SITE SPECIFIC SAFE OPERATING PROCEDURE

FILLING PLANT, LPG DEPERTMENT

Moderated on 12th May, 2015

CONTENTS

SOP-1: LPG Cylinder Filling Operation

SOP-2: LPG Tanker Filling Operation.

SOP-3: LPG Tanker Evacuation Operation

SOP-4: Condensate Tanker Filling Operation

SOP-5: Condensate Tanker Evacuation Operation

SOP-6: Maintenance of Vapour Expulsion Unit

SOP-7: Maintenance of Gear Box

SOP-8: Maintenance of Conveyor Track

SOP-9: Maintenance of Carousel

SOP-10: Maintenance of Washing Unit

SOP-11: Maintenance of Tanker Filling arm

SOP-12: Maintenance of Leak Testing Bath

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

ACTIVITIES OF LPG FILLING PLANT

Filling plant is an integral part of LPG department of Oil India Limited, Duliajan. The main functions
of the section are
1. Filling of LPG into cylinders.
2. Filling of LPG into tankers.
3. Filling of Condensate into tankers.

The entire production of LPG is lifted by IOCL for onward marketing and distribution. The cylinders
and tankers are provided by IOCL. The section fulfills all the equipments provided by the customer
(IOCL) in the form of ILP. The capacity of the bottling plant is 20000MTA. The 50 % of
condensate production is dispatched through tankers to private customers.

LPG is filled into cylinders and tank/trucks from storage vessels. The main equipment for LPG
filling in cylinders is a carousel machine with 24 points filling heads. With the filling time 62
seconds the rate of filling of cylinders is 1000-1200 cylinders per hour. After checking all safety
aspects i.e., leakage of cylinder valve ‘O-ring, valve, valve thread, body ; overfilled, under filled
only correct weight and good quality LPG filled cylinders are handed over to IOCL(AOD) for
loading. Leaky and overfilled cylinders are evacuated through the evacuation system.

For LPG bulk despatch a loading gantry with 3 nos. of filling points and two weigh bridges are
provided inside the plant. An evacuation system is also provided for evacuation / unloading of
leaky and defective road tank/trucks.

For Condensate bulk dispatch a loading gantry of 2 nos. of filling points and one no. of Weigh
Bridge is provided inside the plant. An evacuation system is also provided for evacuation /
unloading of leaky and defective road tank/trucks.

LPG filling plant is also equipped with requisite safety system as per safety/statutory regulation as
per guideline.

Marketing of LPG has been entrusted to IOCL (AOD) and the quantum of upliftment in packed
(cylinder) and bulk(road tank/truck) depends on the allocation made by the Oil co-ordination
committee. Generally about 30.%-35% of the total LPG production is sent in Packed and the
balance is despatched in Bulk through LPG road tank trucks.

The total manpower of the plant is 39 nos. including executive, company employee, contractor
labor.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

GENERAL SAFETY PRECAUTION FOR

LPG FILLING PLANT

1.01 Toolbox Meeting must be done everyday before job allocation / starting
Of job.

1.02 Special PPE’s relevant to the specific job must be used while doing the job.
Safety shoes must be used all the times.

1.03 Inspect each tool for damage before use. Get instruction from your
Supervisor, if you are unfamiliar with a tool.

1.04 Periodic (once in two months) tool checking must be done and maintain
tools register. Never use any defective tool. Always use the right tools for
the job.

1.05 Keep all operational area clean. Keep the tools at their proper storage
location.

1.06 Electrical Permit to Work (EPW) must be obtained from Installation

Manager before starting of any non-routine electrical job.

1.07 Do not keep / throw waste materials like oily jute, paper, grease, iron
particles etc. here and there. Keep them in the designated storage bin.

1.08 Un-authorized persons should not be allowed in the working area.

1.09 Outsiders / Trainees / Visitors should be always under supervision.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-1:LPG CYLINDER FILLING OPERATION

PUREPOSE: LPG FILLING TO CYLINDERS
 Unloading of empty cylinder from truck.
 Physical checking of cylinders.
 LPG filling at carousal Machine.
ACTIVITY
 Correction unit for under filled and overfilled cylinder.
 Leak testing operation.
 Sealing & Capping
 Hazard of falling cylinders during unloading from

HAZARDS Truck
 Leakage of LPG from cylinder

PPEs Safety shoe, Dungaree , Hand gloves

 Place the empty cylinder carrying trucks at unloading

point.
PREPARATION
 Put the cylinder slipping table near the truck.
 Properly place the rubber mat over the slipping table
and on the ground.
 Check the position of the truck / vehicle. If Position is
not proper ask vehicle driver to place it properly and
vehicle.
STEP BY STEP  Ask vehicle driver to ensure that vehicle will not move

