OISD STANDARD - 144 Second Edition, October 2005 FOR RESTRICTED CIRCULATION ONLY
LIQUEFIED PETROLEUM GAS (LPG) INSTALLATIONS
Prepared by FUNCTIONAL COMMITTEE ON LIQUEFIED PETROLEUM GAS (LPG)
OIL INDUSTRY SAFETY DIRECTORATE GOVERNMENT OF INDIA MINISTRY OF PETROLEUM AND NATURAL GAS
7th Floor, New Delhi House 27, Barakhamba Road Connaught Place, New Delhi 110 001
NOTE
Oil Industry Safety Directorate (OISD) publications are prepared for use in the oil and gas industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD. Though every effort has been made to assure the accuracy and reliability of the data contained in these documents, OISD hereby disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended to supplement rather than replace the prevailing statutory requirements.
FOREWORD
The Oil Industry in India is more than 100 years old. As such, a variety of practices have been in vogue because of collaboration/ association with different foreign companies and governments. Standardisation in design philosophies , operating and maintenance practices was hardly in existence at a national level. This, coupled with feed back from some serious accidents that occurred in the recent past in India and abroad, emphasised the need for the industry to review the existing state of art in designing, operating and maintaining oil and gas installations. With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a Safety Council assisted by the Oil Industry Safety Directorate (OISD) for formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly, OISD constituted a number of functional committees comprising of experts nominated from the industry to draw up standards and guidelines on various subjects. Liquefied Petroleum Gas (LPG) has been used extensively as domestic fuel as well as with industrial applications due to its unique properties and environmental benefits. The document on "LPG Bottling plant operations" was prepared in 1994. The present document "LPG Installations" has been prepared by the functional based on the accumulated knowledge and experience of industry members and updation of national and international codes and practices related to LPG.
This document will be reviewed periodically for improvements based on the new experiences and better understanding. Suggestions may be addressed to :
The Coordinator, Committee on “LPG” Oil Industry Safety Directorate, 7th floor, New Delhi House, 27, Barakhamba Road, New Delhi – 110001
FUNCTIONAL COMMITTEE ( Second Edition - October, 2005)
NAME
ORGANISATION
LEADER Sh. R. Krishnan
Hindustan Petroleum Corporation Ltd., Mumbai
MEMBERS Sh. A.N. Biswas
Deptt. of Explosives, Nagpur
Sh. N. Rajkhowa,
Engineers India Limited, New Delhi
Sh. B.S. Giridhar
Indian Oil Corporation Ltd., - HQ, Mumbai
Sh. N. Dasgupta
Bharat Petroleum Corporation Ltd., Mumbai
Sh. T.Koteeswaran
Chennai Petroleum Corporation Ltd., Chennai
Sh. B.J. Phukan
Numaligarh Refinery Ltd., Assam
Sh. P. Jaidevan
Indian Oil Corporation Ltd., Calicut
Sh. S. Ramesh
Bharat Petroleum Corporation Ltd., Noida
MEMBER COORDINATOR Sh. S. C. Gupta
Oil Industry Safety Directorate, New Delhi
FUNCTIONAL COMMITTEE MEMBERS
( First Edition – April 1994 )
NAME
ORGANISATION
LEADER Sh. S.C. Tandon
Indian Oil Corporation Ltd., ( Ref.)
MEMBERS Sh. H.G. Bhinde
Indian Oil Corporation Ltd., ( Mkt.)
Sh. A.C. Kelkar
Indian Oil Corporation Ltd., ( Mkt.)
Sh. V. Narayana Rao
Bharat Petroleum Corporation Ltd., (Mkt.)
Sh. P. Kumaraswamy
Bharat Petroleum Corporation Ltd., ( Ref.)
Sh. P.P. Nadkarni
Hindustan Petroleum Corporation Ltd., (Mkt.)
Sh. S. Mathur
Engineers India Limited, New Delhi
MEMBER COORDINATOR Sh. S. C. Gupta
Oil Industry Safety Directorate, New Delhi
CONTENTS ---------------------------------------------------------------------------------
SR. No. ITEM PAGE NO --------------------------------------------------------------------------------1
Introduction
2
Scope
3
Definitions
4
Statutory Rules/ Regulations
5
Installation Layout
6
Design Considerations
7
Storage & Handling of Bulk LPG
8
Bottling Operations
9
Maintenance & Inspection
10
Statutory Testing of LPG Cylinders
11
Fire Protection Facilities
12
Gas Monitoring System
13
Emergency Management Plan
14
Safety Audit
15
References
---------------------------------------------------------------------------------
LIQUEFIED PETROLEUM GAS (LPG) INSTALLATIONS
1.0 INTRODUCTION Liquefied Petroleum Gas (LPG) is a mixture of light hydrocarbons primarily C3 & C4 derived from petroleum, which is gaseous at ambient temperature and atmospheric pressure, is liquefied at ambient temperature with application of moderate pressure. LPG due to its inherent properties is susceptible to fire, explosion and other hazards. Such hazards can have an impact on the property, equipment, plant personnel and public. Liquefied Petroleum Gas (LPG) handling, bottling and distribution throw major challenges due to its inherent properties. Major incidents i.e. fires/explosions in LPG facilities in world have underlined the need for total in depth review of design, procedures, maintenance, fire fighting and safety aspects in LPG handling. The oil and gas industry over the years have learnt lessons from fires and explosions and have been updating and standardising design, operations, bottling and distribution of LPG.
•
LPG has an explosive range of 1.8% to 9.5% volume of gas in air. This is considerably narrower than other common gaseous fuels. This gives an indication of hazard of LPG vapour accumulated in low lying area in the eventuality of the leakage or spillage.
•
Water, being insoluble in LPG, if present in LPG can cause rust and corrosion and freeze-up of valves, drain valves, excess-flow check valves, cylinder valves and regulators thereby affecting their functioning and at times can lead to leakage of LPG.
•
LPG liquid has low viscosity of around 0.3 CS @ 45 oC and can leak when other petroleum products normally cannot, thus demanding a very high integrity in the pressurised system to avoid leakage.
•
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however, suffocate when in large concentrations due to the fact that it displaces oxygen. In view of this the vapour posses mild anaesthetic properties.
Some of the important properties of LPG are as below : •
LPG at atmospheric pressure and temperature is a gas which is 1.5 to 2.0 times heavier than air. It is readily liquefied under moderate pressures. The density of the liquid is approximately half that of water and ranges from 0.525 to 0.580 @ 15 oC.
•
LPG is colourless both in liquid and vapour phase. During leakage the vapourisation of liquid cools the atmosphere and condenses the water vapour contained in them to form a whitish fog which may make it possible to see an escape of LPG.
•
The pressure inside a LPG storage vessel/ cylinder is equal to the vapour pressure corresponding to the temperature of LPG in the storage vessel. The restriction on vapour pressure is stipulated by IS-4576.
•
The coefficient of expansion is around 0.00237 per oC. At liquid full condition any further expansion of the liquid, the container pressure will rise by approx. 14 to 15 kg./sq.cm. for each degree centigrade.
•
LPG has only a very faint smell, therefore, ethyl mercaptan is normally used as stenching agent for identifying the leakage as per IS : 4576.
Approved Type : Any equipment which has specific approval for use under specified conditions by competent authority or authorised person as the case may be.
•
The auto-ignition temperature of LPG ranges from 410 to 580 oC.
Area Classification : It is a method of classifying an area zone wise/ group wise based on the presence of explosive gas/ vapour - air mixture vis-a-vis the requirement of precautions for construction and use of electrical apparatus.
2.0
SCOPE
This standard lays down the minimum safety requirements on design, layout, storage, loading / unloading, operation, inspection & maintenance, fire protection, emergency planning and safety audit systems of LPG Installations. This standard does not cover process plants, the distribution of LPG to domestic & non-domestic consumers and pipeline operations, road / rail transportation, refrigerated and mounded storage facilities for LPG. This standard is not applicable to bottling plants having a bulk LPG inventory not exceeding 100 MT with minimum two storage vessels and with LPG bottling a total quantity not exceeding 20 MT per shift of 8 hrs. The safety requirement for such LPG Bottling plants are covered in OISDGDN-169. Safety requirements for mounded Storage facilities are covered in OISDSTD-150. The requirements for Auto LPG Dispensing Stations are covered in OISD-STD-210. The green belt /buffer zone beyond the installation boundary is outside the scope of this standard. Such provisions may be considered based on local environment / security requirements. 3.0
DEFINITIONS
Bonding : Bonding is the process by which two electrical conducting bodies are connected using a conductor to maintain electrical continuity to prevent sparking between two conducting bodies. Bulk Vessels : A pressure vessel used for more than 1000 litres water capacity for storage or transportation of LPG. Bullet : A horizontal cylindrical pressure vessel used for storage or transportation of LPG by rail/ road. Compressed Gas : Any permanent gas, liquefiable gas or gas dissolved in liquid under pressure or gas mixture which in a closed container exercises a pressure either exceeding 2.5 kg/sq.cm. abs @ 15 o C or a pressure exceeding 3.0 kg/Sq.cm. abs @ 50 oC or both. Cylinders : A portable LPG container upto 1000 litres water capacity used for both domestic and industrial purposes. Explosive mixture : It is a mixture of combustion agent (oxidising productgas, vapour, liquid or solid) and a fuel (oxidisable product - gas, liquid or solid) in such proportions that it could give rise to a very rapid and lively oxidisation reaction liberating more energy than is
dissipated through convection.
conduction
and
Earthing : Earthing is the provision of a safe path of electrical current to ground, in order to protect structures, plant and equipment from the effects of stray electrical current, and electrostatics discharge. Filling Ratio : It is the ratio of weight of LPG in a container to the weight of water the same container can hold at 15 o C. Fire safe : As applied to valves, it is the concept of controlling the leakage to an acceptable level after damage encountered during and after the fire achieved by dual seating. Fire proofing : It is an insulation that provides a degree of fire resistance to protect substrates like vessels, piping and structures for a predetermined time period against fire. Flammability : It is the percentage of volume of any flammable vapour in airvapour mixtures capable to form an explosive mixture. Flammable (or Inflammable) : Any substance which when tested in a specified manner will ignite when mixed with air on contact with a flame and will support combustion. Gas-Free : it means the concentration of flammable or toxic gases or both in a pressure vessel or pipeline is within the safe limits specified for persons to enter and carryout hotwork in such vessels/ pipelines. Horton Sphere : A spherical pressure vessel used for storage of LPG.
Hot Work : It is an activity which may produce enough heat to ignite a flammable air-hydrocarbon mixture or a flammable substance. Installation : The facilities where LPG is stored or loading/ unloading operations or bottling operations are carried out. Kerb Wall : A wall of appropriate height and size constructed of suitable material and designed to contain the LPG spillage and to direct it to a safe location around the storage vessel. Liquefied Petroleum Gas (LPG) : 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 and conforming to IS : 4576 or IS: 14861. Purging : It is the act of replacing the atmosphere within a container by an inert substance in such a manner as to prevent the formation of explosive mixture. Purging into Service : is the replacement of air in a closed system by an inert substance and replacement of the later by combustible gas, vapour, or liquid. Purging out of service : is the replacement of normal combustible content of a closed system by an inert substance, and replacement of the later by air. Tare Weight : The weight of the cylinder together with any fitting permanently attached to it including the weight of valve.
¾ Air (Prevention & Control of Pollution) Act- 1981
Maximum Working Pressure : It is saturated vapour pressure of LPG at 65 o C for LPG cylinders and 55 oC for bulk vessels.
¾ The Environment (Protection) Act – 1986
Water Capacity : The maximum volume of water in litre that the a container can hold at 15 oC.
¾ Manufacture, storage & import of Hazardous chemicals Rules 1989.
4..0 STATUTORY RULES / REGULATIONS The LPG installation & various facilities are covered under many regulations and require specific approval / licence from concerned statutory authorities. The various regulations applicable to LPG installation facilities are as below : a.
Gas Cylinders Rules, 1981 (under Indian Explosives Act,1884)
b.
Static & Mobile Pressure Vessels (unfired) Rules-1981 (Under Indian Explosives Act 1884).
c.
The Factories Act, 1948.
d.
Indian Electricity Rules
e.
The Standards of Weight & Measures Rules - 1987 Under Weight & Measures Act - 1976.
¾ Guidelines for Environmental clearance of new projects - 1981. In addition to the above Statutory regulations, there are various recommended guidelines emerging out of the various Committees set up by the Govt. of India from time to time for streamlining/ improving the safety standards of LPG Bottling/ Distribution: a.
Vasudevan Committee - 1983 Ministry of Energy (Department of Petroleum).
b.
Expert Committee Review of Safety and Operating Procedures in LPG facilities - 1986, Ministry of Petroleum & Natural Gas (Department of Petroleum)
c.
Sudha Joshi Committee for better services to LPG users - 1987 (Ministry of Petroleum & Natural Gas).
f.
The Standards of Weight & Measures (Packaged Commodities Rules-1977)
g.
Liquefied Petroleum Gas (Regulation of supply and distribution Order 1993).
h.
The Motor Vehicles Act - 1988.
5.0 INSTALLATION LAYOUT
i.
Environmental Regulations :
5. 1 GENERAL
¾ Water (Prevention & Control of Pollution) Act, 1974.
The layout of the LPG facilities including the arrangement and location
of plant roads, walkways, doors and operating equipment shall be designed to permit personnel and equipment to reach any area effected by fire rapidly and effectively. The layout shall permit access from at least two directions. The general principles of layout of LPG storage, bottling and bulk handling facilities have been detailed. The various facilities within LPG installation shall be located based on Table-I and Table-II. 5.2 LOCATION & SEPARATION DISTANCES : 5.2.1
5.2.2 SEPARATION DISTANCES The separation distances as given in Table- I & II are the distances in plane between the nearest point on a vessel other than the filling/ discharge line and a specified feature, e.g. adjacent vessel, site boundary etc. 5.3 LAYOUT The following aspects shall be considered while establishing layout of LPG storage vessels. Bullets or spheres are used for above ground storage of LPG.
LOCATION
While assessing the suitability of any site for location of LPG installation, the following aspects shall be considered :
a. The access of mobile fire fighting equipment to the storage vessels shall be at least from two sides.
a) The location of residential quarters, other industries, railways, roads, waterways, overhead power lines, places of public assemblies etc.. This shall be covered in risk analysis study of the proposed site. The study shall also be used to plan for emergency measures.
b. Longitudinal axis of static storage vessels (bullets) shall not be pointed towards other vessels, vital equipments e.g. LPG cylinder sheds, tank lorry/tank wagon gantries, LPG pump house and buildings wherein control panels for fire and gas detection/ actuation panels are situated.
b) Adequate availability of water from a reliable source or alternate arrangements proposed.
c. Storage vessels to be located preferably in downwind of potential ignition sources at lower elevation.
c) The topographical nature of the site with specific reference to its effect on the accidental release of LPG.
d. No foreign material / combustible substances shall be stored in storage area.
d) The availability of space for future extension of LPG facilities, if any, shall also comply with the safety norms.
e. Storage vessels shall be laid out in single row in each group. f. Storage vessels shall not be located one above the other.
e) The meteorological data of the location including predominant wind direction & velocity, high flood level, temperatures etc.
5.4 LPG STORAGE FACILITIES: (a) CONFINEMENT/ GRADING -
Kerb wall shall be provided around all sides of the storage vessel with concrete flooring of the ground under vessel and extending upto minimum distance of D/2 or 5M whichever is higher and atleast 5 M (min.) from the edge of the storage vessel with a slope of 1:100 (min.). Grading of the ground underneath should be levelled and directed to an area connected with water seal away from the storage vessel. Kerb wall height shall be minimum 30 cm but shall not exceed 60 cm otherwise evaporation of spilled LPG may get affected. Spillage diversion area shall be located at a distance where the flames from fire will not impinge on the vessel. This distance shall not be less than the diameter of the nearest vessel or minimum 15 M. No accumulation of LPG should be possible underneath the storage vessel in any condition. (b) PIPING - Only piping associated with the storage vessels shall be located within the storage areas or between the storage area and the manifold system. (c) SURFACE DRAINAGE - In order to prevent the escape of spillage into the main drainage system, surface water from the storage area and from the manifold area shall be directed to the main drainage through a water seal to avoid the spread of LPG. (d) GROUPING - Vessels shall be arranged into groups, each having a maximum of six vessels. There shall be minimum spacing as specified in Table-I between adjacent vessels. Each group shall be separated by
roads on all four sides for easy access and emergency handling. (e) Spheres and bullets shall be treated as separate groups with minimum 30 M distance between two groups. Top surfaces of all the vessels installed in a group shall be on the same plane. It is necessary to provide separate manifolds preferably with independent pumping facilities for bullets and spheres. Alternatively, fail safe interlocks like two way valves shall be provided so as to avoid any chances of overfilling of adjacent vessels due to gravitation. 5.5
LPG BULK LOADING / UNLOADING FACILITIES
5.5.1
LPG tank lorry loading/ unloading gantry shall be covered and located in a separate block and shall not be grouped with other petroleum products.
5.5.2
LPG loading/ unloading rail gantries shall have separate rail spur and be grouped separately at least 50 M from other rail shunting facilities.
5.5.3
Space for turning with minimum radius of 20 M for tank lorries shall be provided commensurate with the capacities of the tank trucks. 5.5.4 LPG tank wagon loading/ unloading shall be restricted to a maximum of half rake, not exceeding 600 tonnes. If full rake loading/ unloading is envisaged this shall be done on two separate rail gantries separated by a minimum distance of 50M. 5.5.5
Maximum number of LPG tank lorry bays shall be restricted to 8
in one group. Separation distance between the two groups shall not be less than 30 M. 5.5.6
For adequate permanent protection for tank lorry discharge, pipeline island shall be provided. The minimum width of such pipeline island shall be 1 M.
5.5.7
The layout of the unloading location shall be such that tank truck being unloaded shall be in drive out position.
5.5.8
The weigh bridge of adequate capacity shall be provided and proper maneuverability for vehicles.
5.5.9
5.6.2
LPG Bottling section shall be of single storey. Antistatic mastic flooring conforming to IS-8374 shall be provided in the LPG filling shed/ cylinder storage including valve changing shed to avoid frictional sparks. The shed shall be supported by RCC columns alternatively structure steel columns shall be covered with concrete or fire-proofing material upto full height of columns. Anti static mastic coating upto 1.5 m (Min.) shall be done of the supporting columns of the shed.
5.6.3
The bottling operation shall be carried out in the filling shed. Separate sheds for filled cylinders storage, valve changing, degassing, if any, shall be provided. Valve changing unit without evacuation can be provided in filling shed itself.
Tank truck shall be loaded/ unloaded with suitable arrangement for cold flaring of hose content, if used at the end of the operations.
Empty cylinders storage area shall be properly segregated from filling machines by 5 M (Min.). Cylinders shall always be stacked vertically with maximum stack height of 1.5 m. For details of cylinders stacking pattern refer Figure - I .
5.5.10 LPG tank truck parking area (Bulk/ Packed) shall be located in a secured area and provided with adequate no. of hydrants / monitors to cover the entire parking area. 5.6
LPG BOTTLING FACILITIES
5.6.1
LPG bottling facilities shall be located at a safe distance from other facilities with minimum ingress of traffic and upwind direction with respect to bulk storage. There shall not be any deep ditches in the surrounding areas at least within 15 M from storage sheds to avoid settling of LPG vapour.
