improper post filling, quality control checks, improper
decantation etc.).
(b) Apparent losses / gains, due to errors in measurements,

calculation, recording, etc.

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11.6 REAL LOSSES / GAINS

11.6.1 Real losses / gains can be minimized by using the correct procedures
and control.
11.6.2 The accuracy of the gauges is to be checked periodically with

reference to datum and high level benchmark. It is advisable to have
both the gauges with high reliability and accuracy like servo gauge,
Radar gauge , Rochester gauge, Ultrasonic gauge..
11.6.3 To minimise the product losses / gains and for safety reasons, water and
other contaminants must be drained off carefully from the storage
vessels as detailed in Chapter No.7. The quantity of water drained
should be assessed and recorded in the gauge book.
11.6.4 Excessive sampling should be avoided. Necessary sampling should be

carried out in accordance with the standard procedures and using
standard equipment. Sampling should not be carried out as a routine
operation at the plant. However, for the vessel used for receipt / issue,
the density is to be taken and recorded in the gauge book along with
the temperature and pressure.
11.6.5 Overfilling of vessels / cylinders must be avoided for safety reasons.
Despatch of over filled cylinders to Distributors would lead to higher

operational loss and therefore strict monitoring and control should be
exercised on the filling machine accuracy and check scale calibration.
Overfilling beyond the permissible norm is also unsafe and therefore,
must be avoided.
11.6.6 All equipment / gauges should be properly maintained. Flanged joints,

pump seals, etc. which are potential areas of leakage, should receive
constant attention.
11.6.7 It should be checked that all receipts (tank wagons, tank trucks etc.)
tally with the quantity as per the supply documents. Booking of losses /
gains is to be done as brought out in the section.
11.6.8 Inter-vessel transfers should be minimum and consistent with

the operational requirement.

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11.6.9 Losses / gains of the product by pilferage or unauthorized use should

be avoided by ensuring that the plant security, operational supervision
and stock control arrangements are adequate. Surprise checks should
be carried out at irregular frequencies to maintain the element of
‘surprise’. All operations, stocks and procedures should be examined in
detail, during such checks.
11.6.10 Monitoring and controlling the transit loss is very highly important. It
shall be ensured that the bullet tankers are weighed before and after
unloading by designated officers . The officer weighing the bullet
tankers shall take the print outs of weighment slips and the weighment
slips shall be signed. The signed weighment slips shall be preserved
safely and kept under safe custody. Transit loss shall be monitored
continuously and corrective actions taken then and there. Loading
locations and Regional LPG to be informed in case of transit loss,
besides taking possible corrective actions by plant. Calibration of
weighbridge to be done quarterly and record maintained.
11.7 APPARENT LOSSES / GAINS
11.7.1 Apparent losses / gains give a false impression of operating efficiency

and can hide real losses / gains. These can be eliminated only by
applying correct measuring, recording and calculating techniques and
the use of correct, properly maintained and calibrated measuring
equipment.
11.7.2 Apparent losses / gains in LPG operations are usually due to the
following reasons :
(a) Not accounting for the liquid equivalent of LPG vapour (LEV) held in
the system. Sample calibration chart considering LEV for 14 M & 18
M dia Horton Sphere is given in Annexure No.14.
(b) One or combination of the following can contribute apparent losses:
 Use of faulty, inaccurate or the wrong type of instruments.

 Incorrect use of the instrument.
 Incorrect reading of the instrument.

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 Incorrect recording of readings.

 Inaccurate calibration of the vessels.
 Inaccurate calculations.
 Inaccurate weight of the filled or empty cylinders
 Inaccurate calibration of weighing machines, meters, gauges
 etc.
 Tank behaviour at different levels ( Permissible limits for the tank
behaviour as per PD 5500 and as per the illustration given in
Annexure No. 15)
 Limitation of gauging equipment in terms of accuracy
 Failure to account for inter-plant transfers or for ‘own-use’ of the
product.
11.7.3 Observance of the recommended operational procedures and

techniques will assist in the elimination of apparent losses / gains.
11.8 BULK STOCK MEASUREMENT

11.8.1 LPG, unlike most of the other petroleum products, is usually measured in
the vessel in one form (e.g. volume) and recorded or invoiced in
another form (e.g. weight). Moreover, it is invariably the custom to
measure the product at ambient temperature, but to record / invoice
at standard temperature of 15C . All accounting at the bottling plants
of IOC, whether the product is bulk or packed, should be done on
“Weight basis”.
11.8.2 For the effective control of the stock and deliveries / receipts, the
practice necessitates accurate determination of the volume, weight,
temperature, pressure and density and also correct recording and
correct calculations / conversion. However, accurate measurement
begins with the accurate calibration of the tanks, meters, gauges etc.
Many of the procedures applicable to the measurement of general
petroleum products also apply to LPG, but the following points are
peculiar to LPG:
(a) The composition of different grades of LPG can vary widely

and assumptions regarding specific gravity can be misleading.
(b) LPG liquid has a high coefficient of cubical expansion so that

errors made in the measurement / recording of the product

DEPARTMENT 11
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temperature lead to large errors when used for volume

correction.
(c) LPG is to be measured both in liquid and vapour forms, but the
method / equipment used must differentiate between them,
e.g., vapour must be excluded from the liquid, if the accuracy is
required.
(d) LPG is stored and handled in a sealed system at its vapour

pressure and must be measured using the equipment designed
for relatively high pressures.
(e) LPG liquid changes to vapour, if the pressure is allowed to fall

below the vapour pressure.
(f) The quantity of vapour above the liquid phase in the storage and
the transport vessels can be significant in relation to the liquid
volume.
(g) Vapour measurement involves volume, temperature and

pressure determinations.
11.9 BULK RECEIPTS / DELIVERIES

Bulk receipt and delivery of LPG can be determined in one of the
following ways:
(a) By volumetric stock measurements of receiving/delivery vessels

before and after the receipt / delivery. The method can be
adopted irrespective of the mode of delivery / receipt.
(b) By weighing the quantity received / delivered, i.e., by determining

the Gross weight of the vehicle and subtracting the Unladen
Weight (ULW- i.e. tare weight). The main points are:
i. A weigh bridge is required.

ii. Not influenced by the transfer method used for delivery/receipt.
iii. Can be used only for tank trucks and tank wagons.

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(c) By metering the receipts / deliveries. This method is impracticable,

if the pressure differential method of transfer is adopted, using
vapour return (equalisation) lines.
(d) Presence of water content in the tank truck should be verified by

bringing the ‘Roto Gauge’ of the tank truck to ‘Zero’ position
before connecting the liquid and vapour lines. In case water is
detected, draining of water should be done at the designated
place, where the facility for water drainage exists or is provided
duly approved by CCOE. After draining of the water, tank truck
should be re-weighed for achieving the receipt of correct quantity
of LPG. Such cases should be brought to the notice of the
concerned transporter, loading location and controlling office.
Water draining if any shall be done in the presence of competent
peson, duly following all safety precautions and guidelines.
(e) Presence of water content in the tank wagon can be checked by

venting through the sampling tube before making connection. As
this is a risky operation, the safe method to compute the water
content received through tank wagons / rake is through the
receiving vessel only by carrying out water drainage activity
before and after decantation of tank wagons / Rake. Quantity
arrived at should be brought to the notice of the concerned
loading location and controlling office.
(f) In case of tank wagons having defective gauges, net quantity

received by the tank wagons / rake should be arrived at by
computing the vessel quantity after measuring the content before
unloading and after unloading. Quantity arrived at should be
brought to the notice of the concerned loading location and
controlling office.
(g) Tank wagon dips should be recorded and the quantity be

computed per wagon by using the TW chart as given in Annexure
No. 11.
(h) At tank wagon loading locations, the tare weight of the empty
tank wagons should be taken after purging of the tank wagons for
newly inducted, re-tested POH wagons.

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11.10 PACKED STOCKS OF LPG

As far as packed stocks of LPG are concerned, filling of cylinders and
sales of packed LPG are done on weight basis. Details of the cylinders
(types, sizes etc.) filling equipment and filling techniques are given in
Chapter No. 8.
11.11 BULK STOCK GAUGING

11.11.1 GENERAL
The gauging of LPG bulk storage vessels consists of accurately

determining the liquid level in the vessel in relation to the pressure /
temperature conditions. Using this level in conjunction with the vessel’s
calibration tables, both liquid and vapour volumes are determined.
Sample format for Gauge book is given in Annexure No. 12.
Because LPG is stored in a pressurized and sealed system, the gauges

must be designed to function under these conditions and the difficulties
of maintaining and repairing them must also be considered, as opening
up of a vessel may be operationally difficult or even impossible at any
point of time. All the main storage vessels must, therefore, be equipped
with two liquid level gauges both of which have to be robust and
reliable.
11.11.2 REQUIREMENT FOR ACCURATE GAUGING
Although the actual gauging of the LPG vessel is a simple operation,

precautions are necessary to ensure that the results obtained provide
the required accuracy. It is, therefore, necessary to be aware of the
following:
(a) Accurate gauging is of little use, if the vessel is not properly

calibrated.
(b) When the turbulence of the product occurs i.e., during

the movement of product at different temperatures, gauging
cannot be accurate and certain types of gauges can get
damaged, if the floats are not well located or are not lifted clear
of the liquid.

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(c) Accurate gauging is possible only if the gauges are properly

installed by the competent personnel in accordance with
manufacturer’s instructions. Also it should be ensured that :
(i) gauges are properly instructed regarding the correct use of

the gauges and the avoidance of errors such as parallax,
etc.
(ii) Observed readings are always recorded accurately, legibly
and quickly.
(iii) Routine gauging is carried out using the main accurate)
gauge.
(iv) After the receipt of the product through tank wagons,
a settling time of minimum one hour must be allowed
for turbulence (boiling off) caused due to the differences
of product temperatures to subside and after carrying out
water draining.
(v) damage to gauges (e.g. seized or broken guide wires
/ tapes, etc.) or unaccountable readings must be reported
immediately.
(vi) Contaminants such as water should not normally be present
because they are required to be removed by routine
controlled draining operation.
11.11.3 TEMPERATURE MEASUREMENT
(a) Accuracy in the temperature measurement is essential because

an error, say 3C, in the determination of the average temperature
of a parcel which has a coefficient of expansion of approximately
0.003 perC would cause an error of 1% in the volume calculations.
The necessity for determining both vapour and liquid temperatures
for bulk quantity determination is illustrated later in this Chapter.
(b) The ‘liquid equivalent’ of the vapour in a vessel half full of liquid at
30C is approximately 3% of the liquid contents but for the same
vessel one quarter full (at 30C) the ‘liquid equivalent’ of the
vapour rises to approximately 10% of the liquid contents. All LPG
storage vessels should, therefore, be provided with at least one
thermometer located in each of the liquid and vapour phases.

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11.11.4 PRESSURE MEASUREMENT
(a) Determination of pressure in the vapour space of LPG storage

vessels is necessary for the following reasons :
(i) As a check on the product quality, such vapour

pressure is directly linked to the temperature and product
characteristics.
(ii) To enable the ‘liquid equivalent’ of vapour, quantities are
to be calculated.
(iii) As a safety check against over pressurisation
.
(b) Pressure Gauges are also useful for operational control purposes
as they provide details of the pump differential pressures and thus
performance. They can also give warning of the incorrect
opening or the closure of the valves or pipeline / equipment
failure during the operations.
(c) Pressure Gauges should be checked for the accuracy at regular

intervals. They should be located in a position, where they can
be easily located and read and should be replaced / rectified
immediately on failure.
(d) Operators should be trained for the use and correct reading of
the gauge.
11.11.5 DENSITY DETERMINATION
(a) Bulk stock quantities in weight unit can be worked out from the
volume measurement, only if the density of the product is known.
Dispatching location should ensure that the dispatch document
carries quality certificate containing the details of density,
composition etc. along with the invoice. The unloading location
to take up with the loading location periodically for quality
certificate in case the same is not received along with invoice .
(b) Since the density has a major role in determining the stock, online
precision equipment suitable for LPG application for measuring
the density and temperature should be provided.

DEPARTMENT 11
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(c) Only fully trained personnel should be allowed to make these

measurements using the approved equipment ( sampling bomb
with a hydrometer ) and prescribed procedures. While making
density determinations, it should be ensured that:
 the apparatus is cleaned.

 the apparatus is purged thoroughly, using part of the sample.
 the sample is obtained in a safe manner.
 the sample is representative.
 the apparatus is properly calibrated.
11.11.6 METERING (Liquid LPG)-MASS FLOWMETER TYPE
(a) Although mass flow meters are sufficiently accurate for the stock
control purposes, their accuracy is inadequate where the safety
controls are concerned. For example, a meter may show that a
quantity of 10m3 has been pumped into the vehicle, but will not
show when the vehicle has been filled to its maximum safe level,
which is the function of the maximum ullage gauge.
(b) Meters can be relied upon to measure the quantities with the
required degree of accuracy only when incorporated in a
properly designed and maintained system which include the
following :
i. the meter
ii. a fine mesh strainer to catch small particles
iii. automatic vapour eliminator to remove the vapour to avoid
false reading
iv. a back pressure / differential valve to prevent vapourisation
of the product.
(c) The above units are normally included as a part of the meter
package. To work satisfactorily, meter system should meet the
following design requirements :
i. Suitable for pressure associated with the product being

metered i.e., vapour pressure plus pump differential.

DEPARTMENT 11
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ii. Capacity to match their associated prime mover.

iii. Always flooded with LPG liquid. The products will deposit any
contaminant, it contains if allowed to evaporate in the meter
and further evaporation could result in false meter reading.
(d) (LPG meter may be fitted with the temperature compensating

equipment and ticket print out equipment as an accessory for the
accurate meter reading and recording.
(e) A new meter is normally calibrated by the manufacturer just

before the dispatch and is supplied with the test certificate
showing the percentage error over its rated flow range. Periodical
recalibration is necessary to determine the change in the
accuracy brought about by wear and tear. Regular servicing /
maintenance should include cleaning, lubrication, etc., in
accordance with the manufacturer’s recommendations. Strainers
must be cleaned regularly.
(f) Leaks, signs of wear (noise) or mal-functioning should be attended

immediately. Records should be kept of original calibration,
subsequent re-calibration and / or servicing and maintenance.
(g) Meter used as delivery equipment MUST be certified by Legal

Metrology Dept / Authority.
11.11.7 WEIGHING
(a) Although the volumetric measurement of bulk LPG is normal, the

weigh bridges can be used to arrive at the weight directly.
(b) For packed LPG, weighing is the standard method, because it is

the simplest and requires simpler equipment than any other
cylinder filling method.
(c) The following points related to the use of weighing

equipment should be observed:
I. Only approved equipment meeting the requirement of Legal

Metrology should be used.

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II. All the weighing equipment must be checked regularly for

the accuracy as a routine
III. Regular servicing / maintenance should be arranged
through the agencies approved by the manufacturer or
specialists in the field.
IV. Re-calibration should be done as per statutory regulations.
V. Material / objects to be weighed must be located
centrally on the scale platform .
VI. (Log books should be maintained showing all service /
maintenance work carried out on the weighing
equipment with the details of initial and subsequent
calibrations.
11.12 CALCULATION OF LPG QUANTITIES

11.12.1 PRELIMINARY PROCEDURES
Calculations / conversions required in connection with the stock control

are dealt with in this section. The quantity of LPG will be substantially
correct if:
i. the measured quantity is correct i.e.
(i) the storage vessel has been accurately calibrated and its
calibration table is correct.
(ii) the level of liquid in the vessel is measured and recorded
correctly.
(iii) the meters used are correctly installed, calibrated and used.
ii. the storage vessel or the pipeline is properly sampled.
iii. the temperatures of both the liquid and vapour are properly
determined or in the case of temperature compensated meter,
the correct coefficient of expansion is applied to the
compensating device.
iv. the pressure in the vapour space of the vessel is correctly

measured and recorded.
v. the density of the product is correctly determined .


DEPARTMENT 11
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(Note: Due to inherent hazards, sampling for the purpose of

determining the density should not be adopted as a routine
practice at the plants. For the purpose of quantity
calculation, the density of 0.54 gram/cc is taken at 150C)
vi. All calculations, including applied corrections are accurate.
vii. Errors in the calculation and those inherent in measurements are

independent of each other. Consequently, the accuracy of final
calculation of the quantity is affected by the use of abbreviated
tables which only indicate the approximate or rounded off-
figures. Very little time or effort is saved by using short cuts instead
of recommended methods.
viii. ASTM-IP Petroleum measurement tables are suitable for the use
with computing aids and are prepared in order to provide the
required degree of accuracy. The use of these tables is,
therefore, desirable for the conversions instead of any abridged
tables or other short-cut methods.
11.12.2 BASIC REQUIREMENT
The method of calculating the quantity of LPG in a vessel or

consigned in a transfer operation from the observed volume and
temperature conditions is basically the same as is used for other POL
products, but additionally involves a method for determining the liquid
equivalent of LPG vapour in the vessel. The importance of accounting
for vapour quantity is illustrated earlier in Clause No. 11.11.3.
Guidelines for calculations are given in Clause No.11.12.3 below :
11.12.3 CALCULATIONS
(a) GENERAL
i. Bulk stocks of LPG and receipt / deliveries are recorded by direct

weighment. Alternatively weight can also be determined by
measuring the volumetric quantities and converting into weight
through calculations.

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ii. To enable the vapour above the liquid contents of a vessel to be

taken into account, the temperature and pressure of vapour; in
addition to normal measurements related to the liquid; must be
determined.
iii. In case of direct weighing, vapour content is
automatically included.
iv. Cylinder stocks are measured by direct weighing and sold /
invoiced by product weight.
(b) Conversion to liquid volume at standard temperature (15C) from

the given weight
i. For weights ‘in vacuo’ divide the weights by the appropriate

density at standard temperature. Weight derived by
calculations of measured volumes are weights ‘ in vacuo’ ?
Example : 1
What would be the volume in m3 occupied at 15C, by 90 MT of LPG in a

storage bullet; the density of LPG being 560 Kg/m3 at15C.
Volume in m3 @ 15C = Weight (in Vacuo) in Kgs.

—————————————
Density at 15C in Kgs./m3
90 x 1000
= ——————
560
= 160.714 m3
ii. For the weights in air, multiply the weights by the factors for he
volumes as per the unit weight given in the appropriate ASTM-
IP tables (i.e. No. 56 of Metric edition). Weights obtained by
direct weighing (i.e. weight of LPG in a cylinder) are the
weight ‘in air’.

DEPARTMENT 11
PAGE No.
CONTROL
Example : 2
A quantity of 15 Kgs. of LPG having a density of 0.560 Kgs./Litre at

15C is filled in a cylinder using a weighing scale. What would be
the volume in liters at 15C ?
Enter the ASTM-IP table no. 56 with 0.560 Kgs./Litre density under
“Density at 15C column and note that the volume occupied by
1 metric ton (under ‘Litre per Metric ton’ column) is 1789.3 Litres.
Therefore, volume occupied by 1 Kg is 1789.3/1000

= 1.7893 L
Therefore, volume occupied by 15 Kgs is 1. 7893 x 15 L = 26.8 Litres.
(c) Conversion to liquid volume at standard temperature (15C) from

volume at observed temperature (tC).
Multiply the measured volume at the observed temperature by

the Volume-Correction-Factor (VRF). VRF can be obtained from
ASTM-IP Table No. 54 (Metric edition), based on the known density
and temperature of the product.
Example : 3
If LPG, having a density of 560 Kg/m3 at 15C occupies a

volume of 1.6 m at 25C , calculate the equivalent volume in m3
3
at 15C?
-- Volume at 15C = Volume at 25C x V.R.F.
Note : To find VRF, use Table No. 54 of ASTM-IP tables. Enter

the Table with the column headed “Density at 15C” ‘under
560 Kg/m3’ column and against the observed temperature of
25C, the factor is 0.978).
— Therefore, volume in m3 at 15C = 1.6 x 0.978 = 1.5648 m3


DEPARTMENT 11
PAGE No.
CONTROL
(d) Liquid equivalent of vapour at the observed temperature (tC)
Convert the volume of vapour at the observed temperature

and pressure to its equivalent volume at standard reference
temperature (15C) and pressure. ( Zero gauge pressure) using
formulae given in Example No.4 below: (Apply appropriate
vapour / liquid volume ratio)
Example : 4
On gauging, a Horton Sphere of 1420 m3 capacity was found to

contain 570 m3 of liquid LPG having a vapour pressure of 14.6
Kg/cm2 at 65C. Its vapour content was at a temperature of
30C and pressure of 6 Kg/ cm2 at the time of gauging. Find out
the liquid equivalent of the vapour ?
Step : 1
Vapour volume = water capacity of storage vessel minus volume
of liquid LPG@ 30C = 1420 — 570 = 850 m3
Step : 2
Convert the vapour volume at 30C and 6 Kg/cm2 pressure to
NTP ( i.e. Normal Temperature and Pressure ) where the
normal temperature is 5C and normal pressure is 0 Kg./cm2..Using
the following formulae.
P1 V1 P2 V2
———— = ————
T1 T2
where
P1 = Observed gauge pressure + atmospheric pressure (i.e. 1.0335
Kgs./ cm2 )
V1 = Volume of vapour at observed temperature (i.e. 300C)
T1 = Observed temperature + 2730C.
P2 = Zero pressure in the vessel + atmospheric pressure (1.0335
Kgs./Cm2)
V2 = Volume of vapour at150C and zero pressure
T2 = 150C (Standard Temp.) + 2730C

DEPARTMENT 11
PAGE No.
CONTROL
P1 xV1 xT2
Therefore, V2 =
T 1 xP 2
(6.0  1.0335) x(1420  570) x(15 0 C  273 0 C )
=
(30 0  273 0 C ) x(0  1.0335)
= 1721800.8/ 313.1505= 5498 m3
Step : 3
Using liquid-vapour ratio of 247.7: 5498, vapour volume at zero
gauge pressure and 150C would work out to liquid equivalent of :
5498 / 247.7 = 22.2 m3 at 150C

= 3.9% of measured liquid volume.
(Note: At IOC’s plants, liquid vapour ratio of 248 may be
used unless specified otherwise)
(e) Total volumetric quantity at Standard temperature (15 0C)
Add the liquid equivalent of the vapour as determined in (d) to

the result of the liquid volume as determined in (c) to arrive at
the total volumetric quantity of LPG in the vessel.
(f) Weight from volume at standard temperature (150C)
When the quantity cannot be directly weighed, weight

should be determined as follows:
i. Determine the volume at standard temperature (150C) ae

explained in (c). (d) and (e) as applicable
ii. Multiply the volume at standard temperature (150C)

by the minus 0.011 by using ASTM-IP table (No. 56 of Metric
edition). The result would give total weight of LPG in a
container.

DEPARTMENT 11
PAGE No.
CONTROL
Example No. 5
On gauging, a 1420 m3 Horton Sphere was found to contain 570 m3 of

liquid LPG having a vapour pressure of 14.6 Kgs/ Cm2 at the time of
gauging. Find the total quantity by weight of LPG in the sphere, if the
density of liquid LPG is 560 Kgs/m3 @ 150C.
Step — 1
Convert liquid volume at 300C to equivalent volume at standard

temperature (150C) as explained in Example No, 3 above
Liquid volume = Vol. At 300C (in m3) x V.R.F. @ 150C
Step — 2
Convert ‘liquid equivalent’ of vapour contents in the sphere as

explained in Example No. 4 above.
Liquid equivalent of 850m3 vapour = 22.2 m3 at NTP
(Note : Refer Example No. 4 for detailed working)
Step — 3
Add volume of liquid LPG and liquid-equivalent of vapour, as worked

out in Step No. 1 and Step No. 2 above, respectively. The sum would
give total quantity of LPG in the vessel @ 150 C.
Total quantity of LPG = Liquid Vol. + Liquid equivalent of vapour

= 547.2 + 22.2 m3.
Step — 4
Using ASTM—IP table No. 56 work out W.R.F (Weight Reduction Factor)
for LPG having density of560 @ 150C. Against the reading of 560, a figure
of 558.9 would be observed ‘gm/m3’.

DEPARTMENT 11
PAGE No.
CONTROL
Step — 5
To arrive at weight of total LPG in the vessel, multiply the total volume at
150C (Step No. 3) with W.R.F. (Step No.4).
Weight of total LPG In the vessel = Total volume at 150C x W.R.F.

= 569.400 x 558.9
= 318237.660 Kgs.
= 318.238 MT
11.13 STORAGE VESSEL CALIBRATION

11.13.1 INTRODUCTION
Accurate calibration of storage and transport vessels is essential for

effective LPG stock and loss control, because the accuracy of stocks in
the vessel can be determined only within the precision limit of its
calibration. Any error in calibration of the vessel affects the accuracy of
stocks on recurring basis, until it is re-calibrated.
The following BIS publications provide details of the recommended

calibration methods and procedures for pressure vessels:
(a) IS : 2827 — Method for Calibration of Pressurised Storage Tanks.

(b) IS: 2808 — Method of Computation of Capacity Tables for
pressurised Storage Tanks.
11.13.2 CALIBRATION
It should be ensured that all vessels are calibrated and that the certified
calibration tables for each storage vessel are available. If the accuracy
of any calibration is in doubt, then re-calibration should be considered.
11.13.3 CALIBRTION TABLES
(a) Each calibration table should be prepared and certified by a

party specialized in the field. It should further be countersigned
as correct and approved calibration by the State Office /
Regional Office. If required, it should also be countersigned by
officials of the relevant authorities as per local regulations.

DEPARTMENT 11
PAGE No.
CONTROL
(b) The volumetric vapour content of the vessel for any given liquid
content can be obtained by subtracting the liquid volume from
the total volumetric capacity of the vessel, which should
appear on the calibration table.
(c) LPG vessel calibration tables should preferably show the

equivalent liquid and vapour volume for any liquid depth. The
liquid and vapour volume should be in separate columns and
the table should carry a caution note that vapour volume must
not be used directly in the stock calculations but must be
converted to liquid equivalent.
(d) No Changes should be made to any calibration tables unless

authorized by State Office / Regional Office / Head Office.
11.14 CONTROL DOCUMENTATION

11.14.1 GENERAL
(a) For accurate and effective control of stocks and losses / gains
the Plant Manager must compile and maintain complete control
documentation. The documentation should include bulk receipts,
deliveries, stock transfers and cylinder receipts, deliveries, and
filling as applicable. Sample format for daily stock loss / gain
analysis is enclosed in Annexure No. 16.
(b) The statements and records as required to be maintained are

intended to ensure that bulk and cylinder stocks are maintained
at satisfactory levels to meet the market demand, but they
should also be compiled in such a manner that they can form a
part of IOC’s overall stock / loss control documentation, thus
avoiding duplication.
11.14.2 INFORMATION FOR STOCK LOSS CONTRL
The information required for stock and loss control at plant is based on
the following :

DEPARTMENT 11
PAGE No.
CONTROL
(a) Bulk Stock Measurement Returns
Measurement should be recorded for each individual vessel on a

daily basis. Reporting should include:
i. Liquid level or percentage volume of liquid product

ii. The temperature of both the liquid and vapour phase.
iii. The pressure of the vapour phase.
iv. The density of the liquid phase (To be taken as 0.54 for all
calculation purpose).
(b) Bulk Stock Compilation
Bulk Stock calculations should be completed based on the

measurement recorded and recorded daily to give the total bulk
stock. As a rule, bulk stock accounting for LPG should be on the
basis of weight. Following steps are necessary to work out the
quantities :
i. For each vessel, calculate and record both the liquid and
vapour volume at observed temperature, using the
measurements and calibration tables. For each vessel, record
observed temperature of both liquid and vapour, the pressure
in the vapour phase and density of the liquid. As temperature
gauge is not provided in the vapor phase of storage vessel,
temperature reading of liquid LPG be taken as the base for
vapor temperature. Density of LPG for calculation purpose to
be taken as 0.54 gram/cc irrespective of variation in
temperature and density of LPG, to ensure uniformity, in stock
calculations. LEV to be arrived at and recorded in the gauge
book on daily basis for all LPG Plants. Each plant to arrive at
stock accounting as above.
ii. For each vessel convert liquid volume at observed

temperature to liquid volume at standard temperature and
record.
iii. (For each vessel calculate and record the liquid equivalent of
the vapour at standard temperature.

DEPARTMENT 11
PAGE No.
CONTROL
iv. (For each vessel calculate and record the total volumetric
quantity at standard temperature (liquid + liquid equivalent of
vapour)
v. For each vessel calculate and record product weight from
total volume.
vi. Record the day’s bulk receipts (through pipeline, tank
wagons, and tank trucks).
vii. Summarise and record the day’s deliveries/transfers.
viii. Calculate and record the day’s total loss / gain. Any
ix. abnormal loss or gain should be promptly investigated.
(c) Cylinder Stock Compilation
i. Stocks of LPG stored and distributed through cylinders should

be calculated and recorded daily. The quantity of bulk
product supplied to the filling plant should be compiled on the
basis of supplying vessels’ measurements taken before starting
and after completion of the filling operation. The cylinder
stock accounting essentially consists of following:
(1) Total opening and closing no. of filled cylinders in stock.