PROCEDURE at all, during un-loading of cylinder. Place stopper to

the vehicle wheels.
 Cylinders are unloaded from trucks by CCL loader
group under M/s IOCL to conveyor chain at the floor
one by one.
 Verify the number of cylinders and segregates the non

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
serviceable cylinders from the serviceable ones. The
non serviceable cylinders are kept separately and
precautions are taken to prevent unintended use of
non serviceable cylinders.
 Non serviceable cylinders should be identified by
checking the validity date and their physical
appearance (Damaged foot rings, dented, rusted
body).This cylinder are handed over to M/s IOCL.
 Open the caps of unserviceable cylinders manually and
allow passing through washing unit by conveyor
system.
STEP BY STEP
 Allow the cylinders pass through dryer unit to remove
PROCEDURE traces of water.
 Mark tare weight of the cylinders which are not visible.
 Put the tare weight of the cylinder at encoding system.
 Introduction unit of carousal machine automatically
transfer LPG cylinder from chain conveyor to Carousal
Filling Machine one by one. The Cylinder is filled in the
course of one rotation of carousal. At the exit side of
the carousal cylinders are filled cylinders are ejected
automatically and put in the conveyor chain.
 The filled cylinders the passed through dynamic check
scale and underweight or overfilled are rejected and
correctly filled cylinders move through the main
conveyor.
 Measure the under filled and overfilled cylinders in the
machine attached with the track. Top up and evacuate
undefiled and overfilled cylinders respectively to
maintain the correct weight of the cylinders. Pass the
corrected cylinders through the main conveyor.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-2: LPG BULK FILLING OPERATION

PUREPOSE: LPG FILLING TO ROAD TANKER
 Physical checking of empty t/tanker.
 Documents verification.
ACTIVITY  Placing the t/tanker at filling point.
 Filling of t/tanker.
 Sealing the t/tanker.

 High flow of LPG.

HAZARDS  Leakage of LPG while filling.
 High pressure inside the LPG bullet.

PPEs Safety shoe, Dungaree , Hand gloves , Helmet, Face Mask

 Check the physical condition of empty t/tanker with

check list.
 Check/verify the documents of empty t/tanker.
 Take the empty weight of t/tanker in weigh bridge and
take the printout.
 Place the empty t/tanker at Tanker filling point.
 Fix the LPG filling arm and vapour return line properly.
PREPARATION
 Switch ON the power switch of 230 V in the skid.
 Check whether the normal valves for LPG loading,
vapour return, bypass etc are properly opened/
closed as per operational requirement.
 Check and ensure that the loading arm is not in its
parking condition and is connected to the tanker in
its individual way.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
 Check the proper body earth of the tanker to be
filled by connecting the earthling clamp with the
tanker from the skid. If earthling is OK then bulb will
glow in green colour relay of the skid. Otherwise
Earthling Fail will be indicated in red colour.

 If the above steps are OK, the batch controller will

come into loading condition and permissive power
LED will glow.
 Give the quantity of LPG to be filled in the tanker as
an input to the batch controller as per the filling
advice following the underneath steps-
- Press ALT+ENTER
- Enter password 1234
- Give the value of LPG to be filled in KG
STEP BY STEP
- If any alarm is there, press ALT+CLEAR three
PROCEDURE
times to reset
- To start filling press START button in the batch
controller.
- The valves of both the tanker and the filling plant
have to be opened.
- The valve of the liquid line at the filling plant has
to be opened.
- The valve of the liquid line of the tanker is to be
opened.
- The filling is to be done with continuous
monitoring of the Rota gauge.
 When it is required to stop the filling process,
disconnect the earth clamp from the tanker and
attend the problem and then resume filling after
reconnecting earth clamp.

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SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
 After filling up LPG into t/truck the arm has to be
evacuated by evacuation compressor.
 After filling seal the t/truck with metallic wire and
seal.
 Take the gross weight of the t/truck at Electronic
Weigh Bridge and print out the slip.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-3: CONDENSATE BULK FILLING OPERATION

PUREPOSE: CONDENSATE FILLING TO TANKER
 Physical checking of empty t/tanker.
 Documents verification.
ACTIVITY  Placing the t/tanker at filling point.
 Filling of t/tanker.
 Sealing the t/tanker.
 Failing of object
HAZARDS  Leakage of condensate while filling.

PPEs Safety shoe, Dungaree , Hand gloves , Helmet, Mask

 Carry out the physical check of the truck as per

check list and Check the documents as per record.
 If acceptable then place the t/truck at Electronic
weigh Bridge record the tare weight.
PREPARATION
 Place the truck at Filing point
 After filling seal the t/truck
 Take the gross weight of the t/truck at Electronic
Weigh Bridge.
 Placed the t/truck at a free / open area.
 Carry out the physical check of the truck as per
check list.
 Check the documents as per record.
STEP BY STEP  Place the acceptable t/truck at Electronic weighs

PROCEDURE Bridge and prints the empty weight of the t/truck.