5.6.4
LPG cylinder filling machines and other related testing facilities shall be provided in sequential order.
5.6.5
A separate shed shall be provided for carrying out degassing of defective cylinders.
5.6.6
Cylinder storage shall be kept on or above grade and never below grade in cellar or basement.
5.6.7
Filled cylinders shall not be stored in the vicinity of cylinders containing other gases or hazardous substances.
5.6.8
Escape routes shall be specified and marked in LPG sheds for evacuation of employees in emergency.
5.6.9
There shall be sufficient no. of crossovers to avoid trapping of personnel in LPG sheds by conveyors, cylinders and other facilities. Further, sufficient no. of escape routes shall be provided.
5.6.10 All steps forming part of the escape routes shall be minimum 1.2 M with treads 30 cms (minimum) and maximum rise of 15 cms. 5.7 PROTECTION OF FACILITIES 5.7.1
Properly laid out roads around various facilities shall be provided within the installation area for smooth access of fire tenders etc. in case of emergency.
5.7.2
Proper industry type boundary wall atleast 3 M high with 0.6 M barbed wire on top shall be provided around the installation unless the bottling plant is protected as a part of refinery complex.
5.7.3
Emergency exit with proper gate shall be provided in the earmarked zone.
5.7.4
In case provision for green belt is made, the same shall be segregated from hazardous area by 1 M high wall / chain link fencing. Alternatively, it shall be treated as a part of hazardous area.
5.8 UTILITIES Utilities consisting of fire water pumps, admin. building, canteen, motor control centre, DG room, air compressors, dryers etc. shall be separated from other LPG facilities and located as per the separation as specified in Table-I.
TABLE - I INTERDISTANCE FOR LPG FACILITIES ---------------------------------------------------------------------------------------------------------------------------
1 2 3 4 5 6 7 8 --------------------------------------------------------------------------------------------------------------------------1.
LPG Storage vessels
*
T-II
30
30
50
30
15
60
2.
Boundary/property line/ T-II group of bldgs. not associated with LPG installation
-
30
30
50
30
30
-
3.
Shed-LPG
30
30
15
30
50
30
15
60
4. Tank truck gantry - LPG
30
30
30
50
50
50
30
60
5. Tank wagon gantry
50
50
50
50
50
50
30
60
6. LPG/other rail spurs
30
30
30
50
50
50
30
60
7. Pump house/Comp.house 15 30 15 30 30 30 60 (LPG) 8. Fire Pump House/ storage tank 60 ** 60 60 60 60 60 --------------------------------------------------------------------------------------------------------------------------Notes : 1.
2.
3. 4.
All distances are in metres. All distances shall be measured between the nearest points on the perimeter of each facility. except in case of tank vehicle loading/unloading area where the distance shall be measured from the centre of each bay and for storage vessels where the distance shall be measured from the nearest point on the vertical shadow of the vessel. Notation : T-II - Refer Table - II • 1/4 of sum of diameters of adjacent vessels or Half the diameter of the larger of the two adjacent vessels, whichever is greater. ** Any distance for operational convenience. Distance of stabling line shall be as per minimum Railway Standards. Distance of stabling line shall be as per Railway guidelines.
TABLE - II DISTANCE BETWEEN LPG STORAGE VESSELS AND PLANT BOUNDARY/GROUP OF BUILDINGS NOT ASSOCIATED WITH LPG INSTALLATION --------------------------------------------------------------------------------------------------------------------------Capacity of each Distance vessel (Cu.Mt. of water) ( in metre ) --------------------------------------------------------------------------------------------------------------------------10-20 15 > 20-40 20 >40-350 30 >350-450 40 >450-750 60 >750-3800 90 > 3800 120 --------------------------------------------------------------------------------------------------------------------
6.0 DESIGN CONSIDERATIONS 6.1 GENERAL
This section describes the design and safety features required in a typical LPG bottling installation.
6.2 LPG STORAGE VESSELS The minimum requirements w.r.t. design considerations and various fitting to be provided LPG storage vessels shall be as under :
The recommended design pressure and temperature shall be treated as MINIMUM requirement and other design consideration and Statutory requirements shall also be considered. v.
Other Design Considerations
6.2.1 MECHANICAL DESIGN i.
The storage vessel shall be designed in accordance with the codes i.e. ASME SEC. VIII or IS-2825 or PD - 5500 or equivalent duly approved by CCE. Design shall take into account the Static and Mobile Pressure Vessels (Unfired) Rules 1981 also. A single code shall be adopted for design, fabrication, inspection and testing i.e. ASTM and BS shall not be combined.
ii. Material shall be in line with design
code. ASTM A516 Gr. 60 shall be used for refinery service (BS-5500 shall not be used for the same) and for marketing installation where H2S is not present ASTM A 516 Gr. 70 or A 537 CLASS 1 can be used. Microalloyed steel containing Ni, Mo, Va shall not be considered. Maximum specified tensile stress shall not be more than 80,000 psi. o
iii. Design temperature : (-) 27 C to o
(+) 55 C. 2
iv. Design Pressure : 14.5 Kg/ cm g on
top as per IS: 4576 at 55 oC. Marketable LPG conforming to IS: 4576 can have a maximum vapour pressure of 16.87 Kg/ Sq.cm.g at 65 o C temperature. LPG with higher vapour pressure are not expected to be stored in bottling installations.
Corrosion Allowance : mm
minimum 1.5
Radiography : Full Stress Relieving : 100% irrespective of thickness. Wind pressure : as per IS: 875 Earthquake pressure : as per IS:1893 Hydro test pressure : As per Design Code Where ever extreme climatic conditions or security reasons warrants, suitable alterations in design can be made with approval from statutory bodies. 6.2.2 FITTINGS Spheres/ bullets other than underground shall have a single nozzle at the bottom for liquid inlet as well as outlet. The nozzle shall be full welded pipe, stress relieved along with the vessel and shall extend minimum 3 meters from the shadow of the sphere/ bullet. A remote operated shutdown valve (ROV) shall be provided on this bottom nozzle at a distance of at least 3 meters from the shadow of sphere/ bullet. The nozzle pipe shall have a minimum slope of 1.5 o . There shall not be any other flanges, manhole, instrument tapping on this nozzle upto the ROV or on sphere/ bullet bottom. In order to avoid stress on the nozzle due to relative settling of support
and storage vessel, suitable supports for the bottom nozzle shall be provided. The top vapour zone of the vessel shall be provided with nozzles for vapour outlet, recirculation wherever applicable. These lines shall be provided with fire safe ROV. Fire safe ROVs shall also be provided on liquid line at TLD & Tank wagon gantry & isolation valve (quick closing type) on the entry of liquid lines at LPG filling shed at a safe location. Nozzles for two independent level indicators of different type, a high level switch, two safety relief valves, pressure gauge and a manhole shall be provided on top. All the fittings shall be suitable for use at the design parameters of the storage vessels and for the temperatures appropriate to the worst operating conditions. The remote operated valves on the storage vessel connecting pipelines shall be fire-safe type conforming to API 607 or equivalent. The flange joints of these valves shall either have spiral wound metallic gaskets or ring joints. Plain asbestos sheet / reinforced gaskets shall not be used. Gasket used shall conform to ASME B16.20 or equivalent. The studs used shall conform to ASTM A 194 Gr 2 H/ ASTM A 193 Gr B7 or equivalent. Flange connections shall be a minimum of 300 lb rating confirming to ANSI B16.5 class 300 or equivalent. (pipe flanges and flanged fittings. All tapings or openings shall be of minimum 20 mm thickness. 6.2.3 INSTRUMENTS i) The storage vessel shall have minimum two independent level
indicators and one independent high level switch. High level alarms shall be set at not more than 85% level of the volumetric capacity of the vessel. Audio visual indication shall be at local panel & control room. On actuation of high level alarm, the ROVs of the affected vessel shall close. ii) Each storage vessel shall have at least two safety relief valves with isolation arrangement set at different values and at not more than 110% of design pressure of the vessel and each having 100 % relieving capacity adequate for limiting the pressure build up in the vessel not more than 120% of design pressure. The relieving load for the safety valves, shall be based on fire condition and no credit shall be taken for fire proofing on the vessel, if provided. The discharge of safety valves shall be connected to flare system, wherever available. In this case, safety valves shall have lock open (or car seal open) type isolation valves on both sides of safety valves. In case of non availability of flare system, the discharge from safety valve shall be vented vertically upwards to atmosphere at an elevation of 3 meter (minimum) for effective dispersion of hydrocarbons. In this case, isolation valve on down stream of safety valve is not required. A weep hole with a nipple at low point shall be provided on the vent pipe in order to drain the rain water which may get accumulated otherwise. Weephole nipples shall be so oriented that in case of safety valve lifting and consequent fire, the flame resulting from LPG coming out from weephole does not impinge on the sphere or structure. A loose fitting rain cap with a chain (non
sparking) fitted to vent pipe shall be provided on top of safety valve. Typical safety fittings on a LPG storage vessel are indicated in Figure-II. 6.3
LPG LOADING/ UNLOADING FACILITIES
Unloading of LPG from tank truck is carried out with vapour compressors using pressure differential method of liquid transfer. The compressor used for unloading shall be provided with the following facilities: (i) Vapour line with isolation valves
Each loading station of the following :
shall
consist
i. Excess flow check valve & non return valve shall be provided in LPG loading lines.
(ii) Excess flow check valve & non return valve shall be provided in LPG unloading lines with isolation valves (iii)
ii. A vapour return line with an isolation valve connected back to the storage vessel/ suction line with NRV. iii. Properly designed loading arm or LPG hoses shall be provided at the end of filling and vapour return lines for connecting to the tank truck vessel. The loading shall be provided with break away couplings or smart hoses shall be used. Loading arm shall be of approved type and be tested as per OEM recommendations. In case, LPG hoses are used, it shall conform to OISD-STD-135. iv. The hose - coupling / flange joint shall be of Class 300 lb rating with metallic gasket. The hose coupling shall be provided with a cap or blind flange by which the nozzle can be closed when not in use. v. Weigh bridges of suitable capacity for road / rail movements and mass flow meters for pipeline transfers shall be provided. The mass flow meters shall be certified for its use with LPG. vi. A check valve shall be provided in the vapour return line.
Weigh bridge of suitable capacity
Additionally following shall be ensured. i. Suitable provision shall be made for evacuation of LPG from bulk storage vessels to tank truck or another vessel to empty the vessel in case of emergency or for statutory testing. ii. Tank truck shall be loaded/ unloaded with suitable arrangement for flaring of hose content at the end of the operations. iii. The unloading arms shall be used for unloading the LPG TT at LPG installation. In case, LPG hose are used, it shall conform to OISD-STD135 or equivalent as approved by CCOE. iv. The hose - coupling / flange joint shall be of 300 lb rating with metallic gasket. The hose coupling shall be provided with a cap or blind flange by which the nozzle can be closed when not in use. 6.4
CYLINDER FACILITIES
FILLING
i) The cylinder filling area shall be completely open type and covered from top with roof designed to ensure good natural ventilation. RCC roofing shall not be used. The filling area shall not be on upper floors of building or in cellars unless specifically required on account of extreme weather conditions. ii) As far as possible, the floor area shall not have any channels or pits. Where these are necessary for conveyors or other equipment like weigh machine etc., suitable gas detection system shall be provided. Additionally, proper ventilation system through ducts fitted with blowers shall be provided to release LPG outside of the shed at safe location. The whole of the LPG filling shed flooring shall be provided with mastic flooring. All carousels & leak detectors including electronic shall be of approved type. iii)
Adequate lighting shall be provided in the cylinder filling area. Emergency lighting shall also be provided at critical places.
iv) Water drains from the cylinder filling area where they enter an outside drainage system, shall be provided with vapour seals. v) Proper access shall be made available for other fire fighting equipment i.e. fire tender, foam trolley etc.
vi)
Cylinder storage area requirement shall be worked out based on the stacking pattern of filled and empty cylinders as described in Figure-I. vii) The filling machines shall be provided with auto cut-off system so that LPG supply is cut off when the desired quantity of product has been filled in the cylinders. The filling pressure shall not be more than the design pressure of the cylinders i.e. 16.9 kg/sq.cm.g. viii) Filling machines in a carousel/ stationary filling machines shall not have a weighment error of more than + 150 gm of the net quantity of the LPG filled in the cylinder, with a capacity of 14.2 kg or as specified in Weights and Measures Rules. ix) On-line check weigh scales with a minimum of 50 gms. graduation be installed so that all the cylinders are check weighed after filling. x) Compact Valve Tester to check valve and 'O" ring shall be installed on line. Alternatively electronic leak detectors shall be provided. xi) Water test bath or electronic leak detectors shall be provided to detect body and bung leak cylinders. xii) Vapour extraction system at strategic locations near carousel, cylinder evacuation unit, valve changing unit, degassing shed and at locations where leaking LPG is expected to accumulate shall be provided. Further, it shall
be interlocked with filling machine so that filling do not start without vapour extraction unit being functional. 6.5
UTILITIES
(A)
Compressed air
The quality of instrument air shall conform to the requirements as recommended by the manufacturers of instruments/ equipment: If one compressor is envisaged to run normally, another standby compressor of 100% capacity shall be provided. When more than one compressor running is envisaged, 50% standby capacity shall be provided. (B) Service Water Service water is required for the cylinder washing equipment and leak check bath, compressor cooling and in hose stations for washing etc. Water may be provided at a pressure of about 3 Kg/sq.cm.g. If one pump is envisaged to run normally, another pump with 100% capacity shall be provided as a standby. Where more than one pump running is envisaged, 50% capacity as standby shall be provided. Water Quality Water shall be of potable quality conforming to IS : 10500 - Specification for Drinking Water. (C) Emergency Power The installation shall be provided with battery / diesel generating set for operating the essential systems such as the instrumentation and safety systems (gas detectors, automatic fire water
sprinkler system) and minimum lighting during the grid power failure. 6.6 LPG PUMPS i. LPG Pumps shall be designed for handling of LPG and safely withstand the maximum pressure which could be developed by the product and / or transfer equipment. Pumps shall conform to API 610 or equivalent. ii. Check valves shall be installed on the delivery side of all centrifugal pumps. iii. LPG Pumps shall be provided with suction and discharge pressure gauges, a high point vent to safe height or flare, and a suction strainer. iv. Double Mechanical seal with seal failure alarms shall be provided. v. A pressure switch actuating a low pressure alarm in control room and locally shall be provided, taken from discharge end. vi. Pumps shall be designed to build a discharge pressure such that the pressure at the carousel filling machine is at least 5.0 kg/sq.cm.g. above the vapour pressure at the operating temperature. vii. Pumps shall have a by-pass valve and other suitable protection against high discharge pressure on the delivery side. viii. The electrical motor drive and switchgear shall conform to area classification as per OISD Standard-113 / IS -5572. Belt
Typical sketch of compressor installation is enclosed as Figure-IV.
drives shall be of the anti-static type. Typical sketch of a bottling pump installation is enclosed as Figure-III. 6.7 LPG COMPRESSOR
VAPOUR
i. Compressors shall be suitable for handling LPG and designed to safely withstand the maximum outlet pressure to which these will be subjected. Compressors shall conform to API 618 or API 619 or equivalent.
6.8
PIPING
Piping shall be designed for handling of LPG. Piping that can be isolated and need thermal safety valves shall have minimum design pressure of 24 kg/cm2 or the maximum pressure which could be developed by the transfer equipment or any other source etc, whichever is higher and comply with the following : (i) Piping shall conform to provisions of ANSI B 31.3.
the
ii. The belts used in shall be of antistatic type & fire resistant.
(ii) The material shall conform to API 5L Gr. B / ASTM A106 Gr B or eqv.
iii. Compressor shall be provided with the following features as a minimum :
(iii) Seamless pipes shall be used. Furnace butt welded or spiral welded pipes shall not be used.
-
(iv) Pipe joints should be welded as far as practicable with full penetration weld. Number of flanged or threaded joints should be kept to a minimum.
-
-
Pressure gauges in suction and discharge. Temperature gauge in discharge Discharge safety valve and a vent valve, their outlets leading to flare/ safe height outside the shed. Low Suction Pressure Trip Suction strainer High Discharge Pressure Trip High Temperature Trip Check valve in discharge A discharge to suction recycle valve for achieving capacity turndown during startup.
iv. A suitable size scrubber or liquid knockout drum shall be installed upstream of the vapour compressor. It shall be equipped with a gauge glass, safety relief valve, a drain and high liquid level shut down device.
(v) Low point drains and high point vents shall be plugged or capped suitably. (vi) Buried piping shall be protected against physical damage and corrosion with suitable sleeves, properly sealed at both the ends, at road crossings.
6.9
THERMAL RELIEF SYSTEM
PRESSURE
Any equipment or section of pipeline in which liquid LPG may be trapped e.g. between shut off valves, shall be protected against excessive pressure developed by thermal expansion of the LPG by providing suitable
thermal pressure relief valve(s). If pressure relieving devices discharge to atmosphere, the discharge shall be done in a safe manner.
-
The LPG line exit cylinder evacuation area to be provided with a non-return valve before joining the main LPG return header. Independent earthing connections.
6.9 VALVES Steel valves conforming to relevant API standards shall be used. Cast iron valves should not be used. 6.10 FITTINGS (i) Steel flanges and flanged fittings conforming to API 105 Class 300 (forged) or eq. shall be used. Slip on or weld neck flanges should be used. Screwed flanges for sizes 50 mm or smaller may be used. Steel flanges should conform to the applicable provisions of ANSI B 16.5. (ii) Steel screwed fittings and couplings shall conform to ANSI B 16.11 or equivalent. Steel unions shall have ground metal to metal seats. Gasket type unions shall not be used. (iii) Plugs shall be of steel. Cast iron or brass plugs shall not be used. (iv) All flanges shall be connected for bonding for electrical continuity. 6.10 EVACUATION FACILITY FOR DEFECTIVE CYLINDERS a. The cylinder evacuation facility shall consist of : -
Cylinder emptying vessel (s) Compressor Four way valves or equivalent Cylinder rack, header to be provided with pressure gauge and a strainer with isolation valves.
b. Each of cylinder emptying vessels mentioned above shall be equipped with the following : -
Pressure gauge Level gauge high level alarm switch set at 85 % with trip / switchover arrangement. Pressure relief valves, Vent valves discharging to 1.5 m above the shed. Other trims like drain valve, utility connection.
-
Typical sketch of cylinder evacuation facility is enclosed as Figure-V. 6.11
PURGING OF NEW CYLINDERS/ TANKERS
(a) The new LPG cylinders containing air shall be evacuated with a vacuum pump.. The evacuation facility shall consist of : -
Vacuum pump (water/ oil / air cooled type) Purging manifold Vacuum receiver fitted with vacuum gauge, vent and drain. LPG vapour header Purging adapters Vacuum pump with suction strainer Pressure regulator, relief valves
Typical sketch of new cylinder purging system is enclosed as Figure-VI. (b) Purging of tankers/ vessels shall be done using either Nitrogen or
by filling water and displacing with LPG vapours.
stainless steel trim and stainless or aluminized steel spring.
EQUIPMENT FOR ETHYL MERCAPTAN SERVICE
(iv) For transfer valves, stainless steel ball valves with fluoroplastic seats and stainless steel (SS316) trim or their equivalent are recommended.