(2) No. of cylinders filled during the day.
(3) No. of filled cylinders issued during the day.
ii. Stocks of cylinders worked out at the filling plant should be

reconciled with the stock figures worked out on the basis of all
relevant receipt / delivery accounting documents. The
reasons for any discrepancy should be immediately
investigated.
iii. Details of each type/size of cylinders should be incorporated

in the stock statement.

DEPARTMENT 11
PAGE No.
CONTROL
11.14.3 STOCK AND LOSS REPORTING STATEMENTS
The features of stock and loss reporting statements are as follows :
(a) Data should be complied by the plant on a daily basis and be

used immediately to investigate and prevent recurrence of
undue losses / gains or unbalance of stock.
(b) Stock movement and losses / gains should be on the basis of
weight only (MT).
(c) Information provided should be compatible with the company’s
stock accounting system and overall information needs.
11.14.4 Stock accounting procedures available in SAP and latest guidelines of

the Finance Department are to be implemented fully.
12
QUALITY CONTROL
QUALITY CONTROL OF LPG IS MORE
IMPORTANT FROM SAFETY POINT OF
VIEW THAN ANYTHING ELSE BECAUSE
CONTAMINATION OF LPG ; SPECIALLY
WITH WATER ; IS A SERIOUS
SAFETY HAZARD


DEPARTMENT 12
PAGE No.
March 2014 QUALITY CONTROL 12-1
12.1 GENERAL
12.1.1 The quality control assumes all the more importance where more
than one grade of LPG is stored at the same plant / location.
Presently, at any bottling plant, only one grade of LPG is being
stored / handled. It is likely that in the coming years, it may be
required to handle more than one grade of LPG at the same plant.
It is with this background that the details of various aspects of
quality control of LPG are covered below. Many of the measures
described relate to the plants handling single grade LPG also.
12.1.2 Although LPG is stored and handled in a closed and pressurised

system, it may still become contaminated by air, water, other
petroleum fractions and even with other grades of LPG, if sufficient
care is not taken. Any such contaminant can affect its quality or
safe handling as LPG with high vapour pressure when mixed with
LPG with low vapour pressure for instance, will lead to over filling
and over pressurisation of containing systems.
12.1.3 This chapter covers not only the quality control of bulk LPG but also
random quality control of filled LPG cylinders which is very vital
both from safety as well as customers’ satisfaction point of view.
12.1.4 Quality Control and the procedures related to its achievement /

retention are thus necessary not only to safeguard the quality of
the product but also for safety reasons.
12.2 OBJECTIVES
12.2.1 Uniform Quality Control procedures are to be evolved for handling
LPG at following places:
(a) Refinery Locations

(b) Fractionators Locations
(c) LPG Import / Coastal Movement Terminals.
(d) LPG Loading Terminals
(e) LPG Bottling Plants.

DEPARTMENT 12
PAGE No.
12.3 PURPOSE
12.3.1 The purpose of the procedures outlined is to ensure:
(a) that LPG produced indigenously at Refineries / Fractionators

and received through Imports and coastal movement is in
accordance with the standard specification.
(b) that the commercial propane, commercial butane and

predominant mixture of two (LPG) enter the marketing and
distribution system in accordance with the specification.
(c) that the commercial propane, commercial butane and

predominant mixture of two (LPG) are delivered from various
storage points by different modes of transportation in good
condition and conforming to specification.
(d) that a well-defined system of quality control checks and

documentation exists to achieve the purpose and has
traceability and transparency.
12.4 QUALITY CONTROL RESPONSIBILITIES

12.4.1 The primary responsibility of implementation of Quality Control
manual and procedures will be of Plant Manager. However, the
overall responsibility for ensuring proper quality control in various
import terminals and LPG bottling plants rests with the LPG
Operations Department at Head Office. Each terminal and LPG
bottling plant shall identify an Officer as a Quality Control Co-
ordinator, who will be responsible for the implementation of quality
control guidelines at that location.
12.4.2 The responsibility for ensuring proper quality control in Refineries

and Fractionators rests with the production sources.
12.4.3 Quality Control Implementation Officers of the LPG Operations

Department / Controlling Offices shall carry out inspection to
ensure proper implementation of the laid down quality control

DEPARTMENT 12
PAGE No.
procedures. Such inspection shall be carried out at least once in a

year for each location.
12.4.4 All those associated with the delivery of LPG bear the responsibility
to ensure that the product is delivered in a clean and good
condition meeting the relevant quality standards. Delivery of “Off
Specification / contaminated Product” should not be made.
12.4.5 Plant Manager shall maintain quality control of the product

perfectly at all stages starting from the receipt of the product to
storage, loading, unloading, filling etc. and thus ensure delivery of
the product from the plant as per the specification. Necessary
facilities and apparatus are to be provided at the plant.
12.4.6 Plant Manager should ensure that all personnel engaged in

handling of LPG are thoroughly familiar with LPG quality control
procedures.
12.5 QUALITY AUDIT INSPECTIONS

12.5.1 Officers of the Quality Control Department / LPG Operations
Department from State Office / Regional Office / Head Office shall
carry out quality audit inspections. Such inspections shall be
carried out at all production centers and import locations at least
once in a year and the observations be entered in quality control
check form as per Annexure No. 17.
12.6 DOCUMENTATION
12.6.1 All quality control activities are to be documented and duly
reviewed by the Plant Manager and the documents are to be
preserved for a period of one year for the next annual inspection.
12.7 PRODUCT QUALITY & SPECIFICATIONS

12.7.1 IMPORT SPECIFICATIONS
Import specifications of the commercial butane, commercial

propane and commercial butane-propane mixture are given in

DEPARTMENT 12
PAGE No.
Annexure Nos. 18, 19 and 20 respectively and shall be binding for

all imports
12.7.2 SPECIFICATIONS FOR INDIGENOUS LPG PRODUCTION
The specifications for commercial butane, commercial Propane

and butane-propane mixture should conform to IS: 4576-1979,
which are given in Annexure No. 21.
12.7.3 QUALITY ASSURANCE AT REFINERIES AND FRACTIONATOR

LOCATIONS
(a) Quality of LPG produced at Refineries & Fractionator

locations shall be tested / certified batch wise in line with BIS
Specification No. IS: 4576-1999 as per Annexure No. 21.
(b) A copy of the Quality Certificate shall be issued to Marketing

Division/Pipeline Division, which shall also indicate the density
of the product at 150C temperature.
(c) (In case the quality of LPG fails in any of the characteristics,
the same shall not be released for despatch. The quality of
the product must be corrected by re-processing, before
releasing the product.
(d) Before despatch, the product shall be doped with

mercaptan and ensured that 18-20 ppm of mercaptan is
present with a view to have distinct odour and the same is
recorded in the Quality Certificate. Subject to the agreement
between the purchaser and the supplier, the odour
requirements of LPG may be changed for certain application,
when un-odourised LPG is required to be supplied.
(e) The water from the storage vessel shall be drained off daily to
ensure that the product is free of water and the observation
shall be recorded. Water draining shall be done as per the
procedure given in Chapter No. 6.

DEPARTMENT 12
PAGE No.
12.7.4 TANK TRUCK AND TANK WAGON LOADING
Whenever bulk loading is involved i.e., transfer of the product to

tank trucks or tank wagons, the following checks are necessary:
(a) The product is to be loaded / transferred as per the product

grade indicated in the relevant indent / challan after
ensuring that the tank wagon / tank truck is fit for loading.
(b) The tank truck and Tank wagon in which the product is to be
loaded shall be checked for compatibility of the same e.g.
the vessel in which propane is to be loaded should be of
propane rating. However, presently in LPG bottling plants,
propane alone is not handled.
(c) After loading, vapour pressure, density and temperature of

the product in the transport vessel shall be checked for
acceptable limits and recorded on the invoice.
12.7.5 TANKER LOADING (Coastal Movement)
(a) Procedures are to be followed in line with “TANK TRUCK AND

TANK WAGON LOADING” mentioned above. Prior to loading,
the quality certificate shall be scrutinised to ensure that all
characteristics as per BIS specification are tested and
certified by the loading Refinery. The surveyor shall ensure
fitness of the tanker before loading and necessary fitness
certificate shall be issued in line with Annexure No. 22.
(b) After loading the product, the sample shall be drawn from
the individual tank of the tanker for retention and conducting
tests, if required, in case of any dispute in the quality. Two sets
of each sample shall be drawn as follows :
i. From the loading arm jointly with the representative of

Refinery. One set of the sample shall be retained by the
Refinery and another set shall be with Marketing
Company.

DEPARTMENT 12
PAGE No.
ii. From the individual tanks of the tanker jointly taken with
the Master of the tanker. One set shall be retained with
the Marketing Company and the second set shall be
handed over to the Master of the tanker for handing
over to the receiving company at the disport.
(c) All the sample(s) shall be retained, till the quality of the
product is established at the disport or maximum up to 30
days, whichever is earlier. In case of failure in the quality of
the product either in the pre-discharge test or batch
formation test, the sample shall be retained till further advice
from the Controlling Office.
12.8 QUALITY CONTROL AT LPG IMPORT/COASTAL

MOVEMENT TERMINALS
12.8.1 IMPORT RECEIPTS
(a) Quality Control Checks are to be made before the discharge

of the tanker.
(b) Before discharging the import cargoes, the load port quality
certificate shall be verified with contractual specification.
(i) For C&F Cargoes: If the load port quality certificate

shows that the product is not meeting the contractual
specification, the cargo is to be rejected and a report to
be sent to the Controlling Office / HO Shipping
Department for further necessary action.
(ii) For FOB Cargoes: If the load port quality certificate

meets the contractual specification, the sample from
the individual tank(s) shall be drawn and tested as per
the following characteristics in line with the contractual
specification:
1) Vapour Pressure
2) Copper strip corrosion
3) Volatility* (See Note No. 1&2)
4) Density

DEPARTMENT 12
PAGE No.
Note 1: In case the load port quality certificate indicates the test
only for the gas composition, the volatility test shall be
carried out in line with BIS specification IS: 4576-1999 and the
test method. If the product meets the limit of this
specification, the product shall be discharged.
Note 2: If in the load port quality certificate and the test

report, the volatility and the gas composition are reported,
then the sample shall be tested for volatility and the result be
compared with the contractual specification of volatility. If
the sample meets the specification, the product shall be
discharged.
(c) In case the product fails in the volatility and the supplier has
certified in respect of gas composition only, the laboratory
shall carry out the gas composition test as per either of the
following test methods:
(I) ASTM D 2163/IP: 264: Analysis of liquefied petroleum

gases and propane concentrates by Gas
Chromatography
OR
(II) ISO 7941:1988/IP 405-94: Commercial propane and
Butane analysis by Gas Chromatography
Note 1: If the product meets the specification in respect of the gas

composition in line with the contractual specification, the
product shall be discharged.
Note 2: If the product does not meet the specification in respect of

the gas composition in line with the contractual
specification, the product shall not be discharged.
(d) If the product is not cleared for discharge, the detailed test
results along with pertinent information shall be
communicated to the Controlling Office and HO Shipping
Department immediately for necessary advice. Meanwhile,
without loss of time, 3 sets of fresh samples shall be drawn
jointly with the representatives from the concerned agencies.

DEPARTMENT 12
PAGE No.
One set should be immediately tested as per the contractual

specification in the presence of above representatives. The
balance two sets of samples shall be retained till further
advice from Shipping Department.
12.8.2 QUALITY CONTROL BEFORE DESPATCH
(a) After tanker discharge, the product shall be tested in line with
BIS specification. In case the product does not meet the
specification, necessary corrective action shall be taken in
consultation with Controlling Office/ Quality Control
Department to ensure release of the product to the market as
per BIS specification. In case dosing is done on-line during the
despatch of the certified product, a sample has to be drawn
after dosing for odour test. The testing of the product is to be
done shift-wise and the record of the same shall be
maintained.
(b) Mercaptan content of 18-20 ppm must be ensured to

maintain the odour level 2 before despatch of the product to
the bottling plant.
12.8.3 TANK TRUCK AND TANK WAGON UNLOADING
Quality control procedures as outlined in the “TANK TRUCK AND

TANK WAGON LOADING” is to be followed
12.9 QUALITY CONTROL AT BOTTLING PLANT

12.9.1 PRODUCT TESTING
(a) The frequency of testing and types of tests required for LPG
quality control depend upon the local conditions. Excessive
sampling and testing add to operating costs, involve product
loss and introduce hazard on account of venting of the
product to the atmosphere. It should, therefore, be ensured
that the instructions regarding sampling and testing are
closely followed and sampling should be done whenever
required only.

DEPARTMENT 12
PAGE No.
(b) Quality control operations at the plant are generally restricted

to the following:
(i) Reading Pressures.

(ii) Reading Temperatures.
(iii) Checking appearance visually,
(iv) Checking odour
(v) Determining the density.
(vi) Determining the presence of water and other
contaminants such as air, rusted particles, etc. and
dealing with them.
(c) Samples MUST be representative of the whole product parcel

from which they are obtained and correctly and legibly
identified.
12.9.2 VAPOUR PRESSURE / TEMPERATURE
For routine plant operations, the vapour pressure determination

does not require any special equipment or procedure. It is
necessary only to read the pressure gauges and the temperature
sensing Instruments of the vessel.
12.9.3 COLOUR AND APPEARANCE
a) The colour and appearance of LPG can be established

satisfactorily only by sampling of the product.
b) LPG is colourless whether it is in liquid or vapour form.

However, the cooling effect of evaporating LPG on the
surrounding area condenses water vapour causing a visible
white cloud.
c) Liquid LPG should be bright and water-white in appearance.

Cloudiness or dis-colouration should be taken as a possible
indication of contamination.
d) The contents of LPG storage vessels should be sampled and

checked for correct colour and appearance whenever
contamination is suspected.

DEPARTMENT 12
PAGE No.
12.9.4 DENSITY
(a) The density of the liquid phase of LPG is useful guide for the
quality of the product and is indispensable for converting
volumes to weight and vice-versa.
(b) The density of liquid LPG can be readily determined by using

standard procedures and equipment. At the plant level, the
density communicated by the supply source should be used
as reference for calculations. Density through physical
sampling should be checked, only if it is required for any other
specific purpose. In that case, the sampling must be done
under the supervision of a competent person specifically
trained for the purpose.
(c) The product temperature is an essential measurement in

connection with the density and also to study the relative
vapour pressure.
(d) For comparison with Quality Certificates, observed data

should be converted to density at standard temperature
(150C).
12.9.5 ODOUR
(a) Pure LPG is odourless, but the commercial product marketed

for the use of consumers is odourised as per statutory
requirements. Unless odourless gas is needed, it is normal
practice to stench LPG sufficiently to make it detectable in
concentration with air of one-fifth the lower explosive limit.
(b) The distinctive odour of commercial LPG should be used as

quality control check to distinguish from other gases (and
from odourless LPG) and all personnel should be familiar with
the odour of the odouring agent used.
(c) (If LPG, during the draining operation involving venting to the
atmosphere, fails to produce a distinctive odour, the
product (unless known to be odourless grade) shall not be

DEPARTMENT 12
PAGE No.
released. A sample shall be taken for further testing, causes

be investigated and corrective action be taken.
(d) Odourless product shall not be allowed to leave the plant

unless an odourless grade is specified.
12.9.6 SOLID CONTAMINANTS
(a) LPG may become contaminated by solids such as rusted

particles during transportation, handling or processing and
this must be removed. Storage vessels, pipeline systems and
transport media must be kept clean.
(b) As solid contaminants are detrimental to pumps, meters, etc.,

product must be strained / filtered before reaching them. The
filters/strainers, etc. must be inspected and cleaned regularly
as per the guidelines given In Chapter No. 10. The condition
and appearance of the effluent from the storage vessel
drains, give an indication of the cleanliness of the product
and the associated storage and handling system.
(c) The presence of contaminants in the strainers and drained

effluent is the evidence that the vessel requires cleaning.
12.9.7 WATER AND OTHER CONTAMINANTS
(a) Contaminants such as water, other petroleum products,

rusted particles etc., can be detected during the routine
draining operation and should be removed at once. Solid
contaminants also accumulate in the filters. The filters/
strainers should, therefore, be periodically checked and
cleaned.
(b) Water may be present in LPG in its free state i.e. as droplets or
in solution. Water in solution at one temperature can be
precipitated as free water by a fall in temperature. Hence,
the routine draining operation should be preferably carried
out early in the morning.

DEPARTMENT 12
PAGE No.
12.9.8 PRESENCE OF AIR
(a) Before any LPG system is made operational, air in the vessels,
pipelines and equipment, etc., are to be replaced by LPG.
Detailed procedures for purging the storage vessels and the
cylinders are outlined in the Annexure No. 10. Checking and
testing of the product for contamination by air are, therefore,
non-routine procedures and are necessary only during and
after the initial commissioning or after the plant is opened for
maintenance, etc.
(b) Air must be removed from all LPG cylinders because its
presence creates a flammability hazard. The presence of air
can also lead to over-pressurisation of LPG system.
12.9.9 DRAINING
(a) The purpose of draining is to remove water, heavier

petroleum fractions and other contaminants, whose
presence will affect the product quality. The procedure of
draining operation is given in Chapter No. 6
(b) Water or other contaminants found in the storage vessels

during routine draining operation should be removed as
completely as possible. Care is essential, as otherwise LPG
may escape with water or other contaminants.
(c) Water and other contaminants should be removed through

drain valves (a double valve system is required) and piped
away from the immediate vicinity of the vessel
(d) Responsible person MUST be present throughout the draining

operation
(e) As far as practicable, the stocks should be arranged in such a

way that the cargo can be received in one vessel or a group
of vessels, while the normal operation continues from another
vessel. This provides settling time for the new stock,
facilitating drainage of water, etc

DEPARTMENT 12
PAGE No.
(f) The frequency of draining should be minimized to reduce the

hazard arising out of LPG escaping through water, but daily
draining is recommended following any product receipt.
(g) In order to prevent the escape of spilled LPG into the main
drainage system, surface water from the storage area shall
be directed to the main drainage through a water seal to
avoid the spread of Hydrocarbon.
12.9.10 RECOMMENDED MINIMUM REQUIREMENTS
(a) Many of the checks and tests, necessary for satisfactory

quality control of LPG product are also applicable to the
quantity control and safety. Safety is the most important
consideration and governs the timing of the combined
checks but unnecessary duplication should be avoided,
whenever possible.
(b) The frequency and extent of the need for the quality control
checks and tests vary with local circumstances.
12.10 RANDOM QUALITY CONTROL OF LPG CYLINDERS

12.10.1 EMPTY CYLINDERS
(a) It must be ensured that the new empty cylinders and the
empty cylinders received from Statutory Testing Plants / Hot
Repairers and other cylinders containing air are purged
before filling operations.
(b) A batch of new cylinders received at the plant should be

checked at random for the presence of water. If water is
observed in the cylinders, all the cylinders in the batch should
be checked and corrective action be taken by referring the
matter to the supplier through State Office / Regional Office
/Head Office. In any case, no cylinder, where presence of
water is detected, should be taken up for filling, unless the
water is completely drained off.

DEPARTMENT 12
PAGE No.
12.10.2 CYLINDER FILLING
The ultimate objective of the plant is to ensure that the cylinders

while leaving the plant are 100% safe, correctly filled and are
genuine. This calls for strict adherence to all checks for leakage /
weighment / visual inspection and compliance of all statutory
requirements and manualised instructions on the subject. While
various checks to achieve this objective are broadly covered in
Chapter No. 8 and Chapter No.10, further specific guidelines for
these checks are detailed below for adhering to strict quality
control of filled cylinders.
12.10.3 Before each and every filled cylinder leaves the plant, it shall be
critically examined for the following aspects:
(a) Cylinder is genuine (not spurious) and fit for filling as per BIS
norms.
(b) Correct quantity is filled within specified limits.
(c) There is no leakage
(d) The ‘O’ ring is present in the Self Closing valve and is not
defective.
(e) It complies with statutory requirements such as, not ST due,

proper colour, safety cap, neck label, sealing etc.,
12.10.4 For ensuring that the cylinder is genuine and fit for filling as per BIS
norms, following action shall be taken:
(a) Each and every incoming empty cylinder should be critically

examined externally as per IS: 15966: 2013. For details Chapter
No. 8 may be referred. Primarily, it must be ensured that the
cylinders which are badly rusted, dented, pitted, having burn
marks and spurious are not taken up for filling.
(b) Spurious cylinders can be classified into three categories:


DEPARTMENT 12
PAGE No.
i. Those which can be easily identified visually e.g.

cylinders having different dimensions, having patch
welding, having more than one number of
circumferential welds, having vertical welding, having
different colour, etc.
All such cylinders shall be withdrawn from the circulation

during the course of visual inspection. The source of such
cylinders shall be identified and corrective action shall be
taken to prevent recurrence.
ii. Cylinders having non-standard markings such as ISI

monogram, non-standard manufacturer’s symbol etc.
All such cylinders shall also be withdrawn from the

circulation through the process at crucial visual inspection
of the markings.
iii. Cylinders which cannot be easily identified as spurious

through visual inspection and checking of the markings
e.g. cylinders having patches /additional welds which
are covered with putty/thick paint.
All such cylinders normally get detected during the process of

filling due to leakage of the product through the additional
weld points.
Each bottling plant should evolve a method to identify the

source of receipt of such spurious cylinders.
12.10.5 If the adequacy of any cylinder to accept the product involved is

in doubt, the cylinder should be removed from the filling system for
subsequent investigations.
Where different grades of LPG are filled into the cylinders,

cylinders are properly identified (colour, shape or other markings)
as suitable for the particular grade of LPG being filled.
12.10.6 For monitoring accuracy of the quantity of LPG in the cylinder,

following steps shall be taken:

DEPARTMENT 12
PAGE No.
(a) With the type of filling equipment installed in most of the

plants, the accuracy of quantity of the product filled in the
cylinder is a function of correct tare weight marked on the
cylinder. Therefore, the tare weight of incoming cylinder shall
be verified as under:
(i) Tare weight of 10% new (virgin) cylinder shall be verified

at random and records be maintained for the same.
Weighing scale shall have least count of at least 10
gram. Cylinders with variation between stenciled and
actual tare more than +/- 50 grams subsequent to
rounding off as per Indian Standard code IS 2 shall not
be acceptable,. All such cylinders shall be kept aside
and the matter shall be taken up with the concerned
manufacturer through HO LPG Department for
corrective action while carrying out the tare weight
checks, the accuracy of the weighing machine must be
established. The weighing scale shall have verification
scale interval of 10 gms and not more.
(ii) Similarly each and every cylinder returned after hot

repairs / statutory testing shall be verified for accuracy
of the tare weight in the same manner as explained in
paragraph (i) above. In the event of variations
observed, if any, observations are to be recorded in the
proforma given in Annexure No. 23 and the matter to be
taken up with the concerned party to identify the cause
and take corrective action before revising the tare
weight markings (both stencil as well as punch marks).
Old tare weight of the cylinder must be retained on the
stay plate
(iii) The new tare weight of the cylinders shall be stenciled

on the shoulder as well as inside portion of one of the
vertical stays of the cylinder. The height of the figures
should of 40mm and the colour of the paint to be used
for stenciling shall be white.

DEPARTMENT 12
PAGE No.
(b) The accuracy of each electronic filling machine shall be

established at the beginning of each shift and at the interval
of every four hours as detailed in Chapter No. 8 using check
scales. The findings of such checks shall be recorded in the
proforma given in Annexure No. 24 or alternatively print out
of filling machine accuracy can be taken from control
room PC for review and corrective action, However, if
data logging is not provided/working the format has to
be maintained manually for corrective action.
(c) The accuracy of the check scales shall be established

minimum four times in each shift as follows:
1st check: at the beginning of the shift.

2nd check: in the third hour after beginning of the
shift.
3rd check: in the fifth hour after beginning of the shift.
4th check: in the seventh hour after beginning of the
shift.
The checks shall be carried out by using standard weights

duly certified by the Legal Metrology Department. The
weights shall be available with the weight equal to or slightly
greater than the maximum weight of the filled cylinder being
handled. Immediate corrective action for the variations
observed must be taken. The record of the checks, the
observations and corrective action taken shall be
maintained in the proforma given Annexure No. 25.
(d) Correctness of the standard weights used for checking the

accuracy of the weighing scales shall be verified through the
Legal Metrology Department at periodical intervals specified
in the relevant Act.
(e) 100% check weighing of filled cylinders shall be ensured. The

permissible margin for the net quantity of 14.2 Kg LPG cylinder
is minus 100 gm and plus 200 gm. Presently, Legal Metrology
Department allows a variance of  150 gm for 14.2 Kg.
cylinders and +/- 190 gram ( 1% of net weight ) for 19 kg

DEPARTMENT 12
PAGE No.
cylinders and  75 gm ( 1.5% of net weight ) for 5 Kg cylinders

with average net weight of the sample greater than or equal
to declared net weight of the respective cylinders.
(f) Record of total number of under filled / overfilled cylinders

generated in each shift vis-a-vis total number of cylinders
filled during the shift shall be maintained as per proforma
given in Annexure No. 26 and the trend should be watched
carefully.
Efforts shall be made to have a decreasing trend. Causes for

increasing trend shall be investigated and immediate
corrective action shall be taken.
(g) To minimize the possible human errors, persons at the

following work stations shall be rotated every two hours at the
operational convenience of plants :
 Marking of the tare weight of cylinders

 Tare weight setting on the carousel
 Check weighing of the filled cylinders (if available)
 Tightness testing in the water bath (if available)
 Compact Valve Tester (CVT) (if available)
 Bung leak checks (if available)
12.10.7 For monitoring tightness (leakage) test of the filled cylinders,

following steps shall be ensured :
(a) All the filled cylinders shall be checked for bung leak in the
‘in-line’ bath / Electronic bung leak detector.
(b) Cylinder leakage test through water bath shall be properly

supervised by the experienced staff. While the sensitivity of
CVT is limited to 0.5 gm of gas per hour, by testing the filled
cylinders in the ‘in-line’ test bath, the leaks can be detected
down to 0.1 gm of escaped gas per hour which will clearly
manifest during the visual inspection. The limit of possible
escape of gas from an accepted cylinder after tightness
water bath test will not cause any danger to its surroundings.

DEPARTMENT 12
PAGE No.
(c) The record of total number of bung leak / valve leak cylinders
and cylinders with missing / defective ‘O’ rings should be
maintained in the proforma given in Annexure No. 27 and the
trend will be monitored.
Causes for increasing trend, whenever occurs, should be

thoroughly analysed and corrective action be taken
immediately. Efforts should be constantly made to achieve
decreasing trend in all categories.
(d) Soap solution should never be used under any circumstances

for checking leakage through valve seat/spindle of SC type
valve.
12.10.8 From the consumer point of view, it is extremely important that the
filled cylinders, while leaving the plant, must have ‘O’ rings in the
SC type valve outlets and that the ‘O’ rings fixed are not defective.
Towards this objective, the following steps shall be taken:
(a) All incoming empty cylinders shall be visually examined for
the presence of ‘O’ rings before they reach the carousel or
unit filling machine. Cylinders not having ‘O’ rings shall be
fixed with new ‘O’ rings immediately.
(b) With the help of Compact Valve Tester (CVT)/ AVTS/ Pressure
transmitter, test must be conducted to check each and every
filled cylinder for effectiveness of ‘O’ ring (as per the
manufacturer’s instructions). Sufficient time as prescribed by
the manufacturer shall be given for the test. Presently
permissible limit of leakage is 0.5 gm per hour.
(c) In case of leakage through CVT, it must be established that

the leakage is not through the valve seat before changing
the ‘O’ ring.
(d) (The effectiveness of the CVT unit shall be checked at the

beginning of shift and every one hour thereafter by using a
dummy SC valve fitted with defective ‘O’ ring, close to CVT
unit in operation. In case of AVTS, the test shall be conducted
with the help of test cylinder.

DEPARTMENT 12
PAGE No.
(e) Defective ‘O” rings of the filled cylinders should be

immediately replaced with new ‘O’ rings and cylinders are to
be again subjected to CVT test.
(f) The record of missing / defective ‘O’ rings noticed at the

plant level and also in respect of cylinders returned by the
Distributors as defective shall be maintained in a proforma
given in Annexure No. 28.
(g) EVERY CASE OF MISSING ‘O’ RING CYLINDERS RETURNED AS

“MARKET RETURN” SHOULD BE T INVESTIGATED TO IDENTIFY THE
SOURCE AND THE CAUSES FOR FUTURE COURSE OF ACTION.
12.10.9 DRAINING OF WATER
(a) In case any cylinder is returned by the Distributor because of

presence of water in the filled cylinder, the same is to be
treated seriously and thorough investigation should be carried
out with concerned Area Office and State Office to identify
the source and take corrective action
(b) 10 out of every 100 incoming empty cylinders from each of

the following category shall be lifted and turned upside down
to detect the presence of any foreign matter inside the
cylinder such as, water/rust particles/sludge particles, etc.
Categories
 New cylinder
 Cylinder received after statutory testing
 Cylinder received after hot repairs
In the case of suspected presence of any foreign materials

inside the cylinder, the cylinder valve is to be removed, the
contents are to be collected in a clean tray and examined.
The matter is to be taken up with the concerned for
corrective action.