 Place the truck at Filing point
 Connect the two earthling cable at two different
point of the body of the t/truck.
 Fill the required quantity at each chamber either

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SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
measuring in dip stick or through mass flow.
 While filling connect the vapour line at proper point.
 While filling check from time to time whether any
leakage takes place through flange, body, valve etc.
 After filling seal the t/truck with metallic wire and
seal.
 Take the gross weight of the t/truck at Electronic
Weigh Bridge and print out the slip.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-4:LPG TANKER EVACUATION OPERATION

PUREPOSE: TO EVACUATE DEFFECTIVE LPG TANKER
 Take the gross weight of the T/Truck.
 Placing the t/tanker at Tanker evacuation point.
 Connecting the proper lines with the tanker.
 Confirmation of readiness from control room.
ACTIVITY
 Run the evacuation compressor.
 Check the final pressure in the T/Truck.
 Take weight in the Weigh Bridge .

HAZARDS  Leakage of LPG

PPEs Safety shoe, Dungaree , Hand gloves , Helmet,

goggles

 Check all the valve position of tanker evacuation

unit.
 Check the pressure and temperature gauge of
PREPARATION
the tanker.
 Place the defective tanker at tanker evacuation
point.
 Take the gross weight of the defective tanker
and print the weight.
 Check the rotagauge %-age of the tanker.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
 Connect the liquid and vapour line of the t/truck
with the LPG liquid line and vapour line at
tanker evacuation point. The required
connections are made with tanker evacuation
compressor. Connect all earthing properly.
 The communication is to be made with the LPG
Recovery Plant for opening the tanker
evacuation line & LPG tanker vapour line with
the mounded bullet. After getting clearance only
from the shift Engineer, the evacuation process
is done.
 Open the required valves and then start the
evacuation compressor.
 The evacuation process is done with constant
observation and monitoring few salient points,

STEP BY STEP such as the discharge pressure of evacuation

compressor (Not exceed 12 kg/Cm2), the % of
PROCEDURE
the rotagauge, the pressure of the t/truck,
%age of level rising in the storage facility etc.
 After evacuated the liquid the pressure of the
t/truck is reduced by running the compressor in
opposite way up to 25psi.
 All sorts of safety rules and regulation are to be
followed during the job. The remote shut down
switch of LPG dispatch valves are there. In case
of emergency those can be closed by all
personnel of Filling Plant.
 After evacuation completed close the valves &
disconnect the lines. Remove the Earthlings.
 Measure the tare weight of T/truck in Weigh
Bridge and print.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-5:NG TANKER EVACUATION OPERATION

PUREPOSE: TO EVACUATE DEFFECTIVE NG TANKER

 Taking gross weight of the T/Truck.

 Placing t/tanker at Tanker evacuation point.
 Connecting the proper lines with the tanker.
ACTIVITY
 Confirmation of readiness from control room.
 Run the evacuation compressor.
 Check the final pressure in the T/Truck.
 Take weight in the Weigh Bridge.

HAZARDS  Leakage of condensate

PPEs Safety shoe, Dungaree , Hand gloves , Helmet, goggles

 Check all the valve position of NG tanker evacuation

unit.
 Place the defective tanker at point
 Connect the earthing cable
PREPARATION  Connect the evacuation hose with the pump.
 Line up the system with Tank Farm.
 Take the confirmation from control room.
 Run the pump.
 Disconnect the hose, earthlings cable.
 Take the weight of the defective tanker and print the
weight.

 The unloading line from manifold is connected with

pump suction line. All the earthing connection should
properly made.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT
 The communication is to be made with the LPG
Recovery Plant for opening the valve to central tank
farm for the transfer the condensate. After getting
clearance only from the shift Engineer /Shift Operator,
the evacuation process is done.
STEP BY STEP  The required valves are opened and then the pump
PROCEDURE
should start.
 The evacuation process is done with constant
observation and monitoring few salient points, such as
the level of condensate in tank chambers with dip
stick.
 All sorts of safety rules and regulation are to be
followed during the job.
 After evacuation completed valves are to be closed &
lines are to be disconnected. Remove the earthlings.
 Measure the tare weight of T/truck in Weigh Bridge
and print.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-6:MAINTENANCE OF VAPOUR EXPULSION UNIT

PUREPOSE: TO DO MAINTENANCE OF VAPOUR EXPULSION UNIT

ACTIVITY Maintenance of Vapour Expulsion Unit

HAZARDS  Electric shock if power is not isolated properly.

 Fall of object.

PPEs Safety shoe, Dungaree, Hand gloves, Helmet.