6.12
6.12.1 Material of Construction of Ethyl Mercaptan containers Stainless steel and copper free steel alloys are the preferred materials of construction of equipment for mercaptan service. Aluminium of desired pressure rating can also be used. Use of Iron or carbon steel shall be avoided as there is the hazard of formation of iron-sulphur complexes which are pyrophoric. Copper or copper bearing alloys shall not be used for mercaptan service as mercaptan readily attacks and contaminates them.
(v)
Rigid connection should be welded or flanged joint type.
(vi) Fluoroplastics shall be used for gasketing. (vii) For pressure gauges, stainless steel diaphragm type is recommended with stainless steel socket and tip. (viii) Provision for analysis in line with IS:4576 or IS14861 as applicable shall be made. 6.13 SELECTION
OF ELECTRICAL
EQUIPMENT
6.12.2 Pumps for Mercaptan service Only hermetically sealed pumps shall be used. 6.12.3 Piping and Fittings (i)
(ii)
Seamless stainless steel piping shall be used. Threaded fittings can be used provided they meet the service requirement ratings. A fluoroplastic tape sealant is recommended. Flexible connections shall be seamless stainless steel with pipe nipples welded to each end.
(iii) Relief valves shall be full nozzle, disc type, closed bonnet carbon steel body with 304
i. Electrical equipment shall be selected, sized and installed so as to ensure adequacy of performance, safety and reliability. The equipment in general shall conform to relevant Indian Standards and shall be suitable for installation and satisfactory operation in the service conditions envisaged. ii. All electrical equipment shall be selected considering the system neutral earthing. iii. Electrical equipment including for lighting system shall conform to hazardous area classification and be selected in accordance with IS:5571. These shall be tested by agencies such as CMRI, ERTL, CPRI or
independent test laboratory of country of origin for such equipment. Indigenous Flameproof equipment shall comply with relevant BIS standard as per requirements of statutory authorities. All equipment used in hazardous area shall be approved by Chief Controller of Explosives. iv. For details on hazardous area classification, enclosure protection etc., OISD-STD–113, OISD-RP-149, NEC – 1985, IS:2148, IS:5571, 5572, IS: 13408, Petroleum Rules, 2002 shall be referred. 6.14
water pumps, stations etc.
fire
alarm
c. Escape route for safe evacuation of operating personnel. iv) Under normal operation, both emergency and normal lighting shall be fed by normal power source. On failure of normal supply, emergency lighting shall be transferred to emergency source until the start of D.G. set within 15 seconds. Critical lighting (D.C. supply based) shall be normally kept ‘ON’. During power failure, battery bank shall be used to provide power.
Installation Lighting
i) Sufficient lighting shall be provided so as to enable plant operators to move safely within the accessible areas of installation and to perform routine operations. In the event of normal power failure, emergency lighting shall be provided. ii) Normal lighting system shall be on 415/ 240V AC supply, whereas emergency lighting will be either on 220V or 110V DC. iii) Lighting requirements provided during the failure of power supply for Normal lighting are intended broadly, a. to facilitate carrying out of specified operations, for safe shutdown of the installation. b.
to gain access and permit ready identification of fire fighting facilities such as fire
v. Low pressure sodium vapour lamps shall not be installed in hazardous areas. vi. The illumination levels in different areas shall be as per good engineering practice. Depending on the nature of job activities to be carried out the suggested minimum illumination levels for various areas are covered in OISD-STD-149. vii. The lighting fixtures on various circuits shall be suitably interlaced so that failure of any one circuit do not result in complete darkness. viii. Switches controlling the lighting fixtures and exhaust fan shall be installed outside the battery room. ix. Switches of lighting panels installed in hazardous area, shall have a pole to break the neutral in addition to the poles for phases.
• Electrical equipment fencing (e.g. transformer, yard etc.)
When the means of isolation is located in a non-hazardous area, the switch shall break all poles including neutral or alternatively may break only live poles, the neutral being isolated by a removable link. For details on inspection practices OISD standard 147 to be referred.. 6.15 i.
ii.
Installation Earthing
All electrical equipment shall be suitably earthed. Earthing system shall cover the following: ¾ Equipment earthing for personnel safety. ¾ System neutral earthing, and ¾ Protection against Static and Lightning discharges.
• Cable trays and lighting mast and poles. •
Spheres, Bullets etc.
loading
racks,
•
Flexible earth provision for wagon, truck.
Installation earthing design shall be carried out in accordance with the requirements of Indian Electricity Rules and IS : 3043. All earth connections should be visible for inspection to the extent possible.
iv. The resistance values of an earthing system to the general mass of earth should be as below: ¾ For the electrical system and equipment a value that ensures the operation of the protective device in the electrical circuit but not in excess of 4 Ohms.
• System neutral
• Steel structures, platform etc.
Cable shields and armour.
iii. Where installed, lightning protection shall be provided as per the requirements of IS:2309.
The earthing system shall have an earthing network with required number of earth electrodes connected to it. The following shall be earthed:
• Metallic non-current carrying parts of all electrical apparatus such as transformers, switchgears, motors, lighting / power panels, terminal boxes, control stations, lighting fixtures, receptacles etc.
•
¾ 10 Ohms in the case of all noncurrent carrying metallic parts of major electric apparatus or any metallic object. v.
The earth conductor shall be adequately sized to carry the applicable maximum earth fault current without undue temperature rise. All joints shall be protected against corrosion.
v. All the electrical equipment operating above 250 volts shall have two separate and distinct connections to earth grid.
vi. The main earthing network shall be used for earthing of equipment to protect it against static electricity. 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. vii. Every Sphere/ bullet shall be electrically connected with the earth in an efficient manner by not less than two separate and distinct connections. The connections and the contacts required shall have as few joints as possible. All joints shall be
riveted, welded or bolted and also soldered to ensure both mechanical and electrical soundness. The resistance to earth shall not exceed 7 Ohms and the resistance to any part of the fitting to the earth plate or to any other part of fitting shall not exceed 2 Ohms. viii. All joints in pipelines, valves in installations, and associated facilities and equipment for LPG shall be made electrically continuous by bonding or otherwise; the resistance value between each joint shall not exceed 1 Ohm.
7.0 STORAGE AND HANDLING
just before the release of the truck.
7.0 GENERAL This section deals with the safe practices and provisions applying to unloading of bulk LPG and storage of bulk LPG at installations. There should be strict compliance w.r.t selection, deployment of proper skilled manpower for effective operation and maintenance.
7.1 BULK HANDLING MOVEMENT BY ROAD
OF BULK LPG
FOR
The tank truck for road movement shall be designed, constructed and tested in accordance with the Static and Mobile Pressure Vessels (Unfired) Rules, 1981 and OISDSTD-159. 7.1.1 SAFETY PRECAUTIONS Following precaution should be taken due to associated hazards during transfer of LPG to or from a tank truck. 1. No source of ignition must be allowed in the area where product transfer operations are carried out. 2. Fire extinguishers shall be placed near the tank trucks during transfer operations. 3. The first operation after positioning the truck should be to provide proper earthing. Earthing shall be disconnected
4. Before removing plugs or caps, always crack open to allow for release of trapped LPG and further to ensure that the valves are effectively sealing. 5. Hoses shall be handled with care and inspected periodically as per OISDSTD-135. 6. While disconnecting hoses/arm, connections shall be loosened only slightly at first to allow release of trapped pressure, if any. 7. Do not expose hands, face or clothing to liquid LPG. Always use personal protective equipment while making or breaking the connections to avoid cold burns. 8. The master switch shall be put off immediately after parking the truck in position. No electrical switch on the truck shall be turned " on" or " off" during the transfer operation. 9. No repairs shall be made on the truck while it is in the loading area. 10. Availability of wheel chokes.
11. New tank trucks vessels or vessels received after repair shall be purged as per laid down procedure. 12. In case, the receiving vessel is having a pressure of less than 1 Kg/sq.cm.g, it shall not be filled. Such vessel shall be taken for filling only after detailed safety checks. 13. Venting and purging of LPG during transfer operation shall not be carried out in open atmosphere. It shall be piped to a suitable flare system. Where such facility does not exist, vent pipes shall be provided to carry the vented product to a safe distance and released at a height not less than 1.5 m above the eves of the structure. 14. Filling/transfer operations should be stopped immediately in the event of -
7.1.2
(i) Uncontrolled leakage occurring (ii) A fire occurring in the vicinity (iii) Lightning and thunder storm PROCEDURES FOR OPERATION
pressure gauge, temperature gauge on the vessel / bullet. ¾ Fire screen between cabin and vessel is provided. For this purpose, cabins with metallic back cover without any opening will be considered as fire screen. ¾ Provision of 2 nos. of 10 Kgs. DCP Fire Extinguishers. ¾ Fitment of Spark arrestors of approved quality. ¾ No leakage in silencer pipe exists.
exhaust
¾ Manufacturer's name plate with date of testing is fitted on the vessel. ¾ Valid Explosive Licence and RTO certificate is available. ¾ Approved drawings of vessel are available. ¾ Blind flanges/caps provided on vessel. ¾ Availability cable.
of
are
Earthing
¾ Bonding between vessel and chassis and between flanges is satisfactory.
(a) LOADING OPERATIONS 1. Check for following in a tank truck as per statutory regulations before accepting it for filling: ¾ Provision of two safety valves, level gauge, Excess flow check and control valve on liquid and vapour lines,
¾ Earthing / bonding point is available. ¾ Third party inspection/test certificates for vessel/fittings are available. ¾ Liquid / vapour line valves are in good condition.
2. Move truck to the loading bay/weigh bridge and record the weight of the empty tank truck. 3. Place the truck on loading bay and place choke blocks at front and rear wheels. Keep the truck in neutral mode with hand brakes "ON". 4. Stop the engine and switch off all electrical equipment. 5. All persons should leave the driver's cabin. 6. Make earthing connections of the vehicle at specified point to the fixed grounding system. 7. Connect liquid and vapour lines suitably with the loading point. Crack open valves on loading & vapour return lines and inspect hoses & connections for leakage. Loading should start only when the system is leak free. 8. Start the loading pump. 9. The quantity loaded into the truck can be determined by (i)
Liquid level
(ii)
Weighment
(iii)
Positive displacement meter
(iv)
Mass flow meter
The quantity of LPG filled shall not exceed the RLW of the tank truck. 10. Liquid level may be determined by roto-gauge or fixed liquid level gauge. Percentage volume to be filled shall not exceed 85 % at 55OC i.e. the allowable filling limit as per CMV Rules.
11. Where weigh bridge is used, it is necessary to determine the density of the product being loaded to avoid excess filling in terms of volume. The weigh bridge shall be periodically calibrated and stamped by Weights & Measures Authorities. 12. When the filling operation is in progress, the pressure within the tank truck vessel shall be observed to ensure that it does not approach the start-to-discharge pressure of the relief valve. Filling rate may be regulated as required. 13. The couplings may then be removed and plugs/caps replaced on the tank truck valves. Re-check tightness with soap solution.
(b) Unloading Operations 1. Operations described under Item 1 through 6 in para 7.1.2(a) should be carried out. 2. Liquid line and vapour line of the tank truck shall be connected to the respective hoses fixed to the unloading point. 3. Test the connections for leaks by slightly opening the valves for pressurising. When satisfied, valves on the tank truck and the receiving vessel shall be opened. 4. Start the LPG compressor. Vapours will be sucked from the receiving vessel and will be discharged into the vapour space of the tank truck vessel creating pressure differential thereby pushing the liquid from the tank truck vessel to the receiving vessel.
5. Care should be exercised to see that the pressure created within the delivering vessel does not reach or exceed the set pressure of the relief valve. 6. An authorised person of the company shall supervise the transfer operation and respond immediately in the event of an emergency. 7. After the liquid has been expelled, the vapour recovery operation may be started. Care should be taken not to bring down the pressure of the delivering vessel below 1.5 Kg/cm2g. Checklist for bulk LPG tank Trucks at unloading locations is given at Annexure 7 –I. 7.2
BULK HANDLING MOVEMENT BY RAIL
FOR
LPG is moved in Tank Wagons by the Railways. These wagons are designed by RDSO and are fitted with various devices as shown in Figure-VII. The loading facilities are similar as for tank truck loading while unloading of LPG from tank wagons shall be done with the help of compressor. The compressor is used to create a differential pressure between the receiving and discharging vessels by withdrawing vapors from the receiving vessel and forcing it at high pressure into the discharging vessel thereby establishing a smooth flow. The content of tank wagons can be ascertained by weighment on weigh bridge before and after emptying or,
alternatively, mass flow meters can be used. Checklist for bulk LPG tank wagons at unloading locations is given at Annexure 7 –II. 7.2.1
SAFETY PRECAUTIONS
1. Do not allow the locomotive to come on the weigh bridge unless its capacity is designed to take the locomotive load. 2. Sufficient number of dummy wagons may be used to avoid electric loco coming closer to the gantry. Maintain the distance of 15 m from first fill point. 3. The first operation after positioning the wagon shall be to provide for proper earthing. Earthing shall be disconnected just before the release of the wagon. 4. For connecting and disconnecting hoses, only non-sparking tools shall be used. 5. After the wagons are placed on weigh bridge and before the loco is detached, the hand brakes on each and every wagon shall be applied. 6. Like-wise, before the wagons are moved from the weigh bridge, release brakes on all the wagons. 7. Do not use footwear protruding nails.
with
8. Ensure that the lower portion of flapper bridge at wagon side is fitted with rubber or wooden padding.
9. Ensure that electrical continuity of the system is intact. 10. Ensure that all fittings on the wagons are checked physically. 11. Hoses shall be tested as per OISD-STD-135 and records maintained. 12. The loading/unloading operation shall be carried out under close supervision of authorised person. 13. During unloading operation, after the liquid transfer is over, the wagon pressure shall not be reduced below 1.5 Kg/sq.cm.(g). 7.2.2 OPERATING PROCEDURES (a) LOADING OPERATION 1. Place the wagon on weigh bridge taking care to see that all the four wheels are properly accommodated on the platform. Engage hand brakes. 2. Ask loco to move away and exhibit caution sign at suitable distance away from the wagons on both ends. 3. Switch off loco engine, if parked nearby. 4. Apply brakes on all wagons 5. Ensure fire system, safety interlocks, communication system are OK 6. Take loading advice. 7. Connect earthing lugs to the wagons. 8. Lower the flapper bridge slowly on the wagon.
9. Open the lid of the wagon. 10. Take the tare weight reading and set the pointer of the scale to zero. Compare this with the marked tare weight on the wagon. Alternatively, use mass flow meter to fill the wagons. 11. Connect the filling hose or loading arm and vapour return line hose or arm to the wagon. Ensure that the flare connection valves are closed. 12. Ensure that the header is charged with LPG and the bulk loading pump is running. 13. Open the tanker filling line valve and vapour return line valve. 14. Check the system for leaks. 15. Open the valve on the vapour return line. Now slowly open the valve on the filling line. Increase the valve opening and gradually open the valve fully. Ensure filling is upto safe filling level keeping in view temperature factors. Take mass flow meter readings if used. 16. Once the filling is over, close the wagon filling and vapour return lines valves and also valves on filling and vapour return lines at the loading point. 17. Open the valve on flare line connection to both feed line and vapour return line slowly
to avoid ice formation. Thus, the hoses are depressurised. Then, close the flare line connection valves. 18. Disconnect the filling and vapour return line hose connections from the wagon. Replace and tighten the plugs on filling and vapour return lines. 19. Close the top cover of the wagon and seal it properly. Remove earthing connections. 20. Release the hand brake of the wagon. 21. Release all the wagons on the loading points in the lot. 22. Check the gross and net weight at the weigh bridge. Use loading arms for loading / unloading operations. (b) Unloading Operations 1. Ascertain that the liquid discharge valve and the vapour valve within the tank wagon cover are in the closed position. 2. Open the port covers in the side of the dome shell, if exist. Unscrew the plugs in the outlets of the vapour valve and the liquid valves using a box wrench. This must be done slowly. 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 relieve itself past the threads before the plugs are entirely disengaged. 4. If the vapour discharge continues or if there is evidence of a liquid discharge, the valves should be re-tightened. 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. 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. 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. 8. After the vapour and liquid hoses have been connected and before any valve is opened, the valves on the tank wagon are crack opened in order to apply pressure to
the hoses / loading arms as a test for leaks. 9. If any leak appears, the valve should be immediately closed and corrective measures applied. 10. Recheck the lines and connections to make sure that they are connected correctly. 11. After the liquid and vapour lines have been secured and tested, both liquid education valves should be opened slowly and completely. Then, open all other valves in the liquid line working from the tank wagon to the storage tank. 12. If the tank wagon pressure is higher than that in the storage tank, do not open the valves in vapour line or operate the compressor. When the rate of liquid flow drops to an unsatisfactory level with the storage tank filling valve wide open, open the vapour valves between the tank wagon and the storage tank. 13. At this point, make sure that the control valves at the compressor are in a position which allow the compressor to draw vapours from the storage tank and force it into the tank wagon, then start the compressor. 14. When the tank wagon is held at a pressure of 2.0 to 2.5 Kg/sq.cm. above the storage tank pressure, the tank wagon should be emptied into the storage vessel.
15. A 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. 16. 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. 17. If the facilities are so arranged that vapours may be removed from the tank wagon, the pipeline at the compressor should be arranged so that the compressor will draw vapour from the tank wagon and force it into the storage tank. 18. In this operation, the vapour should be discharged below the surface of the liquid in the storage tank to hasten the liquefaction and, in turn, help prevent excessive pressure in the storage tank. 19. Restart the compressor and when the tank wagon pressure is reduced to about 1.5 - 2.0 Kg/ sq.cm., stop the compressor and close all the valves in the vapour line. 20. After bleeding off the pressure in the hoses, disconnect both the liquid and vapour lines. Replace all the plugs in the tank wagon valves and the unloading fittings.
21. Recheck sample valve, gauging device and thermometer well to determine that they have been returned to their original condition and are closed tight. Lower the dome cover carefully and lock it in place with the locking pin or secure by appropriate means. 22. Remove connections.
bonding
23. Reverse or remove and replace the "Flammable" placard with "Dangerous Empty" placard. 24. Remove the "Stop - Tank Wagon Connected" sign and wheel blocks. 25. Any defect observed in the tank wagon should be noted on the appropriate forms and routed in accordance with acceptable procedure. 26. Notify the railways in writing about release of wagon and ensure that it is removed from the siding promptly. 27. Gauge the storage tanks, within the installation, which have received the LPG to determine that the liquid level is appropriate. 28. In the event of LPG received on weight basis, the tank wagon may require weighing following the completion of the unloading operation. 7.2.3
DEGASSING SICK/LEAKY WAGONS
OF TANK
(a) Recommended Procedure In the degassing system recommended for LPG wagons, vacuum cycle purging technique should be followed as outlined below : - Vessel should be evacuated repeatedly by a vacuum pump. - Vapour should be discharged through high rise vent, keeping the steam on. - Maximum possible vapours should be sucked out in first step depending on the capacity of vacuum pump/compressor. As per RDSO, vessel can sustain the full vacuum also. - Between the two vacuum cycles, nitrogen/inert gas should be used for breaking the vacuum. - Cycle should be repeated till the LPG concentration is found below the end point of LPG (for butane, it is 4% by volume when purging is done by nitrogen). Periodically, samples should be drawn from suitable location and analysed for LPG concentration. - Finally the vessel should be flushed with air to displace the nitrogen. Barrel should be tested finally with explosive meter to ensure that hydrocarbon concentration is below 10% of LEL. (b) Alternate Procedure
Alternately, wagons may be degassed by steaming or filling with water. However, it should be ensured that wagon is made water free after degassing. 7.3
BULK HANDLING MOVEMENT BY SEA
FOR
Transportation of LPG in bulk by tankers may be carried out under fully-pressurised, semi-pressurised (semi-refrigerated) or fully refrigerated at atmospheric pressure conditions. 7.3.1 CARGO CARRIER DESIGN & CONSTRUCTION The design and construction of cargo carrier is in line with International Maritime Organisation (IMO) Gas code.
a) Two cargo pumps, one each on either side of the longitudinal bulk head. b) Liquid discharge line from the tank dome, connected to the main liquid line. c) All emergency pump trunk way. d) A liquid loading line connected to the main liquid line. e) Two liquid level indicating devices one on each side. These usually consist of a float attached to a self winding tape which moves up and down, either on guide wires or inside a guide tube. The liquid level is read off the tape through a gastight window at the top of and outside the tank.