DEPARTMENT 12
PAGE No.
(c) Besides checking the correctness of the tare weight markings

on the new cylinders, cylinders received after hot repairs and
cylinders received after statutory testing, as prescribed in
Clause No. 12.10.5 above, the quality of workmanship in the
following area shall also be checked:
 Body leak
 Leakage through weld joint (bung/circumferential)
 Bung leak
 Valve leak
 Details beyond permissible limit as per IS 15966: 2013
(IS:13258- in the case of cylinders received after hot
repairs & IS16054 for cylinders recived after statutory
testing. In the case of new cylinders there should not be
any dent)
 Quality of the punch mark
 Quality of stenciling (tare weight and due date of
testing)
In case any deficiency is noticed, the same is to be

recorded in a separate register to be maintained for the
purpose. The matter shall be referred to HO LPG
Department for corrective action by the concerned party in
the case of new cylinders and through the State Office in the
case of other two categories.
12.10.10 RANDOM QUALITY CONTROL CHECKS (RQC)
(a) Filled cylinders ready for dispatch after sealing shall be

picked up at random for random quality control checks.
These random checks shall be carried out by the Plant
Manager and any other Officer authorised by the Plant
Manager. Visiting officers from the State Office/Regional
Office / Head Office shall also undertake such surprise checks
and record the observation in the register provided at the
plant for the purpose.
(b) The minimum frequency of the random quality control checks

on daily basis in each operating shift at the rate of 10 out of
1000 cylinders should be as under:

DEPARTMENT 12
PAGE No.
i. 1st Check- Minimum 10 cylinders or more, whichever In the

1st hour from the beginning of the shift
ii. 2nd Check- Minimum 10 cylinders or more In the 3rd hour

from the beginning of the shift.
iii. 3rd Check Minimum 10 cylinders or more In the 5th hour

from the beginning of the Shift.
iv. 4th Check- Minimum 10 cylinders or more-In the last hour

from the beginning of the Shift.
(c) The total number of filled cylinders picked up for random

quality control checks in the manner as indicated in the
clause No. 12.10.10 (b) above should not be less than 0.5% of
the net filling on daily basis.
(d) Cylinders picked up for random quality control checks shall

be checked for:
i. Fitness of the cylinder as per visual inspection according

to BIS norms IS15966: 2013.
ii. Due date of cylinder for re-testing as per statutory
regulations.
iii. Correct weight and the extent of under/over filling.
iv. Cylinder valve / bung leak.
v. ‘O’ ring defect/missing in the case of SC type valves.
vi. (Absence of water/dust in the outlet of SC type valves.
vii. Safety cap properly fixed.
viii. (Cylinder properly sealed.
ix. (Any other defect.
(e) The record of surprise checks as above shall be kept in a

separate register to be maintained for the purpose together
with the details of the corrective action taken in the proforma
given in Annexure No. 29. In effect the record of random
quality control checks should work as a parameter for the
various checks exercised at the plant for correct filing
/tightness testing of the filled cylinders.

DEPARTMENT 12
PAGE No.
12.11 BULK RECEIPTS

12.11.1 Certificate of Quality, Bill of Lading (in case of tanker receipts),
delivery challan, pipeline transfer advices etc., must tally with the
requirements and indicate that the incoming parcel is compatible
with the product in the receiving facilities.
12.11.2 In the case of pipeline transfers, verification should be made

through the dispatching location to ensure that the line contents
and the planned LPG parcel are identical or compatible.
12.11.3 The vapour pressure and temperature of each incoming bulk

vessel shipments (road, rail, pipeline or tanker) should be checked
individually to ensure that it is in accordance with the requirements
and with the dispatch advice and that it is compatible with the
contents of receiving facilities. If quality variation or contamination
is suspected, the transferring and receiving tanks should be
isolated and pipeline transfer delayed/suspended. The sampling
and testing of suspected product parcels should be done to
investigate the causes and initiate corrective measures.
12.11.4 Samples of the product should be taken from the tank wagons,
tank trucks (or pipelines) before receiving the product into the
plant only when this prescribed procedure is specifically
authorised. Such samples should be checked/tested for vapour
pressure, temperature, odour, colour, appearance and density.
Presently, the system of checking of tank wagon, tank truck or
pipeline samples, before the receipt should not be followed as a
routine, but should be adopted in specific cases only where
contamination is suspected. The sampling must be done by a
competent person trained for the purpose with the help of
approved apparatus.
12.11.5 During the receipt of any shipment, designated receiving vessels

are to be checked regularly i.e. level and pressure gauges and
temperature readings, to ensure that the correct product is
received into the nominated vessels.
12.11.6 In the case of tanker discharge when two or more grades are
carried, individual tank of the tanker is to be checked regularly

DEPARTMENT 12
PAGE No.
(i.e. ullage) to ensure that only the required grade is being

discharged.
12.11.7 When a common line is used and the product grade change is to
be made, representative line samples should be taken at intervals
before and after switching over in order to detect the stop
interface and to confirm the change and the quality of the
product switched over to the new vessel.
12.11.8 When switching for a common line, grade change is done on a

calculated speed of flow-time basis. Sampling and checking
should be carried out on the receiving vessel or its individual supply
pipe after the switching over as soon as possible in order to check
the absence of the contaminants.
12.11.9 For all forms of receipt, if contamination or quality of the product

being received is suspected, receipt must be stopped and the
receiving lines and the vessels be isolated. Samples should be
checked and operations should be resumed, only if the results of
samples are satisfactory. If the samples are unsatisfactory, State
Office / Regional Office /Head Office should be consulted for
further instructions.
12.11.10 After the receipt of shipment and settling time of minimum one
hour, the following checks/tests should be carried out:
(i) Pressure and temperature readings are to be noted for

checking their correctness.
(ii) Receiving vessel is to be drained and checked for water or
any other contaminants.
12.12 BULK LOADING

12.12.1 Whenever bulk loading is involved i.e. transfer of the product to the
tank truck, tank wagon or tanker, the following checks are
necessary:
(a) The product is to be loaded/transferred as per the product

grade indicated in the relevant indent/Challan.

DEPARTMENT 12
PAGE No.
(b) The vapour pressure/temperature of the products in the

supplying and receiving vessels indicate that the products
are compatible.
(c) After the transfer (loading), it is to be checked that the

vapour pressure and the temperature of the contents of the
transport vessel are within the acceptable limits for the
product.
(d) The vapour pressure and the temperature are checked for
the bulk supplying vessels.
12.13 BULK DELIVERIES TO CUSTOMERS’ PREMISES

12.13.1 The following checks should be made while making deliveries to
customers’ premises by means of tank trucks.
(a) Before discharging the product into customers’ storage

vessels, the contents of the line should be checked to ensure
that it meets the customers’ requirements.
(b) Before the discharge is made, the vapour pressure and the
temperature of the product in both the delivery vehicles and
the receiving vessel, must be checked to ensure that they are
within the acceptable limits and that the products are
compatible. If not, the delivery must be deferred till full
investigation is carried out.
(c) After the discharge is completed, the vapour pressure and

the temperature of the product in the customer’s storage
vessels should be rechecked to ensure that it is within the
acceptable range.
12.14 INTER VESSEL TRANSFERS

12.14.1 Inter vessel transfers should be minimised in the interest of safety,
product loss and product quality. In the case of such transfers, the
following checks/tests should be carried out:

DEPARTMENT 12
PAGE No.
(a) Before the transfer is undertaken (while checking the ullage

capacity), it should be checked that the temperature and
the pressure in both the vessels are within the requirements
and indicate that the products are compatible.
(b) After completion of the transfer, the pressure and the

temperature of the product in the receiving vessels should be
re-checked and draining operation be started after minimum
settling time of one hour to ensure that the contents are free
from water and other contaminants.
12.14.2 When transfers occur in the multi-product plant and/or involve

common lines, the compatibility of the transfer parcel must be
checked both with the contents of the common lines and the
receiving vessels. It is advisable to test the sample from the
receiving vessel after completing the transfer.
12.15 DORMANT STORAGE

12.15.1 As it is contained in a closed pressurised system, clean LPG will
remain as per specification indefinitely, if it is stored in clean
segregated vessels. During the prolonged storage, i.e. , while there
are no receipts, but deliveries may be taking place, the following
checks should be carried out:
(a) Daily checks for the liquid level, pressure and temperature.
(b) Check for draining water should be made daily until no water
or contamination is found on successive tests. Draining should
then be stopped till the receipt of next replenishment, unless
climatic conditions (colder days) might cause soluble water in
LPG to be precipitated.
12.16 COMMISSIONING OF NEW PLANT AND RE-

COMMISSIONING OF EXISTING PLANTS
12.16.1 When an LPG plant is newly commissioned or when the
modifications etc., are carried out to the existing plant, the
following minimum quality checks/tests should be carried out for
the first receipt of the product:

DEPARTMENT 12
PAGE No.
(a) Storage vessels and filling/loading points are to be drained

carefully checking the presence of water or other
contaminants. The drainage operations should be repeated
daily until no water/contaminant is found in successive
operations.
(b) Storage vessel and pipelines are checked for the presence of
water, if any and properly purged to ensure air is not present.
12.17 PRECAUTIONS
12.17.1 MOVEMENT OF LPG
(a) To prevent the product contamination, sufficient care is

necessary during loading / unloading operations.
(b) Competent person in charge of the operation should plan

in advance each operation from start to finish.
(c) All Lines, Pumps, Valves and Storage Vessels must be

identified and checked by physical tracing before starting
the operation. Checks should be repeated when switching
over from one storage vessel to another or when changing
the product grades especially where the pipeline manifolds
are involved.
(d) Before loading or receiving the product from any vehicle or

vessel, it should be ensured that the product in the receiving
and delivery vessels and the inter-connecting pipelines are
similar. A check on pressure and temperature is normally
sufficient.
(e) If the product grade is changed, the contents of the

receiving vessel and inter-connecting pipelines must be
checked so that the mixture formed will not send the inter-
connecting product (off-spec) to the receiving vessel.

DEPARTMENT 12
PAGE No.
12.17.2 IDENTIFICATION OF PIPELINES
To ensure correct identification of the pipeline contents, all

pipelines should be properly colour coded at valves, Flange joints,
Tee, elbows and every ten meters in a straight section. The details
of colour coding of pipelines are given in Annexure No. 30.
12.17.3 IDENTIFICATION OF STORAGE VESSELS
Storage vessels should be identified by means of serial numbers e.g.

1,2,3 etc. painted prominently on the shell in bold block figures. In
addition, the contents should be clearly Indicated by means of
bold figures. Product identification markings should also be
prominently located next to the receipt and withdrawal
connections.
12.17.4 IDENTIFICATION OF STORAGE VESSEL FITTINGS
All fittings on the storage vessels should be clearly marked for

easier identification and correct use.
12.18 HANDLING OF CONTAMINATED PRODUCT

12.18.1 IDENTIFICATION OF SUSPECT GRADES
If during the initial testing at the plant {refer Clause No. 12.9.1(b) } it
does not remove the doubt regarding the quality of LPG, the
suspect stocks should be frozen and State Office / Regional Office /
Head Office be informed immediately. At the same time samples
should be taken, marked for identification and submitted to the
nominated laboratory for testing.
12.18.2 CHANGING OF LPG GRADES
Changing from one grade of LPG to another grade (having

different vapour pressures) should not be undertaken without the
authorisation from State Office/Regional Office/Head Office, unless
the change is a part of the established procedure.

DEPARTMENT 12
PAGE No.
12.18.3 DEALING WITH CONTAMINATED PRODUCT
(a) If testing at the plant before, during and after the receipt of
LPG shows that the vapour pressure/temperature and/or the
density are found to be outside the accepted range for the
grade, State Office / Regional Office/Head Office should be
consulted for further instructions.
(b) Bulk storage vessels suspected or known to be contaminated

e.g. with air and/or water, should be frozen, if practicable.
Other vessels should be used until the contamination is dealt
with. If there are no other vessels, the contaminated vessel
should be drained before the liquid LPG is taken in it and the
LPG vapour should be vented from it before it is connected to
the vapour phase of any other static or mobile vessel.
12.18.4 REPORTING OF LPG CONTAMINATION
(a) The Plant Manager should report all the cases of product
contamination to State Office / Regional Office / Head Office
giving full details of the grade and storage vessel involved
and additional stock and ullage available in the plant. The
causes of the contamination should also be indicated, if
known, together with the proposal for dealing with it and to
prevent its recurrence.
(b) Similar reports should be made for any complaint received

from bulk customers for quality problems related to LPG
12.19 SAMPLING
12.19.1 PURPOSE
(a) Sampling is very important aid to the quality control
(b) Samples are drawn for the purpose of ascertaining the

conformity of the stock to the relevant specifications

DEPARTMENT 12
PAGE No.
12.19.2 SAMPLING STANDARD
(a) Bureau of Indian Standard IS 1447(Part 2) describes the

method of sampling representative of Liquefied Petroleum
Gases such as propane, butane or mixtures thereof, in
containers other than those used in the laboratory testing
apparatus. These procedures are considered adequate for
obtaining representative samples for all routine tests as per IS
4576 Specification.
(b) A liquid sample is transferred from the source into a sample

container by purging the container and filling it with liquid
LPG to 80% of the capacity.
(c) Different sampling bombs are to be used for drawing samples

for different tests like vapour pressure, density, volatility and
copper corrosion.
12.19.3 TYPES OF SAMPLES
(a) Sample for pre-discharge tests: The sample is to be drawn

from the manifold of the vessel grade-wise representing the
group-wise product.
(b) Sample for during discharge tests: The sample is to be drawn

from the sampling arrangement provided on the shoreline /
manifold of the tanker.
(c) Sample before despatch of the product: The representative

sample shall be drawn from the system after dosing of
mercaptan. In case of dosing of mercaptan is done before
the storage vessel, sample is to be drawn from the storage
vessel.
(d) In the case of dosing of mercaptan on line before despatch,

representative sample shall be drawn from the loading line.
12.19.4 SAMPLING PROCEDURE


DEPARTMENT 12
PAGE No.
Observance of the correct sampling procedure is of utmost

importance, since the quality of the product is very much
dependant on the test results of the representative sample. The
following procedures should be followed while sampling:.
(a) Before taking the sample, the product must be in equilibrium.
(b) The sampling bomb should be properly closed and it should

be confirmed that there is no leak.
(c) Sample details should be entered in the prescribed form as

per Annexure No. 31 and attached to the container.
(d) Sampling and filling of sampling bomb should be personally

supervised by an Officer well conversant with the procedures.
12.19.5 PRECAUTIONS DURING SAMPLING
(a) Careful testing and analysis is of little use, if sufficient care is

not exercised in sampling.
(b) LPG presents a particular hazard because it is heavier than air

and is highly inflammable and appropriate precautions must,
therefore, be taken.
(c) Sampling normally involves venting of the product into the

atmosphere and the absence of source of ignition must
always be checked before and during the sampling.
(d) Liquid LPG causes serious cold burns on contact with the skin.
Protective gloves and goggles should, therefore, be worn
during the sampling.
(e) Breathing of LPG vapours during the sampling should be

avoided.
(f) If samples are to be sent through a public transport, the

appropriate regulations must be complied with.

DEPARTMENT 12
PAGE No.
(g) The discharge of LPG from a sampling bomb can cause static
electricity. Sampling bomb must, therefore, be earthed
effectively before and during the discharge.
(h) The condition of sampling bomb must be examined before

use. It should be hydraulically tested at an interval of 12
months, while its control valve should also be checked and
serviced.
(i) Each bomb should be marked with its tare weight, working
pressure, test pressure and the dates on which it was originally
and last tested. The markings are to be etched on the bomb
or stamped on the metal plate attached securely to it.
12.19.6 SAMPLE COLLECTION PROCEDURE
The size of the sample should be related to the test and analysis to
be carried out on it and will influence the size and type of the
sampling container used. The sampling procedure as under shall
be followed:
(a) The liquid content in the bomb is vented out after checking
that there is no source of ignition in the vicinity.
(b) Holding the bomb vertically and connecting to the sampling

point, it should be at least 10 cms. below the liquid level. The
connections should be made to the bottom of the bomb,
which should be the end to which the ullage tube is
connected.
(c) The outlet and inlet valves on the bomb are opened.
(d) The sample source valve is opened and the outlet valve on
the bomb is closed to minimise boiling of Liquid LPG in the
bomb.
(e) When the liquid appears, the liquid outlet valve is closed
followed by the inlet valve and the sample source valve.

DEPARTMENT 12
PAGE No.
(f) The connection is loosened sufficiently to enable the bomb to

be inverted. After re-tightening the connection, the outlet
valve is opened and the liquid LPG contents are allowed to
vent out so as to ensure that any contamination from the
previous sample is removed and that the bomb is chilled.
(g) When the liquid ceases to flow, the outlet valve is closed and
the bomb is re-inverted by slackening and re-tightening the
connection.
(h) Sample source valve is opened followed by the bomb inlet

valve and liquid is allowed to flow into the bomb.
(i) Outlet valve of the bomb is opened momentarily from time to

time until the liquid appears.
(j) The outlet valve is closed, followed by quick closing of inlet

and sample source valves quickly in that order.
(k) The union is slackened and bomb is inverted so that the

ullage tube is at the top. The union is tightened and then the
top needle valve is cracked until the liquid ceases to emerge,
i.e. when appropriate ullage is made in the bomb.
(l) The needle valve is closed and the union is slackened to
bleed off the liquid from the bomb connection tube.
(m) The bomb, the connection tube and the seal/plug sampling
point are disconnected
(n) The sampling bomb is removed to the test/analysis point,

ensuring that it is not overheated.
12.19.7 LABORATORY SUPPORT
12.19.8 PURPOSE
Quality control laboratories are conveniently located at all

Refineries, Fractionators units, LPG Import Terminals, selected
Terminals and Depots for the tests to be carried out on various
samples, as required. These laboratories shall be manned by

DEPARTMENT 12
PAGE No.
qualified Laboratory Officers, who are familiar with the standard

procedures for testing LPG. The laboratories shall be properly
equipped with the standard apparatus in line with the relevant
specifications. Laboratory shall issue suitable test reports for the
samples tested.
12.19.9 FIELD LABORATORIES
Quality Control Laboratories are located at the indigenous source

locations and at Import locations as given at Annexure 1A & 1B
BACK
13
ADMINISTRATION
PROPER ADMINISTRATION OF AN LPG BOTTLING

PLANT WILL RESULT IN EXCELLENCE IN ALL AREAS
OF OPERATION, MAINTENANENCE, SAFETY AND
SECURITY AND SHALL HELP IN ACHIEVING BETTER
CUSTOMER SATISFACTION


DEPARTMENT 13
ADMINISTRATION PAGE No.

March 2014 13-1
13.1 GENERAL
13.1.1 The importance of safety and security at LPG Bottling Plant cannot
be over emphasised. Any activity related to the operations in the
plant should be directed with safety upper most in the minds of the
personnel operating it. The Plant Manager has great responsibility to
ensure that all regular employees within the Plant and all others
associated with the Plant working, such as casual/contract
labourers, Loader / unloaders, transport crew members, etc. are
well aware of the hazards involved at the plant, various safety
precautions and action in case of emergency, to achieve all time
safety.
13.1.1.1 To achieve the above objective all the persons connected with the
plant operations and its working must undergo proper training as
per OISD 154, both on and off the job.
13.2 RESPONSIBILITY
The prime responsibility lies with the individual for the
assignment being carried out by the individual. However, the
overall responsibility of the Plant Manager is to ensure that the
plant operates safely and efficiently. To achieve this objective
following areas need specific attention of the Plant Manager.
13.3 REGULATIONS
LPG operations should be carried out in accordance with the
Statutory Regulations in force and also any local Regulations
applicable at the place where the plant is situated. Likewise,
instructions in the form of a manual, circulars, bulletins, letters etc.
should be strictly enforced.
13.4 SECURITY

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March 2014 13-2
13.4.1 The efficient security of the plant, the assets it contains and the
deliveries made from it should be ensured through proper checks
and systems.
13.4.2 Security measures provided should effectively prevent the entry of

unauthorised persons to the Plant and minimize bunching of
authorised persons within the licensed area. Security protection
scheme should be developed and periodic security drills should be
carried out as per the requirements of the scheme to check
security alertness. Record of the same should be maintained.
Security Protection scheme and Bomb threat contingency plan
duly approved as per Security guidelines shall be available at
location. The Draft copy of Security protection scheme shall be
submitted to local Administration for their final approval.
Intelligence cell & Quick response team (QRT) shall be formed and
shall function in line with the security manual.
13.4.3 Persons authorised to enter the Plant on regular/occasional basis

should be given a photo identity card which should be displayed
on the body of the person while in the plant premises. The system
for issuing photo identity card shall be as under in line with the
guidelines of Security Booklet.
(a) IOC employees: Plant Manager will issue serially numbered

laminated photo identity cards/ACS cards to IOC employees
which should be valid for a period of five years. The same will
be surrendered with the Plant Manager on transfer or
superannuation. The identity card/ACS card will be location
specific.
(b) IOC visitors to locations: Any IOC employee visiting the

location must carry his identity/ACS card which must be
checked by the security staff at the main gate. Security staff
must enter his name, address, purpose of visit, time of entry
and exit and signature in the visitor’s register maintained by
the security staff at the main gate. The visitor should be
permitted inside preferably by checking on intercom from
the Plant Manager or the concerned officer. Visitor slip and
visitor card will be issued by the security staff. The visitor slip

DEPARTMENT 13

March 2014 13-3
and visitor card shall be surrendered at the time of exit of the

visitor from the plant.
(c) Visitors have been segregated further into two categories.
i. Ordinary visitor: The visitor will be issued Visitor Slip and

Visitor Card after getting confirmation from the plant
Manager or the concerned individual with whom visitor
wants to meet over the intercom telephone. Visitor will
not be allowed in the licensed area. The visitor’s name,
address, purpose of
visit, signature and his time of entry and exit must be

entered in the visitor’s register. The visitor slip and the
card shall be surrendered at the time of exit of the visitor
from the plant.
ii. VIP visitor: Necessary entries in the register, visitor slip and
visitor pass will be kept ready before the arrival of the VIP
and given to him immediately on arrival. The visitor card
for the VIP will be used for the visitor. However, visitor to
be considered as VIP will be decided by the Plant
Manager. The visitor slip and the card shall be
surrendered at the time of exit of the visitor from the plant.
(d) Mechanic, vendor, consultant, grass cutters etc: One day

maintenance visitor card and visitor slip will be issued to this
category of visitors. Necessary entries will be made in the
visitor register. Authority for allowing such visitors is bestowed
upon the Plant Manager, Maintenance-in-charge or
authorised officer just below the Plant Manager. In case such
visitor is required to go inside the licensed area, a separate
card will be issued after getting back the visitor card issued
earlier. The visitor slip and the card shall be surrendered at the
time of exit of the visitor from the plant.
(e) Contract labourers, haulage labourers, transport crew, staff

car / bus drivers: The concerned contractor / transporter will
submit the list of labourers along with the application as per

DEPARTMENT 13

March 2014 13-4
annexure H (of Guidelines for issue of passes - booklet) in

contractor/transporter letter head and two photographs of
each labourer to the Plant Manager.
Declaration/undertaking as per annexure given in the
booklet, obtained from the individual labourer will also be
submitted by the contractor. Photo-pass shall be issued to the
labourer for a specific period during the pendency of the
contract not exceeding more than six months at a time
after which the validity of the pass will expire and the pass will
have to be surrendered. Fresh photo-pass- will be issued in
case of extension of work. The plant will keep complete
record of the photo-passes issued to each person with one
copy of the photo pasted in the register and obtain signature
of the person. As and when passes are issued afresh, details
will be recorded in the register.
(f) Transport crew who come once in a while to deliver/uplift

product and may change each time: The transporter or the
representative will submit application on his letter head along
with photo graph of the crew for entry of the crew with
names, full address and also statement that he is responsible
for all acts of the crew within IOC premises. Photo of the crew
pasted on the letter head duly signed by the transporter or his
representative shall also be submitted. On the basis of that
plant Manager will approve entry of the crew. After Plant
Manager’s approval the authorised officer will issue
temporary one day card. The visitor pass shall be surrendered
at the time of exit of the visitor from the plant.
13.4.4 Reconciliation of all the personnel entering the plant shall be

conducted at the end of the day as per the entries made in the
visitor register. Necessary corrective action must be taken in case
of discrepancy.
13.4.5 Normally no vehicle of outsiders should be allowed to park inside

the plant and should only be parked out side the main gate. Plant
Manager may allow some vehicles inside plant in exceptional
cases.

DEPARTMENT 13

March 2014 13-5
13.4.6 Duplicate copies of photo-passes issued to IOC employees and

outsiders are to be issued only after FIR.
13.4.7 All photo-passes are necessarily to be laminated.
13.4.8 All passes can be bilingual, if required.
13.4.9 Entry to the licensed area should be limited to the bonafide

persons only as authorised by the Plant Manager.
13.4.10 Measures must be adopted to ensure that the persons entering the
licensed premises do not carry match box, lighter, lighted
cigarette/ bidi , cell phone or any other source of ignition. This
check is all the more necessary, in case of casual/contract
workers, who may not be initially fully aware of the hazards
involved. Frisking should be adopted in such cases as a regular
practice. Door frame metal detector and hand held metal
detector should always be used.
13.4.11 Proper caution signs should be placed at the gate and at all
other vulnerable locations within the plant to caution against
unauthorized entry and also use of any item providing source of
ignition. These caution signs should be so designed that they could
be understood by all persons entering and working in the plant.
Prohibited area declaration to be obtained from state government
and to be prominently displayed. outside all the gates, as a
deterrent against unauthorized entry.
13.4.12 Random checks by frisking of persons in the licensed area should

be carried out by authorized officers to ensure that they are not in
possession of any item which may provide a source of ignition.
13.4.13 Verification of character and antecedents of all security

employees, contract/casual labourers, tank truck crews of regular
nature should be completed through District Police Administration.
13.4.14 All the operating gates should be manned round the clock and
special attention should be paid during night hours. Watch towers
should be fitted with revolving type flood lights. CCTVs is to be

DEPARTMENT 13

March 2014 13-6
installed in LPG BPs as per corporate Security guidelines for

boundary security. Additionally CCTV cameras are also required to
be installed for monitoring security and safety at operating areas
like bulk storage area, PPH, Sheds, TLD etc. as per HO guidelines
13.4.15 Security staff should not be asked to carry out any other activity
except ensuring the security. However, as Security is responsible for
securing Plant and properties and also for checking
outgoing/incoming materials, Checking of cylinders, PRs, SC valves
and other incoming/ outgoing materials physically for correctness
with respect to invoices/ challans to be carried out physically by
security and records maintained. In case of differences between
the invoice challan and physical quantity, the same to be
recorded and to be brought to the notice of Plant Manager in
writing immediately. Necessary instructions to be issued to security
agency in this regard.
13.4.16 In the Bottling Plant where additional construction work in local

area is undertaken, it should be ensured that the area is excluded
from other operational area by a temporary fencing.
13.4.17 No contract / casual labourer or employee should be permitted

during lunch/tea hours to go into the operational area, especially
in tank farm, gantry etc. and relax there or have their eatables in
that place. It must be ensured that no pretext of availability of shed
or water should be taken to go into that area.
13.4.18 Manpower review should be undertaken and it should be ensured

that sufficient number of persons are positioned to man the
essential security points including patrolling and leave reserve is
available in each shift. In sensitive areas, local administration may
be approached for augmentation of security strength as and
when required.
13.4.19 For relatively more sensitive and vulnerable locations, possibility of

providing electronic surveillance devices should be explored to
protect intrusion through the perimeter and also in sensitive
operational areas.