PREPARATION  Isolate power supply at MCC panel.

 Remove V belt cover and V belt.

 Check all the V belts and V belt pulleys.

STEP BY STEP  Remove bearing cover and grease the bearings

properly.
PROCEDURE
 Replace the V belts with new one.

 Refit the V belt cover.

 Restore electrical power from MCC panel.

 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-7:MAINTENANCE OF GEAR BOX

PUREPOSE: TO DO MAINTENANCE OF GEAR BOX

ACTIVITY Maintenance of Gear Box

HAZARDS  Electric shock if power is not isolated properly.

 Fall of heavy object.

PPEs Safety shoe, Dungaree, Hand gloves.

PREPARATION  Isolate power supply at MCC panel.

 Removed driving chain cover and chain.

 Drained old gear oils and preserved properly at drums.

STEP BY STEP  Clean driving chains and gear boxes with diesel.
PROCEDURE  Refill the gear oil.
 Check all the driving chains.
 Check pedestal bearings.
 Check alignment of gear box with electrical motors (if
motor servicing is done by Electrical Section).
 Refit driving chain covers and chains.
 Restore electrical power from MCC panel.
 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-8: MAINTENANCE OF CONEYOR TRACK

PUREPOSE: TO DO MAINTENANCE OF CONEYOR TRACK

ACTIVITY Maintenance of Conveyor track

HAZARDS  Electric shock if power is not isolated properly.

PPEs Safety shoe, Dungaree, Hand gloves.

PREPARATION  Isolate power supply at MCC panel.

 Remove the damaged railing posts of conveyor track and

replace with new ones.
STEP BY STEP  Replace the damaged Teflon of Conveyor track with new
PROCEDURE one.
 Replace Teflon of conveyor track with new one.
 Remove damaged wear plate and refit with new ones by
welding.
 If any vibrating track is there, modify it by welding.
 Restore electrical power from MCC panel.
 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-9: MECHANICAL MAINTENANCE OF CAROUSAL MACHINE

PUREPOSE: TO DO MAINTENANCE OF CAROUSAL MACHINE

ACTIVITY Maintenance of Carousel

HAZARDS  Electric shock if power is not isolated properly.

 Hand and leg injury.

PPEs Safety shoe, Dungaree , Hand gloves.

PREPARATION  Isolate power supply at MCC panel.

 Remove the covers of the applicable locations.

 Check the sliding plate and wheel bearing.
STEP BY STEP  Grease the wheel bearings.
PROCEDURE  Remove the triplex chain of the Introduction unit,
check, clean and refit.
 Grease the pedestal bearing of the mill arm.
 Refit the covers of various locations in the
machine.
 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-10:MAINTENANCE OF WASHING UNIT

PUREPOSE: TO DO MAINTENANCE OF WASHING UNIT

ACTIVITY Maintenance of Washing Unit

HAZARDS  Hand and leg injury.

 Head injury.

PPEs Safety shoe, Dungaree , Hand gloves, Helmet.

PREPARATION  Isolate power supply at MCC panel.

 Clean the interior of the washing unit by

connecting hose to the nearest fire hydrant point.
STEP BY STEP  Check the nozzles and clean.
PROCEDURE  Restore Electrical power from MCC panel.
 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-11: MAINTENANCE OF TANKER FILLING ARM

PUREPOSE: TO DO MAINTENANCE OF TANKER FILLING ARM

ACTIVITY Maintenance of Tanker Filling Arm

HAZARDS  LPG leakage.

 Hand and leg injury.
 Head injury.

PPEs Safety shoe, Dungaree , Hand gloves, Helmet, Face

mask.

PREPARATION  Gas testing is carried out in and around the

location.

 Isolate all LPG filling line valves.

 Remove leaky swivel joint from the filling arm.

STEP BY STEP
PROCEDURE  Dismantle Male-female joint of the swivel joint and
clean with diesel.

 Replace old O-ring set with new one.

 Assemble Male-female joint properly.

 Take trial run.

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 SITE SPECIFIC SAFE OPERATING PROCEDURE
FILLING PLANT, LPG DEPERTMENT

SOP-12: MAINTENANCE OF LEAK TESTING BATH

PUREPOSE: TO DO MAINTENANCE OF LEAK TESTING BATH

ACTIVITY Maintenance of Leak Testing Bath

HAZARDS  Hand and leg injury.

 Head injury.

PPEs Safety shoe, Dungaree, Hand gloves, Helmet.

PREPARATION Drain the water of the bath and clean the bath
thoroughly.

 Remove the old Teflon of the Leak Testing bath

across the cylinder inlet side and replace those by
STEP BY STEP
PROCEDURE new ones.

 Refilled fresh water in the bath.

 Take trial run.

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