7.3.2 TANKER FACILITIES The cargo handling equipment in a tanker usually comprise of Cargo pumps (submersible and booster), Compressors, Condensers, Heat Exchangers, Vapourisers, Cargo heaters etc. The deep well pump supplies liquid to the booster pump to send the product ashore. In pressurised ship, liquid is withdrawn by pressurising the tank through vapour compression from other tanks. All semi and fullyrefrigerated tankers are provided with cargo heaters to enable the vessels to discharge into pressure storage ashore and a booster pump if the discharge pressure is significantly above 9 bars. Each cargo tank is provided with the following equipment:
f) Two sets of purge lines at the top and bottom of the tank. These are used to distribute inert gas or vapour for gasfreeing or gassing-up of the cargo tanks. g) A vapour line for withdrawal of vapour to the compressor. h) Sample tubes. Safety Devices (a) Atleast two safety valves in each cargo tank (b) High and Low level alarms (c) Overfill alarm. When actuated, this will shuttle main loading valve and sound an alarm.
However, the design of the tankers with regard to provision of facilities, equipment, accessories and safety features must be in accordance with the IMO requirements.
pressure of the shore tank. A suitable vapour recovery system or re-liquefaction of the gas from the receiving tank shall be provided. 7.3.5 UNLOADING OPERATIONS It is essential that the ship and terminal operators are familiar with the basic characteristics of each other's facilities, are aware of the precise division of responsibilities and are able to communicate effectively during the time they are together involved in the joint operation of cargo handling.
7.3.3 TRANSFER PIPING The following facilities on transfer piping between Terminal and Shore tanks should be provided: (a) ROVs at both the ends of transfer line.(Additional ROV at critical locations in the pipe line route.)
7.3.6 COMMUNICATION (b) Relief valves on liquid line to surge vessel with an audible alarm system connected to high safe venting system
Reliable and effective communications, irrespective of whether these are directly between the tanker and the terminal or indirectly via third party, are prerequisites of safe and efficient cargo operations before the tanker comes alongside and during the period of cargo operations and until the tanker departs. Terminal communication shall be compatible with tanker's system.
(c) Physical protection against impact to vent/drain pipes (d) Protection of pipeline against corrosion, particularly when the pipeline passes under public road way, which is likely to be water-logged (e) Pipe work passing public road way be designed to acceptable public highway authority standard in terms of roadway axle weights 7.3.4 TERMINAL FACILITIES Transfer of LPG from ship to terminal and vice versa is accomplished using loading arms of approved type as per OCIMF guidelines. Provision of vapour return facility shall be made. In case of pressurised gas transfer, it is observed that the pumping rate falls off gradually due to back
7.3.7
PRE-CARGO DISCUSSIONS
TRANSFER
Before any cargo transfer operation, it is imperative that the intended procedures are thoroughly discussed between the responsible personnel from the tanker and the terminal with a view 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.
The broad outlines for discussions are as under : (a) The names terminal and who will be cargo transfer be noted.
the
and roles of ship personnel responsible for operations may
(b) The terminal representatives shall check that pre-arrival instructions to the ship on cargo, cargo disposition and cargo conditioning have been carried out. They also shall check that all necessary tanker equipment inspection and tests have been performed. (c) Similarly, the tanker's officers shall satisfy themselves that the relevant terminal equipment and inspection checks have been carried out satisfactorily. (d) Terminal representatives and customs and/or independent surveyors, where necessary, will be informed of the cargo tank data e.g. temperature, pressure, whether free of cargo, liquid heel or arrival dip, composition of tank vapour and quantity of cargo on board. 7.3.8 SHIP / SHORE CHECKLIST
SAFETY
Checklist for Ship/Shore safety is given in Annexure 7-III. 7.3.9 DISCONNECTION OF HOSE/ UNLOADING ARM On completion of unloading operation the tanker discharge pipeline need to be purged to push
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 arm, it is to be ensured that there is no liquid LPG left between the tanker main valve and shore isolation valve. Product from this length of pipeline is to be safely vented. 7.4 STORAGE OF BULK LPG Precautions for storage of LPG in bulk : a) Liquid level in the vessel shall not exceed the permissible limits. Filling shall not exceed safe permissible filling ratio. b) Vessel shall be inspected daily for any LPG leakage and corrective action taken. c) All gauges, viz. High level alarm, measuring gauges, pressure gauges, temperature gauges should be kept in operating condition at all times and be checked daily. 7.5 SAMPLING AND DRAINING 7.5.1 SAMPLING Sampling is primarily required at supply locations i.e. Refineries, Gas Processing Plants, Import Terminals, etc. Sampling of LPG for different analytical tests shall be carried out in accordance with IS:1448. During handling of LPG samples, the following safety precautions shall be followed : (i) Special sampling bombs shall be used for LPG sampling. Arrangement of rupture disc or any other suitable safety relief device
shall be incorporated in the sampling bomb. (ii) Sampling bombs shall be inspected periodically and tested hydrostatically at regular intervals. Record of such inspection/test shall be maintained. (iii) Sample bombs shall be earthed effectively before and during discharge of sample. (iv) LPG samples shall be collected only in open/ventilated areas and the person taking the sample shall stand on the windward side. (v) The sampler shall wear protective goggles, hand gloves, shoes etc. while taking samples. (vi) Samples, after collection, shall be properly labeled and kept at designated place. (vii) Sampling of LPG should preferably be done in bombs with provision of pre-charge at one end. This will not only eliminate the possibility of undesirable presence of air in the bomb, which may become a safety hazard, but also minimises flashing of sample during collection, thereby providing a truly representative sample. 7.5.2 DRAINING Storage vessel should be drained regularly for its water content, sediments, caustic contents etc. Draining operation should be carried out under the supervision of an authorised person. For draining of water from LPG vessels , following procedure shall be followed :
(i) The valve nearer to the vessel shall be opened first and closed. Then, draining shall be carried out by gradually opening the valve farther from the vessel. The operation shall be repeated till LPG release starts. (ii) It shall be ensured that the drain outlet is at a safe distance from the vessel so that accidental ignition of any escaping vapour would not expose the vessel to flame impingement. It is important not to attempt removal of the entire quantity of water as considerable liquid LPG may escape in the process. At the first sign of appearance of LPG, the operation shall be stopped. Escape of LPG may lead to formation of ice block at the valve seat, preventing closure of valve. This will result in escape of uncontrolled vapour to the atmosphere causing a very serious hazard. The valve shall be operated slowly to avoid ice formation.
ANNEXURE - 7 - I CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION 1.
CHECKS REQUIRED TO BE CARRIED OUT BEFORE ALLOWING ENTRY OF TT INSIDE LICENCED AREA
-
Height barrier provided as per specifications
ON THE TANK TRUCK :
-
Fuel tank is protected by means of stout guard and fuel tank cap is locked.
-
Properly fitted spark arrestor of make and design approved by CCE, Nagpur.
-
Paint of bullet is not peeling off.
-
Proper Fittings i.e. SRV, EFCV, temperature & pressure gauges etc. as SMPV Rules & OISD-STD-159.
TANK TRUCK
GENERAL
-
2 nos. 10 kg. DCP extinguishers in easily accessible and removable position with Truck No. date of checking and charging painted on it.
-
Provision of quick closing manifold valve with lever indicating close and open status.
-
No visible dent on the bullet. ELECTRICALS :
-
First aid kit is available.
3.
CHECKS REQUIRED TO BE CARRIED OUT ON RANDOM BASIS MINIMUM ONE DAY, ONCE IN A MONTH : TANK TRUCK :
-
Internals of fire extinguishers in good condition
-
Carries TREM CARD, instructions booklet detailing instructions on handling emergencies en route.
-
All junction boxes are properly sealed
-
Any loose electrical wiring/ terminal
-
Carries route map
-
Electrical wiring is insulated and provided with suitable over current protection.
-
Has valid CCE licence and authenticated copy of drawing
-
Truck is self starting
-
Carries RTO permits
-
Readily accessible master switch for switching off the engine is provided inside the cabin.
-
RLW-ULW> Licenced capacity
-
HAZCHEM sign, name of contractor with address and telephone No. displayed prominently.
-
Bullet has no sign of external corrosion.
-
Dipole wiring. (Note 1) TANK FITTINGS :
-
Leakage from any fittings or joints.
2.
CHECKS REQUIRED TO BE CARRIED OUT BEFORE ISSUING LOADING MEMO (DURING THE COURSE OF UNLOADING OPERTIONS)
TANK FITTINGS : -
Excess flow check valves are functioning.
-
-
-
Liquid / vapour lines are adequately anchored and are well protected by means of stout steel guard.
Following are available in Tank Truck : -
Tools for all fittings
Liquid/ vapour pipe lines are in single piece from excess flow check valve to discharge valves - Safety fittings viz., safety valve, roto-gauge, pressure gauge and temperature gauge are adequately protected. Operative fittings like roto gauge, pressure gauge and temperature gauge are operational.
-
4 Nos. caution sign board with luminous paint for stopping traffic in case of any emergency.
GENERAL : -
Flanges and bend pipe on liquid / vapour lines should be of rating of 300.
Based on the nature of defects either all the deficiencies should be got corrected at the unloading location itself or the tanker should be allowed to get the repairs done en route and submit the details at loading location.
ANNEXURE - 7- II CHECKLIST AT UNLOADING LOCATION FOR BULK LPG TANKWAGONS VISUAL EXAMINATION OF WAGON FOR -
POH/ ROH OVERDUE : FOR BARREL
Y/N
-
FOR UNDERFRAME
Y/N
-
Damage to Tank Barrel
Y/N
-
Damage/ missing tank fittings
Y/N
-
Leakage from dome fittings
Y/N
-
Seal intact
Y/N
-
All valves, fittings are in working order
Y/N
-
The surface is free from rust. The paint on the barrel is in good condition and has not lost its reflecting characteristics.
Y/N
The matter regarding tank wagon not complying with any of above checks shall be taken up with loading location for corrective action.
ANNEXURE 7 - III LIQUEFIED GAS-CARGO TRANSFER CHECK LIST
(Items to be checked before cargo transfer begins) SHIP:_________________________________________DATE:______________ PORT &BERTH:_________________________________TIME:______________
S.NO
CHECK POINT
FOR SHIP
1.
Has information on cargo and shipshore connection been supplied ?
2.
Is the agreed ship-shore communic ation system operative ?
3.
Are fire and other procedures agreed ?
4.
Are local observed ?
5.
Has safe access been provided and warning notices posted ?
6.
Are moorings secure and agreement reached on the use of tension winches ?
7.
Are emergency towing-off wires correctly positioned ?
8.
Is the ship ready to move under its own power ?
9.
Are smoking restrictions in force and notices posted ?
10.
Are naked light restrictions being observed ?
11.
Are portable electrical equipment cables disconnected ?
12.
Are all hand torches and portable R/T sets of approved type ?
emergency
regulations being
FOR SHORE
13.
Are ship's main transmitting aerials and radar switched off and earthed ? Counted....
S.NO
CHECK POINT
14.
Some doors and ports have to be closed : are they actually shut ?
15.
Are all air conditioning intakes correctly trimmed and window type units closed ?
16.
Is the water main ready for immediate use ?
17.
Is the water spray system ready for immediate use ?
18.
Are dry powder and all other fire fighting appliances correctly positioned and ready for immediate use ?
19.
Is necessary protective clothing available or being worn ?
20.
Are void spaces properly inerted ?
21.
Is the required ventilation equipment in operation ?
22.
Is the cargo system set for the operation ?
23.
Are all remote control valves in working order ?
24.
Are cargo tank relief valves correctly set and in good order ?
25.
Are the required cargo pumps and compressors in good order ?
26.
Is reliquefaction or boil-off control equipment in good order ?
27.
Is gas detection equipment set for the cargo, calibrated and in good order ?
28.
Are cargo system gauges and alarms correctly set and in good order ?
FOR SHIP
FOR SHORE
29.
Are scuppers plugged and suitable drip trays in position ? Contd...
S.NO
CHECK POINT
30.
Are cargo and bunker hoses in good condition and properly rigged, have certificates being checked ?
31.
Are unused bunker connections blanked and bunker tank lids closed ?
32.
Are unused cargo connections (including inert gas line)securely blanked ?
33.
Are automatic shutdown systems working properly ?
34.
Does shore know the closing rate of ship's automatic valve at operating temperature ; does ship have a similar details of shore system ?
35.
Are all personnel (including supernumeraries and new arrivals) aware that cargo transfer is to begin ?
36.
Have all personnel been allocated emergency stations ?
37.
Are non-essential personnel clear of the cargo area ?
FOR SHIP
FOR SHORE
38.
Are those directly involved aware of the agreed cargo transfer sequence ? ======================================================================== REMARKS : We have checked with each other the items on the above check list and have satisfied ourselves that the entries we have made are correct to the best of our knowledge.
CHECKED BY______________________ (For Ship)
_______________________ (For Terminal)
8.0 BOTTLING OPERATIONS 8.1 GENERAL -
This section covers the operations in the LPG bottling plants, Safe work practices shall be established to ensure safe operation, maintenance, and modification activities while carrying out various jobs. These practices shall be documented and approved. The manuals shall be updated at least once in a year by authorised personnel.
(b) Filling operation - All cylinders shall be filled on gross weight basis on filling machine. Maximum permissible errors on net quantity declared by weight shall be in accordance with the Standards of Weights & Measures (Packaged Commodities) Rules 1977 and Amendment Rules, 1992. The filling pressure should not exceed maximum working pressure of cylinder i.e. 16.9 kg/cm2 at 65 deg.C.
Activity on bottling line including valve change, shall be carried out by trained personnel. (c)
8.2 BOTTLING OPERATIONS The Bottling Operations can classified under following heads :
be
i) Receipt of LPG cylinders ii) Filling & despatch of LPG Cylinders iii)
Handling & storage of LPG cylinders
iv) Auxiliary Operations 8.2.1
Receipt of LPG cylinders
Cylinders shall be received in capped condition. Cylinder shall conform to IS:3196. 8.2.2 Filling of LPG cylinders (a)
Pre-filling operation : Cylinder before filling shall be checked for following : - Visually inspected IS:5845/ IS : 13258
as
per
`O' Ring (joint packing) is present and there is no apparent damage to valve. Tare weight is legible.
Post Filling Operation - Cylinder shall be counter weighed with check scale for accuracy of weight. Variation of net weight. Variation of net weight shall not exceed permissible limits. All under-filled/ over-filled cylinders should be corrected on correction scale. Cylinder shall be checked for `O" ring condition and for valve leak by means of Compact valve Tester (CVT) or electronic leak detector. CVT or electronic leak detector shall be calibrated to detect leakage beyond 0.5 gm/hr. For cylinders found with `O' ring defect, the `O' ring shall be replaced with a new one. Further all "O" ring or valve change cylinders shall be rechecked for leakage with CVT or electronic leak detectors. The on line valve removal machines is used shall be checked for integrity of the system with regard to proper sealing. The machine shall be further
checked for leak tightness, torque settings before being put in use every day. The maintenance shall be carried out as OEM recommendation. Cylinder shall be checked for body leak and bung leak by dipping in water test bath or by an established electronic leak detection system. Cylinder shall be capped prior to dipping in test bath water. Only those cylinders found passing all above checks shall be processed further for sealing. Cylinders shall be sealed with PVC seal or Aluminium seal. Seal shall have identification mark of oil company, preferably name of plant and period of filling. No bypassing of safety interlocks, fire water system, gas detection system, vapour extraction system and heat detection system shall be permitted unless authorised by plant manager in writing. 8.2.3
Handling & Storage of LPG
Handling and storage of LPG cylinders shall be governed by Gas Cylinders Rules, 1981. Following observed :
safe
practices
shall
be
a) Handling of LPG Cylinders - LPG cylinders shall not be dropped, rolled on body and shall not be subjected to any violent contact with any other cylinder or object cylinder shall be moved by rolling on its foot ring or on conveyors or hand trolleys. b) Defective filled cylinders - Any cylinder having body leak, bung
leak, bulge, fire ravaged or spurious shall be evacuated immediately. Any cylinder with valve leak shall be immediately capped and thereafter evacuated immediately. Cylinders requiring repairs other than valve leak shall be degassed for repairs. All above cylinders shall be clearly identified, with markers, to their nature of defects and shall be kept capped during storage. c) LPG cylinder storage - All cylinders shall be stacked vertically (with valve in upright position) in not more than 1.5 m. Cylinders of different capacity and type shall be stacked separately. All cylinders shall be capped during storage. The cylinders shall be stacked in small lots of 4 rows and 25 cylinders length. A minimum access path of 1 mtrs. must be maintained on both sides of 4 rows and 2 metres after every 5 such lots. After each length of 25 cylinders, there must be a passage of 2 metres. The cylinder storage space shall be properly marked/ painted on the flooring. Typical stacking arrangement for 14.2 kg cylinder is given in Figure-I. Empty and filled cylinders shall be demarcated clearly. Minimum distance of 15 metres from cylinder loading area and minimum distance of 10 metres from filling point shall be observed for all filled cylinders stack.
of air prior to be taken up for refilling with LPG. Following safe procedure shall be observed for purging of LPG cylinders :
8.2.4 Auxiliary Operations a) Cylinder requiring valve removal and valve fixing -
Connect the cylinder valve to vacuum pump and evacuate air so that the pressure in cylinder is brought down to maximum 0.35 kg/cm2 absolute. Inject LPG vapour in the cylinder so that pressure is minimum 1 kg/cm2 and not above working pressure of cylinder i.e. 16.9 kgf/cm2 at 65 degree C.
c)
Degassing of Cylinders :
Cylinder having defective valve and with bung leak shall have to undergo valve removal and valve refixing operation. Following safe procedures shall be observed for the operation : -
Cylinder shall be evacuated of its product upto pressure, 1.5 kg/cm2 or less, thereafter depressurised to near atmospheric pressure through cold flare before opening the defective valve.
-
The valve of cylinders with bung / valve leak shall be replaced.
-
Cylinder bung shall be cleaned with 3/4" NGT tap and cylinder bung threads checked with L1 and L9 gauge.
-
Only cylinders passing above tests shall be taken up for valve change operation.