DEPARTMENT 13

March 2014 13-7
13.4.20 Plant Manager should interact with local DM/SDM/SP/SHO at least

once in a quarter and discuss about possible threats and
necessary assistance & record to be maintained. This is absolutely
essential for plants located in North East States, J&K, Punjab or any
other sensitive areas.
13.4.21 All the vehicles entering the plant should be searched with under
carriage mirror, inside the driver cabin and the carriage to ensure
non-availability of any explosive material.
13.4.22 No temporary structure such as jhuggi / dhaba / tea stall etc.

should be allowed to come up next to the perimeter wall of the
plant. Immediate action should be taken in such cases and these
structures be removed with the help of local administration. Efforts
should also be made to remove any unauthorized settlement next
to the plant.
13.4.23 Standing orders should be passed to the security agency and to

security staff about their duty allocation. It should be prominently
displayed in the security cabin. Surprise check should be
conducted at-least once in a month and alertness of security staff
be checked. Any observation or suggestion for improvement
should be informed to the Security agency in writing.
13.4.24 Records maintained by the security staff including Visitor register,

Material in/out register, Gate pass register etc. should be checked
by the Plant Manager at least once in a fortnight to ensure
correctness and also no entry of any unauthorized person in the
plant. It shall be ensured that all details in the registers are filled as
per the format for registers given in Security Manual. It shall be
ensured that all registers are serially numbered and list of registers
maintained in the location is available with the Location In Charge.
It shall be ensured that the following registers as per Security

Manual are maintained by the security.
Visitors’ entry register, IOCL employees/officer from other location/

unit/installations entry register, Foreign nationals gate pass register,
Contractors’ vehicle permission register, Contractors’ vehicle

DEPARTMENT 13

March 2014 13-8
permission register, key register, patrolling register, Contractors’

empty vehicle register, Incoming IOCL materials register, Outgoing
IOCL returnable materials register, IOCL outgoing materials register,
Contractors' incoming materials register, Contractors’ outgoing
materials register, Contractor outgoing returnable materials
register, Surprise security check register, Message
register/telephone message register at main gate-security, Mock
drill register, Security order register, Main gate Security/(CISF)
property handing/ taking over register, Details of contractors'
labour register, Security equipment registers.
13.4.25 Adequate numbers of sand bags should be provided at some
strategic locations in the plant to be used in case of bomb scare.
13.4.26 Branches of trees should never extend outside the peripheral

boundary wall of the plant to facilitate scaling of the wall by any
intruder. There should not be any tree near the boundary wall and
clear vision of 23 metre should be maintained from the perimeter.
13.4.27 Possibility of penetrating from underneath through drains, ducts,

culverts and tunnels etc. should be eliminated by providing
suitable gratings.
13.4.28 Proper communication system such telephone, intercom, walkie-

talkie should be provided to the security staff. Adequacy and
efficiency of the communication system should be reviewed
regularly.
13.4.29 Important telephone numbers such as Police, District

Administration, State Fire Brigade, Nearest hospital, Ambulance,
Bomb disposal squad and plant officials should be displayed in the
security cabin and other prominent place near the telephone. Dos
& Don’ts for dealing with suspicious objects to be displayed at
prominent place.
13.4.30 List of authorized signatory should be provided to the security staff.
13.4.31 Proper training for security personnel on emergency handling

should be conducted as per OISD 154. One security guard to be

DEPARTMENT 13

March 2014 13-9
positioned round the clock for patrolling including control of

movement of TTs a truck parking area. Parking of the vehicle in
truck parking area to be streamlined and monitored. Cooking of
food in the truck parking area should not be allowed. TT number in
queue to be displayed in drivers rest room. Cleaner of TT not having
valid license should not be allowed to drive the vehicle. It shall be
ensured that trucks when enter the premises of the corporation,
shall have at-least a driver and a cleaner and any reversing of
trucks shall be permitted only with the assistance of a cleaner.
13.4.32 ROLE OF UNITS: The following are the role of location, not
comprehensive but illustrative, with regard to security aspect
of the Location.
a) Implementing security instructions issued by Divisional,

Regional and State headquarters.
b) Creating security intelligence cell in each location
c) Keeping higher echelons informed about security
related issues
d) Ensuring regular patrolling by security personnel, along
the perimeter wall.
e) Examining the observations of the patrolling parties
and intelligence units carefully.
f) Implementing IB’s recommendations
g) Implementing the recommendations of:
i. Inter Unit Security audit teams
ii. Corporate Security audit teams
h) Preparing location specific Bomb Threat Contingency
Plan as per the format provided in the booklet,
“GUIDELINES TO PREPARE CONTINGENCY PLAN TO DEAL
WITH BOMB THREAT” distributed by Corporate Security
Department.
i) Interacting periodically with State Police and civil
authorities.

DEPARTMENT 13

March 2014 13-10
j) Raising Village Defense Parties for maintaining vigil

along pipelines, wherever applicable.
k) Exercising supervision and control over security staff at
the location.
l) Ensuring proper functioning of security gadgets.
m) Ensuring effective access control at the location.
n) Ensuring issuance of passes as per guidelines given in
the booklet circulated by Corporate Security.
o) Imparting fire fighting training to all security personnel.
p) Organizing mock fire and bomb threat drills periodically
q) Ensuring that important telephone numbers are

displayed at key points.
r) Ensuring surprise checking of security personnel by
senior officers of the unit/installation and maintaining
record of the same.
s) Ensuring periodical security sensitization of employees
and other workers.
13.5 HOUSEKEEPING
13.5.1 Although cleanliness and tidiness are desirable for the safe and
efficient handling of general products, they are essential for LPG,
because of inherent hazards of bad housekeeping.
13.5.2 Responsibility of housekeeping of the plant should not be

delegated below the level of an officer who should ensure that the
acceptable standards are maintained by making frequent and
critical inspections.
13.5.3 Some of the items that may need specific attention in relation to
housekeeping are as under:
(a) To ensure that all the cylinders in the plant are neatly stacked
in the areas licensed for the purpose and have proper sign
boards to identity the category of the cylinders stacked such

DEPARTMENT 13

March 2014 13-11
as filled, empty (serviceable), defective, 10 /5 year testing,

scrapping etc.
(b) The ground under the storage vessels should be properly

compacted and free of water-logging. Proper drainage
system as per OISD standard should be provided.
(c) Unwanted plants, weeds, grass, vegetation, etc. should not

be allowed to grow in the storage area or tank wagon siding
or any other area in the plant.
(d) Unwanted papers, carbons, torn out stationary should not

litter here and there inside the office and floor area. It should
be thrown in the dustbins only. For this purpose, sufficient
numbers of dust bins should be provided at different places in
the plant.
(e) Items such as safety caps, aluminium / plastic seals, `O’ rings,
neck labels, worn out maintenance materials etc. should not
be littered all around the floor in the sheds. Proper bins should
be used for neat storage and handling of such items.
(f) Soap solution, oils and greases should not spill over the floor
and area to be kept cleaned of these slippery items to avoid
accidental falling.
(g) Cables, pneumatic piping etc. should be properly secured

and dressed to present a neat look.
(h) The condition of paint on storage vessels, pipelines, pumps,

compressors and other buildings and structures should be
regularly attended so as to ensure that the same is not
deteriorating and does not give a shabby appearance.
Periodic repainting shall be done as per the following
schedules. The periodicity, however, can be increased if the
condition is assessed to be satisfactory at the end of this
period or reduced if the condition has deteriorated before
this period.

DEPARTMENT 13

March 2014 13-12
 Buildings: Once in three years.

 Boundary wall: Once in three years.
 Shed structure: Once in five years.
 Conveyors: Once in a year.
 Water bath: Once in two months.
 Equipment/ pipelines: Once in two years.
 Storage vessels/ fire water tanks: Once in five years.
(i) All the pipelines and valves should be properly colour coded.
(j) Condition of mastic flooring should be checked and

maintained properly.
(k) Roads inside the plant should be maintained free from the
digs, pits and potholes etc.
(l) Trucks should be parked properly in the plant as per HO

guidelines on Truck Parking area and movement should be
controlled.
(m) General cleanliness in the canteen should be ensured and

food items be kept under cover.
(n) Consumables and spares should be kept in proper place and

bin card system should be maintained.
13.5.4 ‘Place for Everything and Everything on its Place’ is the basic
concept of a good housekeeping and must be followed.
13.5.5 In general, the housekeeping standard should be such that an

overall appearance of the plant should present a well maintained
and well organised look.
13.6 SAFETY
13.6.1 Safety precaution applicable to the storage, handling and
distribution of LPG are sufficiently covered in Chapter No. 4
exclusively devoted to the subject of safety at LPG plants. It should

DEPARTMENT 13

March 2014 13-13
be ensured that all concerned are aware of the various safety

practices.
13.6.2 All personnel at the plant should be familiar not only with the list of
DOs and DON’Ts given in the Annexure No. 8 but should also
imbibe those points as a working habit.
13.6.3 Manning of Plants by officer and employee, on holidays and non

operative shifts, was withdrawn vide ref: HO/INDANE OPS/1/2004
dated 12.04.2004 and HO/INDANE OPS/3/2004 dated 25.05.2004,
keeping in view of various automated safety systems. It shall be
ensured that at the end of each operating shift and prior to
commencement of non operating shift,
a. the plant will be checked and all LPG vessels/LPG handling

equipments shall be isolated. Area wise checks and the status
will be recorded and signed jointly by the designated officer
and by the Security Supervisor, as per the standard format
and the charge will be handed over to the non operating
shift Supervisor on duty.
b. Plant Managers will issue an emergency duty roster wherein

one officer shall be designated for emergency duty for non
operating shift. Such officer will remain available for any call
from the plant in case of exigency. In case the officer is
required o go outstation due to any other exigency, the same
shall be with the permission of Plant Manager only. In such
case, alternate officer shall be nominated for emergency
duty and the same will be intimated to the Security
Supervisor also. The job assignment for non operating shift for
Security Supervisor, Security Guards, Officer on emergency
duty and Plant Manager to be clearly defined.
c. The Security Supervisors will also maintain a logbook with

respect to the Safety/ Security checks made during off shifts
including on Sundays and Holidays. Any untoward incident
shall also be recorded in the log book. This log book shall be
reviewed and countersigned by the Plant Manager on daily
basis.

DEPARTMENT 13

March 2014 13-14
d. Plant Managers/designated officers shall also make surprise

checks of the plant during off shift hours and observations
shall be logged in the log book. Any shortcomings to be
noted in details and corrective actions to be taken.
e. Adequate training shall be imparted to security personnel

including Supervisors and guards and also to the other
contract workmen available during non working shifts and
records maintained, in line with circular dated 25.05.2004
referred above.
f. After normal working hours and on Sundays and holidays,

adequate security staff should be present at the plant and be
alert to take all possible safety measures in the event of any
emergency. At the beginning of their shift, they should also
take minimum one round of the various operating/vulnerable
areas in the plant to ensure that no unsafe conditions exist
and that the controlling valves of the storage vessels and
loading/unloading points are closed and secured as per
routine.
13.6.4 As an aid for effective communication system within the plant,

approved public address / paging system and walkie-talkie (flame-
proof) should be provided.
13.6.5 Safety instructions of vital nature should be displayed at all

appropriate places within the plant either symbolically or through
language(s) that could be understood by all personnel working at
the plant.
13.6.6 A well co-ordinated emergency set up with the control room

located at a suitable place within the plant should be provided.
13.6.7 The installation of safety devices should be so arranged that in

case of an emergency an audio visual signal is transmitted to the
control room indicating the nature/location of the emergency. It
should also be possible to activate the control devices (e.g.
shutting off the remote control valves, activating the sprinkler

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March 2014 13-15
System, etc.) from the control room itself. The system should be
provided as per Clause No. OISD 11.11. IV)
13.6.8 Mutual aid scheme should be prepared with neighbouring

industries and the same should be reviewed every six months and
minutes made during each emergency response mock drills
conducted once in six months.
13.7 GENERAL GUIDELINES

13.7.1 All connected references in the Manual such as Gas Cylinder Rules
2004 , the Static and Mobile Pressure Vessels (Unfired) Rules 1981; ISI
specifications, BIS codes, R.D.S.O. specifications for LPG tank
wagons, norms for providing fire fighting arrangements, applicable
Electricity Rules, Motor Vehicles Act, the Contract Labour Act,
Workmen’s Compensation Act, relevant OISD standards etc.
should be kept together in a folder form and should be used as
supplement to the “LPG OPERATIONS MANUAL”. Corporate
governance guidelines as applicable to plants to be followed in
total and confirmation on compliance to be given to state office
every quarter.
13.7.2 Complete set of engineering drawings, duly certified by HO

Engineering Department and Chief Controller of Explosives and lay
outs approved by factory department should be kept in a folder
form. The list of drawings should include the drawings related to
layout, storage vessels and its fittings, buildings, structures, pipelines,
electrical installations, fire fighting arrangements, safety
installations, P&I diagram, area classification drawing, single line
diagram, risk analysis, HAZOP study etc. These drawings/manuals
should be up-dated as and when any modification is carried out
quoting the reference of the approval.
13.7.3 Each plant should develop its own “Plant Operating Manual”
based on the facilities, equipment available and the nature /
period of work. The manual should basically cover the details of
basic facilities / equipment provided at the plant and specific
guidelines / check-lists for their operation, inspection, maintenance
and repairs. The manual should be updated as and when

DEPARTMENT 13

March 2014 13-16
changes take place. The “Plant Operating Manual” developed by

each plant should be got approved by the controlling State
Office / Regional Office and a copy of approval should be sent to
HO LPG Department for reference and record.
13.7.4 All applicable Licenses and certificates should be properly

displayed and renewed on time.
13.7.5 Manufacturers’ catalogues, operating instructions, spare parts lists,

maintenance schedules and instructions, etc. should be kept
securely. For the purpose of reference by the field personnel, an
extra copy should be made available. In case two copies are not
available, required number of photo-stat copies may be made
from the original. Manuals can also be maintained in digital form
and prints can be taken for field reference as and when required.
All manuals issued by IOC including policies and circulars issued by
IOC should also be kept secured at the plant either digitally or
physically and the list of available manuals should be provided for
reference.
13.7.6 The report of handing over / taking over the charge of the plant
should cover handing over / taking over of the various manuals,
licenses, certificates, etc. referred above with specific mention of
licenses / certificates that might have been sent out for renewals.
Physical inventory /stock of cylinders, pressure regulators, sc
valves, bulk LPG, HSD etc to be taken and the same is to be
reconciled with SAP book stock. Differences if any to be clearly
brought out and recorded, while handing over/taking over the
charge. Various SAP documents on the same to be signed jointly.
Gauge book for LPG Bulk stock , HSD stock and register for Physical
inventory of cylinders to be jointly signed at the time of handing
over/taking over of location by in charges.
13.7.7 It shall be ensured that Physical inventory of cylinders is carried out

daily by security and reconciled with book stock as per SAP.
Besides, receipt and issues of cylinders as per Security Register and
also as per SAP ( LPG 15 /15A,etc as applicable) for distributors,
ST,HR, OMC transactions, new cylinders etc shall be checked and
reconciled on day to day basis and records maintained.

DEPARTMENT 13

March 2014 13-17
13.7.8 Further, joint physical inventory of cylinders along with security by

plant personnel shall be taken monthly and to be reconciled with
book/SAP figures. Discrepancy if any to be noted and
proportionate amount to be recovered from Security agency, as
per agreement terms, in case of shortfall in inventory.
13.7.9 Necessary terms and conditions shall be included in the security

contract covering various aspects including the inventory of
equipments.
13.7.10 Record to be maintained for:
i) daily physical inventory of cylinders by security,

ii) SAP v/s Physical inventory matching, on daily basis,
iii) Joint physical inventory at least once in a month duly
reconciled with SAP stock. These records to be signed by
plant personnel (Finance and also operations as nominated
by Plant Manager) besides security.
13.7.11 Gauge book as per format given in the LPG OPS Manual for
physical stock of Bulk LPG to be maintained. Gauge book to be
maintained also for Diesel in case of Consumer Pump on daily
basis.
13.7.12 It shall be ensured that bulk and packed payments are effected as
per RTD and also rates duly approved by competent authority.
RTD re-verification shall be once in three years in general.
Thereafter, payment for transportation shall be released on re-
verification of RTD. In case of new markets or diverted routes,
payments to transporters may be made maximum for a period of
one month on the basis of provisional RTD. RTD for the new route is
to be certified within the said period.. Location to maintain details
of various markets to which supplies are effected/sources from
which bulk is received along with RTD details and also their
validity. Co-Ordination with area office/state office to be
maintained by Plant in advance so as to get the RTD verification
including approvals by competent authority in time.

DEPARTMENT 13

March 2014 13-18
13.7.13 It shall be ensured that minimum wages, PF and ESI

coverage/payments are ensured for the labors engaged in
handling, PMCC, etc through contractors. Payments to the
contractors to be effected only after they submit proof of PF &ESI
remittances for the labors engaged by them fo the previous
month(s).
13.7.14 It shall be ensured that various licenses such as Factory license,

PCB consents for air and water, CCOE approvals for filling LPG in
cylinders, keeping LPG in packed form, Storing LPG in vessels,
License to store diesel in tank for consumer pump, CCOE approval
before and after carrying out any modifications, Approval from
Factory Inspector before after carrying out any modifications ,etc
are applied in time and renewal obtained. These are only
illustrative not exhaustive
13.7.15 The following is to be noted and ensured.
Alert is declared , When the situation becomes tense due to strike

notice, civil disturbance, terrorist activity, etc. Under exceptional
circumstances, such as development of a war-like situation, or
imminent and intensive terrorist activity, a “Red Alert” may be
announced by Corporate Security. Under such circumstances, the
guidelines given in the Security manual for ALERT and RED ALERT
are to be followed in total. Action in case of alert and red alert as
below.
Alert when the situation becomes tense due to strike notice, civil
disturbance, terrorist activity, etc.
On the announcement of an “alert” the following security

measures, over and above the normal security drill, would have
to be adopted:
 Ensuring that the number of people entering in the morning, exit in the
evening.
 Ensuring frisking of at least 70% of the employees.
 Minimizing entry of visitors to the plant area.

DEPARTMENT 13

March 2014 13-19
 Seeking patrolling by State force personnel outside the installation.

 Requesting Local Police to enhance their vigil around the area.
 Asking State Government to provide additional armed personnel for the
installation(s).
 Providing additional lighting, if required
 Arranging for continuous watch in the area used for parking of trucks.
 Maintaining discreet watch on employees known to have weaknesses
of character which can be exploited by subversive elements.
 Ensuring that the number of people entering in the morning, exit in the
evening.
 Ensuring frisking of at least 70% of the employees.
 Minimizing entry of visitors to the plant area.
 Seeking patrolling by State force personnel outside the installation.
 Requesting Local Police to enhance their vigil around the area.
 Asking State Government to provide additional armed personnel for the
installation(s).
 Providing additional lighting, if required
 Arranging for continuous watch in the area used for parking of trucks.
 Maintaining discreet watch on employees known to have weaknesses
of character which can be exploited by subversive elements.
RED Alert: Under exceptional circumstances, such as development

of a war-like situation, or imminent and intensive terrorist activity, a
“Red Alert” may be announced by Corporate Security
On the announcement of a “Red Alert” the following additional

security measures, over and above those specified for a simple
alert would have to be adopted:
No visitor
 would be allowed inside the plant area. In exceptional cases Unit
Head/ Location In-charge may accord permission to enter.

DEPARTMENT 13

March 2014 13-20
 The number of contract labour to be reduced to the minimum.

 100% frisking of employees to be ensured.
 Prohibiting contract/contractual labour to carry any baggage inside,
including lunch boxes, writing pens, electronic gadgets or other
implements.
 No function to be permitted inside the location in which outsiders, like
school children or visitors, are allowed to participate.
 Organizing patrolling with the help of local police along the
vulnerable sections of pipelines.
 Village Defense patrolling parties to assist the local police In
protecting pipelines.
 Engaging security staff to restrict movement of contract/casual
labour to their defined work area.
 Special precautions to be taken for the security of senior officers,
particularly during their movements
 Information about tour programmes of senior officers to be restricted
to the minimum number persons.
 In case of pipeline stations, strict adherence of patrolling schedule
along the chain-age, crossings, culverts, etc., to be ensured.
 Guards to be posted at crossings of pipelines
 Close liaison to be maintained with district authorities and the local
police.
13.7.16 Control on Issue of Loading advice for Bullet Trucks:
Check List Cum Loading advice booklets should have a fixed

number of 50 or 100 leaves , to be under the safe custody of
Location In Charge and should be properly numbered and
continuity of serial numbers to be maintained at all times even
while printing new books. Issuance of filling advice should be in the
order of serial number. Copies of check list cum loading advice to
be kept at plant under safe custody in the order of serial number.
Unloading Plants should fill the loading advice legibly and avoid
overwriting. Overwriting if any shall be properly authenticated by
signature and stamp.
14
TRAINING
THE SAFETY AND PRODUCTIVITY LEVEL OF ANY
LPG PLANT IS DIRECTLY PROPORTIONAL TO THE
OPERATING PERSONNEL’S KNOWLEDGE OF THE
PRODUCT AND TRAINING IMPARTED TO THEM
FOR CARRYING OUT VARIOUS OPERATIONS AT
THE PLANT SAFELY


DEPARTMENT 14
PAGE No.
TRAINING 14-1
March 2014
14.1 GENERAL
14.1.1 The only reason why this subject has been taken at the end is that it must
be regarded as most vital.
14.1.2 There is no point in having fulfilled to the highest extent, what all has been
mentioned in the previous Chapters, if the persons working do not know
how to ensure safe working or react in an emergent situation .
14.1.3 Within the same organisation, the conditions for two or more filling plants
will not be precisely the same. Even if the components at two plants are
completely identical, the physical conditions under which they are
installed and operated will seldom be the same. Therefore, constant
efforts are needed at each individual plant to turn out better “LPG
people” imparting the related training.
14.1.4 LPG training should include constant training on the job and participation
in exercises particularly for fire / spillage controls.
14.1.5 A record should be maintained at the plant of the training received by

each employee. The records must be checked, whenever planning a
change of job to ensure that the operator is adequately trained for his new
responsibilities and duties.
14.2 NEED FOR TRAINING

14.2.1 The functions of the LPG plant are adjusted and adopted to fundamental
principles such as emptying of tank truck / tank wagons by a compressor
working according to the method of differential pressure, transfer of LPG
by centrifugal pump etc. It sounds easy and is in a way simple. What
complicates the matter is that the product is not a pressure-less liquid at
normal temperatures unlike any other petroleum products such as SKO,
HSD or MS, but it is a product that has to be pressurized in order to remain
liquid at normal temperature or cooled to sub zero temperature under
atmospheric pressure
14.2.2 In view of the special conditions under which the product is stored and
handled, it calls for a specialised training at all levels. Unless the persons

DEPARTMENT 14
PAGE No.
TRAINING 14-2
March 2014
handling operations or jobs at the plant are properly trained, serious

hazards and consequent huge losses may develop at the plant.
14.2.3 With the above in mind, it is obvious that an all around mechanical know-
how is not sufficient to run the LPG plant safely.
14.2.4 Many accidents at LPG plants are caused not only by carelessness or non-
observance of the precautionary measures, but also primarily because of
insufficient knowledge of the product handled, lack of education or
training in the performance of the actual operations or ignorance and
insufficient understanding of the safety regulations. Such accidents are
absolutely unnecessary and it is emphasised that the LPG plant is not a
risky or a dangerous plant to work as long as the regulations are observed,
or to put it in another way – the safety level of any LPG plant is directly
proportional to the staff’s knowledge of the product and training imparted
to them for running the plant.
14.2.5 It takes time to become a competent LPG man, but an investment in the
training of the personnel operating the plant will yield interest in the form of
more effective production and higher safety level. This result is achieved
when the staff knows exactly what to do at any time and in any given
situation and last but not the least, knows what not to do.
14.2.6 Due to phenomenal growth of LPG markets, road / rail transportation

has increased tremendously. There are inherent hazards associated with
transportation of LPG. It has been observed that many road accidents
have not been dealt with promptly and efficiently, due to the lack of
knowledge of the transport crew.
14.2.7 With change in technology, many new equipment / systems have been
added while handling LPG. Proper know how and maintenance of these
equipments requires structured training about design philosophies and
operability of these equipments.
14.3 PROGRAMMED LEARNING

14.3.1 To ensure that the prescribed standards of performance in distribution,
productivity and safety are achieved, all the employees, contract
labourers, security personnel, transport crew should go through structured
training process in the following areas :

DEPARTMENT 14
PAGE No.
TRAINING 14-3
March 2014
14.3.2 Training schedule for safety
a) Safety training for fresh entrant Officers and Supervisors in LPG

storage, bottling and distribution.
 Participants: Fresh entrant Officers and Supervisors.

 Duration: Three days.
 Objective: To provide knowledge on the hazards associated
with LPG operations / maintenance and safe way to perform
job. To evoke correct and prompt response in any emergency
situation.
 Course contents:
 Characteristics of LPG and associated hazards.

 Safety regulations (Statutory and in IOC) and accident
prevention.
 Safety aspect in design, operation and maintenance of
LPG plants / cylinders and accessories.
 Fire protection facilities / equipment.
 Safety in transportation of LPG in bulk, emergency rescue
systems.
 Disaster Management Plan, Emergency Procedures and
Drills.
 Supervisor’s role in safety.
 Work permit system.
 Industrial first aid.
 Electrical safety.
 Housekeeping.
 Occupational health hazards.
 Personal protective equipments.
 Relevant security systems.
b) Safety training for Officers and Supervisors in service (Refresher

course) in LPG storage, bottling and distribution.
 Participants : Officers and Supervisors in service,

(Refresher Course).
 Duration : Three days.

DEPARTMENT 14
PAGE No.
TRAINING 14-4
March 2014
 Objective : To refresh and update knowledge on safety in

Operation/maintenance, handling emergencies.
 Course contents :

 Safety regulations (Statutory and in IOC) and accident
prevention.
 Fire fighting facilities/ equipment and their application.
 Safety in transportation of LPG in bulk, emergency rescue
systems / analysis of accidents with case studies. Disaster
Management Plan, Emergency Procedure and Drills.
 Work permit system.
 Industrial first aid.
 Electrical safety.
 Housekeeping.
 Occupational health hazards.
 Personal protective equipment.
 Responsibility of supervisor in implementing safety
regulations.
 Safety audit.
c) Safety training for Workmen in LPG storage, bottling and distribution.
 Participants : Workmen.
 Duration : Two days.
 Objective : To familiarize with safety aspects of LPG handling
and emergency procedure.
 Safety regulations (Statutory and in IOC).
 Safe operating and maintenance procedures in :
 Bulk handling and storage.
 Bottling.
 Despatch of cylinders.
 Fire prevention and control.
Drills.
 Industrial First Aid.
 Housekeeping.

DEPARTMENT 14
PAGE No.
TRAINING 14-5
March 2014
d) Safety training for Security Personnel in LPG storage, bottling

and distribution.
 Participants : Security personnel.

 Duration : One day.
 Objective : To educate about hazards associated with LPG
and to evoke correct and prompt response in any emergent
situation.
 Course content :
 Role of security personnel in safety.
 Fire prevention and control.
Drills.
e) Safety training for Drivers / helpers in LPG storage, bottling and

distribution.
 Participants : Drivers / helpers.

 Objective : To educate on safety in LPG transportation on road
and handling of emergencies.
 Safety in LPG transportation by road, DOs and DON’Ts
 Tank/truck fittings and their usage.
 Safe loading/ unloading practices.
 Use of fire extinguishers.
 Handling of emergencies.
f) Safety training for Labourers and Supervisors in LPG storage, bottling

and distribution.

DEPARTMENT 14
PAGE No.
TRAINING 14-6
March 2014
 Participants : Contract labourers and supervisors.

 Objective : To inculcate safety consciousness and to evoke
correct and prompt response in any emergent situation.
 Characteristics, hazards associated with LPG and
preventive measures.
 Work permit system
 Basic fire fighting.
 Response during emergencies.
 Supervisor’s / labourer’s responsibility for safety.
 Housekeeping.
14.3.3 Training schedule for operations
a) Training for Blue Collar Workmen on LPG Operations
 Participants : Blue Collar Workmen.

 Duration : Three days.
 Objective : To impart knowledge on LPG characteristics, plant
operation and fire fighting techniques.
 LPG Characteristics.
 Bulk unloading operation.
 Bottling operations.
 Know how about Cylinders and valves.
 Pneumatics and instrumentation.
 MCC / Generator / Fire fighting pumps / transformers.
 Pump house operations – LPG pump, LPG
Compressors and air compressors (mechanical aspect)
 Maintenance procedures of LPG equipment.
 Electronic systems, if available.
 Hazard identification management.
 OISD recommendation, statutory and mandatory
requirements.
 Fire drill.

DEPARTMENT 14
PAGE No.
TRAINING 14-7
March 2014
 Standing orders.
b) Training of Officers on LPG operations and maintenance.
 Participants : Officers
 Duration : Five days.
 Objective : To inculcate safety consciousness, to update the
knowledge of correct operating procedures and prevalent
statutory regulation.
 Characteristics of LPG.
 Design aspects of LPG bottling plant.
 Details of codes.
 Facility planning.
 LPG cylinder, valve manufacturing / testing.
 Detailed description / specification of Cylinders
/ valves.
 Activities of ST/ HR of cylinders.
 Chemistry of the fire and theory of extinguishments.
 Basics about fire triangle.
 Various means for extinguishing and
controlling LPG fire.
 Fire protection system and operation at plants :
 Details of fire protection facilities at plant.
 Details about their operation and maintenance.
 Control of leakages without fire.
 Safety equipment handling :
 Details of safety equipment provided at plant.
 Demonstration of their handling and maintenance.
 OISD standards and salient features pertaining to LPG.
 Acts, rules governing LPG operations – SMPV rules, Gas
Cylinder Rules, Factories Act, Pollution Control Act,
Weights and Measures Act, Contract Labour Act, ESI & PF
Act, Standing Orders, CDA rules, Industrial Dispute Act,
Minimum Wages Act etc.
 Layout / facilities at LPG bottling plant :
 Aspects regarding finalisation of plant layout.
 Criterion for selection of facilities.
 Overview of typical Plant facilities.

DEPARTMENT 14
PAGE No.
TRAINING 14-8
March 2014
 Filling equipment – operating and maintenance

practices.
 LPG filling operations :
 Details about line operations.
 Receipt and dispatch of cylinders.
 Lubricants used for plant equipment.

 Bulk transportation, handling, storage and stock
accounting including design aspect of LPG transport
vehicle.
 Statutory testing of pressure vessels, SRVs, hoses and
calibration / checking of protective gadgets.
 Control and communication system at plant.
 Operation and maintenance of electrical system at plant
including safety aspects and energy audits.
 Safety practices at bottling plants :
 Safe operating practices and inspection.
 Handling emergent situations and mock drill.
 Security aspect at plant – movement control and gate
pass system.
 S&D planning / PDM operation and other soft wares.
 Pricing.
 Preventive/predictive maintenance aspect :
 Preventive maintenance overview.
 Maintenance schedule of various equipment.
 Trouble shooting of equipment.
 Plant KRAs and its significance.
14.4 TRAINING FACILITIES

14.4.1 For imparting training to various personnel working and associated with the
working of the LPG plant, suitable arrangements for class room training
should be provided at each plant. With class-room facility at the plant,
whatever has been explained in the class room can be straightway co-
related to the actual work situation.
14.4.2 Training for operation and maintenance of equipment should preferably

be done at site only. Training at vendors’ premises may also be
undertaken.

DEPARTMENT 14
PAGE No.
TRAINING 14-9
March 2014
14.4.3 Any person before initiation to LPG operations should be properly trained
as explained in Clause No. 14.3 above. Training facilities at the Plant level
will, therefore, be of immense help.
14.4.4 Besides a suitable hall for the class room training, various associated
training facilities as under should be provided:
(a) Over-head projector.

(b) Video set with TV.
(c) Slide Projector.
(d) Cut models or slides showing cut models of various equipment/
fittings in use at the plant.
(e) Library of books/video cassettes related to various aspects of LPG
operations, safety, fire protection etc.
(f ) Video Projector.
14.4.5 In addition to training of the employees, the training facilities at the plant
can also be used for training :
(a) Casual / contract workers.

(b) Drivers / helpers of bulk and stake trucks.
(c) Distributors, their mechanics and delivery boys in the surrounding
area.
15
ANNEXURES


DEPARTMENT 15
PAGE No.
March 2014 ANNEXURES 15-1
ANNEXURE-1-A
SOURCE WISE LPG PRODUCTION AT VARIOUS INDIGENOUS SOURCES
SOURCE 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13

(All figs. In TMT)
1 KOYALI 406 368 346.5 384 498 489
2 PANIPAT 411.1 464 509.356 572 656 708
3 MATHURA 282.7 307 269.33 292 256 292
4 GUWAHATI 41.42 43 42.037 48 44 38
5 BARAUNI 280.6 276 293.307 340 291 309
6 DIGBOI 10 10 8.108 9 8 8
7 HALDIA 171 170 147.3 181 226 214
8 NARIMANAM 20 17 16.6 21 18 18
9 BRPL 48 46 45.17 45 48 49
10 CPCL 340 342 343 365 364 310
TOTAL - IOC 2010 2043 2020.708 2257 2409 2436
11 BPC MUMBAI 446 420 454 505 487 449
12 KRL 439 395 418 465 463 468
13 NUMALIGARH 57 47 60 43 60 47
14 BINA 0 0 0 0 45 178
TOTAL – BPC & JV 942 862 932 1013 1055 1142
15 HPC MUMBAI 241 226 252 248 438 434
16 HPC VIZAG 367 364 310 280 351 382
17 MRPL (JV) 294 262 272 298 290 279
18 HMEL (JV) 0 0 0 0 0 479
TOTAL – HPC & JV 902 852 834 826 1079 1573
19 ONGC ANKLESHWAR 10 9 9 7 6 6
20 ONGC HAZIRA 538 560 609 599 627 620
21 ONGC GANDHAR 33 28 29 27 22 11

DEPARTMENT 15
PAGE No.
22 ONGC URAN 451 430 458 415 376 362

TOTAL - ONGC 1032 1027 1105 1048 1031 999
23 GAIL AURAIYA 211 244 254 214 244 211
24 GAIL GANDHAR 254 231 230 236 236 222
25 GAIL VAGODIA 81 79 83 85 84 83
26 GAIL VIJAYPUR 421 455 463 456 490 504
27 GAIL LAKWA 27 29 27 27 30 28
28 GAIL USSAR 51 48 43 51 40 34
TOTAL - GAIL 1044 1086 1100 1069 1124 1082
29 OIL DULIAJAN 48 48 44.69 45 52 45
30 RIL-DTA 2703 2869 2136 593 600 590
31 RIL-SEZ 0 0 1579 2044 1503 1071
32 ESSAR OIL 146 500 548 593 586 843
TOTAL 8827 9287 10299.4 9488 9439 9781
ANNEXURE- 1B
PORT WISE IMPORTS BY OMCs FOR YEAR 2012-13- ( MT)

PORT IOC HPC BPC TOTAL
KANDLA 109471 51978 61371 222819
MANGALORE 752051 495224 301786 1549061
VIZAG 367507 531329 168313 1067149
HALDIA PORT 932517 207425 178307 1318249
ENNORE PORT 578143 0 63555 641699
PORTBLAIR 6907 0 0 6907
AEGIS, MUMBAI 0 77200 39050 116250
DAHEJ 0 16000 133927 149927
JNPT (URAN) 33963 0 236930 270893
JAMNAGAR 184213 60060 89926 334198
TUTICORIN 22500 100400 122900
PIPAVAV 50319 50319
G.TOTAL 2964771.989 1512034.707 1373565.791 5850372.487

DEPARTMENT 15
PAGE No.
ANNEXURE 2
INDUSTRY WISE / REGIONWISE / STATEWISE LPG BOTTLING PLANTS

AS ON 01.04.2013
STATE
OPERATING
Tankage
SR. BOTTLING
(
N CAPACITY
REGN BOTTLING PLANTS M
O (TMTPA)
T
. AS ON
)
01.04.2013
NR UTTAR PRADESH 1 ALLAHABAD 60 1850

2 KANPUR 180 6000
3 LUCKNOW 90 2400
4 TRISUNDI 11 99
5 VARANASI 120 3100
6 ALIGARH 30 600
7 ETAWAH 23 600
8 FARUKHABAD 60 960
9 LAKHIMPUR KHERI 23 1850
10 LONI 180 9300
11 MATHURA 120 3600
12 PATTIKALAN(KASHIPUR) 53 1850
13 SHAHJAHANPUR 60 3250
SUB TOTAL 1010 35459
UTTARANCHAL 14 HALDWANI 60 300
15 HARIDWAR 60 350
SUB TOTAL 120 650

DEPARTMENT 15
PAGE No.
RAJASTHAN 16 AJMER 120 2000

17 BIKANER 60 960
18 JAIPUR 90 4200
19 JHUNJHUNU 30 1050
SUB TOTAL 300 8210
DELHI 20 DELHI (TIKRIKALAN) 240 10600

21 M'PUR KHADAR 180 5100
SUB TOTAL 420 15700
HARYANA 22 GURGAON 60 450
23 KARNAL 180 7200
SUB TOTAL 240 7650
PUNJAB 24 JALANDHAR 180 6600
25 NABHA (PATIALA) 180 3800
SUB TOTAL 360 10400
HIMACHAL 26 BADDI 30 370
27 UNA 60 900
SUB TOTAL 90 1270
JAMMU & 28 JAMMU 60 1800
KASHMIR
29 LEH 5 1500
SUB TOTAL 65 3300
NR TOTAL 2605 82639
ER WEST BENGAL 30 BUDGE BUDGE 120 1850
31 DURGAPUR 120 2600
32 KALYANI 180 2800
33 RANINAGAR 60 1850
34 MALDA 15 1050
SUB TOTAL 495 10150

DEPARTMENT 15
PAGE No.
BIHAR 35 PATNA 120 3250

36 BARAUNI 120 0
37 MUZAFFARPUR 60 1800
SUB TOTAL 300 5050
JHARKHAND 38 BOKARO 30 1850
39 JAMSHEDPUR 60 3700
SUB TOTAL 90 5550
ORISSA 40 BALASORE 60 1365
41 JHARSUGUDA 15 1050
SUB TOTAL 75 2415
TRIPURA 42 BISHALGARH 21 83
SUB TOTAL 21 83
SIKKIM 43 RANGPO 11 300
SUB TOTAL 11 300
ANDAMAN & 44 PORT BLAIR 6 900
NICOBAR
SUB TOTAL 6 900
ASSAM 45 BONGAIGAON (BRPL) 30 0
46 GUWAHATI (SARPARA) 30 900
47 NORTH GUWAHATI 60 1557
48 SILCHAR 40 500
49 ***DULIAJAN 23 0
50 GOPANARI(DIGBOI) 30 1800
SUB TOTAL 213 4757
ARUNACHAL 51 KIMIN 8 100
SUB TOTAL 8 100
NAGALAND 52 DIMAPUR 11 100
SUB TOTAL 11 100
MIZORAM 53 MUALKHANG 11 100
SUB TOTAL 11 100
MANIPUR 54 SEKMAI 30 600
SUB TOTAL 30 600
ER TOTAL 1271 30105

DEPARTMENT 15
PAGE No.
WR MAHARASHTRA 55 AKOLA (DHANAJ) 60 1850

56 MANMAD 60 1850
57 PUNE 60 600
SUB TOTAL 180 4300
GOA
SUB TOTAL
GUJARAT 58 AHMEDABAD (SANAND) 120 4400
59 BHAVNAGAR 30 1850
60 GANDHAR 30 2000
61 HAZIRA 60 6600
62 RAJKOT 120 1000
63 BARODA 60 8328
SUB TOTAL 420 24178
MADHYA 64 BHOPAL 120 8200
PRADESH 65 GUNA 60 900
66 UJJAIN 60 1850
SUB TOTAL 240 10950
CHATTISGARH 67 RAIPUR 60 400
SUB TOTAL 60 400
WR TOTAL 900 39828
SR TAMIL NADU 68 COIMBATORE 120 900
69 ENNORE 180 900
70 ERODE 60 1850
71 ILAYANGUDI 30 450
72 MADURAI 60 900
73 MANNARGUDI 11 99
74 MYLADATURAI 11 99
75 SALEM 45 1200
76 TRICHY 120 1000
77 CHENGLEPET 120 1800
78 ***CPCL 120 4800
SUB TOTAL 877 13998

DEPARTMENT 15
PAGE No.
ANDHRA 79 CHERLAPALLI 120 2300

PRADESH 80 CUDDAPAH 60 1850
81 THIMMAPUR 120 1800
82 VIJAYWADA 105 1350
83 VIZAG 60 1800
SUB TOTAL 465 9100
KARNATAKA 84 BELGAUM 60 600

85 DEVANAGONTHI 180 3150
86 SHIMOGA 60 1800
SUB TOTAL 300 5550
KERALA 87 CALICUT 45 900
88 COCHIN 180 1250
89 QUILON 120 900
SUB TOTAL 345 3050
PONDY 90 PONDICHERY 30 300
SUB TOTAL 30 300
SR TOTAL 2017 31998
TOTAL ( IOC MD) 6793 184570

DEPARTMENT 15
PAGE No.
ANNEXURE 3
GLOSSARY OF TERMS
ABSOLUTE PRESSURE
See under "Pressure"
ATMOSPHERIC PRESSURE
BAROMETRIC PRESSURE
BLOW DOWN PRESSURE
I See under "Pressure"
BOILING
This is the action which takes place when a liquid changes its state
from a liquid into a gas or vapour. The heat required to bring this
change of state is called Latent Heat.
BOILING POINT
The Boiling Point of a liquid is defined as the temperature at which the
vapour pressure is one atmospheric absolute.
BOYLE'S LAW
See under "Gas Laws"
BULLET
A horizontal pressure vessel designed for storage of LPG. Horizontal
tanks mounted on pedestals at the Plants, mounted on a truck chassis
or a rail chassis are also known as Bullets.
CO-EFFICIENT OF EXPANSION
It is defined as the increase in volume of unit volume of a
substance when its temperature rises by 1°C.
COMMERCIAL BUTANE
Butane used as a fuel or for other purposes. It is not a chemically

DEPARTMENT 15
PAGE No.
pure product but the impurities are adjoining members of the

hydrocarbon series and small amounts of other impurities which do
not materially effect its use as a fuel.
COMMERCIAL PROPANE
Same as commercial butane except the primary component is
propane.
COMPETENT PERSON
A person in officer's grade having the necessary ability for particular
operation or type of Plant and equipment to which the text refers,
such as to render him capable of the work involved, and who has
been duly authorized to undertake this work.
COMPETENT STAFF
Staff of 'competent persons' trained for the job.
COMPRESSED GAS
Any permanent gas, liquefiable gas or gas dissolved in liquid under
pressure or gas mixture which in a closed gas cylinder exercises a
pressure either exceeding 2.5 Kgf/Cm2 abs (1.5 Kgf/Cm2 gauge)
at + 15°C or a pressure exceeding 3 Kgf/Cm2 abs
(2 Kgf/Cm2 gauge) at 50°C or both
CONDENSATION
This is evaporation in reverse. If a vapour becomes supersaturated,
condensation takes place and heat is surrendered.
CONTAINER
The term includes all vessels such as tanks, cylinders or bullets
used for the transportation or storage of LPG.
CONVERSION
Converting LPG from the liquid phase to the vapour phase or vice
versa.
CORROSION
All forms of wastage, and includes oxidation, scaling,
mechanical abrasion and erosion.
CRITICAL TEMPERATURE

DEPARTMENT 15
PAGE No.
The critical temperature of a gas is the temperature above which it

cannot be liquefied regardless of pressure.
CRITICAL PRESSURE
See under 'Pressure'.
DESIGN
Includes drawings, calculations, specifications, models, codes & all
other details necessary for the complete description of the pressure
vessel and its construction.
DESIGN PRESSURE
DENSITY OF LIQUIDS
Density of a liquid is defined as mass of the liquid occupying unit
volume at a given temperature.
DENSITY OF VAPOURS
Density of a liquid is defined as the mass of the liquid occupying
unit volume at a given temperature.
EVAPORATION
This is the process of converting a liquid into a vapour, and it
requires latent heat to do this.
FILLING OF CARGO TANKS
The correct maximum volume of liquid that should be loaded in a
cargo tank is such a quantity that after allowance for the product to
warm up and expand to a temperature the saturated vapour pressure
of which would lift the safety valves, prescribed percentages, of the
space would remain. A tank so filled is described as 'Full'. A tank filled
above this level is described as 'Overfull'. A tank completely filled with
liquid is described as 'one hundred per cent - full'.
FILLING DENSITY
The per cent ratio of weight of liquefied gas allowed in a pressure vessel
to the weight of water that the vessel will hold at 15°C.
FILLING PRESSURE

DEPARTMENT 15
PAGE No.

liquid.
FILLING RATIO
The ratio of weight of liquefied gas allowed in a pressure vessel to
the weight of water that the vessel will hold at 15°C.
FLAMMABLE COMPRESSED GAS
Gas, 13 per cent or less of which when mixed with air forms a
flammable mixture or whose flammable range with air is greater
than 12 per cent.
FLAMMABLE
The term is synonymous with 'Inflammable'. It refers to any

substance, solid. liquid, gas or vapour which is easily ignited. The
addition of the prefix “ non" indicates that the substance is not
readily ignited, but does not necessarily indicate that it is non-
combustible. The use of term "flammable" is preferred to
''inflammable” to avoid ambiguity.
FLAMMABLE GAS
Any gas which, if either a mixture of 13 per cent or less (by
volume) with air forms a flammable mixture or the gas which has
flammability range greater than 12 per cent regardless of the
lower limits. These limits shall be determined at atmospheric
temperature and pressure.
FLAMMABILITY RANGE
The term is synonymous with "Inflammability Range·· The difference
between the minimum and maximum percentage by volume of the
·gas in mixture with air that forms a flammable mixture at
atmospheric pressure and ambient temperature.
FLASH VAPOURISATION
The instantaneous and complete conversion of liquid to gas
FOG NOZZLE
A water nozzle which produces a fine fog-like spray It is very
effective in cooling and

DEPARTMENT 15
PAGE No.
controlling fires.
FREEZING POINT
The temperature at which liquid changes to a solid state : solidifies
GAS CYLINDER OR CYLINDER
Any closed metal container intended for the storage and transport
of compressed gas. designed not to be fitted to a special transport
or under-carriage. and having a volume exceeding 500 ml. but not
exceeding 1 0 0 0 liters.
GAS LAWS
(a) AVOGADRO'S HYPOTHESIS
Equal volumes of different gases at the same pressure and
temperature contain the same number of molecules.
(b) BOYLE'S LAW
The volume occupied by a given mass of gas varies inversely with
the absolute pressure if the temperature IS not allowed to
change.
(c) CHARLE'S LAW

The volume of a given mass of gas varies directly with the
absolute temperature provided the pressure remains constant
Volume at t°C = (273+t)/273 x Volume at 0°C
Density at t C= 273/(273+t) x Density at 0oC
0
(d) CLERK MAXWELL'S KINETIC THEORY

A gas may be imagined as a vast number of molecules moving in
all directions at irregular velocities, colliding with one another and
with the walls of the containing vessel. The path of a molecule is
zigzag in three dimensions and the mean free path is defined as
the average length between collisions, the denser the gas, the
shorter will be the mean free path. T h i s theory co-relates
Avogadro's Hypothesis, Boyle's Law & Gay Lussac's Law.
(e) DALTON'S LAW OF PARTIAL PRESSURES

The pressure of a mixture of gases is the sum of the pressures each would
exert if it alone were to occupy the containing vessel.

DEPARTMENT 15
PAGE No.
(f) GAY LUSSAC'S LAW .

The density of a gas at standard pressure and temperature is proportional
to its molecular weight. This is a corollary of Avogadro's Hypothesis.
(g) JOULE'S LAW
When a perfect gas expands without doing external work and
without taking in or giving out heat and therefore, without
changing its stock of internal energy, its temperature does not
change.
GAS FREE
In relation to a pressure vessel means concentration of flammable or
toxic gases or both in case of such pressure vessel is within the safe
limits specified for persons to enter and carry out hot work in such
vessels.
HEAT
(a) LATENT HEAT

This is the heat used up in changing the state of a substance
•
without changing its temperature. In the case of changing the
state of a substance from solid into a liquid (melting), it is called
the latent heat of fusion, and in the case of heat changing the
state of a liquid into a gas or vapour (boiling), it is called the
latent heat of vaporization. The value of latent heat of
vaporization varies with . temperature and pressure.
(b) SENSIBLE HEAT
This is the heat used in raising the temperature of a substance without
changing its state. 1 calorie is used to raise the temperature of 1 gram of
water by 1°C.
HORTON SPHERE
Spherical pressure vessel designed for storage of LPG. These are usually
of capacities above 400 cubic meters.
HIGH PRESSURE LIQUEFIABLE GASES
A liquefiable gas having a critical temperature between - 10°C +
70°C.
HYDROCARBON
An organic compound consisting primarily of hydrogen and
carbon. All petroleum products are hydrocarbons.

DEPARTMENT 15
PAGE No.
HYDROSTATIC STRETCH. TEST

Subjecting the cylinder to a hydrostatic pressure equal to the test
pressure of the cylinder and recording the permanent stretch
undergone by the cylinder.
HYDROSTATIC TEST
The test in which a cylinder is subjected to a hydrostatic pressure
equal to the test pressure of the cylinder
INERT GAS
A gas which will not support combustion and normally does not
react with other compounds under normal conditions and
temperature (e.g. Nitrogen)
INFLAMMABLE
See "Flammable".
INFLAMMABILITY RANGE
See "Flammability Range".
INLET PRESSURE
INSTALLATION
Any premises wherein any place has been specially prepared for the
manufacture
(filling) or storage of compressed gas in cylinder.
INSPECTOR
A person authorized by the licensing authority for the purpose of
inspecting vessels i n accordance with the approved design &
specification and code.
LATENT HEAT
See under "Heat".
LATENT HEAT OF VAPOURISATION
The quantity of heat absorbed by a unit mass when changing
from the liquid to gaseous phase while remaining at the same
temperature.

DEPARTMENT 15
PAGE No.
LIQUEFIED PETROLEUM GAS

A material having a vapour pressure not exceeding that allowed for
commercial
propane composed predominantly of the following hydro carbons,
either by themselves or as mixtures : Propane, Propylene, Butane
(Normal Butane or Iso-Butane) and Butylenes including Isomers.
"Liquefied Petroleum Gas" is also expressed by terms
'LP-Gas' and 'LPG'.
LIQUEFIABLE GAS
Any gas that may be liquefied by pressure above 0 °C. but will be
completely vaporized when in equilibrium with normal atmospheric
pressure (760 mm Hg) at
30°C.
LIQUID CARRY OVER
This occurs when vapour moves swiftly over the surface of a liquid
and droplets of liquid become entrained with the vapour and are
earned over with it.
LIQUID LEVEL INDICATOR
A fixed liquid level gauge, a rotary gauge. a magnetic gauge. or
other type of gauge which will indicate the quantity or the level of
a liquid in a container.
LIQUEFACTION
Converting a gas into the liquid phase by compression or cooling or
a combination of both.
LOW PRESSURE LIQUEFIABLE GAS
A liquefiable gas having critical temperature higher than + 70°C.
MAGNETIC GAUGES
A gauge in which a float, through mechanical means, causes a
magnet to revolve as the float rises or falls with the liquid level. The
magnet causes a magnetized needle to follow and indicate the liquid
contents of the container on a suitable scale.
MANUFACTURE OF GAS
Filling of a cylinder with any compressed gas and also includes transfer
of compressed gas from one cylinder to any other cylinder.

DEPARTMENT 15
PAGE No.
MAXIMUM ALLOWABLE WORKING PRESSURE

The pressure for which a storage container is designed or the
maximum pressure allowable according to the condition of the
tank when it is designed.
MERCAPTANS
A family of petroleum sulphur compounds having a disagreeable
odour. Some of them are used to odourise LP-Gas so that it can be
detected in case of gas leaks.
METER
A device for measuring the flow of fluids.
NAKED LIGHTS
Naked lights include all unconfined flames. fires, exposed
incandescent material, lamps of an unapproved pattern, electric
welding arcs and. portable hand or power operated equipment liable
to cause incendiary sparks.
NATURAL GAS
The term applied to gas as commonly associated with
petroliferous geologic formations. The main combustion
constituent is methane but varying amounts of ethane are usually
present with small percentages of propane and butane. Some
natural gases contain helium, carbon dioxide, nitrogen and
sulphide in varying quantities.
PURGING
Removing an unwanted substance from the container. pipeline or other
enclosure.
PRESSURE
(a) ABSOLUTE PRESSURE
The absolute or total pressure of a gas is the sum of the gauge
pressure plus the barometric pressure of the atmosphere. In other
words this is the pressure above a vacuum. Thus a pressure of 7 psi
absolute, is really a suction pressure of 7 7
psi at atmospheric pressure (atmospheric pressure equals 14.7 psi)
(b) ATMOSPHERIC PRESSURE
This is the pressure exerted at sea level. This pressure varies from

DEPARTMENT 15
PAGE No.
place to place and from time to time The standard atmospheric

pressure is 1012.5 millibars. corresponding to 29.90 inches or 760
mm of mercury (Hg)
(c) BAROMETRIC PRESSURE
The pressure due to the weight of the earth's atmosphere as indicated
by a barometer.
(d) BLOW DOWN PRESSURE
The term IS applicable to pressure relief valve. The pressure at
which the seat of the valve closes tight after release of excessive
pressure IS known as 'Blow Down Pressure'. This value is generally
lower than the set 'Start to Discharge Pressure'.
(e) DESIGN PRESSURE.
Design pressure means the pressure used in the design calculations
of a vessel for the purpose of determining the minimum thickness of
the various component parts of the vessel. This should not be lower
than the 'Working Pressure'.
(f) FILLING PRESSURE
The maximum permissible gauge pressure, converted to + 15°C, at
which a gas cylinder for permanent gas or gas dissolved under
pressure can be filled.
(g) INLET PRESSURE
The pressure at the inlet side of a regulator, pump, meter or
entrance to a system or process cycle.
(h) PRESSURE RELIEF VALVE
See 'Safety Relief Device' (Valve)
(i) PRESSURE VESSEL
Any closed metal container of whatever shape, intended for the
storage or transport of any compressed gas which is subjected to
internal pressure and whose water capacity exceeds one thousand
liters and includes interconnecting parts and components thereof
up to the first point of connection to the connected piping and
fittings.
(j) START TO DISCHARGE
The term is related to pressure relief valve also known as safety relief
valve. The set pressure at which the valve seat is designed to lift
slightly and start releasing the excessive vapour pressure. At this
stage the valve will open slightly and not full. This pressure MUST be

DEPARTMENT 15
PAGE No.
less than 110% of the working pressure of the vessel on which it is

mounted.
(k) TEST PRESSURE
The internal pressure required for the hydrostatic test or hydrostatic
stretch test of the cylinder. This is indicated on all the pressure
vessels.
(I) VAPOUR PRESSURE
The vapour pressure of liquid at a given temperature is defined as
the equilibrium pressure developed at that temperature in a closed
vessel containing the liquid and its vapour only. The vapour
pressure of LP-Gas depends upon the temperature of the liquid and
the composition in terms of primary hydrocarbons present.
(m) WORKING PRESSURE
The maximum saturated vapour pressure at which the vessel should
be operated in actual service. For un-insulated storage and transport
pressure vessels this is based on the maximum temperature of 55°C,
where as for LPG cylinders it is based on the maximum temperature
of 65°C. Working Pressure is· indicated on all the pressure vessels.
(Note : F o r the values of saturated vapour pressure of different gases
refer IS : 3710)
PERMANENT GAS
A gas whose critical temperature is below (-) 10°C that is to say a
gas which cannot be liquefied under any pressure at a temperature
above(-) 10°C.
QUICK CLOSING VALVE
A valve which can be closed quickly by the movement of release of
a lever instead of by the rotation of a stem.
RECEIVING TANK
A storage tank into which liquid is loaded.
REGULATOR
A device used to reduce the pressure of a fluid from a higher
pressure to a lower controlled pressure.
RELIEF DEVICE
·A device used to prevent a dangerous condition of pressure or temperature
from occurring in an enclosed space. Refer 'Safety Relief Device'.

DEPARTMENT 15
PAGE No.
RELIEF VALVE MANIFOLD

A manifold containing two or more relief valves but with only one
connection to the container. Some manifolds are designed to permit the
removal of one relief device without impairing the relieving capacity
required by the container.
TEST PRESSURE
VALVE, AUTOMATIC CUT·OFF
A valve either pressure or electrically energized which automatically
closes when certain undesirable conditions such as an abnormal low or
high pressure are experienced.
VALVE, BACK FLOW CHECK

A valve which permits flow of fluid in one direction but closes
automatically to prevent flow in the opposite direction.
VALVE, BALL CHECK
A form of check valve which utilizes a ball as a medium to stop the
flow.
VALVE, DIFFERENTIAL
A special valve used in liquid metering systems to create a back
pressure on the liquid stream as it passes through the meter and prevent
vapour formation in the meter.
VALVE, EXCESS FLOW CHECK
A valve which permits uninterrupted flow in one direction but
when flow in the opposite direction exceeds a predetermined
rate or a predetermined differential pressure across the valve. the
valve closes and stops the flow.
VAPOUR
A gaseous form of substances which are normally in the solid or liquid
state.
VAPOUR PRESSURE
VEHICLE
A mechanically propelled carriage designed to transport by land.
compressed gas in a pressure vessel mounted thereon. and shall not

DEPARTMENT 15
PAGE No.
7include a vessel forming the barrel of a rail tank wagon.