-
Good valve shall be fixed using a torque wrench. The torque shall not exceed 20 +/-2kg.m. Before fixing the valve suitable jointing compound shall be used. Jointing compound shall be compatible with LPG, water and metallurgy of cylinders and valves. Teflon tape/ paste of suitable valve joining material are recommended as jointing material.
Cylinders shall be evacuated and depressurised to near atmospheric pressure. The residual LPG in the cylinder should be cold flared in the atmosphere at a vent outside the shed at 1.5 m height above the eves of the shed. Valve shall be removed with suitable torque wrench or by using online valve changing machines. Cylinders shall be filled with water fully and water should be allowed to over flow. Thereafter, cylinders shall be emptied out of water and checked with explosimeter for degassing. Not more than 6 cylinders shall be degassed at a time. 8.3 DISPOSAL OF ETHYL MERCATAN CONTAINERS It shall be ensured that the drums are emptied of mercaptan to the extent possible. The empty drums then can be washed with water and detergent, followed by wash with a 5% bleach solution. After again washing with copious amount of water, the drums will be ready for disposal.
b) Purging of cylinders (ii) Treatment of Leaks and Spills -
New cylinders and cylinders degassed for repairs shall be purged
Leaks and spills of mercaptan can be treated with commercially available masking agents (e.g.Aldor and Neutroleum Alpha etc.) to make them odourless. Large mercaptan spills shall be covered with sand or activated carbon or any other absorbing material, which are then buried or incinerated. The area over
the spill should then be washed with ordinary household bleach solution and then thoroughly with water. Dry bleaching powder should never be used in treating mercaptan spills. A violent reaction could occur.
9.0 MAINTENANCE & INSPECTION OF EQUIPMENT 9.1 GENERAL : This section covers the maintenance and inspection practices to be followed to ensure safe and trouble free operation of various equipment.
2. Electrical maintenance / inspection, provisions of OISD-STD-137 shall be adhered to. 9.5 INSPECTION & MAINTENANCE OF VARIOUS FACILITIES IN LPG INSTALLATIONS :
9.2 MAINTENANCE SCHEDULES : 9.5.1 STATIC EQUIPMENT : To facilitate the maintenance service to be rendered in a planned manner, a preventive maintenance schedule covering the necessary work to be done, mentioning the periodicity i.e. daily, weekly, monthly, half yearly and yearly schedules, must be worked out. While basic recommendations given by the manufacturers should be considered and modified bearing in mind the local conditions (refer Annexure 9- I-IV). 9.3
PERSONAL PROTECTIVE EQUIPMENT :
Necessary personal protection equipments such as Hand gloves, Safety shoes, Helmets, Safety belts, Safety goggles etc. shall be used ( for details refer OISD- STD-155). 9.4 WORK PERMIT SYSTEM : Any maintenance, inspection, disassembly or removal of fittings while any part of the system is under pressure shall not be carried out without a proper work permit and approved procedure. 1. All Maintenance/ Inspection jobs shall be carried out in line with OISD Standard ; OISD-STD-105 on "Work Permit System".
a)
PRESSURE VESSELS STORAGE FACILITIES :
&
OISD Standard OISD-STD-128 on "Inspection of Pressure Vessels shall be followed. Weld cracking has been experienced in the lower half portions of LPG vessels. Small amounts of wet H2S present in LPG is supposed to be responsible for this in service stress corrosion cracking of welds. LPG vessels made from micro-alloyed high tensile steels have shown greater susceptibility to such cracking. Wet Fluoroscent Magnetic Particle Testing (WFMPT) is considered the most reliable test method for detecting these micro-cracks. WFMPT should be carried out prior to hydraulic test wherever cracks are found, their depths should be assessed by ultrasonic testing. All cracks having depths less than corrosion allowance may be removed by grinding, edges smoothened and areas left as such after final WFMPT check. Weld build up of grooves so formed is essential wherever depths of groove is more than corrosion allowance.
b)
SHUT-OFF VALVES, CONTROL VALVES, NONRETURN VALVES, EXCESS CHECK VALVES, PIPELINES, VALVES AND FITTINGS : All new valves shall be inspected and tested to ensure conformation to required specifications and for leak tightness. All new valves shall be inspected and tested as per requirements of API-598. The closure torque during testing for hand wheel and gear operated valves shall not be greater than that obtainable by hand tightening. Further fire safe valves shall comply with following : Low pressure seat test shall be conducted with the ball and seat dry and free of oil, grease or any lubricant. The high pressure seat test is not required except for threaded and valves. No leakage shall be permitted. Fire-safe test shall be carried out as per API : 607.
Valves shall be dismantled at the time of specified comprehensive inspection or during the shutdown of the line to permit examination of all internal parts. Body thickness measurements shall be made at locations inaccessible before, dismantling, particularly at locations showing evidence of erosion. Bodies of valves operating in severe cyclic temperature service shall be checked internally for cracks.
Gate valves, which have been used for throttling, shall be measured for thickness at the bottom between the seats, as serious deterioration may have occurred because of turbulence. This is particularly weak point because of the wedging action of the disc when the valve is closed. The seating surface shall be inspected visually for defects which might cause leakage. The wedging guides shall be inspected for corrosion and erosion. The stem and threads on the stem and in the bonnet of valves shall be examined for corrosion which might cause failure., The connection between stem and disc shall be inspected to assure that the disc will not detach from the stem during operating. Swing check valves shall be inspected by removing the cover or cap. The clapper or disc shall be checked for freedom of rotation and the nut holding it to the arm shall be checked for security and presence of a locking pin, lock washer, or tack weld. The arm should be free to swing and the anchor pin shall be inspected for wear. Also the seating surface on both the disc and valve body shall be checked for deterioration by feeling them with the fingers. After the valve has been reassembled, it shall be hydrostatically and/or pneumatically tested for tightness. If tested pneumatically, a soap solution shall be applied to the edges of the seating surface and observed for any evidence of leakage. 9.5.2 Flanges, Gaskets and Bolts The gasket faces of flanged joints, which have been opened, shall be inspected visually for corrosion and for defects such as scratches, cuts and gouges which might cause leakage. The gasket faces shall be checked for true flatness or warping by placing a straight edge
thickness externally.
across the diameter of the face of the flange and rotating it about an axis through the center line of the flange. Grooves and rings of ring joints shall be checked for defects. Flanges bolts should be inspected for stretching. Where excessive bolt loading is indicated or where flanges are deformed, nuts may be rotated along the entire length of the stud. If studs are stretched, thread pitch will be changed and nuts will not turn freely. Inspection involve checking to determine whether bolts of the proper specification have been used and may involves chemical analyse or physical tests to determine the yield point and the ultimate strength of the material. If flanges are bolted too tightly, they may bends until the outer edges of the flanges are in contact. When this occurs, there may be insufficient pressure on the gasket to assure a tight joint. Visual inspection of the gasket will reveal this condition. Permanently deformed flanges must be replaced.
9.5.3 (i)
(ii)
External inspection of LPG pipelines within the installation shall be carried out once in three years which shall include both visual inspection and ultrasonic
taken
The details of thickness survey shall be maintained on an isometric sketch. (iii)
Comprehensive inspection of LPG pipelines shall be carried out once in 6 years which shall cover the following : i) Visual inspection ii) Hammer test iii) Ultrasonic thickness measurement iv) Dye penetration test or Magnetic particle test v) Hydrotest
(iv)
Piping in coastal installations and in corrosive environment shall be visually inspected once a year. Years of inspection experience have revealed that failures of most of the Offsite pipelines are due to external corrosion and that internal corrosion failures are minimum.
(v)
The underground lines having wrapping and coating as well as cathodic protection shall be inspected whenever current leaks are observed and/or any damage to the coating is suspected. Parameters of cathodic protection like pipe-to-soil voltage or pipeto-water voltage shall be monitored once a month.
(vi)
All underground lines having only wrapping and coating shall be inspected once in three years using Pearson Survey for locating coating damage, if any. Additionally, all these lines shall be visually inspected at random once in ten years by digging at a
PIPELINES Inspection data as well as thickness data of newly constructed pipelines shall be collected at the earliest and with in two years of their commissioning to function as base for establishment of corrosion rates.
readings
few locations. Pipelines crossing the roads and dykes shall be inspected once in ten years by digging and exposing the line completely. Provisions of OISD Standard ; OISDSTD-130 on "Inspection of Pipes and Valves and Fittings" shall be followed. 9.5.4 HOSE AND CONNECTION :
FLEXIBLE
LPG hoses shall be inspected & tested at maximum interval of 4 months as detailed in OISD Standard ;. OISD-STD135 on "Inspection of Loading and Unloading Hoses for petroleum products" and records maintained thereof. LPG hoses shall be discarded after 3 years of service or earlier in case the permanent elongation exceeds 5%.
a) Gags, blinds do not exist. b) Upstream and down stream isolation valves, if any, are opened and sealed. c) Seals protecting the spring setting have not been broken. d) Relief device is not leaking. This may be checked visually and by thermography, contact thermometers or by hand touch at outlet nozzle wherever practicable. e) The continuous operation of heat tracing provision, if any, provided for low temperature application on valve and discharge piping. f) Condition of insulation and cladding on the heat traced piping and valves. a) Inspection and test of the valve shall be done in as received condition. This is important and helps in establishing the frequency of inspection. Provisions of OISD Standard ; OISD-STD-132 on "Inspection of Pressure Relieving Devices" shall be followed.
9.5.5 STRAINERS AND FILTERS : Strainers & filters shall be inspected and cleaned as per following frequency, unless sluggish operation warrants earlier inspection :
9.5.6 ROTARY EQUIPMENT :
TYPE / LOCATION FREQUENCY
a)
COMPRESSORS : OISD Standard No. OISD-120 on "Inspection of Compressors" shall be followed. In addition, periodic maintenance checks, as detailed in Annexure-I to be followed.
b)
PUMPS : OISD Standard No. OISD-110 on "Inspection of Pumps" shall be followed. In addition, periodic checks as detailed in Annexure-II to be followed.
c)
DIESEL ENGINES: OISD Standard No. OISD-123 on "Inspection and Maintenance of
Air filters Strainers on evacuation line Pump Suction Up stream of filling carousel up stream of PD-Meter
Weekly Weekly Quarterly Quarterly Quarterly
e) SAFETY RELIEF VALVES Safety Relief valves shall be tested once in a year. Further an on stream visual inspection should be carried out at least once in every 6 months to check the following:
Rotating Equipment shall be followed.
components
Pressure gauges shall be checked daily for its proper functioning and shall be calibrated once in 6 months.
9.5.7 FILLING EQUIPMENT d) FLOW MEASURING DEVICES It shall be ensured that the equipment is in good working condition to ensure quality output and also safe operation. Inspection checks are given at Annexure 9-III for the following equipment: a)
b) c) d) e) f) g)
Ejection
Check Weigh Scales Chain/ Roller conveyor Drive Units for Conveyors CVT-leak detector Cylinder Test Bath General
9.5.8 INSTRUMENTATION a) TEMPERATURE INDICATING DEVICES Temperature indicating devices shall be checked daily for its proper functioning and shall be calibrated once in 6 months. b) LEVEL GUAGING DEVICES The gauging devices shall be checked daily for proper functioning. Zero level check and calibration shall be carried out monthly and annually as applicable. c) PRESSURE GAUGES
9.5.9 FIRE FIGHTING EQUIPMENT Fire fighting equipment shall be inspected and tested as per. OISDSTD-142 - "Inspection of Fire Fighting Equipment".
CAROUSEL i) Drive units ii) Centre column iii) Running Rail iv) Introduction and devices v) Filling machines
All flow measuring devices shall be checked daily for proper functioning and calibration shall be carried out monthly and quarterly as applicable.
9.5.10 ELECTRICAL EQUIPMENT Proper functioning of electrical equipment can only be ensured by means of periodic preventive and predictive maintenance of the equipment. This enhances equipment life and also ensures safety of the equipment, installation and operating personnel. Maintenance shall be daily, weekly, quarterly or annual depending upon the type of equipment. Adequate logs shall be maintained to ensure that maintenance is carried out as per approved checklists. Preventive maintenance should be carried out as per schedules laid down in OISD-STD-137. Special emphasis shall be laid on the maintenance of equipment installed in hazardous areas. All electric apparatus and wiring in a hazardous area shall at all times be so maintained as to retain the
characteristic on which approval has been granted”
their
Precautions to be taken for repairs and testing of flameproof equipment shall be as below: i. No Flame proof or intrinsically safe apparatus shall be opened and no work likely to impair the safety characteristics of such apparatus or electric wiring connected thereto shall be carried out until all voltage has been cut off from said apparatus or wiring. The voltage shall not be restored thereto until the work has been completed and the safety characteristics provided in connection with the apparatus and wiring have been fully restored. ii. Use of soldering apparatus or other means involving flame, fire or heat or use of industrial type of apparatus in a zone “1” area shall be permitted for the purposes of effecting repairs and testing and alterations, provided that the area in which such apparatus or wiring has been installed, has first been made safe and certified by a competent person after testing with an approved gas – testing apparatus to be safe and free from inflammable vapours, gases or liquids and is maintained in such conditions, so long as the work is in progress. iii. No alteration that might invalidate the certificate or other document relating to the safety of the apparatus, shall be made to any apparatus.
Replacement fasteners, nuts, studs and bolts shall be of the type specified by the manufacturer for the particular apparatus. No attempt shall be made to replace or repair a glass in a flameproof enclosure e.g. in a luminaire or other enclosures, except by replacement with the complete assembly or part obtainable from the manufacturer, complying with the approval certificate. If replacement components such as cable glands, conduit 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. iv. 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. v. If at any time, there is a change in the area classification or in the characteristics of the flammable material handled in the area or if the equipment is relocated in the area, the area classification drawing should be correspondingly revised and a check shall be made to ensure that the equipment selection corresponds to the revised area classification. vi. A system shall be established to record the results of all inspections and the action taken to correct defects.
ANNEXURE 9-I
MAINTENANCE SCHEDULE COMPRESSORS -------------------------------------------------------------------------------------------------------------------------------Sr. Equipment Checks PERIODICITY -------------------------------------------------------------------------------------------------------------------------------Daily Weekly Monthly Qrtly (1) (2) (3) (4) (5) (6) -------------------------------------------------------------------------------------------------------------------------------1. Check Lub. Oil Level of plunger * pump unit & top up if necessary. 2.
Check the oil level in the crank case & top up if necessary.
*
3.
Before start check flow of cylinder cylinder jacket cooling water.
*
4.
Check oil flow from plunger pump to gland packing assembly.& compressor cylinder.
*
5.
Check for flow rate from plunger pump
*
6.
Drain water from receiver/ liquid trap.
*
7.
Check belt tension and adjust if necessary. *
8.
Ensure tightness of foundation bolts.
9.
Flush out lube oil system : a) Crank case b) Pump chamber and fill fresh oil.
10.
Flush jacket water cooling system.
11.
Check alignment of compressor & motor pullies.
12.
Change lube oil filter and clean LPG Suction filter.
13.
Clean oil strainer
14.
Clean Breather
15.
Open and inspect suction and discharge valves.
*
* *
* * * * * *
16. Check instrumentation calibrate if necessary. * --------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------Sr. Equipment Checks PERIODICITY -------------------------------------------------------------------------------------------------------------------------------Daily Weekly Monthly Qrtly (1) (2) (3) (4) (5) (6) -------------------------------------------------------------------------------------------------------------------------------17.
Check safety release valve.
*
18.
Suction & discharge valves of compressor cylinder
*
19.
Interlock with High level alarm
*
20.
All Trips
*
21.
Pressure & Temperature Gauges
22.
Control Panel
.
* *
23. Complete over-haul. * --------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-II MAINTENANCE SCHEDULE CENTRIFUGAL PUMP -------------------------------------------------------------------------------------------------------------------------------Sr. Equipment Checks PERIODICITY -------------------------------------------------------------------------------------------------------------------------------Daily Weekly Monthly Qrtly Annually Yrly (1) (2) (3) (4) (5) (6) (7) -------------------------------------------------------------------------------------------------------------------------------1.
Check lub oil & top up level if necessary.
*
2.
Check cooling water flow (where provided).
*
3.
Check mechanical seal/ gland leakage. *
4.
Check the "AMPS" are within limits.
5.
Change lube oil every 800 running hours.
6.
Check coupling and coupling bolts and replace worn out parts.
*
7.
Check tightness of foundation bolts.
*
8.
Clean suction strainer of : a) Product pumps b) Other pumps
*
9.
Check alignment of pump and motor.
10.
Overhaul.
11.
Greasing of Bearings.
12.
High Level Alarm
13.
Relief Valve
* *
* * * * *
--------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-III MAINTENANCE SCHEDULE FILLING EQUIPMENTS -------------------------------------------------------------------------------------------------------------------------------Sr. Equipment Checks PERIODICITY -------------------------------------------------------------------------------------------------------------------------------Daily Weekly Monthly Qrtly Half Annually Yrly (1) (2) (3) (4) (5) (6) (7) (8) -------------------------------------------------------------------------------------------------------------------------------I.
CAROUSEL : (A) DRIVE UNIT :
1.
Check oil level & top up if required.
*
2.
Check oil pressure.
*
3.
Put oil drop in orifice of cut-off valve. *
4.
Grease guide rollers.
5.
Check & adjust drive belt.
6.
Unscrew magnetic plug and clean.
7.
Change hydraulic oil &clean filter.
8.
Clean hydraulic oil tank.
9.
Inspect gears for wear and tear.
* * * * * *
10.
Check electric motor & grease motor bearing.
11.
Complete overhaul of the drive unit.
* *
(B) CENTRAL COLUMN 1.
Check air & gas joints for leakage.
*
2
Grease bearing.
*
(C) RUNNING RAIL : 1.
Clean & apply graphite.
2.
Lubricate rail wheels.
3.
Check rail levels.
* * *
-------------------------------------------------------------------------------------------------------------------------------(1) (2) (3) (4) (5) (6) (7) (8) -------------------------------------------------------------------------------------------------------------------------------(D) INTRODUCTION AND EJECTION DEVICES:
1.
Blow the air filter free of water & dirt. *
2.
Check & top up oil in air lubricator.
*
3.
Oil the introduction arms.
*
4.
Check functioning & adjust if required. *
5.
Greasing all grease points.
6.
Tighten guide rollers.
*
7.
Check & repair leaks.
*
8.
Inspect for wear and tear.
9.
Overhaul the unit.
*
* *
(E) FILLING MACHINES: 1. 2.
Thoroughly cleaning by using dry air. Checking & adjustment of auto cut off device.
* *
3.
Check operation of filling head by supplying air.
*
4.
Check leakage of LPG and repair.
*
5.
Check condition of LPG filling hoses. *
6.
Check oil level in air lubricators.
7.
Lubricate pullies holding filling guns. *
8.
Carry out calibration and adjustment. *
9.
Suspension system bearings & knife edges to be thoroughly cleaned.
10.
Inspect knife edges for wear & tear and repair where required.
*
*
*
11. Complete overhauling. * --------------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------------(1) (2) (3) (4) (5) (6) (7) (8) -------------------------------------------------------------------------------------------------------------------------------(F)
CHECK SCALE :
1.
Thorough cleaning by using dry air.
*
2.
Air Filter : a) Blow-out dirt & condensate. b) Clean.
*
3.
*
Check oil level in lubricator and its functioning.
*
4.
Calibrate with standard weights.
*
5.
Greasing of cylinder stop unit.