VESSEL
A pressure vessel used for storage or transport (road/rail) of LPG.
'
VISCOSITY
The internal friction or resistance of a fluid to flow.
WATER CAPACITY
The volume of water in liters a vessel will hold at 15'C.
WEATHERING
Venting vapour to atmosphere or vaporization of a liquid at atmospheric
pressure.
WORKING PRESSURE
WORKING PRESSURE FOR LOW PRESSURE LIQUEFIABLE GASES
See under 'Pressure'
YIELD STRENGTH
The stress corresponding to a permanent strain of 0.2 per cent of the
original gauge length in. a tensile test. For practical purposes it may be
taken as a stress at which elongation first occurs in the test piece
without the increase of load in a tensile test

DEPARTMENT 15
PAGE No.
ANNEXURE 4
Statutory Licenses and Approvals/Documentation
(A) PESO Related

1 Conveyor Layout- Proposed and also for as built
2 Plant Layout-Proposed and also for as built
3 License to Fill compressed gas in cylinder ( Form E).
4 License to store compressed gas in Cylinders ( form F).
5 License to store compressed gas in pressure vessel or vessels.) Form-III
6 License to store Diesel in Diesel tank for Consumer pump
7 Endorsement for degassing of cylinders
Endorsement for filling of cylinders & storage vessels after sunset and also for
8 unloading/loading of Bulk as applicable
9 NDT & Hydro test of LPG Pressure vessels
10 SRV Testing of Storage vessels and also air receivers/POP action valve test records
(B) Factory License-Related

1 Approval for ERDMP vetted by PNGRB accredited 3rd Party
2 Approval for on site emergency plan
3 Copy of Off Site emergency plan
4 Endorsement on factory license regarding change of occupier.
5 Plant Layout-Proposed and also for as as built
6 Building drawings-Proposed and as built
NDT & Hydro test of other Pressure vessels , Suction and discharge bottles/air
7 receivers
8 Stability Certificate for buildings
9 Safety Audit report- external agency-as required by Factories dpt.
10 First Aid Training and certificates
11 Risk analysis as and when changes in filling/storage system/risk
12 TT Parking area exclusion from Plant layout

DEPARTMENT 15
PAGE No.
13 Report of examination of Pressure Vessel as reqd by Factories dept
© PCB RELATED
1 AIR CONSENT
2 WATER CONSENT
3 Hazardous Waste ( MHIHC) Rule 1989
4 Water test (Potability)
5 Air quality monitoring Test
6 Water quality monitoring Test
7 Noise Monitoring Test
8 DG sets approvals as required from EB/ERC as applicable.
(D) W&Ms Certificates

Certificate of Registration Under Legal Metrology ( Packaged Commodities) Rules
1 2011 )
2 Certificate of Registration [Under Rule 17 of Standards of Weights & Measures 1985 ]
Certification of verification of Stamping Weights & Measures for Carousal Filling M/c,
Check Scales, Weigh Bridge, Standards Weights, 5 ltr measure & HSD Dispensing
3 Pump and any other weighing scales
(E) Prohibited area/place declaration
(F) 1 License from Labor Department for engaging labors for various works
Intimation regarding change/commencement/completion of contract and
2 change of occupier for amendment of license
(E) General
1 Hydro Test of LPG Pipeline- Above ground-Every Five years
2 RTO Approval for Motor Driving Institute-Hazardous endorsement for Cyl TTs and BTs
3 LPG Hose Testing record- Every four months
4 Electrical Audit - Internal-Every year
5 Electrical Audit - External-Every four years

DEPARTMENT 15
PAGE No.
6 Earth Resistance Testing-Every six months

8 Emergency Response Drill-Every six months
9 Fire Hose Testing-Every six months
CEA Inspection- Before commissioning of any new facilities and period not
10 exceeding five years/as per IE rules
11 Bomb Threat Contingency Plan- Approved by corporate office
Security Contingency Plan- Approved by Corporate office and then by district
12 administration
Fire Water Tank Inspection, Thickness testing, cleaning and painting- Cleaning Every
13 5 years & Wall thickness every three years & as Per OISD 129
14 Fire Extinguisher Inspection visual every month and servicing-every three months
15 Hydro - Test of DCP Fire Extinguishers-Every three years
16 Public Liability Insurance-Validity-Copy to be kept
17 Testing of Transformer Oil-Every year
18 Relay Calibrations-Every year
20 Torque Wrench Calibration-Every year
21 Electrical Hand Gloves 33 KVA-Every six months- To have valid test certificate
22 Explosive meter calibration-Every year
Cable Insulation Resistance Test-Every year and corrective actions if insulation value
25 less than 1 mega ohm.
VHF License- for base stations and walkie talkies- Every year-To be kept valid from
26 DOT

DEPARTMENT 15
PAGE No.
ANNEXURE 5
Sr.No. Characteristic Auto LPG as Domestic LPG as per IS

per IS 14861 4576
1 Vapour Pressure at 40 C, kPa Min 520 Comml. Butane 520, Mix
Max 1050 1050 Comml.Propane
1550
2 C5 Hydrocarbons & Heavier, Max 2.0 Comml.Butane 2.5, Mix
( Liquid Vol. %) 2.5 Comml.Propane 0.2
3 Dienes, mole %, max 0.5 Report
4 Total Volatile Sulphur ppm 150 150
5 Motor Octane Number MON 88 -
6 Cu Strip Corrosion at 38 C Class 1 Not worse than no. 1
7 Evaporation Residue, mg/kg, max 100 -
8 Volatility :Evaporation temperature in °C for 95 Comml.Butane 2 , Mix 2

percent by volume at 760 mm Hg Comml.Propane ( - )38
pressure, Max.
9 Free water content Nil Nul
10 Hydrogen Su;phide Pass the test Pass the test


DEPARTMENT 15
PAGE No.
ANNEXURE 6
TYPICAL PROPERTIES OF COMMERCIAL PROPANE & BUTANE
Specification
Commercial Propane Commercial Butane
Formula C3H8 (Propane) C4H10 (Butane)
Boiling Point 0C - 45 -7 to -0.5
Freezing Point 0C -186 -150
Critical Temperature °C 97 152
Critical Pressure at (Kg/cm2) 43 39
(a) Liquid at Vapout Pressure , 150C

a. Density kg/l 0.51 0.575
b. Specific volume, l/kg 1.96 1.73
c. Sp. Gravity ( w.r.t water=1) 0.510 0.575
d. Vapour Pressure, kg/cm2(g) 6.65 1.4
e. Absolute Viscosity , cP 0.10 0.15
f. Co-eff.of Vol. expansion,(10-40 C)
0 0.00324 0.00230
g. Latent Heat, Kcal/Kg ( 1 atm) 95 90
h. Specific Heat, Kcal/Kg/ C0 0.60 0.57
i. Calorific Value (Gross),Kcal/Kg 11900 11800
j. Calorific Value (net),Kcal/Kg 11000 10900
(b) Saturated vapour, 150C

a. Density, Kg/m3 15.3 5.62
b. Specific Volume m3/tonne 65 178
(c) Vapour at 1 atm, 150C

a. Density, Kg/m3 2.0 2.6
b. Specific Volume, m3/kg 0.5 0.38
c. Sp. Gravity ( air=1) 1.5 2.0
d. Sp. Heat, Kcal/kg/0C
i. Cp 0.38 0.39
ii. Cv 0.34 0.35
e. Calorific Value ( gross), Kcal/m3 24000 30700

DEPARTMENT 15
PAGE No.
f. Calorific Value ( net), Kcal/m3 22600 29000

g. Ignition Temp. In air 0C 450-500 420-490
h. Flame Temp. In air, C max
0 1970 1975
i. Combustion air Required 24 30
Stoichiometric Prop., m /m
3 3
j. Limits of Flammability, Vol

% of vapour in air gas
mixture
Lower 2.0 1.8
Upper 10 8.5
-------------- --------------- -------------
* Whereas LPG marketed would conform to IS 4576. the composition is not

guaranteed since the % varies for different crudes and even for same
crude from batch to batch. The composition should, therefore, be taken
only as a general guide.

DEPARTMENT 15
PAGE No.
ANNEXURE 7
WORKING OF SAFE-FILLING QUANTITIES FOR LPG CONTAINERS
1.0 GENERAL
1.1 One of the most important safety aspects at LPG bottling plant is to
ensure that the LPG containers are not over-filled. LPG containers
should be so filled that there is always sufficient vapour space left to
allow the liquid LPG to expand with the expected maximum increase
in temperature as stipulated in relevant statutory rules.
1.2 On account of safety considerations, statutory regulations stipulate

basis for arriving at maximum quantity that can be filled in an LPG
container. For storage vessels, tank wagon bullets and tank truck
bullets, the stipulations laid under ‘The Static and Mobile Pressure
Vessels (Unfired) Rules, 1981” are applicable. whereas for LPG cylinders
the rules covered in ‘The Gas Cylinder Rules, 2004 are applicable.
1.3 “The Static & Mobile Pressure Vessels (Unfired) Rules 1981” pertaining to
safe-filling of bulk LPG containers, reads as under .
“Filling capacity and filling pressure
(1) Maximum quantity of liquefiable gas filled into any vessel shall be
limited by the filling density of the gas, and shall be such that the
vessel shall not be liquid full due to expansion of the contents with
rise of temperature to 55°C, if vessel is uninsulated or to the highest
temperature which the contents are likely to reach in service, it the
vessel is refrigerated or insulated. This requirement shall be
applicable irrespective of the ambient temperature of the product
at the time of filling.”
1.4 “The Gas Cylinder Rules, 1981” reads as under

‘Cylinders charged with liquefiable gases shall not be filled in excess of
the filling ratios specified in IS 3710 for low pressure liquiefiable gases
and IS 8866 for high pressure liquefiable gases’.

DEPARTMENT 15
PAGE No.
(Note LPG cylinders fall into category of low-pressure liquefiable

gases).
1.5 A vapour space or OUTAGE must be left above the liquid to permit
room for expansion under any temperature conditions. In India Design
Pressure or Maximum Working Pressure for filling LPG in cylinders has
been fixed at 65°C. Since LPG in liquid form has relatively high co-
efficient of expansion (10 times more in case of Butane and 15 times in
case of Propane compared to water) and in case sufficient outage is
not left in LPG cylinder due to defective cut-oil system/weighing
machine, the hydrostatic pressure inside the cylinder would shoot up
by 14 to 15 Kg/cm’ per 1°C rise in temperature once the container
becomes liquid full. This would cause great strain over cylinder body
which could burst with normal increase in ambient temperature and
release LPG in the surrounding areas, This in turn could instantly form
flammable mixture which could spread and get ignited if it reaches a
source of ignition which may otherwise be away at a safer distance in
the un-licensed premises or even outside the plant area. This could
lead . worst possible disaster and the catastrophe that could be
caused by such a mishap could well be imagined. It is therefore,
imperative. that all possible care Is exercised to avoid overfilling of
containers beyond prescribed safe limits.
1.6 Minimum data required to work out safe-filling capacity of a container

consists of:
(a) Water capacity ol the container.
(b) Density of liquid LPG to be stored
(c) Filling density as per statutory rules.
The safe capacity of a container depends upon the density of the

product to be stored, which in turn depends upon the composition of the
LPG to be stored. It is, therefore, imperative that whenever there is
change in composition of LPG to be stored, safe tilling quantities should
be reworked out and safety gadgets such as fixed-level gauges and high
level alarm re-adjusted as per revised safe quantity. This is particularly
most important in case of switch over from heavier grade to lighter

DEPARTMENT 15
PAGE No.
grade. It is however assumed that the container in question is designed to

suit the vapour pressure of the lighter grade whenever switch-over from
heavier grade to lighter grade is made.
1.7 The safe-filling quantities can be worked out either in terms of weight
(Kg or MT) or volume (Lts. or KL). Weight method should be used if the
container is designed and equipped to be filled by weight (e.g.
cylinders, LPG tank truck or LPG tank wagon), using following formula:
W = FR x WC where
W = Safe-filling weight in Kg,
FR = Filling Ratio,
WC = Water capacity of the container in litres.
1.8 Whenever LPG tank wagons or tank trucks are required to be filled on
volumetric basis, ‘it must be ensured that the quantity so filled is not in
excess of the maximum permitted filling density on weight basis when
the liquid LPG reaches the temperature of 55°C. Maximum volume of
liquid LPG that can be “filled in a vessel at given temperature can be
worked out using the following formula
FR x WC
V = ________ where
D x VRF
Vl = safe maximum volume in Litres at temp. t°C,
FR = Filling Ratio (Refer Table J-2),
WC=Water Capacity of the vessel in Litres,
D =Density@15°C of liquid LPG in Kgs/Litre,
VRF = Volume Reduction Factor for Density D at temp t°C
using ASTM - table 54
Based on the above formula, safe maximum volume for a
container could be worked out in terms of “percent volume”
of the container as under
%Vl = Vl x 100
WC
or = FR x100
D x VRF

DEPARTMENT 15
PAGE No.
1.9 To comply with the requirement set out In clause 1.8 above, It is
essential to ascertain temperature of liquid LPG at the time of tilling
when working out safe filling volume at any particular temperature.
1.10 For the purpose ot computing safe-tilling quantities, insulated vessels to

be treated as uninsulated vessels as far as IOC’s vessels are
concerned.
1.11 Various calculations for safe-filling of LPG cylinders/vessels are best

understood through the examples given in Clause-1.13.

DEPARTMENT 15
PAGE No.
TABLE J-1
FILUNG RATIOS FOR LPG TO BE FILLED IN LPG CYLINDERS
Liquid LPG Density Filling atio Liquid LPG Filling Ratio

g/m I Density Filling g/ml
@15°C Ratio
@15°C
0.500 0.388 0.560 0.467

0.505 0.396 0.565 0.475
0.510 0.402 0,570 0.480
0.515 0.409 0.575 0.486
0.520 0.415 0.580 0.491
0.525 0.421 0.585 0.498
0.530 0.428 0.590 0.504
0.535 0.435 0.595 0511
0.540 0.442 0.600 0.510
0.545 0.448 0.605 0.520
0.550 0.454 0.610 0.525
0.555 0.462 --- ---
NOTE:1. Filling Ratio is based on assumed maximum temperatre of 65°C as

laid down for LPG Cylinders as per statutory rules.
2. Filling Ratios given above are as per IS 3710-1978 (Filling Ratios for Low
Pressure Liquefiable Gases contained in cylinders).
3. In case density of liquid LPG is observed at a temperature other than
15.0°C, it should be converted to 15.0°C with the help of ASTM table
53 before using above table.

DEPARTMENT 15
PAGE No.
TABLE .J-2
MAXIMUM FILLING DENSITIES AND CORRESPONDING MAXIMUM LIQUID

CONTENTS IN TERMS OF PERCENTAGE VOLUME OF THE CONTAINER FOR
LPG OF VARIOUS DENSITIES AND ABOVEGROUND UNINSULATED
CONTAINERS ABOVE 5000 LITERS CAPACITY.
Liquid Fiiling Ratio Filling Density` Maximum LPG volume at 15.5 °C

LPG Density (% water capacity)
g/Mi @ 15.5°C
0.496 - 0.503 0,41 41 81.5
0.504 - 0.510 0.42 42 82.3
0.511 - 0.519 0.43 43 82.8
0.520 - 0.527 0.44 44 83.5
0.528 - 0.536 0.45 45 83.9
0.537 - 0.544 0.46 46 84.3
0.545 - 0.552 0.47 47 85.1
0.553 - 0.560 0.48 48 85.7
0.561 - 0.568 0.49 49 86.3
0.569 - 0.576 0.50 50 86.7
0.577 - 0.584 0.51 51 87.4
0.585 - 0.592 0.52 52 87.8
0.593 - 0.600 0.53 53 86.3


DEPARTMENT 15
PAGE No.
NOTE: 1. Above figures are based on IS 6044 (Part-Il) — 1972.

2. Filling Ratios under column-2 and Filling Density under column-3 are
based on assumed maximum temperature of 55°C as laid down for
uninsulated above ground containers under statutory rules.
(FD = FR x 100).
3. In case density of liquid LPG is observed at a temperature other than
15.5°C, it should be converted to 15.5°C using ASTM table 53.
4. Density (6D 15.5°C (Density @ 15.0°C 0.0001) approx.
1.12 EXAMPLES :
EXAMPLE: 1
If volumetric capacity of a Horten Sphere is 1418 M3 and LPG to be stored
has a density of 0.5430 Kg/Litre @ 15°C, calculate the safe filling capacity for
the Horton Sphere in terms of
(a) Metric Tons,
(b) % volume of the total volumetric capacity of the Horton Sphere, at 15°C.
STEP—1
Density of 0.5430 @ 15°C is equal to 0.5429 D 15.5°C.
STEP — 2
As per clause 1.8 of the annexure
W = FR x WC, where;
W = safe-filling weight in Kgs. (to be ascertained),
FR = Filling Ratio; 0.46 (as per table J-2),
WC = Water capacity in Litres, 1418 x 1000 (given),
Therefore, W = 0.46x 1418 x 1000

= 652280 Kgs
or 652.280 MTs. (1000 kgs 1 MT)
STEP—3:
% safe-filing volume against the density of 0.5429 @ 15.5°C (or 0.5430 @ 15°C)
is already given in table J-2 as 84 5°/o.
STEP — 4
% safe-filling volume at 15°C can alternatively be worked out by dividing the
safe-filling capacity in MT with the density @ 15°C.
%V15 = FD FD = 46 from table J-2
D15 D15 = 0.5430 (given)

DEPARTMENT 15
PAGE No.
=46/05430
=84.7%
NOTE : % safe-filling volume worked out as per step-4 is more accurate as it

takes into account the actual density of the product instead of range of
density as is the case for the figures in Table J-2.
EXAMPLE — 2
An LPG tank wagon having a gross weight of 34.0 MT, tare-weight of 18.8
MT and 33 M3 water capacity is to be loaded on volumetric basis at a
temperature of 25°C. The density of LPG to be loaded is 0.5450 Kgs/Litre @
15°C. Calculate safe-filling volume at 25°C and safe-filling quantity in MT
for the tank wagon.
STEP—i:
Maximum carrying capacity of LPG tank wagon, as permitted by the
railways, is the difference of gross weight and tare weight of the tank
wagon subject to maximum limit of 15.4 MT. In the present case maximum
carrying capacity as per railways would be 15.2 MT (34.0 gross wt. 18.8
tare weight).
STEP — 2
Using formula in clause 1.8 of the annexure it must be verified that the
filling ratio for the tank wagon bullet is not exceeded, if the LPG is loaded
as per carrying capacity worked out on the basis of Step-i above. In case
filling ratio is exceeded based on the carrying capacity, the loading
should be limited to safe- filling quantity worked out on the basis of
formula in clause 1.8 of the annexure.
Filling ratio in the present case, based on carrying capacity of 15.2 MT


DEPARTMENT 15
PAGE No.
works out to 0.46 (15.2 MT CC ÷ 33 M3 water capacity). This is within the FR

of 0.47 shown in table J-2., safe. Filling capacity for the tank wagon,
therefore, can be considered as 15.2 MT.
STEP — 3
Using formula given in clause 1,9 of the annexure, safe filling volume at
25°C can be worked out as under
FR x WC
V1 = ________ where;
D x VRF
V1 = Safe max. volume in Litres at 25°C (to be ascertained),
FR = Filling Ratio; 0.47 (from table J-2)
WC = Water Capacity in Litres 33 x 1000 (given),
D = Density @ 15°C; 0.5450 (given),
VRF= Volume Reduction Factor for Density of 0.5450 @ 15°C
and temperature 25°C; 0.9760 (from ASTM table — 54).
0.47 x 33 x 1000
Therefore, VI= _________________ = 29158 Litres.
0.5450 x 0.9760
EXAMPLE — 3
Volumetric capacity of an LPG tank truck bullet is 22 M3 . LPG having
liquid density of 0.5440 Kg/Litre @ 15°C is to be loaded in the tank truck.
Calculate the safe vapour space in terms of percentage volume for fixing
the fixed level gauge.
STEP—i:
For the purpose of working out safe maximum volume for a “fixed level
gauge”, the minimum operating temperature should be considered. LPG
tank truck bullets are designed for operating temperature range of —
6°C, to (+)55°C, therefore, safe maximum volume should be calculated
for (—) 6°C in the present case.

DEPARTMENT 15
PAGE No.
STEP — 2
As per formula in clause 1.9 of the annexure
FRxWC
Vi = ________ where;
DxVRF
V1 = Safe max. volume in Litres at temp. (—)6°C, (to be ascertained),

FR = Filling Ratio; 0.46 (from table J-2),
WC = Water Capacity in Litres 22 x 1000 (given),
D = Density @ 15°C; 0.5440 (given),
VRF = Volume Reduction Factor for Density of 0.5440 @15°C and
temperature (—)6°C; 1.048 (from ASTM table — 54).
0.46 x 22 x 1000
Therefore, V1= ________________ = 17751 Litres.
0.5450 x 1.048
Or % V1= 17751 x 100 = 80.6%
22 x 1000
STEP — 3
Percentage safe vapour space ( (-) 6°C would therefore,
be
100 — 80.6 = 19.4%
NOTE : In case the “actual” minimum operating temperature is

different than the minimum “designed” operating temperature, the %
volume could also be worked out as above for the “actual” minimum
operating temperature. It must however, be ensured that the “actual”
minimum operating temperature is within the temperature range as per
design of the bullet.
EXAMPLE — 4:
Calculate the minimum water capacity required for LPG tank truck bullet
for carrying 10 MT of LPG, with the assumption that the lowest density of LPG
to be transported would be 0.5280 @ 15°C.
STEP— 1:
As per formula given in clause 1.8 of the annexure

DEPARTMENT 15
PAGE No.
W = FRxWC, or,
WC = W / FR ; where
WC = Water capacity in Litres, (to be ascertained),
W = Safe maximum capacity in Kgs; 10 x 1000 (given),
FR = Filling Ratio, 0.45 (as per table J-2).
Therefore, WC 10 X 1000 = 22,222 Litres or 22.3 m3
0.45
EXAMPLE — 5:
An LPG tank truck is having a bullet with a volumetric capacity of 13,200
Litres. If it is required to be filled on volumetric basis, calculate the
percentage setting for Rotogauge it liquid LPG with density of 0.5400
Kg/Litre is to be titled at a temperature of 28°C.
STEP — I
V1 = FR x WC ; where
D x VRF
V1 = Safe maximum volume in Litres; (to be calculated),
FR = Filling Ratio; 0.46 (as per table J-2),
WC = Water capacity in Litres; 13,200 (given)
D = Density of LPG at 15°C; 0.5400 (given)
VRF = Volume Reduction Factor, based on density of 0.5400 at
15°C and temperature 25°C; 0.967 (from ASTM table 54),
Therefore, v1 = 0.46 x 13200 = 11628 Litres
0.54 x 0.967
or %V1= 11,628x 100 = 88
13,200
NOTE :
(1) As a normal practice, LPG tank trucks are filled on weight basis only.
(2) Whenever the tank truck is filled on volumetric basis, care must be
exercised to ensure that
(a) Correct volumetric capacity of the tank truck bullet is known.


DEPARTMENT 15
PAGE No.
(b) The temperature of the product in the tank truck is identical to

the temperature for which the safe maximum volume has been
calculated. In any case the actual temperature of the product
should not be less than the temperature for which the safe
maximum volume has been calculated.
(c) The Rotogauge on the tank truck is correctly calibrated and iS in

working order. This could be checked against the setting of fixed
level-gauge mounted on the tank truck bullet. Further, if the Roto-
gauge is functioning properly, readings on left-hand side as well
as right hand side of the gauge would be identical when quantity
filled in the tank truck is checked.
(3) Even though the tank truck is filed on volumetric basis it is advisable
to determine through weigh bridge, the weight of the product
loaded to ensure that the weight does not exceed the safe filling
weight. This also helps to work out transit loss at unloading point.
EXAMPLE — 6
Calculate safe-filling quantity for cylinder of 33.3 Litres water capacity
@ 15.0°C. assuming that the density of LPG to be filled in is 0.550
Kg/Litres @ 15.0°C.
STEP — 1:
W = FR x WC ; where ;
W = Safe filling quantity in Kgs; (to be ascertained),
FR = Filling Ratio; 0.454 (from Table J-1),
WC = Water capacity in Litres, 33.3 (given),
Therefore, W = 0.454 x 33.3,
= 15.1182 Kg. (say 15 kg.).

DEPARTMENT 15
PAGE No.
ANNEXURE 8
LIST OF DOs AND DON’Ts
S. NO DOs DON’T’s
1. Adhere to the Dos listed Do not ignore points listed below
below.
2. Get familiarised with the Do not ignore Statutory Rules and
Glossary of Terms (Annexure Regulations.
No. 3)
3. Understand Properties, Do not undertake modifications without
Characteristics and Hazards of proper approvals.
LPG (Chapter No. 3)
4. Ensure that all relevant Do not undertake any operation without
licensees as per Statutory competent supervision.
Regulations are available,
valid and renewed in time.
5. Comply with the conditions of Do not carry out hot work without
applicable licenses. adequate precautions and hot work
permit.
6. Avoid presence of water and Do not start any LPG operation without
air in LPG system including proper grounding and bonding
cylinders. Purge wherever arrangement.
necessary (Annexure No. 8)
7. Wear protective gloves / Do not enter into a storage vessel until
clothing at vulnerable points all connecting lines are disconnected,
of liquid exposure. blanked-off, vessel thoroughly purged
of residual gases and certified Gas Free’
in writing by a competent person.
8. Familiarise with Do not commission plant or a facility
(i) Common sources of without detailed inspection and all
leakage; applicable licenses and certificates.
(ii) Common sources of
ignition;
(iii) Common sources of fire.
9. Avoid venting of LPG to Do not use LPG system for the grade

DEPARTMENT 15
PAGE No.
atmosphere having higher vapour pressure than that
of the grade for which it was designed.
10. Drain water from storage Do not fill any container beyond its safe
vessels regularly and carefully. filling capacity.
11. Ensure good house-keeping Do not use LPG system for the grade
having higher vapour pressure than that
of the grade for which it was designed.
12. Strictly enforce “NO SMOKING” Do not use pressurised system beyond its
within the plant area. due date of re-testing
13. Discontinue operation at the Do not place any part of the body over
first sign of major leak. a slip tube device nor over the
discharge end of a pressure relief valve.
14. Ensure all plant personnel are Do not expose hands, face or any part
familiar with the knowledge of of the body to liquid
action in emergencies.
15. Report accidents as per laid LPG without protective clothing /
down procedures and equipment.
investigate causes.
16. Conduct regular Safety Audit Do not carry out any operation after
of the Plant to eliminate daylight unless adequate flame-proof
hazards. lighting arrangement is provided,
17. Prepare and display ‘Fire Do not drain water from storage vessel
Fighting Organisation Plan’ at without provision of double valve on the
prominent water drain.
18. locations in the plant ensuring Do not bang or roll the cylinders during
that all concerned understand loading / unloading and handling
their role and responsibility operations.
clearly.
19. Check fire protection and Do not store filled cylinders or cylinders
safety devices regularly. containing LPG vapour in open.
20. Maintain liaison with Local Fire Do not vent out cylinder contents to
Brigade and involve them in atmosphere at plant.
regular exercises.
21. Maintain proper records of fire
Do not dispose off condemned
drills, checks, incidents,
cylinders as scrap unless they are de-
accidents etc. shaped by pressing and marked as de-
faced.
22. Ensure periodic checking of Do not store empty and filled cylinders

DEPARTMENT 15
PAGE No.
pressure relief valves beyond stacking or the licensed
capacity, whichever is less.
23. Before filling LPG tank truck, Do not throw cylinders from a height.
ensure that valid CCOE’s
license is available and the
receiving location has a
storage license.
24. Check tightness of hose Do not send cylinders to the repairers
connections for tank wagon without making them gas-free.
and tank truck operations with
soap solution by only cracking
the valve initially.
25. Always replace caps and Do not leave any over-filled / leaky
plugs of transfer connections cylinder at the close of working hours.
ensuring that they are leak
free.
26. Ensure that the receiving vessel Do not transport filled cylinders by rail.
has sufficient ullage before
discharging tank wagons or
tank trucks.
27. Apply chock blocks on tank Do not use stake trucks for
wagons and tank trucks during
operation.
28. Disconnect LPG hoses from cylinder transportation which do not
tank wagons and tank trucks meet basic safety requirements.
during prolonged suspension
of operation.
29. Place caution signs on railway Do not transport leaky cylinders.
siding, whenever the
operation is on.
30. Keep the sealing material Do not transport LPG cylinders with
away other goods.
31. from the end of the threads, Do not use lifting magnet for loading of
while making any threaded cylinders.
connection.
32. Maintain operating log for Do not fill a cylinder whose due date of
commissioning testing has expired.
/decommissioning of storage

DEPARTMENT 15
PAGE No.
vessels and all other important
operations within the plant.
33. Educate tank truck drivers for Do not dip cylinder valve threads into a
over the road procedure, sealing compound.
parking during transit, vehicle
parking in the plant, vehicle
garaging, vehicle repairing,
emergencies in transit,
accident reporting
34. Ensure strict checks for Do not use LPG hose beyond its due
segregation of cylinders due date of testing.
for statutory testing.
35. Ensure correct tare weight Do not attempt sampling of LPG unless
marking and check for proper sampling arrangement exists,
presence of water, at random, concerned person is trained for the job,
specifically in case of new sampling is required for a specific
cylinders, cylinders returning purpose and authorized by SO/RO/HO.
from testing plants and
repairers.
36. Ensure test for ‘O’-ring of filled Do not continue operations if safety /
cylinders with SC type valve, fire protection devices are rendered
using dummy regulators or ineffective.
CVT.
37. Ensure that water / dust from Do not allow entry of vehicles not
the cavity of the ‘SC’ type conforming to statutory requirements.
valve outlet is blown using air
pressure.
38. Ensure use of conveyor system Do not release the truck loaded with
to the maximum. filed cylinders unless check is carried
out with Explosimeter and readings are
within permissible limits.
39. Ensure 100% check weighing of Do not compromise on any norm
filled LPG cylinders. governing safety.
40. Use portable trolleys within the Do not allow unauthorised / untrained
plant for transporting cylinders persons when unsafe condition is
in vertical position and to noticed.
avoid rolling wherever use of
conveyor is not practicable.

DEPARTMENT 15
PAGE No.
41. Ensure cylinders are Do not leave any LPG operation
evacuated before filling in unattended.
case of filling through
machines operating on ‘Tare-
Off’ system.
42. Use evacuation units for Do not continue LPG operation, if any
evacuating contents from leak or unsafe condition is noticed
leaky / defective cylinders.
43. Ensure security nut on the Do not allow weed / vegetation to grow
cylinder valve outlet is fixed at in yard area.
all times except for the
duration when removal is
necessary for any specific
operation.
44. Leave adequate pathways Do not stack filled cylinders horizontally.
around stacks of cylinders for
easy detection and removal
of leaky cylinders.
45. Minimise manual handling of Do not allow rough handling or filled /
cylinders as far as practicable. empty cylinders.
46. Earmark storage areas for Do not despatch any filled cylinder
different categories of without proper valve protection seal
cylinders and provide proper and neck-label.
sign boards for identification of
each stack.
47. Stack filled cylinders verticallyDo not ignore liquid-equivalent of vapor
only. quantities while accounting LPG bulk
stocks.
48. Evacuate leaky and overfilled Do not allow accumulation of vapour in
cylinders on priority. plant area, especially in low lying areas
such as drains, sumps, etc.,
49. De-pressure the cylinder Do not carry out cylinder repairs in the
before valve removal. filling- shed.
50. Use proper clamp / vice for Do not carry out water draining
holding the cylinder at the operation in dark hours.
time of valve removal / fixing
51. Inspect critical area around Do not open back cover of the truck
internal periphery of the foot and cross bars used in the truck for

DEPARTMENT 15
PAGE No.
ring during visual inspection supporting the cylinders prior to parking
and painting operation of LPG of the truck.
cylinders.
52. Verify the due date of testing Do not roll cylinders on belly for faster
at the test plant, before unloading of cylinders.
undertaking the testing
operations.
53. Examine defective valves Do not start unloading operation,
carefully for retrieval-worthy without counting the numbers by
condition before sending for supervisor.
retrieval.
54. Maintain proper records at all Do not drop cylinders from a height
stages of operations. during unloading operations .
55. Ensure test certificate is issued Do not start the truck till the back cage
for cylinders tested at the cover is closed and locked.
Statutory testing plant.
56. Follow inspection and Do not attempt lubrication of carousel
maintenance schedules filling guns when carousel is in operation
strictly. as it may lead to oil spillage.
57. Test LPG hoses at stipulated Do not lubricate the running rail.
intervals.
58. Measure, calculate and Do not tamper with speed of rotation of
record all stocks care-fully, carousel.
accurately, regularly and in
conformity with standard
procedures.
59. Investigate promptly, any Do not bypass gas stop valve under any
abnormal loss or gain. circumstances.
60. Keep close watch on pressure Do not remove or introduce cylinders
and temperature in the either after encoding or before check
storage / transport vessels
during operation.
61. Ensure training for all regular scale in electronic carousal system as it
employees within the plant disturbs the sequence
and all others associated with
the plant working such as
truck crew/ contract
labourers.

DEPARTMENT 15
PAGE No.
62. Ensure strict security checks at Incase of cylinders struck up at check
the gate to prevent scale platform do not forcibly pull or
unauthorised entry and drag the cylinders.
carrying of match box,
cigarette lighters or any other
source of ignition.
63. Ensure display of identity No jet of water/air should be used to
badge for each person within clean the surrounding floor which may
the plant. lead to water seepage to load cell
check scale and junction boxes.
64. Place proper caution signs at Do not tamper settings of electronic
the gate and all other check scale.
vulnerable locations within the
plant.
65. Enforce random checks by Do not allow dust accumulation around
frisking of persons by electronic parts.
authorised officers to ensure
that they are not in possession
of any items which may
provide a source of ignition.
66. Maintain copies of all Manuals, Do not increase the rejection range from
applicable Statutory rules, 0.5 gm/hr
manufacturers instructions for
operations/ maintenance /
inspection, etc. Secure them
in plant library.
67. Keep fire fighting equipment in Do not allow air leaks from the
good order and condition, pneumatic hoses.
ready for immediate use at all
times.
68. Conduct fire drills atleast once Do not use oil other than Kerosene.
in a month.
69. Conduct checks for gas Do not allow gap between cylinders
leakage through Explosimeter while entering test bath, to avoid falling
at all vulnerable points within of cylinder.
the plant on daily basis.
70. Ensure periodic earthling test. Do not allow filling of evacuation vessel
more than 85%.

DEPARTMENT 15
PAGE No.
71. Ensure proper colour coding of Do not keep leaky cylinders
pipelines and valves. unevaluated at the end of the shift.
72. Ensure daily draining of ‘air Do not use non standard tools for
compressor’ tanks. evacuating cylinders having pin struck /
broken valves
73. Ensure proper cushioning on Do not remove valves with out properly
cylinder storage / filling shed clamping the cylinders.
flooring.
74. Provide and maintain first-aid Do not keep cylinders haphazardly near
kits at strategic locations. the valve ON/OFF screw machine.
75. Conduct hydrostatic stretch Do not over tighten the valve.
test instead of hydrostatic test
at the time of third Statutory
re-testing. Ensure supports of
Horton Sphere are encased in
cement concrete.
76. Ensure one of the ends of Do not use worn out head for screw and
bullet supports has provision unscrewing of valves as it may damage
for sliding. hexagonal portion of the valves.
77. Provide effective Do not leave any serviceable
communication system cylinderwith open bung after removal
(PA/Paging) in the plant, of the valve.
ensuring that the system is
Flame-Proof within licensed
area.
78. Replace dirty water in cylinder Do not roll the cylinders on belly.
test baths with clean water.
79. Paint interior surface of test Do not store filled cylinders beyond the
baths with white paint and licensed capacity.
provide adequate lighting
(FLP) for better visibility of
leaks.
80. Keep the water drain Do not stack filled cylinders horizontally.
connection of storage vessels
locked and sealed when not
in us.
81. Do set maximum inventory Do not allow rough handling of filled
levels for the stocks of filled cylinders.

DEPARTMENT 15
PAGE No.
and empty cylinders
individually as well as
maximum inventory level for
combined stock of filled and
empty cylinders as per norms.
82. Unloading of serviceable
empty cylinders should be
made at unloading platforms
only.
83. Trucks should be securely
parked with hand brake and
gear.
84. Engine should be put off and
master cut off switch should
be isolated prior to any
unloading operations.
85. The unloading contract
labourers should wear shoes
and hand gloves.
86. Telescopic conveyers should
be used to unload the
cylinders.
87. Cylinders while unloading
should be handled carefully
without dropping or rolling.
88. Ensure oil level in FRL &
Hydraulic oil tank prior to
starting the carousel.
89. Ensure filling heads are
properly earthed.
90. Any leak of LPG from filling
head to be attended
immediately.
91. Monitor pressure of LPG &Air
for the accuracy of filling.
92. Ensure carousel is interlocked
with vapour extraction unit.
93. Accuracy of the electronic

DEPARTMENT 15
PAGE No.
filling machine are to be
checked in intervals of every
four hours & maintain records.
94. Filling hoses should be tested
periodically, once in four
months.
95. Only stamped and certified
scales by Dept. of Legal
Metrology should be used.
96. Accuracy of check scale
should be checked at an
interval of every 2 Hrs by
standard weight.
97. Adequate air pressure should
be maintained
98. FRL need to be checked for oil
level and cleaning of the
filter element.
99. The maximum limit of rejection
at check scale should be
within +200/-100 grams.
100. Always keep the kerosene
chamber clean in CVT.
Replace if required.
101. Ensure CVT Clamping properly
on the cylinder valve.
102. CVT should be periodically
checked with the CVT verifier
and also after any repair to
the CVT.
103. AVTS/GD-PD should be
calibrated weekly with
comparator and checked for
functioning at both rejection
level of 0.5 gm/hr and also at
acceptable level say 0.3 gm/hr
104. Ensure air pressure between
5-6 Kg/sq cm.

DEPARTMENT 15
PAGE No.
105. Re-check ‘O’ ring effectivenss
after replacement.
106. Ensure the water level in the
bath for complete immersion
up to the bung level of
cylinders.
107. Ensure clean water in the bath.
Evacuate the leaky cylinders
immediately.
108. Use cold flare line to vent out
residual LPG.
109. Ensure proper earthing of
evacuation adopters.
110. Ensure proper stacking of leaky
cylinders.
111. Ensure capping of cylinders
before and after the
evacuation Handle the
cylinders in vertical position at
all stages of loading .
112. Attend leaky adapters
immediately.
113. LPG hoses should be tested
periodically once in 4
months.
114. Ensure cylinders are
depressurised before
removing the valve.
115. Do not change the valve for
bung defect cylinders unless
the valve thread found to be
damaged.
116. Check the torque setting of
the machine in the beginning
of the shift and also every two
hours with a torque wrench.
117. Ensure bung cleaning and
checking before fixing of

DEPARTMENT 15
PAGE No.
valve .
118. Ensure proper application of
thread sealant.
119. Use portable trolley for cylinder
movement inside the plant, if
conveyor is not available.
120. Store cylinders vertically only,
within the plant shed.
121. Ensure safety cap is fitted on
all cylinders stored in the
plant.
122. Ensure different categories of
cylinderslike(filled, serviceable
empty /ST due, new etc), with
Identity Boards.
123. Separate tags should be
maintained for 14.2 Kg, 19 Kg,
, 5 Kg and 47.5 Kg cylinders.
124. Ensure de-gassing of
unserviceable cylinders.
125. Handle the cylinders in vertical
position at all stages of
loading .
126. Trucks should be properly
parked keeping on the gear
and hand brake with ignition
‘OFF’ and key removed.
127. Fire extinguishers of the trucks
should be taken out of the
cabin and position suitably
for easy access, in case of
emergency .
128. Use of personal protective
clothing like hand gloves,
shoes, helmets etc should be
ensured.
129. Use Telescopic conveyer for
loading cylinders on to the

DEPARTMENT 15
PAGE No.
truck.
130. Ensure positioning of wooden
crossbars for supporting of
cylinders and back cover are
closed and locked prior to
movement of the truck from
the loading platform.

DEPARTMENT 15
PAGE No.
ANNEXURE 9
BAY WISE CHECKLIST BEFORE START & AFTER COMPLETION OF TLD/TLF OPERATION
Date: Batch No. Name Of Plant
PART-1 BEFORE START

For Part 1- S.No 3-10 & Part 2 S.No 2-9 If OK-“Y” Not OK-N”
S. CHECKPOINT BAY1 BAY2 BAY3 BAY4 BAY5 BAY6
1 TT NO
2 Record Pressure (psi) / Temp
oC
3 Rotogauge Readiing
4 Master cut-off switch in Off
Position & Hand Brakes
applied
5 TT Fire Extinguisher placed in
front of the vehicle
6 Wheel chokes placed at
front and back tyre
7 Ignition Keys of TT handed
over by driver to workman
and kept in the key box
under lock and key by the
Workman
8 Earthing connectors
connected to chassis and
Tank
9 Unloading arms/ Hoses
connected to TT flange
through SS metallic gaskets
and eight nos. studs and nuts
and bonding of flange
done. No CAF/Rubber/Non
metallic gaskets used
10 No LPG leakage from
flange/coupling/swivel joint.

DEPARTMENT 15
PAGE No.
Unloading/Loading started at ( in
24 hr. format
Driver Signature
Signature of Workman
PART-2- AFTER COMPLETION AND BEFORE HANDING OVER THE KEYS

S.No CHECKPOINT BAY-1 BAY-2 BAY-3 BAY-4 BAY5 BAY-6
1 Record Pressure in psi /
Temp (oC )
2 TT valve and manifold
valves closed
3 Unloading/Loading
arm/hoses
depressurized
4 Arm/Hoses and
couplings
disconnected and kept
at designated place.
Open ends are capped
5 Earthing cables
disconnected and
placed/fixed at
designated place
6 Choke Blocks removed
and kept at designated
place
7 TT Fire extinguishers put
back on the TT
8 Gaskets & studs issued
by Plant, if any, are
returned
9 The Area around the
Vehicle is Gas Free
Keys handed over at (Time

in 24 hr. format )
Driver Signature
Signature of Workman

DEPARTMENT 15
PAGE No.
- ANNEXURE 10
- PURGING
8.1 GENERAL
8.1.1 Presence of air in any LPG system; be it a storage vessel, pipeline, transport
vessel, or a Cylinder; is undesirable. Therefore, necessary to remove air from
LPG systems before filling it with LPG. The process of replacement of air in a
closed containers/system by LPG vapour, using safe methods, is known as
‘purging into service” commonly referred as “purging”.
8.1.2 Presence of LPG vapour in a container/system is equally undesirable from

safely point of view if it is to be opened up for inspection, maintenance or
repair. In this case LPG vapour has to be displaced by water followed by air
or directly by inert gas. This process is known as “purging out of service”.
8.1.3 The objective of purging containers/systems “into service” or “out of service”

is to reach “end-point” where the concentration in percentage by volume of
LPG vapour in the closed system being purged “into service” or of inert
substance if “purging out of service” will not result in the formation of an
explosive mixture.
8.1.4 “Purging into service” is normally required in the following cases

(a) Commissioning new containers/systems.
(b) Re-commissioning containers/systems after repairs or pneumatic test,
(c) Any eventuality when the container/system is de-pressurised and exposed
to atmosphere.
8.1.5 As the term itself suggests, “purging out of service” is required when LPG
container/system is required to be taken out of service for inspection,
maintenance, repairs or any other purpose.
8.1.6 Purging procedures for following systems are covered

(a) Storage vessels and connected pipelines.
(b) LPG tank trucks.
(c) LPG tank wagons.
(d) LPG cylinders.

DEPARTMENT 15
PAGE No.
8.2 PURGING OF LPG TANK WAGONS
8.2.1 PURGING INTO SERVICE
8.2.1.1 Once new tank wagons are ready they are sent to refinery points for loading.
However, before actual loading, they are required to be “purged into
service”,
8.2.1.2 The normal method of “purging” using water to displace air and LPG vapour
to displace water is not practicable in case of LPG tank wagons in
drain connection at bottom of the tank wagon bullet. In view of this, the
procedure described in Clause 8.2.1.3. below is followed.
8.2.1.3 Approximately 50 Kg. of liquid LPG is tilled into the tank wagon initially and
vapour released to the atmosphere gradually using sate venting means.
Again 200 kg. of liquid LPG is tilled thereafter and similarly released to the
atmosphere using safe venting means. The tank wagon is thereafter ready for
loading.
8.3 PURGING OUT OF SERVICE
8.3.1 Inspection, maintenance and repair of LPG tank wagons is done by the
railways who take care to purge the tank wagons “out of service” before
attempting inspection, maintenance or repair.
8.4 PURGING OF LPG CYLINDERS
8.4.1 (a) A set of cylinders to be purged(the number can vary depending upon
the requirement) is connected to air-line manifold which in turn is connected
to suction side of a vacuum pump.
(b) Vacuum pump is started. The air is sucked from all the connected
cylinders simultaneously. The delivery side of the vacuum pump is connected
to a suitable sate venting system.
c) As soon as pressure on the suction side of the vacuum pump reaches the
level of (- 0.65 kg/cm?/(-)494 mm Hg (indicated through pressure gauge
mounted on the air-line manifold. This gauge pressuire is equivalent to 0.35
kg/cm2 absolute) air-line connections are closed and vacuum pump suction
switched over to next batch of cylinders which are kept connected.
(d) Control valve on LPG vapour line is opened to allow entry of LPG vapours
into the cylinders from filled LPG cylinder connected to LPG line (or LPG
vapour line directly). Once positive pressure (minimum 1.0 kg/cm2) is attained

DEPARTMENT 15
PAGE No.
within the cylinders, LPG vapour supply is cut-off and the cylinders are
disconnected which can thereafter be used for LPG filling. (e) The cycle is
repeated for the next batch of cylinders.
8.5 PURGING OUT OF SERVICE
8.5.1 Cylinders must be purged out of service under following circumstances

(a) Before sending for hot repairs
(b) Before statutory testing
(c) Before de-shaping scrapped cylinders.
8.5.2 In case of hot repairs. assurance must be gained that the cylinder is “gas-
free” before attempting the repairs.
8.5.3 Most common method for purging the cylinders ‘out of service” is to remove
the cylinder valve, fill the cylinder with water allowing to over-flow and keep
the water filled for minimum one hour before draining.
As an alternative method, inert gas (e.g. Nitrogen) could be used to purge

the cylinders out of service. The equipment and procedure would be similar
to the one for “purging into service” described in clause 8.2.1 above with the
exception that the nitrogen cylinder is connected to gas-line instead for LPG
cylinder. Further, after completion of introduction of Nitrogen into the
cylinders, the cylinders are inverted, and the cylinder valve slightly opened to
allow escape of remnant LPG vapours, if any.

DEPARTMENT 15
PAGE No.
ANNEXURE 11
1. CALIBRATION CHART FOR TANK WAGONS ( 4 – WHEELER)
Overall Length of Wagon ... 8350

Diameter of Wagon ... 2300
Length of cylindrical portion ... 7200
Density of LPG ... 0.540
CALIBRATION CHART FOR TANK WAGONS
Dip Volume Mass Dip Volume Mass

(mm) (in m3) (in MT) (mm) (in m3) (in MT)
0 0.0000 0.000 2300 32.5007 17.550
10 0.0147 0.008 2290 32.4860 17.542
20 0.0413 0.022 2280 32.4594 17.528
30 0.0759 0.041 2270 32.4248 17.509
40 0.1163 0.063 2260 32.3844 17.488
50 0.1626 0.088 2250 32.3381 17.463
60 0.2138 0.115 2240 32.2869 17.435
70 0.2695 0.146 2230 32.2312 17.405
80 0.3293 0.178 2220 32.1714 17.373
90 0.3930 0.212 2210 32.1077 17.338
100 0.4603 0.249 2200 32.0404 17.302
110 0.5310 0.287 2190 31.9697 17.264
120 0.6050 0.327 2180 31.8957 17.224
130 0.6821 0.368 2170 31.8186 17.182
140 0.7622 0.412 2160 31.7385 17.139
150 0.8452 0.456 2150 31.6555 17.094
160 0.9309 0.503 2140 31.5698 17.048
170 1.0194 0.550 2130 31.4813 17.000
180 1.1104 0.600 2120 31.3903 16.951
190 1.2039 0.650 2110 31.2968 16.900
200 1.2998 0.702 2100 31.2009 16.848
210 1.3981 0.755 2090 31.1026 16.795
220 1.4987 0.809 2080 31.0020 16.741

DEPARTMENT 15
PAGE No.

230 1.6015 0.865 2070 30.8992 16.686

240 1.7065 0.922 2060 30.7942 16.629
250 1.8136 0.979 2050 30.6871 16.571
260 1.9228 1.038 2040 30.5779 16.512
270 2.0339 1.098 2030 30.4667 16.452
280 2.1482 1.160 2020 30.3525 16.390
290 2.2633 1.222 2010 30.2374 16.328
300 2.3802 1.285 2000 30.1205 16.265
310 2.4990 1.349 1990 30.0017 16.201
320 2.6195 1.415 1980 29.8812 16.136
330 2.7418 1.481 1970 29.7589 16.070
340 2.8659 1.548 1960 29.6348 16.003
350 2.9915 1.615 1950 29.5092 15.935
360 3.1189 1.684 1940 29.3818 15.866
370 3.2478 1.754 1930 29.2529 15.797
380 3.3783 1.824 1920 29.1224 15.726
390 3.5103 1.896 1910 28.9904 15.655
400 3.6439 1.968 1900 28.8568 15.583
410 3.7789 2.041 1890 28.7218 15.510
420 3.9154 2.114 1880 28.5853 15.436
430 4.0532 2.189 1870 28.4475 15.362
440 4.1925 2.264 1860 28.3082 15.286
450 4.3331 2.340 1850 28.1676 15.210
460 4.4751 2.417 1840 28.0256 15.134
470 4.6184 2.494 1830 27.8823 15.056
480 4.7629 2.572 1820 27.7378 14.978
490 4.9087 2.651 1810 27.5920 14.900
500 5.0558 2.730 1800 27.4449 14.820
510 5.2040 2.891 1780 27.1473 14.660
530 5.5040 2.972 1770 26.9967 14.578
540 5.6557 3.054 1760 26.8450 14.496
550 5.8085 3.137 1750 26.6922 14.414
560 5.9624 3.220 1740 26.5383 14.331
570 6.1173 3.303 1730 26.3834 14.247
580 6.2733 3.472 1710 26.0704 14.078
600 6.5883 3.558 1700 25.9124 13.993
610 6.7473 3.644 1690 25.7534 13.907

DEPARTMENT 15
PAGE No.

620 6.9072 3.730 1680 25.5935 13.820
630 7.0681 3.817 1670 25.4326 13.734
640 7.2299 3.904 1660 25.2708 13.646
650 7.3925 3.992 1650 25.1082 13.558
660 7.5561 4.080 1640 24.9446 13.470
670 7.7205 4.169 1630 24.7802 13.381
680 7.8840 4.257 1620 24.6167 13.293
690 8.0500 4.347 1610 24.4507 13.203
700 8.2169 4.437 1600 24.2838 13.113
710 8.3844 4.528 1590 24.1163 13.023
720 8.5528 4.618 1580 23.9479 12.932
730 8.7218 4.710 1570 23.7788 12.841
740 8.8916 4.801 1560 23.6091 12.749
750 9.0621 4.894 1550 23.4386 12.657
760 9.2333 4.986 1540 23.2674 12.564
770 9.4051 5.079 1530 23.0956 12.472
780 9.5776 5.172 1520 22.9231 12.378
790 9.7506 5.265 1510 22.7501 12.285
800 9.9243 5.359 1500 22.5764 12.191
810 10.0986 5.453 1490 22.4021 12.097
820 10.2735 5.548 1480 22.2272 12.003
830 10.4489 5.642 1470 22.0518 11.908
840 10.6248 5.737 1460 21.8759 11.813
850 10.8012 5.833 1450 21.6995 11.718
860 10.9782 5.928 1440 21.5225 11.622
870 11.1556 6.024 1430 21.3451 11.526
880 11.3335 6.120 1420 21.1672 11.430
890 11.5118 6.216 1410 20.9889 11.334
900 11.6906 6.313 1400 20.8101 11.237
910 11.8698 6.410 1390 20.6309 11.141
920 12.0493 6.507 1380 20.4514 11.044
930 12.2293 6.604 1370 20.2714 10.947
940 12.4096 6.701 1360 20.0911 10.849
950 12.5903 6.799 1350 19.9104 10.752
960 12.7712 6.896 1340 19.7295 10.654
970 12.9525 6.994 1330 19.5482 10.556
980 13.1341 7.092 1320 19.3666 10.458
990 13.3160 7.191 1310 19.1847 10.360

DEPARTMENT 15
PAGE No.

1000 13.4981 7.289 1300 19.0026 10.261

1010 13.6805 7.387 1290 18.8202 10.163
1020 13.8631 7.486 1280 18.6376 10.064
1030 14.0459 7.585 1270 18.4548 9.966
1040 14.2289 7.684 1260 18.2718 9.867
1050 14.4121 7.783 1250 18.0886 9.768
1060 14.5955 7.882 1240 17.9052 9.669
1070 14.7790 7.981 1230 17.7217 9.570
1080 14.9626 8.080 1220 17.5381 9.471
1090 15.1464 8.179 1210 17.3543 9.371
1100 15.3302 8.278 1200 17.1705 9.272
1110 15.5141 8.378 1190 16.9866 9.173
1120 15.6981 8.477 1180 16.8026 9.073
1130 15.8821 8.576 1170 16.6186 8.974
1140 16.0662 8.676 1160 16.4345 8.875
1150 16.2503 8.775 1150 16.2503 8.775

DEPARTMENT 15
PAGE No.
ANNEXURE 11 ( cont’d)
2. CALIBRATION CHART FOR TANK WAGONS ( 8 – WHEELER)
Overall Length of Wagon ... 17960

Diameter of Wagon ... 2400
Length of cylindrical portion ... 16760
Density of LPG ... 0.540
0 0.0000 0.000 2400 78.7571 42.529
10 0.0348 0.019 2390 78.7223 42.510
20 0.0982 0.053 2380 78.6590 42.476
30 0.1800 0.097 2370 78.5771 42.432
40 0.2757 0.149 2360 78.4814 42.380
50 0.3852 0.208 2350 78.3719 42.321
60 0.5062 0.273 2340 78.2509 42.256
70 0.6375 0.344 2330 78.1196 42.185
80 0.7785 0.420 2320 77.9787 42.108
90 0.9283 0.501 2310 77.8288 42.028
100 1.0866 0.587 2300 77.6705 41.942
110 1.2527 0.676 2290 77.5044 41.852
120 1.4264 1.074 2250 76.7681 41.455
160 2.1896 1.182 2240 76.5676 41.346
170 2.3961 1.294 2230 76.3610 41.235
180 2.6086 1.409 2220 76.1485 41.120
190 2.8267 1.526 2210 75.9304 41.002
200 3.0503 1.647 2200 75.7069 40.882
210 3.2791 1.771 2190 75.4780 40.758
220 3.5132 1.897 2180 75.2439 40.632
230 3.7522 2.026 2170 75.0049 40.503
240 3.9961 2.158 2160 74.7610 40.371
250 4.2448 2.292 2150 74.5124 40.237
260 4.4980 2.429 2140 74.2591 40.100
270 4.7557 2.568 2130 74.0014 39.961
280 5.0204 2.711 2120 73.7367 39.818
290 5.2868 2.855 2110 73.4703 39.674

DEPARTMENT 15
PAGE No.

300 5.5574 3.001 2100 73.1997 39.528

310 5.8320 3.149 2090 72.9251 39.380
320 6.1106 3.300 2080 72.6465 39.229
330 6.3931 3.452 2070 72.3641 39.077
340 6.6793 3.607 2060 72.0778 38.922
350 6.9692 3.763 2050 71.7879 38.765
360 7.2628 3.922 2040 71.4943 38.607
370 7.5599 4.082 2030 71.1972 38.446
380 7.8605 4.245 2020 70.8966 38.284
390 8.1645 4.409 2010 70.5927 38.120
400 8.4717 4.575 2000 70.2854 37.954
410 8.7823 4.742 1990 69.9749 37.786
420 9.0960 4.912 1980 69.6611 37.617
430 9.4128 5.083 1970 69.3443 37.446
440 9.7327 5.256 1960 69.0245 37.273
450 10.0555 5.430 1950 68.7016 37.099
460 10.3813 5.606 1940 68.3758 36.923
470 10.7099 5.783 1930 68.0472 36.745
480 11.0414 5.962 1920 67.7157 36.566
490 11.3756 6.143 1910 67.3815 36.386
500 11.7125 6.325 1900 67.0446 36.204
510 12.0520 6.508 1890 66.7051 36.021
520 12.3941 6.693 1880 66.3630 35.836
530 12.7388 6.879 1870 66.0183 35.650
540 13.0859 7.066 1860 65.6712 35.462
550 13.4355 7.255 1850 65.3216 35.274
560 13.7874 7.445 1840 64.9697 35.084
570 14.1417 7.637 1830 64.6154 34.892
580 14.4982 7.829 1820 64.2589 34.700
590 14.8570 8.023 1810 63.9001 34.506
600 15.2180 8.218 1800 63.5391 34.311
610 15.5811 8.414 1790 63.1760 34.115
620 15.9463 8.611 1780 62.8108 33.918
630 16.3136 8.809 1770 62.4436 33.720
640 16.6828 9.009 1760 62.0743 33.520
650 17.0541 9.209 1750 61.7031 33.320
660 17.4272 9.411 1740 61.3299 33.118

DEPARTMENT 15
PAGE No.

670 17.8022 9.613 1730 60.9549 32.916

680 18.1753 9.815 1720 60.5818 32.714
690 18.5540 10.019 1710 60.2031 32.510
700 18.9344 10.225 1700 59.8228 32.304
710 19.3165 10.431 1690 59.4406 32.098
720 19.7002 10.638 1680 59.0569 31.891
730 20.0857 10.846 1670 58.6715 31.683
740 20.4727 11.055 1660 58.2845 31.474
750 20.8612 11.265 1650 57.8959 31.264
760 21.2513 11.476 1640 57.5058 31.053
770 21.6429 11.687 1630 57.1143 30.842
780 22.0359 11.899 1620 56.7213 30.629
790 22.4303 12.112 1610 56.3269 30.417
800 22.8260 12.326 1600 55.9311 30.203
810 23.2231 12.540 1590 55.5340 29.988
820 23.6215 12.756 1580 55.1356 29.773
830 24.0212 12.971 1570 54.7360 29.557
840 24.4220 13.188 1560 54.3351 29.341
850 24.8241 13.405 1550 53.9330 29.124
860 25.2273 13.623 1540 53.5298 28.906
870 25.6316 13.841 1530 53.1255 28.688
880 26.0370 14.060 1520 52.7201 28.469
890 26.4434 14.279 1510 52.3137 28.249
900 26.8509 14.499 1500 51.9063 28.029
910 27.2593 14.720 1490 51.4978 27.809
920 27.6686 14.941 1480 51.0885 27.588
930 28.0789 15.163 1470 50.6782 27.366
940 28.4900 15.385 1460 50.2671 27.144
950 28.9020 15.607 1450 49.8551 26.922
960 29.3148 15.830 1440 49.4423 26.699
970 29.7284 16.053 1430 49.0287 26.476
980 30.1427 16.277 1420 48.6144 26.252
990 30.5577 16.501 1410 48.1994 26.028
1000 30.9734 16.726 1400 47.7837 25.803
1010 31.3897 16.950 1390 47.3674 25.578
1020 31.8066 17.176 1380 46.9505 25.353
1030 32.2241 17.401 1370 46.5330 25.128

DEPARTMENT 15
PAGE No.