*
6.
Clean suspension system bearings knife edges etc.
*
7.
Check for wear & tear of knife edges & replace if necessary.
8.
Complete overhauling.
II.
CHAIN CONVEYOR :
*
*
1.
Top up soap solution trays.
*
2.
Check position of tension roller of chain and adjust if required.
*
3.
Lubricate tension rollers & wheels.
4.
Clean soap solution tray.
*
5.
Grease the bearing
*
6.
Check foundation bolts of conveyor frame for tight- ness.
*
*
III. DRIVE UNIT OF CONVEYORS : 1.
Check & top up oil level.
2.
Check coupling bolts & rubber bushings. Replace the cracked or worn out bushings.
3.
Check alignment of gear box & correct if necessary.
* *
*
-------------------------------------------------------------------------------------------------------------------------------(1) (2) (3) (4) (5) (6) (7) (8) -------------------------------------------------------------------------------------------------------------------------------4.
Clean & lubricate chain.
*
5.
Tighten foundation bolts.
*
6.
Drain & change oil.
*
7.
Inspect for wear & tear.
*
IV.
CVT/ DCVT LEAK DETECTOR :
1.
Check for proper functioning.
*
2.
Top up kerosene chamber.
3.
Check leakage rate thru verifier.
*
4.
Dismantle/ clean the interiors & apply silicon grease to "O" ring.
*
Every shift
V.
CYLINDER TEST BATH:
1.
Fill with clean water.
2.
Lubricate moving parts.
*
3.
Clean tank walls from inside.
*
4.
Check & lubricate pneumatic circuitry of all equipments.
*
5.
Check all fasteners and tighten.
*
*
6. Paint tank walls from inside. * --------------------------------------------------------------------------------------------------------------------------------
ANNEXURE 9-IV
DIESEL ENGINES MAINTENANCE STEPS 1.
KEEP THE DIRT OUT OF THE ENGINE.
2.
MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.
3.
REGULATE THE ENGINE'S FUEL.
4.
CONTROL OPERATING TEMPERATURES.
5.
GUARD AGAINST CORROSION.
6.
LET THE ENGINE BREATHE.
7.
PREVENT OVERSPEEDING.
8.
KNOW YOUR ENGINE'S CONDITION.
9.
CORRECT TROUBLES WHILE THEY ARE SIMPLE.
10.
SCHEDULE AND CONTROL YOUR MAINTENANCE.
DIESEL ENGINES "A" CHECK EVERY DAY ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
CHECK PREVIOUS DAY'S ENGINE LOG BOOK.
1A CORRECT AS REQUIRED
2.
DRAIN WATER AND SEDIMENT FROM FUEL TANK AND FUEL FILTER THROUGH DRAIN COCK.
2A
3.
CHECK ENGINE OIL LEVEL AND TOP UP IF NECESSARY
3A MUST BE SLIGHTLY LESS THAN OR EQUAL TO "H" MARK ON DIP STICK WHEN ENGINE IS STOPPED AND HAS STOOD FOR 20 MINUTES OR MORE (MUST BE MEASURED AFTER ALL OIL IS DRAINED BACK INTO OIL PAN).
4.
CHECK FOR FUEL,OIL,WATER
4A CORRECT IF LEAKING.
5.
FILL RADIATOR/SURGE TANK WITH TREATED WATER (CHROMATE CONCENTRATION 3500 PPM).
5A RADIATOR CAP MUST BE FIRMLY TIGHTENED BACK INTO THE RADIATOR/SURGE TANK NECK, ENGINE MUST NOT BE OPERATED WITHOUT THE RADIATOR CAP SINCE THIS WILL CAUSE AERATION AND OVERHEATING OF THE COOLANT.
6.
CHECK AIR CLEANER OIL LEVEL AND CHANGE OIL, IF REQUIRED (IF OIL BATH TYPE) CLEAN DUST PAN AND PRECLEANER OF DAY TYPE AIR CLEANER.
6A
7.
CHECK AIR LINE CONNECTIONS FOR LEAKS.
7A CORRECT AS REQUIRED
8.
REMOVE AND CLEAN AIR COMPRESSOR BREATHER, IF EQUIPPED.
9.
DRAIN AIR RECEIVER TANK AT THE BEGINNING OF EACH SHIFT AND THEN CLOSE THE DRAIN COCK.
BEFORE STARTING ENGINE.
USE CLEAN ENGINE OIL.
8A FILL WITH CLEAN OIL, UPTO MARK.
DIESEL ENGINES "A" CHECK EVERY DAY ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------10. CLEAN CRANKCASE BREATHER
10A
DISCARD PAPER TYPE ELEMENT, IF CLOGGED.
11. CHECK OIL LEVEL IN HYDRAULIC GOVERNOR,IF PROVIDED.
11A
CHECK FOR LEAKS, USE SPECIFIED ENGINE OIL FOR TOPPING UP.
12. START THE ENGINE AND NOTE THE OIL PRESSURE BOTH AT IDLING AND MAXIMUM SPEED.
12A
13.
RECORD OIL PRESSURE
13A
14. FILL FUEL TANK AT THE END OF THE SHIFT.
14A
IF THERE IS A CHANGE IN OIL PRESSURE FROM THAT RECORDED IN THE LONG BOOK ON EARLIER OCCASION THEN STOP ENGINE AND CHECK THROUGH TROUBLE SHOOTING TECHNIQUE THE CAUSE FOR OIL PRESSURE CHANGE AND CORRECT IF NECESSARY (FOR ASSISTANCE IN DIAGNOSING THE CHANGE IN OIL PRESSURE CALL YOUR SERVICE REPRESENTATIVE IF NECESSARY. REFER O&M MANUAL FOR LUB. OIL PRESSURE LIMITS.
USE CLEAN FUEL AND A STRAINER. ALSO CLEAN THE CAP AND SURROUNDING AREA BEFORE OPENING THE FILLER CAP. --------------------------------------------------------------------------------------------------------------------------
"B" CHECK EVERY 250 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
REPEAT ALL MAINTENANCE STEPS OF CHECK "A" 1 TO 14.
1B
2.
CHANGE ENGINE OIL
2B
WHEN LUB. OIL IS EXAMINED THROUGH LUB. OIL ANALYSIS IN LABORATORY. OIL CHANGE PERIOD MAY BE EXTENDED IN SUCH CASES (REFER TO YOUR SERVICE REP.)
DIESEL ENGINES "B" CHECK EVERY 250 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------3.
FIT NEW LUBRICATING OIL FULL FLOW FILTER ELEMENT
3B INSPECT THE CHANGED FILTER ELEMENTS AND CHECK FOR METAL PARTICLES AND OIL SLUGING/ OXIDATION.
4.
REMOVE CLEAN AND INSPECT DRY TYPE AIR CLEANER ELEMENT, REMOVE AND CLEAN DUST PAN. INSPECT FOR HOLES AND TEARS, CHECK GASKETS AND "O" RINGS FOR DAMAGE
4B BLOW OUT DUST WITH COMPRESSED AIR IN THE OPPOSITE DIRECTION OF THE NORMAL AIR FLOW, IF VERY DIRTY WITH OIL AND CARBON WASH IN SOLUTION OF WARM WATER (120-140 DEG F) AND NON-SLUDGING DETERGENT ALLOW IT TO DRY FIRST, THEN USE COMPRESSED AIR. REPLACE IF WASHED TWO TIMES. CAUTION EXCESS AIR PRESSURE WILL DAMAGE PAPER. AIR NOZZLE MUST BE KEPT AT LEAST 20 cm FROM THE ELEMENT. MUST NOT BE USED IF EVEN ONE PIN HOLE EXISTS. DISCARD ELEMENT IF PUNCTURED AND ALSO CHANGE GASKET ALONG WITH
ELEMENT. 5.
CLEAN OIL BATH AIR CLEANER TRAY SCREEN
5B
6.
CHANGE LUBRICATING OIL BY-PASS FILTER ELEMENT AND GASKET, IF PROVIDED.
6B RECORD OIL PRESSURE.
7.
CLEAN FLOAT TANK AND/OR MAIN FUEL TANK BREATHER.
7B
8.
CHECK COOLANT PH VALUECONCENTRATION OF DCA/ CHROMATE CONCENTRATION (3500 PPM).
8B CHANGE CORROSION PRESISTER ELEMENT IF PH VALUE IS BELOW NORMAL RANGE 8.5-10.5. CHECK CHROMATE CONCENTRATION AT 3500 PPM. FOR DCA REFER O&M MANUAL.
9.
CHECK MAGNESIUM PLATE IN ASSEMBLY CORROSION REGISTER CHANGE WATER
9B CHECK MAGNESIUM PLATE FOR PITTING OR BEING EATEN AWAY CHANGE IF MORE THAN 50% OF
DIESEL ENGINES
"B" CHECK EVERY 250 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------FILTER ELEMENT.
OF AREA IS LOST. USE DCA SERVICE ELEMENT OR CHROMATE ELEMENT OR CHROMATE ELEMENT BAGS (AR95679) IF CONCENTRATION IS LOW.
10. CHANGE FUEL FILTER ELE MENT WASHER AND "O" RING ON MOUNTING BOLT.
10B CLEAN SHELL FUEL FILTER CHANGE ELEMENT WHEN RESTRICTION EXCEEDS VACUUM 200MM OR MERCURY.
11. CHECK OIL IN ANEROID CONTROL, IF REQUIRED.
11B
USE SAME OIL AS USED IN OIL PAN.
12. CHECK & ADJUST BELTS.NEW BELTS WILL STRETCH WITHIN ONE HOUR OR USE THEY MUST BE READJUSTED.
12B
TIGHTEN BELT TENSION REFER MAINTENANCE MANUAL.
13B
CORRECT AS REQUIRED.
13. TIGHTEN FOUNCTION BOLTS AND FLEXIBLE COUPLING BOLTS OF ENGINE AND ALTERNATOR. 14. CHECK ALL AIR CLEANER CONNECTIONS FOR CRACKS. CHAFING ETC. TIGHTEN ALL AIR INTAKE CONNECTIONS. 15. CHECK FAN HUB AND DRIVE.
14B USE SPECIAL TOOL FOR TIGHTENING THE FAN HUB NUT.
16. CLEAN/CHANGE AIR COMPRESSOR BREATHER ELEMENT.
15B
17. CHECK THROTTLE LINKAGE.
CHANGE ELEMENT FOR NATURALLY ASPIRATED ENGINE CLEAN SCREEN FOR TURBO ENGINE.
DIESEL ENGINES "C" CHECK EVERY 1500 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------1.
REPEAT ALL MAINTENANCE STEPS OF CHECKS "A" & "B".
2.
CHECK THERMOSTATE OPERATION
2C
IT SHOULD START OPENING AND OPEN FULLY WITHIN RANGE 165 DEG. F. OR 170 DEG. F. DISCARD AND FIT NEW THERMOSTATE IF OPERATION IS NOT SATISFACTORY.
3.
CHECK FAN HUB AND DRIVE BEARING
3C
CHECK MOUNTING BOLTS AND END PLAY.
4.
CHECK IMPLELLER WATER PUMP FOR PLAY.
4C
CORRECT IF NECESSARY.
5.
CHECK FOR TURBOCHARGER OIL LEAKS.
5C
CORRECT AS REQUIRED.
6.
TIGHTEN TURBOCHARGER MOUNTING NUTS.
6C
TIGHTEN TO THE SPECIFIED TORQUE DO NOT TIGHTEN WHEN ENGINE IS HOT.
7.
CHECK INLET AIR RESTRICTION
7C CHECK AFTER CLEANING DRY TYPE AIR CLEANER ELEMENT. IF RESTRICTION IN EXCESS OF 1000 MM WATER A NEW ELEMENT MUST BE FITTED.
8.
CLEAN OIL BATH AIR CLEANER
8C
REMOVE COMPLETE ASSEMBLY AND CLEAN INCLUSIVE OF FIXED
SCREENS. 9.
CLEAN AND TIGHTEN ALL ELECTRICAL CONNECTIONS.
10.
CHECK GENERATOR BRUSHES AND COMMUTATOR.
11.
CLEAN ENTIRE ENGINE
9C
10C
REPLACE AND CLEAN AS REQUIRED.
11C
HIGH PRESSURE AND SOAP WATER MIXTURE PREFERRED AFTER SPRAYING ENGINE WITH CLEANSER
DIESEL ENGINES
"C" CHECK EVERY 1500 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
---------------------------------------------------------------------------------------------------------------------------TAKING CARE OF PROTECTING ELECTRICAL SYSTEM. 12. TIGHTEN ALL MOUNTING BOLTS AND NUTS.
12C TIGHTEN AS REQUIRED. OVER TIGHTENNING MAY RESULT IN DISTORTION OR DAMAGE.
13. CLEAN ANEROID AIR BREATHER.
13C REPLACE BREATHER IF NECESSARY.
14. CHECK SEA WATER PUMP (MARINE APPLICATION ONLY)
14C CHECK FOR LEAKS/ OPERATION/ PERFORMANCE.
15. CHECK HEAT EXCHANGER ELEMENT 15C CLEAN ELEMENT TUBES/CHANGE ZINC PLUG (MARINE APPLICATION) PLUGS. 16. CHECK EXHAUST AND INLET MANI- 16C FOLD NUTS AND CAPSCREWS. 17. CHECK ENGINE BLOWER.
17C
READINGS IN EXCESS OF RECOMMENDED LIMITS. CORRECTIVE ACTION MUST BE TAKEN. THOROUGH ANALYSIS WITH THE HELP OF TROUBLE SHOOTING CHART.
18. CLEAN RADIATOR
18C
BLOW AIR THROUGH THE RADIATOR CORE IN OPPOSITE DIRECTION TO THE NORMAL FLOW OF AIR, IF WORKING UNDER DUSTRY/ DIRTY CONDITIONS. (REVERSE FLUSHING OPERATION)
19. CHECK AIR COMPRESSOR
19C
CHECK SHAFT END CLEARANCE.
20. ADJUST INJECTORS AND VALVES.
20C
FINAL ADJUSTMENTS MUST BE CARRIED OUT WITH ENGINE HOT AND WITH CORRECT TORQUE AS SPECIFIED (REFR O&M MANUAL).
21. CLEAN FUEL INLET CONNECTIONS.
21C
22. CHANGE HYDRAULIC GOVERNOR OIL/ ANEROID OIL.
22C USE ENGINE LUBRICATING OIL.
23. CHECK VIBRATION DAMPER.
23C
CHECK WOBBLE AND ECCENTRICITY ALIGNMENT MARKS ON RUBBER TYPE. DISCARD DAMPER IF MISALIGNMENT IF MORE THAN 1/16 IN.
DIESEL ENGINES
"D" CHECK EVERY 4500 HOURS ----------------------------------------------------------------------------------------------------------------------------
MAINTENANCE STEPS
REMARKS
----------------------------------------------------------------------------------------------------------------------------
1.
REPEAT ALL MAINTENANCE STEPS OF CHECKS "A", "B" & "C".
1D
2.
CHECK EXHAUST AND INLET 2D MANIFOLD NUTS AND CAPSCREWS.
3.
TIGHTEN ALL MOUNTING BOLTS AND NUTS.
3D
4.
CLEAN TURBOCHARGER DIFFUSER AND IMPELLER AND CHECK END FLOAT.
4D
5.
CHECK TURBOCHARGER REARING CLEARANCES
5D ONLY END FLOT ON SEMI FLOATING BEARINGS IF IN EXCESS OF LIMITS, REPLACE.
6.
CHECK CRANKSHAFT END FLOAT
6D IF IN EXCESS OF RECOMMENDED LIMITS. CORRECTIVE ACTION IS INDICATED.
7.
CLEAN INJECTOR INLET SCREENS.
8.
CLEAN AND CALIBRATE ALL INJECTORS.
MUST BE DONE ONLY IF A PERFORMANCE DETERIORATION IS EVIDENT. SOME OF THE INDICATIONS FOR PERFORMANCE DETERIORATION ARE:
9.
CHECK FUEL PUMP CALIBRATION
10.
REPLACE ANEROID BELLOWS AND CALIBRATE ANEROID.
1 2 3 4
11.
REPLACE FUEL PUMP FILTER SCREEN AND MAGNET.
12.
STEAM CLEAN ENGINE
BLACK SMOKE. CHANGE IN FUEL MANIFOLD PRESSURE LOSS OF POWER MALFUNCTION OF ANEROID.
12D IF STEAM IS NOT AVAILABLE, THEN USE CLEAN SOAP WATER SOLUTION AS OUTLINED IN "C" CHECK ITEM-11C.
`E' CHECK EVERY 8000 HOURS
1.
REPEAT ALL MAINTENANCE STEPS OF CHECK `A', `B', `C' & `D'.
2.
THE `E' MAINTENANCE CHECK IS NECESSARY ONLY WHEN THE ENGINE OPERATING CONDITIONS SIGNIFY DETERIORATION IN PERFORMANCE AS CAN BE ASCERTAINED BY THE SYMPTOMS : (1) HEAVY SMOKE (2) LOSS OF POWER (3) HIGH OIL TEMPERATURE HIGH WATER TEMPERATURE (4) LOSS OF LUB. OIL PRESSURE (5) UNUSUAL NOISE & VIBRATIONS. THE `E' MAINTENANCE CHECK IS A METHODOLOGY FOR INSPECTION OF WEAR OR ASSEMBLY DETRIORATION OF PARTS AND ASSEMBLIES, AND SHOULD BE RESORTED TO ONLY WHEN TROUBLE SHOOTING IN ADDITION TO PERFORMING A,B,C AND D MAINTENANCE CHECKS, WHICH MAY ELIMINATE THE ENGINE PERFORMANCE PROBLEM AND BRING THE ENGINE BACK TO NORMAL OPERATING CONDITIONS. IT IS ANTICIPATED THAT GOOD OPERATING AND MAINTENANCE PRACTICES AS PRESCRIBED THROUGH A,B, C & D CHECKS WILL ENSURE THAT THE ENGINE WILL PERFORM BEYOND 25000 HOURS BEFORE THAT THE ENGINE MUST BE DISMANTLED FOR INSPECTION PRELUDE TO A MAJOR OVERHAUL. THE TIME INTERNAL OF 8000 HOURS IS A PERIOD AT WHICH THE ENGINE MAY DEVELOP SYMPTOMS ASCRIBED ABOVE 1-5 AND ARE INDICATIVE OF PERFORMANCE DETERIORATION DUE TO INADEQUATE A,B,C & D CHECKS AND FAILURE TO IDENTITY PERFORMANCE DETERIORATION. THIS FIGURE HAS BEEN ARRIVED AT ON THE BASIS OF CURRENT MAINTENANCE PRACTICES AND SHOULD NOT BE TREATED AS AN ABSOLUTE FOR MAKING AN `E' CHECK. HOWEVER, IT IS ESSENTIAL THAT THE ABOVE ROUTINE ANALYSING ENGINE PERFORMANCE BE STRICTLY FOLLOWED IN ORDER TO PREVENT DISMANTLING OF ENGINE WHOSE PERFORMANCE CAN BE SIMPLY CORRECTED BY TROUBLE SHOOTING AND ROUTINE MAINTENANCE CHECKS.
3.