1040 32.6421 17.627 1360 46.1150 24.902

1050 33.0607 17.853 1350 45.6964 24.676
1060 33.4797 18.079 1340 45.2774 24.450
1070 33.8992 18.306 1330 44.8579 24.223
1080 34.3191 18.532 1320 44.4380 23.997
1090 34.7394 18.759 1310 44.0177 23.770
1100 35.1600 18.986 1300 43.5971 23.542
1110 35.5810 19.214 1290 43.1761 23.315
1120 36.0022 19.441 1280 42.7549 23.088
1130 36.4237 19.669 1270 42.3334 22.860
1140 36.8453 19.896 1260 41.9118 22.632
1150 37.2673 20.124 1250 41.4898 22.405
1160 37.6894 20.352 1240 41.0678 22.177
1170 38.1114 20.580 1230 40.6457 21.949
1180 38.5336 20.808 1220 40.2236 21.721
1190 38.9560 21.036 1210 39.8011 21.493
1200 39.3786 21.264 1200 39.3786 21.264

DEPARTMENT 15
PAGE No.
ANNEXURE 12
FORMAT FOR GAUGE BOOK
PAGE NO.
TOTAL NO OF PAGES IN THE GAUGE BOOK

DATE : MONTH :
YEAR : PRODUCT : LPG
Time Storage Vessel Opening LPG Liquid – Pressure Temp Density Remarks
Gauge Qty (MT)
Reading
1.
2
3
4
5
6
Note : Water draining should be carried out before the commencement of

operation and should be recorded in “Remarks” column.
Separate Gauge book to be maintained for every month, duly serially

numbered.
Shift Officer’s
Signature
Plant Manager
Signature

DEPARTMENT 15
PAGE No.
ANNEXURE 13
QUANTITY OF LPG IN A 14.2 KG CYLINDER
What is the quantity of LPG required for vapour filling inside a cylinder of 33.3 ltrs.
capacity having a vapour content at a temperature of 30.C and a pressure of 2
Kgs/ cm2
Find the liquid equivalent of the vapour. Density of liquid LPG is 0.56 kg/litres.
Step : 1
Vapour volume = 33.3 litres.
Step : 2
Convert the vapour volume at 30C and 1.5 Kg/ cm2 pressure to NTP (i.e. Normal
Temperature and pressure where normal temp. = 15C and normal pressure =
0) using the following formulae.
P1 V1 P2 V2
———— = ————
T1 T2
Where P1 = Observed gauge pressure + Atmospheric pressure

T1 = Observed temperature + 2730C.
P2 = Zero pressure in gauge + Atmospheric pressure (1.0335 Kgs/Cm2)
V2 = Volume of vapour @ 150C and zero pressure
T2 = 150C (Standard Temp) + 2730C = 2880C
P1 xV1 xT2
Therefore, V2 =
T1 xP2
( 2  1.0335) x (33.3) x (15 0 C  273 0 C )

(30 0  273 0 C ) x (0  1.0335)
= 92.90 litres.
Step : 3
Using liquid / vapour ratio of 247.7: 92.90 litres of vapour volume at zero gauge
pressure and 150C would work out to liquid equivalent of :

DEPARTMENT 15
PAGE No.
92.90 - 247.7 = 0.375 litre at 150C
Step:4
Density of LPG of 0.560 kg/litres at 15 degrees cent.
Hence the weight of LPG i= 0.21 kg. say 200 gms

DEPARTMENT 15
PAGE No.
ANNEXURE 14
CALIBRATION CHART FOR 14 MT DIA HORTON SPHERE INCLUDING LEV
OBSERVED 35
TEMP.
OBSERVED PR. 6
DENSITY 0.54
HORTON DIA. 14
LIQ. LIQ. VOL. LIQ. QTY. VAP. SPACE VAP. VOL LEV PRODUCT
LEVEL
0 0.00 0.00 14 1437.33 19.94 19.94
0.5 5.37 2.90 13.5 1431.96 19.87 22.76
1 20.95 11.31 13 1416.38 19.65 30.96
1.5 45.96 24.82 12.5 1391.37 19.30 44.12
2 79.62 42.99 12 1357.71 18.84 61.83
2.5 121.13 65.41 11.5 1316.20 18.26 83.67
3 169.71 91.65 11 1267.62 17.59 109.23
3.5 224.58 121.28 10.5 1212.75 16.82 138.10
4 284.95 153.87 10 1152.38 15.99 169.86
4.5 350.04 189.02 9.5 1087.30 15.08 204.10
5 419.05 226.29 9 1018.29 14.13 240.41
5.5 491.20 265.25 8.5 946.13 13.13 278.37
6 565.71 305.49 8 871.62 12.09 317.58
6.5 641.80 346.57 7.5 795.54 11.04 357.61
7 718.67 388.08 7 718.67 9.97 398.05
7.5 795.54 429.59 6.5 641.80 8.90 438.49
8 871.62 470.67 6 565.71 7.85 478.52
8.5 946.13 510.91 5.5 491.20 6.81 517.73
9 1018.29 549.87 5 419.05 5.81 555.69
9.5 1087.30 587.14 4.5 350.04 4.86 592.00
10 1152.38 622.29 4 284.95 3.95 626.24
10.5 1212.75 654.89 3.5 224.58 3.12 658.00
11 1267.62 684.51 3 169.71 2.35 686.87

DEPARTMENT 15
PAGE No.
11.5 1316.20 710.75 2.5 121.13 1.68 712.43

LIQ. LIQ. VOL. LIQ. QTY. VAP. SPACE VAP. VOL LEV PRODUCT
LEVEL
12 1357.71 733.17 2 79.62 1.10 734.27
12.5 1391.37 751.34 1.5 45.96 0.64 751.98
13 1416.38 764.85 1 20.95 0.29 765.14
13.5 1431.96 773.26 0.5 5.37 0.07 773.34
14 1437.33 776.16 0 0.00 0.00 776.16

DEPARTMENT 15
PAGE No.
ANNEXURE 15
TANK BEHAVIOUR - CONTRIBUTOR OF APPARENT STOCK LOSSES
As per BS 5500, the tolerance allowed in the circularity of the vessels is based on
the following Formula :
Tolerance in circularity = +/- (0.5+625/D)% OR 1% whichever is lower.

( Variation in actual inner where D = diameter in mm.
Dia. from std. Dia.)
FOR 600 MT. HORTON SPHERES

Tolerance = +/-(0.5 + 625/ 14000) %
= +/- 0.54%
(Inner dia. may vary from 14.076m. to 13.924m,)
Variation in Water Capacity due to variation in diameter when diameter

is taken as D = 14.07 m.
= 4/3x22/7x(d/2)3
= 4/3x22/7x14.076x14.076x14.076/8
= 1460 cum.
When diameter is taken as D = 13.924 m.

Water capacity = 4/3x22/7x(d/2)3
= 4/3x22/7x13.924x13.924x13.924/8
= 1414.0 cum.
Water capacity of the vessel is taken as 1437 cum. as per the manufacturer’s
recommendation.
Hence variation in water capacity = (1460-1437) to ( 1437-1414)
= +/- 23 cum.
= +/- 12.42 MT( taking LPG density as 0.54)
Variation in Qty.for 600 MT capacity used = +/-600/(1437x0.54)x12.42

= +/- 9.60 MT

DEPARTMENT 15
PAGE No.
FOR 1200 MT. HORTON SPHERES

Tolerance = +/-(0.5 + 625/ 17000) %
= +/- 0.536%
Inner dia may vary from 17.091m. to 16.908 m.
Variation in Water Capacity due to variation in diameter :

When diameter is taken as D = 17.091 m.
= 4/3x22/7x17.091x17.091x17.091/8
= 2615 cum.
When diameter is taken as D = 16.908 m

= 4/3x22/7x16.908x16.908x16.908/8
= 2531 cum.
Water capacity of vessel is taken as 2573 cum.
Hence variation in water capacity = (2615-2573) to ( 2573-2531)

= +/- 42 cum.
= +/- 22.68 MT( taking LPG density as 0.54)
Variation in QTY.for1200 MT capacity used = +/-1200/(2573x0.54)x22.68

= +/- 19.58 MT

DEPARTMENT 15
PAGE No.
ANNEXURE 16
STOCK LOSS/GAIN DAILY ANALYSIS REGISTER

Date :
Name of Officer : A: B: C:
VESSEL READING
Time #1 #2 #3 #4 #5 #6 #7 #8 Total Qty.

0600
Qty.
1400
Qty.
2200
Qty.
BULK RECEIPT BY TANK TRUCKS

Time Vessel Opening AC-5 Qty. Book HS Physical Loss/ No. of TT Remarks
Qty. Balanc Reading Balance Gain Decantat
e Closing
Total
BOTTLING
Shift Vessel Opening Bottling (No of Total no. Qty. Book Vessel Physical Loss/
Qty. cyl) of cyls. (MT) balance Readin Balance Gain
14.2 Kg 19 kg
Total

DEPARTMENT 15
PAGE No.
OVER ALL ANALYSIS
Opening Qty : 2200 Hrs. to 0600 Hrs.

Receipt Qty. : 2200 Hrs. Qty. :
Issue Qty. : 0600 Hrs. Qty. :
VD Adj. Qty. : Loss/Gain :
B. Balance : Remarks :
P. Balance :
Day’s Loss/Gain:
Cum Loss/Gain : Signature of Officer
Cum Loss/Gain :
Month
Cum Loss/Gain :
Year Signature of Location In-charge
RAIL RECEIPT
Date Vess Opening Opening Date Closing Qt Recd CC/ Loss/ Remarks
& el Reading Qty. & reading y. .Qty. AC-5 gain
Hrs. Used Hrs. Qty.
A Shift B Shift
HS # HS #
Evacuation by pass open in
Pump by pass & crousel by pass open in
A Shift Stock Loss/Gain Analysis
Over All Analysis Horton Sphere Wise


DEPARTMENT 15
PAGE No.
ANNEXURE 17
INSPECTION CHECKLIST ON QC FOR LPG STORAGE/HANDLING

LOCATIONS
LOCATION DATE OF INSPECTION LAST INSPECTED

BY/ON BY/ON
QUALITY CONTROL MANUAL AND CIRCULARS
YES / NO
a. Is QC Manual on LPG available ?
b. Are all QC circulars/bulletin available properly filled ?
QC APPARATUS
Is the following apparatus available in proper working condition ?
a. Vapour pressure sampling bomb.

b. Density bomb.
c. Volatility test apparatus.
d. H2S test apparatus.
e. Copper corrosion test apparatus.
PRODUCT MONITORING
a. Vapour pressure carried out as per requirement and record

maintained.
b. Monitoring of mercaptan dosing maintained.
c. PPM level of mercaptan dosing in product.
d. Water draining done regularly and record maintained.
e. Are the test report available.

DEPARTMENT 15
PAGE No.
FAILURES
a. Has there been a failure of any product during receipt/storage/

despatch at the location ? How was the product released ? Confirm
if the instructions as per manual followed.
COMPLIANCE
a. What is status of compliance of the last inspection ?
SUGGESTIONS
a. As per location in-charge, are there any impediments in carrying out

the manualised QC procedures ?
TANKERS RECEIPT
a. Are the Load port test report available ?

b. Pre-discharge test/during discharge test carried out and record
maintained.
c. After receipt complete analysis of the product received done and in
line with IS:4576 specifications.
TANK TRUCK / TANK WAGON LOADING
a. Is the product release only after the lab? Conformed that the product
meets IS specifications.
b. Is the test report sent to respective receiving locations ?
INSPECTING OFFICER LOCATION INCHARGE
NAME
SIGNATURE

DEPARTMENT 15
PAGE No.
ANNEXURE 18
IMPORT SPECIFICATION OF COMMERCIAL BUTANE
Sl. Characteristics Commercial Method of Test Ref.

No. Butane to ASTM :
(1) (2) (3) (4)
i Vapour pressure at 37.8OC/100 483 D 1267
OF, kPa (psi), gauge, Max. (70) D 2598
ii Composition, liquid, mole/vol D 2163
percentage IP 405-94
a) C2 Hydrocarbons ----- ISO 7941-88
b) C3 Hydrocarbons Report
c) C4 Hydrocarbons Report
d) C5 Hydrocarbons & heavier 2.5 max
e) Unsaturated hydrocarbons Report
OR
Volatility :
Evaporation Temp. In deg C for 2.0 max D 1837
95% by vol. at 760 mm HG
pressure
iii Total volatile sulphur ppm max. 150 D 2784
D 3246
iv Copper Strip Corrosion at 38OC Not worse than D 1838
for 1 hour No. 1
v Hydrogen Sulphide Pass D 2420(Note 1)
vi Free water content None Visual(Note 2)
Note 1 :
Hydrogen Sulphide by UOP 212.77 test method is also acceptable, with limit for
Hydrogen Sulphide Max 5 ppm. “Pass” test as per test method D 2420 indicates
Hydrogen Sulphide not more than 5 ppm.
Note 2 :
Water content by ASTM E-700 test method is also acceptable, with limit of max. 10
ppm.

DEPARTMENT 15
PAGE No.
ANNEXURE 19
IMPORT SPECIFICATION OF COMMERCIAL PROPANE

No. Propane to ASTM :
(1) (2) (3) (4)
i Vapour pressure at 37.8OC/100 1380 D 1267
OF, kPa (psi), gauge, Max. (200) D 2598
percentage ISO 7941-88
a) C2 Hydrocarbons Report IP 405-94
b) C3 Hydrocarbons 95.0 min
c) C4 Hydrocarbons 4.0 max
OR
Volatility :
Evaporation Temp. In deg C for -38.0 max D 1837
pressure
Iii Total volatile sulphur, ppm max. 150 D 2784
D 3246
Iv Copper Strip Corrosion at 38OC Not worse than D 1838
for 1 hour No. 1
v Hydrogen Sulphide Pass D 2420
(Note 1)
vi Free water content None Visual
(Note 2)
Note 1 :
Note 2 :
ppm.

DEPARTMENT 15
PAGE No.
ANNEXURE 20
IMPORT SPECIFICATION OF COMMERCIAL BUTANE - PROPANE MIXTURE

No. Propane – to ASTM :
Butane mixture
(1) (2) (3) (4)
i Vapour pressure at 37.8OC/100 520 – 890 D 1267
OF, kPa (psi), gauge, Max. (75-130) D 2598
percentage ISO 7941-88
a) C2 Hydrocarbons ----- IP 405-94
b) C3 Hydrocarbons Report
c) C4 Hydrocarbons Report
OR
Volatility :
Evaporation Temp. In deg C for 2.0 max D 1837
pressure
Iii Total volatile sulphur, ppm max. 150 D 2784
D 3246
Iv Copper Strip Corrosion at 38OC Not worse than D 1838
for 1 hour No. 1
v Hydrogen Sulphide Pass D 2420
(Note 1)
vi Free water content None Visual
(Note 2)
Note 1 :
Note 2 :
ppm.

DEPARTMENT 15
PAGE No.
ANNEXURE 21
REQUIREMENT FOR LIQUIFIED PETROLEUM GASES AS PER IS 4576 1999
Sl. Characteristics Requirement for Method of

No. Commercial Test Ref. to:
Butane Butane Propane
Propane
mixture
(1) (2) (3) (4) (5) (6)
i Vapour pressure at 40OC, 520 1050 1550 D 1267
kPa, gauge, Max (Note 1) (Note 2)
ii Composition, liquid mole
percentage
a) C2 Hydrocarbons -- Report Report D 2163
b) C3 Hydrocarbons Report Report 95.0 min
c) C4 Hydrocarbons Report Report 4.0 max.
d) C5 Hydrocarbons & 2.5 Max. 2.5 max. 0.2 max.
heavier
e) Unsaturated Report Report Report
hydrocarbons
OR
Volatility :
Evaporation Temp. In OC 2.0 2.0 -38.0 D 1837
for 95% by vol. at 760
mm Hg pressure, max.
iii Total volatile sulphur 150 150 150 D 2784
ppm, Max. D 3246
iv Copper Strip Corrosion at Not worse Than No.1 D 1838
38OC for 1 hour
v Hydrogen Sulphide Pass Pass Pass D 2420
(Note 3)
vi Free water content None None Visual
None
ASTM Test Methods can be followed till “P” of IS 1448 method under revision are finalised

DEPARTMENT 15
PAGE No.
Note 1 – Vapour pressure may be determined at any other temperature and converted
to 40OC by means of suitable vapour pressure – temperature graph. The
same can also be determined by analysing the gas by means of a gas
chromatograph and then using the composition, the vapour pressure can be
calculated at 40OC from the standard values of vapour pressures at various
temperatures.
Note 2 – Each consignment of commercial butane-propane mixture shall be designated

by its maximum vapour pressure in kPa at 40OC. Further, if purchaser and the
supplier agreed, the minimum vapour pressure of that mixture shall be not
lower than 200 kPa gauge compared to the designated maximum vapour
pressures and in any case the minimum for the mixture shall be not lower than
520 kPa at 40OC.
Note 3 - ‘Pass’ test indicates Hydrogen Sulphide not more than 5 ppm.
Note 4 – Subject to agreement between the purchaser and the supplier, odour
requirements of LPG may be changed for certain applications when
unodourized LPG is required.
Note 5 - Product shall contain 20 ppm minimum ethyl mercaptan at the first
despatching location to ensure the detection of odour.
To detect the odour, the following procedures may be adopted :
5 ml Doctor Solution + 8 ml Iso-Octane + Pinch of Sulphur powder in 25 ml

stopped cylinder. Shake and add 2 ml LPG (Aq). Shake slowly by releasing
pressure.
Odour is adequate if sulphur turns yellowish brown.
P:75, Odour test method is also acceptable as an alternate method.


DEPARTMENT 15
PAGE No.
ANNEXURE 22
TANKER TANKS FITNESS CERTIFICATE
The tanker tanks __________________ nominated to carry the product

(Propane, Butane or admixture of two) bulk heads / manifolds, etc. has /
have been jointly inspected and it is certified that the tank (s), bulk heads /
manifolds, etc. are clean and fit to carry the product to be loaded into the
tanker tank.
Signature Signature
(Name) (Name)
Surveyor Master
*Tanker tank fitness certificate to be issued either by the master and surveyors, wherever
surveyor has been appointed.

DEPARTMENT 15
PAGE No.
ANNEXURE 23
CYLINDER TARE WEIGHT CORRECTNESS CONTROL RECORD
TARE WEIGHT INSPECTION AND REPORTING

Sr. MRN Categ Manufacturer Cylinder Observed Tare Differenc Cylinders
No No. ory Sr. No. Weight Data e with found to
. and (New/ Actual be not
Details of defects
Date HR/ST) Party Actu Pun sten Pun Ste meeting
a c c quality
c n
l h i h c
e l e i
d e d l
d e
d
DATE LOCATION OPS OFFICER PLANT

MANAGER

DEPARTMENT 15
PAGE No.
ANNEXURE 24
FILLING MACHINE ACCRACY CHECK RECORD
LOCATION :
______________________________________________DATE
:_______________SHIFT :_______
CHECK NO CHECK -1 CHECK -2 CHECK -3 CHECK -4 CHECK -5
Time of checking
Filling Machine Observe Checke Observe Checke Observe Checke Observe Checke Observe Checke
no. d d by d d by d d by d d by d d by
variation variation variation variation variation
FM –1
FM -2
FM -3
FM -22
FM -23
FM -24
LPG PRESSURE
KG/CM2
AIR PRESSURE
(KG/CM2)
Checked by
Shift in Charge
Plant Manager

DEPARTMENT 15
PAGE No.
ANNEXURE 25
CHECK SCALES ACCURACY CHECKS RECORD

LOCATION : CHECK SCALE -1 CHECK SCALE -2 CHECK SCALE -3 CHECK SCALE –4
DATE : Observed Chkd Observed Chkd Observed Chkd Observed Chkd

SHIFT : V B V B V B V B
a y a y a y a y
r r r r
i i i i
a a a a
t t t t
i i i i
o o o o
n n n n
TIME 1/4 LOAD
1/2 LOAD
CHECK -1 3/4 LOAD
FULL LOAD
TIME 1/4 LOAD
1/2 LOAD
CHECK -2 3/4 LOAD
FULL LOAD
TIME 1/4 LOAD
1/2 LOAD
CHECK -3 3/4 LOAD
FULL LOAD
TIME 1/4 LOAD
1/2 LOAD
CHECK -4 3/4 LOAD
FULL LOAD
TIME 1/4 LOAD
CHECK -5 1/2 LOAD
3/4 LOAD
FULL LOAD

DEPARTMENT 15
PAGE No.
ANNEXURE 26
FILLED CLINDERS WEIGHT CONTROL RECORD

Total No. Generation of O/F, % Generation of O/F,
Date Shift of U/F Cylinders U/F Cylinders
Cylinders Over Under Total Over Under Total Analysis of the Probable Initials of
Filled Filled Filled Filled Filled Causes for Weight Variation Plant
and Remedial Measures Manager
Taken
Average for
previous
month
generation O/F,
Lowest
achieved C/F
cylinders

DEPARTMENT 15
PAGE No.
ANNEXURE 27
FILLED CYLINDER TIGHTNESS CONTROL RECORD
Date Shift Total No. Categorywise Details of Defective Cylinders Analysis of Initials of
of Valve % Bung % Bung Body % Body O-Ring % O-Ring O-Ring % O-Ring Probable Causes Plant
Cylinders L V L L L L M M D andD Remedial Manager
Filled e a e e e e i i e Measures
e Taken
a l a a a a s s f f
k v k k k k s s e e
y e y y y y i i c c
n n t t
L g g i i
e v v
a e e
k
y
Previous month's average

generation Lowest achieved
achieved generation

DEPARTMENT 15
PAGE No.
ANNEXURE 28
RECORD OF CYLINDERS RECEIVED WITHOUT O-RING
Date Name of the Truck No. Erv. No. Name of the No. of Cyls Remedial Initials
Transporter and Date Distributor Without O- measures Taken of PM
Ring
BACK

DEPARTMENT 15
PAGE No.
ANNEXURE 29
DAILY RECORD OF RANDOM QUALITY CHECKS OF FILLED CYLINDERS
DATE:
Sr. Observed Weight Observed Defects
Gross wt. Tare wt Net wt Diffe Valve Bung Body Due for Oth Remarks
in Kg renc leak leak leak 5yr test/ ers
O –Ring
Missing
O-Ring
defect
e in Hot
wt repair
LOCATION : COMMENTS:
Details Inspecting
Location-in-charge
Officer
Signature
Name
Designation
Time
n.b. Data to be recorded by the officer concerned in his / her own handwriting.

DEPARTMENT 15
PAGE No.
ANNEXURE 30
COLOUR CODING OF PIPELINES AND VALES

1.0 GENERAL
1.1 All pipelines, valves and fittings at LPG plant should be colour-doded as
per details given below.
1.2 Colour-coding is adapted to cover liquid LPG lines, LPG vapour lines, Pressure
Relief Valves, other valves/fittings, compressed air lines for pneumatic
operations and water service lines.
1.3 Colour scheme for fire-hydrant and fire-protection facilities to be adopted as

per “HS&E Manual”.
1.4 Colour scheme to be adopted as under :

___________________________________________________________________
Background ISI No. Colour for
Service Grade colour Lettering
____________________________________________________________________
Liquid LPG Yellow 356 Black
LPG vapour Green 284 White
Compressed air Grey 632 White
Pressure Relief Valves Blue __ __
Service Water Black 695 White
Auto LPG Liquid Yellow with
2 Red oxide bands
Auto LPG Vapour Green with
2 Red oxide bands
Propylene Liquid Yellow with
2 Oxford Blue bands
Propylene Vapour Green with
2 Oxford Blue bands
________________________________________________________________

DEPARTMENT 15
PAGE No.
1.5 Pipeline, valves and fittings mounted on IOC’s LPG tank trucks should also be
colour coded as per above colour scheme.
2.0 COLOUR-CODE FOR PIPELINES
2.1 All pipelines to be painted with white/aluminium paint.
2.2 One colour band of 500 mm width with lettering for service grade to
be painted as per colour scheme detailed in Clause 1.3 above.
For illustration, refer enclosed diagram.
2.3 Colour band on the pipelines should be provided at following places :

(a) Every 10 meters along the pipeline.
(b) The points where the lines go under-ground.
(c) Near the operating valves, at Elbows,bends and T-joints
(d) Any other location considered necessary for ease of identification.
2.4 Direction of flow also to be indicated on the pipelines with the help of arrows.
Arrows to be marked close to the colour bends.
2.5 The width of the additional bands for auto LPG and Propylene shall be 50 mm
each and spaced 25mm apart i.e from the center of the base colour band
two bands of 50 mm width on either side shall be provided and the same
shall be at a distance of 12.5 mm from the center of the base colour band.
3.0 COLOUR-CODE FOR VALVES/FITTINGS
3.1 Valves/fittings fixed on the respective lines to be painted as per colour

scheme described in clause 1.4 above.
4.0 COLOUR-CODE FOR PRESSURE RELIEF VALVES
4.1 Pressure Relief Valves on vessels as well as on pipelines to be painted

blue including the vent pipes, wherever provided.

DEPARTMENT 15
PAGE No.
COLOUR CODING OF PIPELINES AND VALVES
20"
D/2 LIQUID (LPG) D


yellow
20"

D (LPG) VAPOUR D/2
 
green
20"

D COMPRESSED AIR D/2
 
grey

DEPARTMENT 15
PAGE No.
20"

D SERVICE WATER D/2
 
black
NOTES All valves and fittings on respective line to be painted as per

colour scheme described in clause-13
Direction of flow to be shown by an arow
Lettering in black/white colour as per clause-13


DEPARTMENT 15
PAGE No.
ANNEXURE 31
SAMPLE DETAILS TAG :
Performa for labelling samples is given hereunder :
Serial number -
Name of location -
Date sample drawn -
Time sample drawn -
Type of product -
Sample drawn from -
Officer Supervising sampling

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LPG

3. PROPERTIES, CHARACTERISTICS AND HAZARDS OF LPG

4. SAFETY AT LPG PLANT

5. FIRE PREVENTION AND CONTROL

6. BULK STORAGE AND HANDLING FACILITIES

7. PLANT OPERATIONS: BULK LPG

8. LPG CYLINDERS, RELATED EQUIPMENT

9. STATUTORY TESTING OF LPG CYLINDERS

10. INSPECTION AND MAINTENANCE

11. MEASUREMENT AND STOCK CONTROL

12. QUALITY CONTROL

ACT WITH CARE-

LPG CHAPTER TITLE: CHAPTER No.

1.1.2 The main sources of availability of LPG are:

1.2 GROWTH OF VOLUME

LPG CHAPTER TITLE: CHAPTER No.

1.3 GRADES MARKETED / TYPES OF SALES

LPG CHAPTER TITLE: CHAPTER No.

1.3.2 IOC markets LPG in bulk as well as packed supplies as under:

I. Bulk supplies to all Industrial customers through bulk tank trucks ex –

1.4.3 The manual is intended to achieve uniformity in operating practices at all

(a) HS&E manual (IOC)

LPG CHAPTER TITLE: CHAPTER No.

(a) Properties of LPG

(b) Physical operations within the LPG plants covering :

(i) Receipt (bulk / packed)

(c) Operation, Inspection and maintenance

1.6.3 The purpose of the manual is to provide a general guidance in safe

LPG CHAPTER TITLE: CHAPTER No.

1.7 MANUAL REFERENCE GUIDELINES

1.7.2 It is also recommended that the Properties, Characteristics and Hazards of

Strict observance of rules will ensure that safe operating practices

LPG CHAPTER TITLE: CHAPTER No.

1.7.8 The emphasis on safety throughout the manual should not be

All regulations pertaining to

LPG CHAPTER TITLE: CHAPTER No.

(a) The Gas Cylinder Rules 2004.

(b) Static and Mobile Pressure Vessels ( Unfired ) Rules 1981

(c) The Factory Act 1948 (amended in 1987).

(d) Indian Electricity Rules with latest amendments.

(e) The Legal Metrology ( Packaged Commodities ) Rules, 2011 under

(f) Liquefied Petroleum Gas (Regulation of Supply and Distribution Order

(i) Environmental Regulations :

i. Water (Prevention and Control of Pollution) Act 1974 (amended

ii. Air (Prevention & Control of Pollution act 1981) (amended up to

iii. The Environment (Protection) Act 1986 and subsequent

iv. Manufacture, Storage and Import of Hazardous Chemicals

LPG CHAPTER TITLE: CHAPTER No.

v. EIA Notification 2006.

(j) Recommendations of various committees :

i. Vasudevan Committee 1983 Ministry of Energy (Department of

ii. Expert committee review of safety and operating procedures

(k) Various OISD standards / guidelines.

(l) Indian Standards manuals for testing of LPG Cylinders in circulation

(m) Other Indian Standard publications issued by Bureau of Indian

It is important to note that there is always a possibility of

2.2 SAFE CUSTODY

LPG CHAPTER TITLE: CHAPTER No.

2.3 LIST OF TOPICS

2.4 LICENSES & CERTIFICATES

2.4.4 A general list of various Statutory licenses / certificates is given in

2.4.5 Proper record of test certificates of other installed facilities with

PROPERTIES , CHARACTERISTICS AND