THE `E' MAINTENANCE CHECK IS OFTEN REFERRED TO AS "IN FRAME INSPECTION" WHERE SOME KEY PARTS, SUCH AS BEARINGS, ARE CHECKED FOR WEAR TO DETERMINE IF THE ENGINE MAY BE OPERATED FOR ANOTHER SERVICE PERIOD. LIKEWISE, OIL CONSUMPTION, OIL PRESSURE AND OTHER SIGNS OF WEAR SHOULD BE ANALYSED DURING THE CHECK WEAR LIMITS AND OTHER INFORMATIONIS AVAILABLE FROM DISTRIBUTOR AND DEALERS. (IT MUST BE CLEARLY UNDERSTOOD THAT THE DECISION TO INSPECT KEY PARTS MUST BE ARRIVED THROUGH ROUTINE OUTLINED IN POINT TWO ABOVE).
10.0 STATUTORY TESTING OF LPG CYLINDERS
10.0
STATUTORY TESTING OF LPG CYLINDERS All cylinders used for filling LPG are required to be tested periodically to ensure fitness of the cylinders for further service. First re-testing is required to be done after 7 years and subsequent re-testing after every 5 years interval. Such tests are to be conducted by the CCE approved parties only.
10.1 TESTING PROCEDURE 10.1.1 DEGASSING CYLINDERS
OF
LPG
cleaning by immersing the cylinder in the caustic soda bath and soap water and the same is then rinsed with water. 10.1.3 CHECKING TARE WEIGHT : All the LPG cylinders shall be weighed and if the loss in tare weight is more than 5% of original weight such cylinders shall be segregated and scrapped. At the time of weighing the weight of valve is also accounted. 10.1.4 VISUAL INSPECTION :
All the LPG cylinders are depressurised in the approved premises by opening valves by means of suitable adapters to ensure that the internal cylinder pressure is reduced to atmospheric pressure. Only after depressurising the cylinder, cylinder valve is removed and LPG cylinder is taken up for water filling and water is overflown and retained in the cylinder for not less than one hour to remove any traces of LPG. Degassing can also be achieved by stripping, Nitrogen purging, etc. 10.1.2 SURFACE CLEANING a)
b)
After depressurising the cylinder and emptying out the water, the same is kept in inverted position and stroked gently with a non-sparking hammer such as wooden mallet to remove any dust, rust or any loose remnants in the cylinders. The depressurized cylinder bung is plugged and is taken up for surface
a) The detailed visual inspection of the cylinder body shall be carried out as per IS:5845/ IS : 13258. b) Depending upon the visual inspection, cylinders are segregated for scrapping, for cold repairs and for hot repairs in case required. c) The interior of the cylinder shall be examined by means of infra low voltage FLP lamp. The internal examination shall be carried out as per IS:5845 / IS : 13258. d) LPG cylinders selected at random may be cut into two holes for assessing internal corrosion. e) In case of dented/ buckled cylinders, visual inspection of welds needs to be done more carefully since the welds are more susceptible to cracking. Denting or buckling by more than nominal plate thickness may be attended by repairs/ replacement.
10.1.5 HYDROSTATIC TESTING : a) All the LPG cylinders shall be taken up for hydrostatic test at an interval of 7 years for first testing and subsequent testing after every 5 years in accordance with IS:8868. Only water should be used as a medium for hydrostatic testing and the pressure to be applied should be the test pressure marked on the cylinder body (25.35 kg/sq.cm) and the same should be retained for a minimum period of 30 seconds. Any reduction in pressure noticed during the test, any leakage, visible bulge or deformation should be treated as a case of failure. Such cylinders should be properly marked, observation recorded and segregated for scrapping and disposal. b) Pressure Gauges shall be calibrated at least once a week and the Pressure Gauges used for verification should be tested once in every three months.
valve and the torque of 20+/-2 kg. m. should be applied. In no case spanners and ordinary wrenches be used for tightening the valves. 10.1.7 PNEUMATIC TEST : a) The Pneumatic test should be applied to the cylinder at a pressure of 7 kg/sq.cm. for a minimum of 60 seconds as per IS:3196. This is basically to check the tightness of the valve cylinder joints. b) With the cylinder under pressure, a soap solution should be applied to the cylinder valve bung joint to ensure that there is no leak. The same can be checked by dipping the cylinders in water bath. Depressurise the cylinders. All the Pressure Gauges used for Pneumatic test shall be calibrated at least once in 3 weeks and the Pressure Gauge used for verification should be tested once in every three months. 10.1.8 PAINTING OPERATIONS :
10.1.6 VALVE FIXING : a) Before commencing the fitting of valve operation, all the water inside the cylinder should be drained and the cylinder should be made dry with the use of hot air jet. Before refitting the valve, internal threads of the cylinder bung should be cleaned with 3/4" NGT thread tap and checked against thread damage. In case old valves are being refitted the same should be tested by compressed air at 7 kg/sq.cm for leakage from seat. b) Teflon paste/ suitable sealing compound should be used as a sealing material for tightening the
a) To enhance the life of the cylinder and to project a better image to the customers, maintaining a well painted surface of cylinder is most desirable. b) All LPG cylinders are painted with one coat of zinc chromate primer and a coat of super synthetic enamel paint of signal red colour (IS:2932 shade 575). Special care should be taken to paint the cylinders in vulnerable areas like underneath the foot ring. c) The valve should be protected while painting the cylinder. 10.1.9 CHECKING MARKING THE TARE WEIGHTS
a) Tare Weight of the cylinder should be ascertained and if in variance with the original tare weight (this could be as a result of change of cylinder valves ) the observed tare - weight should be punched as close to the original tare weight marking as recorded in the register maintained. b) The observe tare weight should be stencilled with paint on the shoulder and as well as on inside of one of the vertical stay. c) Gross weight punched/ stencilled on the cylinder should be changed in case of change of tare weight. -
Weighing machines used for checking the tare weight should be duly certified by Weights & Measures Authority. The machine should be tested daily with the standard weights to verify accuracy. The test used for checking should be tested against standard weights and the same must be stamped periodically by Weights and Measures Authority. The minimum graduations of 50 gms. must be available.
e) Weighing scale error should not be greater than 1.0%. f) The tare weight should be recorded with an accuracy of +/-50 gms. and rounded off as per IS:2. 10.1.10 MARKS :
PUNCHING
OF
In addition to punching of revised tare weight/ gross weight wherever applicable, following details should also be punched on the cylinder
body as close to the previous markings as practicable : a) Date of retest b) Code marking for the Test Plant/ Repairer. c) Tare weight of the cylinder should be stencilled with black paint within the V.P. Ring circle diameter at 3 places for easy identification by filling operators. The recommended lettering size is 25 mm and the thickness of the numerals is 6-7 mm. d) It is also recommended that the net weight of LPG to be filled should be stencilled on the body of the cylinders outside the V.P. Ring diameter. The size of the lettering recommended is 18 mm and the thickness of the numerals is 4-5 mm. Sequence of operations for statutory pressure testing of LPG Cylinders is given at Annexure 10-I. 10.1.11 COLOUR CYLINDER
CODING
OF
This is done primarily to facilitate easy segregation of cylinders for repairs at installations without going through the test date of manufacturing dates punched on each and every cylinder. Currently, the following colour codes have been selected for easy identification of cylinders and the same shall be repeated after every five/ seven years cycle. Colour coding is done on the inside of one of the Stay Plates and the same is given below:
COLOUR CODING SCHEME -------------------------------------------------------------------------------------------------------------------------------Cylinder Cylinder Next Background Shade as Lettering Manufactured retested/hot Retesting colour IS:5 colour in the repaired Date year in the year ------------------------------------------------------------------------------------------------------------------------------1997
1999
2004
Dove grey
694
Black
1998
2000
2005
Aircraft Blue
108
White
1999
2001
2006
Salmon Pink
443
Black
2000
2002
2007
Black
521
White
2001
2003
2008
Yellow
355
Black
2002
2004
2009
White
127
Black
2003 2005 2010 Sea Green 217 Black --------------------------------------------------------------------------------------------------------------------------------
10.1.12
CERTIFICATION : k) External
A detailed record of each cylinder tested at the installation or at the repairer's premises should be maintained. The record should include the minimum following details :
l) Whether passed/ rejected 10.1.13 HYDROSTATIC TEST/ HYDROSTATIC STRETCH TEST :
a) Running serial number - Whether passed/ rejected b) Date of testing
-
Condition of bung threads (internal)
c) Serial number of cylinder & name of manufacturer
-
Whether satisfactory/ rejected Pneumatic Test
d) Month and year of test
-
Whether passed/ rejected
e) Weight of cylinder
-
Quarter/ year of retest punched on the cylinder
-
Stencilling/ colour coding for age profile Relevant test certificate number
f) Punched on cylinder g) Observed weight
-
h) Whether satisfactory/ rejected i) Visual defects j) Internal
REMARKS :
(The Remarks columns should indicate whether the cylinder has been finally passed or rejected besides any other relevant details not covered above).
The test certificate issued by the Plant or by the Repairers should include : -
Running Serial Number of cylinder Cylinder Serial Number Date of testing
ANNEXURE - 10- I SEQUENCE OF OPERATIONS FOR STATUTORY PRESSURE TESTING OF LPG CYLINDERS 1.
Receipt of Cylinders
2.
Depressurising
3.
Recording details (like Sr.No., Test Dates, Tare weight, Manufacturer's name)
4.
Valve Removal
5.
Degassing
6.
External surface cleaning
7.
Internal cleaning and internal inspections
8.
Visual Inspections of external surface and bung threads by L-1 and L-9 plug gauges
9.
Tare weight checking
10.
Hydrostatic testing
11.
Internal cleaning and checking
12.
Primer coating
13.
Signal red painting
14.
Punching of new test date and repairer's identification mark
15.
Tare weighing
16.
Colour code painting to indicate ownership of cylinders, stencilling new tare weight, new weight and next test date
17.
Tapping the bung thread, cleaning the same by brass wire brush and checking the bung threads by L-1 & L-9 plug gauges.
18.
Valve fixing
19.
Pneumatic test
20.
Certification and despatches.
CHAPTER 11
FIRE PROTECTION FACILITIES The main components of the fire water system are :
11.1 GENERAL LPG Installations shall have well defined in-built fire prevention and protection system to mitigate any exigency. The requirements of fire prevention and protection system shall be as under :
-
Fire Water Storage
-
Fire Water Pumps
-
Fire Hydrant/ Monitor distribution piping network.
-
Water Sprinkler/ Deluge system.
11.2 DESIGN CRITERIA i) The single largest fire risk shall be considered. ii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump / compressor Houses, remote operating valves /motor operating valves on LPG lines Bulk Lorry and Tank Wagon Gantries shall be fully covered by medium velocity water spray system.
11.4
The Fire Water pumping requirement for medium velocity spray system shall be calculated based on minimum spray density as 10.2 LPM/Sq.M of the exposed surface or area to be cooled, in case of LPG Pump/ compressor it shall be 20.4 LPM/Sq.M . a.
iii) 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. iv) Heat Detectors for detection of fire for automatic actuation of medium velocity water sprinkler system shall be provided. The QB/EP detectors shall be placed directly overhead or inside the hazard. In areas without specific hazard, detectors shall be placed evenly across the ceiling or with maximum spacing of 3 meter inside the shed. Any other detectors if provided shall comply with the design requirements. 11.3 FIRE WATER SYSTEM
FLOW RATE DESIGN
Storage Vessels
MV sprinkler system with automatic heat detection having remote/ local operated Deluge valve with spray density of Minimum 10.2 LPM/ Sq.M shall be provided on all above ground storage vessels. For water flow calculations aggregate surface area of all vessels within distance of 30 Mts. from the periphery of the affected LPG vessel shall also be considered as single risk . b) Sheds MV sprinkler system with automatic heat detection having remote/ local operated Deluge valve with spray density of minimum 10.2 LPM/Sq.M shall be provided in the entire shed including the loading / unloading fingers.
For spray water calculations, the shed can be divided into suitable number of zones, each served by independent deluge system. The adjacent zones shall be operative around the zone under fire and the same shall be considered as a single risk. The width of a zone shall not be less than 10 meter except of the zone on either end of the shed. As there is no storage of cylinders in the loading / unloading fingers, spray system can be taken as separate zone with independent deluge valve to optimise the fire water requirement .
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. The gantry can be divided into suitable number of zones with minimum zone length of 30 meters and adjacent zones shall operate around zone under fire and same shall be considered as single risk. The spray system shall cover tank wagons surface on either side of tank wagon gantry atleast in two tiers as well as the associated LPG pipelines in the gantry.
c) LPG Pump / Compressor House
The fire water system in the plant shall be designed to meet the highest fire water flow requirement of a single largest risk of any of the above cases at a time plus 288 Cu.M/Hr. for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
MV sprinkler system with automatic heat detection having remote/ local operated Deluge valve with spray density of Minimum 20.4 LPM/Sq.M shall be provided. The entire pump /compressor house shall be considered as single risk area : alternatively it can be divided into suitable number of zones with minimum 10 meter width. d) Tank Lorry Gantry In case of Tank Lorry Gantry, automatic detection of heat for automatic actuation of MV sprinkler system having remote/ local operated deluge valve with spray density 10.2 LPM/Sq.M of surface area shall be provided. A maximum of 8 bays shall be considered as single risk area. In addition to the tank lorry surface, MV spray system shall effectively cover the tyres, manifold and dish ends of various size of tank lorries. There shall be atleast 3 tiers of MV sprinkler system and heat detectors uniformly cool the top , middle and the bottom of the tank lorry. e)
Tank Wagon Gantry
11.5
FIRE WATER DESIGN
SYSTEM
i) 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. ii)
A fire water ring main shall be provided all around perimeter of the LPG Plant facilities with hydrants/ monitors spaced at intervals not exceeding 30 M when measured aerially. Fire hydrants and monitors shall not be installed within 15 Meters from the facilities/ equipment to be protected.
iii)
Fire hydrant network shall be in closed loops to ensure multidirectional flow in the system. Isolation valves shall be provided to enable isolation of any section of the network without affecting the flow in
the rest. The isolation valves shall be located normally near the loop junction. Additional isolation valves shall be provided in the segments where, the length of the segment exceeds 300 Mts.
11.6
FIRE WATER STORAGE
i) Water for the hydrant service shall be stored in any easily accessible surface or underground lined reservoir or above ground tanks of steel, concrete or masonary. The effective capacity of the reservoir above the level of suction point shall be minimum 4 hours aggregate working capacity of pumps. Where make up water supply system is 50% or more this storage capacity may be reduced to 3 hours aggregate rated capacity of pumps. Large natural reservoirs having water capacity exceeding 10 times the aggregate water requirement of fire pumps may be left unlined. ii) Storage tank/ reservoir shall be in two inter connected compartments to facilitate cleaning and repairs. In case of steel tanks there shall be a minimum of two tanks. 11.7
FIRE WATER PUMPS
i) Centrifugal type fire water pumps shall be installed to meet the designed fire water flow rate and head. These pumps shall have a flooded suction, alternatively suitable arrangement for auto priming shall be provided. ii) The system pressure has to be maintained at 7 kg/cm2g at the farthest end of the hydrant system
with the help of Jockey Pump operating automatically. The Jockey Pump shall start-stop automatically actuated by pressure switches. A standby jockey pump shall be provided if the number of hydrant points is more than 100. One monitor shall be considered as equivalent to 4 hydrant points. iii) The fire water pump(s) including the stand by pump(s) shall be diesel engine driven . The pumps shall be capable of discharging 150% of its rated discharge at a minimum of 65% of the rated head. Each engine shall have an independent fuel tank of suitable size for 6 Hrs. continuous running. In refineries / gas processing plants, where reliable source of electric power is available electrical driven centrifugal pumps can be used upto a maximum of 50 % of total pumping capacity. Power supply to the pump motors should be from two separate feeders. iv) At least one standby fire water pump shall be provided upto 2 nos of main pumps For main pumps 3 and more, minimum two standby pumps of the same capacity as the main pumps shall be provided. iv)
v)
Fire water pumps shall be used exclusively for Fire protection and prevention purpose only. Suction and discharge valves of fire water pump shall be kept open all the time.
The fire water pumps shall be provided with automatic starting facilities which
shall function with specified logic even if initial pump does not start or having started , fails to build up the required pressure in the fire water ring main system within 20 seconds.
iii) For Fire water ring main laid underground the following shall be ensured : a)
11.8
FIRE HYDRANT NETWORK
i) Fire hydrant ring main shall be laid above ground ensuring that : a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground level. b) The mains shall be supported at regular intervals not exceeding 6 meters or as per design approved. c) The system for above ground portion shall be analysed for flexibility against thermal expansion and necessary expansion loops where called for shall be provided. ii) However the ring main may be laid underground at the following places : a)
Road crossings.
b) Places where above ground piping is likely to cause obstruction to operation and vehicle movement. c) Places where above ground piping is likely to get damaged mechanically, particularly in the LPG storage area where water supply lines are laid for feeding sprinkler deluge system. d) Where Frost conditions warrant and ambient temperature is likely to fall below zero deg. centigrade underground piping at least 1 meter below the ground level should be provided. Alternatively, for above ground pipelines, water circulation to be carried out.
The Ring main shall have at least one meter earth cushion in open ground, 1.2 meters cushion under the road crossings and in case of rail crossing, provisions stipulated by Indian Railways shall be complied.
b) The Ring main shall be suitably protected against soil corrosion. c) In case of poor soil conditions it may be necessary to provide concrete/ masonry supports under the pipe line. iv) Fire water ring main shall be sized for 120% of the design water flow rate. The velocity of water shall not exceed 5 meter per second in fire water ring main. Design flow rates shall be distributed at nodal points to give the most realistic way of water requirements in an emergency. In case of sea water service, the fire water main pipes shall be concrete mortar lined internally or other suitable coating material shall be used. v) Hydrants/ monitors shall be located considering various fire scenario at different sections of the premises to be protected and to give most effective service. At least one hydrant post shall be provided at a every 30 mtrs of external wall measurement or perimeter of battery limit in case of high hazard areas. For non-hazardous area, they shall be spaced at 45 mtrs. intervals. The horizontal range & coverage of hydrants with hose connections shall not be considered beyond 45 mtrs.
vii) Hydrants
shall be located at a minimum distance of 15 mtrs. from the periphery of storage tank or equipment under protection. In case of buildings this distance shall not be less than 2 mtrs. and not more than 15 mtrs. from the face of building. Provision of hydrants within the building shall be provided in accordance with IS : 3844. Hydrant/Monitors shall be located along road side berms for easy accessibility.
viii) Double headed hydrants with two separate landing valves on 3"/ 4" standpost shall be used. All hydrant outlets shall be 1.2 mtrs. above ground level. ix) Monitors shall be located to direct water on the object as well as to provide water shield to firemen approaching a fire. The requirement of monitors shall be established based on hazards involved and layout considerations. The location of the monitors shall not exceed 45 mtrs from the hazard to be protected. x) Hydrants and monitors shall not be installed inside the dyked areas. xi) LPG tank wagon Loading/ unloading facility and Tank Truck gantry area should be provided hydrants having multipurpose combination nozzles for jet spray & fog arrangement and fire hydrants located at a spacing of 30 mtrs. on both sides of the gantry. The hydrants & monitors shall be
located at a minimum distance of 15 mtrs. from the Tank Wagon/Tank Trucks measured from edge of the facilities. xii) Fire water monitors shall be provided with independent isolation valves. xii) Hose box with 2 nos. hoses and a nozzle shall be provided at each hydrant points. xiii) 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. xiv) The fire water deluge valves shall be kept outside the kerb wall at a safe distance in case of sphere/ bullet, and located 15 M away from limits of other sheds or shadows of spheres. A fire wall shall be provided for the protection of the deluge valve and for personal protection of the operator. 11.9 MATERIAL SPECIFICATIONS All the materials used in fire water system using fresh water shall be of type as indicated below. i) Pipes
:
Carbon Steel (CS) per IS:3589/IS:1239 ii) Isolation Valves Carbon Steel iii) Deluge valve Carbon Steel iv) Hydrant Standpost CS Outlet valves Gunmetal/ Aluminium v) Monitors CS
Equivalent or superior materials meeting the design requirements can also be used . vi) In case of underground mains the isolation valves shall be located in RCC/ brick masonary chamber. vii) The above ground fire water main and the fire hydrant standpost shall be painted with corrosion resistant "Fire Red" paint as per IS : 5. viii) Water monitor, hydrant point and hose box shall be painted "Luminous Yellow' IS : 5. 11.10 MEDIUM VELOCITY SPRINKLER SYSTEM The medium velocity spray system shall be provided in all critical areas like LPG Storage Area, Sheds, LPG Pump/Compressor House, Tank truck/ wagon loading / unloading areas, valve manifolds etc. i) Spray nozzles shall be directed radially to the vessel at a distance not exceeding 0.6 m from the equipment surface. Only one type and size of spray nozzle shall be used in a particular facility. The horizontal extremities of water flow from spray nozzles shall at least meet. Where projections (manhole flanges, pipe flanges, staircase, supports brackets) obstruct the water spray coverage, including rundown or slippages on vertical surface, additional nozzles shall be installed around the projections to maintain the wetting pattern. First valve of the vessel shall be adequately covered with sprinklers. Horizontal dry piping down stream of the block valve and after deluge
valve shall be adequate drain facilities at selected locations. 11.11 AUTOMATIC FIRE PROTECTION SYSTEM i. Automatic fire protection (Fixed) system based on heat detection through thermal fuses/ quartz bulbs/ EP detectors shall be employed. Sensors shall be installed at all critical places wherever medium velocity spray system has been installed as described below : a. In LPG storage area, such detectors shall be provided encircling each vessel, equispaced with a maximum spacing of 1 meter at an elevation of about 1.5 to 2.0 meter from bottom of vessel. Also minimum 2 nos. detectors shall be provided at the top of the vessel and atleast one near the liquid line ROV to take care of failure of flanges. In case of an automatic thermal fuse based fire protection system the instrument air supply pressure to thermal fuses shall be maintained through a pressure control valve and a restriction orifice. b. Detectors shall be placed at critical locations in LPG sheds (filling, cylinder storage, testing, evacuation, etc.) loading/ unloading gantries, LPG compressor house, piping manifold, repair sheds etc. Upon actuation there shall be alarm in control panel, LPG pumps and compressors would trip, ROVs (wherever provided) on LPG supply and return lines would trip and the deluge valves on fire water sprinkler system will get actuated.
ii) In case, Quartzoid Bulbs are used for detection, the same shall be designed to blow at 79 deg. centigrade (max.) and Quartzoid Bulb network shall be maintained with plant air at a pressure not more than 3.5 kgs/sq.cm.g and shall be such that the discharge of air through one Quartzoid Bulb will depressurise the system to actuate the deluge valves. iii) In case of Electro pneumatic (E.P) heat detectors, it shall actuate the deluge valve in any of the following conditions : a) Rate of rise of temp.
The EP detectors shall be divided in groups and alternate detectors shall be connected in one circuit. Two detectors from two different groups shall function/ operate for actuation of sprinkler system. iv) Water spray nozzles and heat detection system shall be of approved type and duly certified for the performance. The actuation of detectors shall initiate the following : i) Opening of deluge valve of the affected zone as well as adjacent zones. ii)
iii)
Closure of all Remote Operated Valves in affected facility.
v)
Tripping of main power supply barring the emergency power
vi)
The water spray from all nozzles within 30 seconds.
vii) The fire water pump(s) shall start based on their set pressure to supplement/ to maintain the fire water pressure in the ring main.
- 10 oC/min
b) At 79 deg. C (max.)
iv)
iv)
Audio-visual alarm indicating the affected zone at the fire pump house and manned control panel. The control panel shall also have status indications for deluge valves with facility for actuation. Fire siren of l km range
Additionally suitable systems like push buttons etc. for initiating all the above actions shall be provided on remote operating panel. Further similar system like push buttons, air release valves etc shall also be provided in the field at safe location for enabling manual actuation by an operator. In case, the zoning concept is used for MV sprinkler system, the operations of sprinklers in various zones shall be clearly earmarked on the push buttons. In the field, manual bypass valves of fire water deluge valves shall also be provided. The performance test certificates after installation in respect of spray density, flow rate, response time for each facility to be protected provided by manufacturer shall be maintained at the LPG Installations and verified once in 6 months and records maintained thereof. Further, all spray nozzles shall be inspected for proper positioning, corrosion and cleaned if necessary at intervals of not more than 12 months or earlier based on actual experience. Care shall be taken in positioning nozzles so that water spray does not miss the targeted surface and reduce
the efficiency or calculated discharge rate. 11.12 FIRST AID FIRE FIGHTING EQUIPMENT 11.12.1 PORTABLE EXTINGUISHERS
FIRE
i) Portable fire extinguishers shall be located at convenient locations and shall at all times be readily accessible and clearly visible.
Other Pump Houses 2 Nos. 10 kg DCP extinguisher Office/Canteen/ Stores
2 X 10 kg DCP extinguishers in each building
MCC/ DG Room/ HT Room
At 2 x. 4.5 kg CO2 extinguisher in each room or for floor Area of about 100 Sq.m.& 4 sand buckets & a stand shall be provided in MCC/ DG Room.
ii) The maximum running distance to locate an extinguisher in working areas shall not exceed 15 meters. iii) The top surface of the extinguisher shall not be more than 1.5 meter high. iv)
The fire extinguishers shall be provided at various locations as under : Area Extinguisher
Portable Fire
LPG Storage Vessel(Each)
2 Nos. 10 kg DCP extinguisher.
LPG cylinder sheds
2 Nos. 10 kg DCP extinguisher per 200 Sq.M.Area.
LPG Pump houses
2 Nos.10 kg. DCP extinguisher per 50 Sq.m. Area.
Tank Truck loading/ 1 No. 10 kg. loading gantries DCP Extinguisher in each bay. Tank Wagon loading/ 1 No. 10kg unloading gantries DCP Extinguisher for every 15/20 meters of gantry.
v) 100% spare CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher Capacities) shall be stored in the LPG plant. 11.12.2 WHEELED/ FIRE FIGHTING EQUIPMENT
MOBILE
i) One No. Mobile 75 Kg DCP fire extinguisher shall be provided in filling shed, LPG storage vessels/ LPG Pump House area, Tank truck loading/ unloading gantry area & tank wagon loading/ unloading gantry area. ii) The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based or Sodium Bicarbonate as per OISD-GDN-115. Nitrogen/ Carbon Dioxide shall be used as expelling gas. iii) A trolley containing first aid fire protective accessories shall be readily available in the LPG plant. 11.12.3 AND
HOSES, NOZZLES ACCESSOREIS
i) Reinforced rubber lined hoses (63mm) conforming to IS : 636 (type A or B) shall be provided.
8. Low tem. protective Min. 2 sets clothing for LPG emergency.
ii)
10. Fire proximity suit
Min. 1 No.
11. Resuscitator
Min. 2 No.
12. Red/Green Flags
As reqd
iii)
The hoses shall be of 15 Meters standard length and shall be provided with Gun metal/ Aluminium alloy male & female couplings of instantaneous pattern. Minimum of two or 25% spare Hoses shall be stored in the LPG plant.
iv) In addition to the nozzles provided in the hose boxes there shall be at least 2 Nos. spare nozzles in each category viz. Jet Nozzles with branch pipes, Fog Nozzles, universal Nozzles, water curtain Nozzles, Spray Nozzles and Tripple purpose nozzles in the plant. v) The following accessories/ first aid items shall be provided in the plant : 1. Fire hoses
Two nos. for each Hose Box
2. Safety helmets 1 no. for each person. (min. 10 nos.)
13. Self contained Min. 1 No. breathing apparatus with one spare cyl. (Cap. 30 minutes) 14. Water jel blankets
Min. 2 nos.
15. Portable Gas detectors min. 2. / Explosimeter The above are guidelines and minimum requirements of each item and can be increased depending upon the scale of operations, statutory/ mandatory requirement of local bodies/ State Governments or any other expert body. 11.13 EMERGENCY CONTROL / ALARM SYSTEM 11.13.1 FIRE ALARM SYSTEM
3. Hose Box
At each hydrant point.
4. Stretcher with Min. 2 Nos. blankets. 5. First aid Box Min. 2 nos. 6. Rubber hand gloves Min. 2 pairs for electrical (BIS approved) purpose. 7. Low temperature 4 pairs rubber hand gloves for LPG emergency as per OISD-GDN-115
i) Manual call points near to filling shed, storage area, tank truck/ wagon gantry, pump house, etc. shall be provided and clearly marked in the installation. Operation of these points shall raise audio visual alarm in control room. ii) Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1 K.M. from the periphery of the plant). iii) Manually operated fire sirens shall be provided at strategic places.
iv) For fire condition the siren shall be wailing sound for minimum `2 minutes and for all clear signal it shall be straight run siren for 2 minutes. v) For Disaster condition the wailing sound given shall be repeated thrice with a minimum 10 seconds gap. 11.13.2 COMMUNICATION SYSTEM i) Communication system like telephone/ PA or paging or walkietalkie shall be provided. ii) In the hazardous areas, flame-proof / intrinsically safe telephones shall be provided. iii)
Wherever possible Hot line connection between City Fire Brigade/ near by major Industries shall be provided.
iv) Plant shall have a ` Mutual Aid' arrangement with near by industries.
fire fighting measures like starting pumps, organising people, opening valves etc. This will also take care automation failure wherever it provided.
The fireproofing of LPG storage vessel should be decided based on the risk analysis keeping in view local considerations, availability of water and societal risk. The fireproofing of LPG storage vessel shall be decided based on the fire safety analysis keeping in view local considerations, population density, availability of water, societal risk and fire protection measures provided. Fire proofing provided on the vessel and supporting legs shall be adequate to protect the shell material from overheating and consequent failure. The minimum rating for fire proofing shall be as under : LPG storage vessel & connected 1 hr. lines upto the fire safe ROVs Supporting legs of all above
11.14 SPECIAL PROTECTION
of of of is
2 hr.
FIRE
The most hazardous situation in LPG vessel is the possibility of BLEEVE. This usually takes place when the vessel is subjected to external fire. The unwetted (vapour space) portion of the shell gets overheated and fails even at the operating pressure. As such, it is important that metal temperature in the vapour space is protected from overheating by some measures. A passive measure like fire proofing/ insulation or fire retardant coating will provide protection in the initial period of fire which is very crucial. This will give some breathing time for activating other
Fire proofing is not required for diagonal bracing, including tie rods, or redundant members that are not necessary for supporting the static loads. Before fire-proofing application, protected metal surfaces shall be prepared through such means as sandblasting and corrosion-protective primers. Particular attention shall be given to the top junction of the fireproofing with the protected metal to prevent water ingress. OISD-STD-164 on "Fire proofing" shall be referred for details on fire proofing. Fire water line to each sphere should be so routed that it is not exposed to direct fire. This is to protect it from failure in
the initial period when water flow has not commenced. It is recommended that riser should be located away from bottom ROV. The horizontal run of the Fire Water line may be buried if fire engulfment cannot be avoided otherwise. Fire proofing shall include connected LPG lines and pipe supports within 15 M of a storage vessel or in the drainage paths. 11.15 INSPECTION AND TESTING The fire protection equipment shall be kept in good operating condition all the time. The fire fighting system shall be periodically tested for proper functioning and logged for record and corrective actions. In addition to routine daily checks/ maintenance the following periodic inspection/ testing shall be ensured.
ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion at least once in week and records maintained thereof. iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/ operation and lubricated once in a month. 11.15.3 FIRE WATER SPRINKLER SYSTEM i) All deluge valves and sprinkler system shall be operated and checked once in a quarter for correct remote operation performance of each nozzle and effectiveness of system in total. ii) Testing of sprinkler system in the sheds shall be carried out by closing the outlet of the deluge valve for correct remote operation once in a quarter.
11.15.1 FIRE WATER PUMPS i) Every Pump shall be in test run for atleast 10 minimum twice in a week at the rated conditions. ii) Once in a month each pump shall be checked and tested and the shut-off pressure observed and logged. Also the pump performance shall be ascertained. iii) The Jockey pump operation shall be checked periodically. Frequent start/ stop condition of Jockey pump indicates that there are water leaks in the system. 11.15.2 FIRE WATER RING MAIN i) The ring main shall be kept pressurised at 7 kg/sq.cm.g with the help of one or more jockey pumps.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a quarter and records maintained. 11.15.4
FIRE WATER RESERVOIR
In case of a Reservoir the same shall be cleaned once in 6 months or earlier as and when needed so that there shall not be any foreign particles/ fungus/ vegetation in the reservoir. 11.16 MAKE UP WATER Facilities to make up water during fire fighting shall be provided.
CHAPTER 12 GAS MONITORING SYSTEM 12.0 GENERAL The best method of prevention of explosion is to avoid basic build up of gas concentration immediately on
occurrence of leakage. This would require basically a reliable and continuous detection system with warning annunciation to alert the
plant personnel to take corrective action. The Gas Monitoring system shall provide early warning on build up of dispersed gas concentration below the LFL limits. The system shall be designed considering small leaks (leaks which have secondary closures) such as mechanical seals failure, sampling point left open, gasket leaks, hose pinholes, valves gland leakage, drain point left partially open, TSV’s relief discharge in manifold area, filling/ evacuation hoses leakage. 12.1 i)
APPLICATION The detectors for the gas monitoring system shall be strategically located in LPG Bottling Plant at all facilities close to the potential source of leakage.
ii) The detection control equipment should be provided in the control room for continuous monitoring even during power failure. 12.2 DETECTORS Amongst the various methods of detection available, the following proven systems for LPG can be considered. i) ii) 12.3
Catalytic detectors Infra-red detectors CONTROL SYSTEMS
i) This is a critical equipment for plant’s safety. Hence, the system should have independent control equipment, power supply, UPS to ensure that the system remains in operation even if the plant DCS or
other common process controls are not functioning. In case of bottling plant in Refineries, dropping of the signals on the DCS is acceptable wherever hot standby DCS control system is available. ii) In case of failure or during maintenance when the system is not in operation, the plant safety officer should keep the plant personnel on alert to be more vigilant during operations and night security patrolling. iii) The control equipment should have data logging facilities to provide print outs of the history of the events with date and time of leakages. iv) The control equipment should be able to generate at least two alarms at different levels of LEL concentration of gas. v) The control equipment is not required to have automatic corrective action capabilities on sensing leakages as this is basically a warning device. However, in case of any specific recommendations made in the risk analysis / HAZOP studies, the same should be implemented. 12.4
ANNUNCIATION SYSTEMS
Appropriate annunciation system shall be available to ensure that all the alarms generated, both, audio and visual are reported to the plant personnel, who are authorized to take corrective action. Depending on the manning practice of the plant, the alarms both, audio and visual can be repeated at additional location to ensure corrective action is taken. 12.5 LOCATION OF DETECTORS
i) The behaviour of the gas leakage governs the positioning of the gas detector. As LPG is heavier than air, the height of the detector should not be more than 0.3 M from the mounting level. ii) The pre-dominant wind direction should be considered with respect to the potential source of leakage to ensure positioning of the detector on the down stream side of the wind direction. iii) The detectors especially the catalytic type should not be positioned very close to the potential source of leakage to avoid poisoning of the detectors(temporary malfunctioning). The detectors should be located at least 0.3 mtrs. away from the potential source of leakage. iv) In case of infra-red detectors, the same shall be installed on the down wind side ensuring the path is free from obstructions. In case any additional expansion/ construction if undertaken, the detectors will have to be pre-positioned. v) The minimum detectors facilitieswise are as given below: 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 No. Valve change shed – 1 No. Empty-cum-filling shed – 2 Nos. near carousel, 1 No. near evacuation unit tank, 1 No. weight correction unit.
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. The location can be decided by assessing the behaviour of gas drift and consequential safety risk. vi) Inspection and testing The gas monitoring system shall be kept in good operating condition all the time. The inspection of the system shall be done at an interval of 1 month in which the gas shall be released at all the detectors and the performance of the systems shall be established. The calibration of the equipment shall coincide with the monthly inspection schedule every three months for calibration of the gas detectors the calibrated gas with known and certified level of concentration shall be used. The drift in the sensitivity of the individual detectors shall be recorded in maintenance history log book during calibration and the detectors with abnormal or wide drift in sensitivity. The plants should have at least 2 Nos. spare detectors for each system maintained at all times to facilitate
immediate replacement of defective detectors.
CHAPTER 13 EMERGENCY MANAGEMENT PLAN 13.0 GENERAL 13.1 The best way to manage any emergency is to prevent it. Following guidelines for emergency prevention shall be followed : a) Sound engineering practice in the design, fabrication, installation and maintenance of facilities.
agencies, such as local administration, Police authorities, Fire Brigade, hospital authorities, home guards, neighbouring industries etc. Periodic mock drills for all such plans to be conducted, and plans to be updated/ modified based on experience gained during such drills. 13.1.3 CHECK FOR LPG LEAKAGE AT FOLLOWING LOCATIONS
b) Careful selection and correct use of equipment.
a)
Through water drain valve while draining.
c) Observance of safety security regulations.
b)
Leaking sample valve.
c)
Breakage of glass on Sight Flow Indicator on the pipeline.
d)
Opening of pop-off valve, gland/ packing etc.
e)
Leakage through LPG compressor/ pump.
f)
Leakage due to bursting/ rupture of hose or through sviwel joints of body arms.
g)
Leakage from the filling guns.
h)
Escape of liquid/ vapour LPG during maintenance/ repairs.
and
d) Proper and constant training and guidance to all personnel working in the Plant, with particular reference to product knowledge and maintenance practices. e) Good House-keeping. f) Constant alertness.
supervision
and
13.1.2 EMERGENCY PLANS : Plant Manager shall ensure that suitable instructions are issued to both Corporation's and contractor's personnel identifying the action to be taken by each one in an emergency. This should be achieved by display of organisation chart/ posters not only for fire-fighting but also for other likely emergencies. Likewise, for emergencies of large magnitude Emergency Response Plan (or Disaster Management Plan) to be drawn out in coordination with related outside
13.1.4 SOME OF THE COMMON CAUSES OF FIRE : (a)
ELECTRICAL : i) Short circuiting due to loose wiring including that of automobile moving in the area.
ii) Use of non-flame proof fittings such as lights, torch, motors, fan, telephone, temporary lighting etc. (Note : Flameproof fittings become non-flame proof due to poor maintenance e.g. increase in gap in junction boxes, due to missing nuts and bolts or improper glands used for connection to junction box, or sealing compound not used in junction boxes etc.) iii) Static electricity as result of improper bonding/ grounding to tanks, conveyor system, tank truck, tank wagon etc. (b)
VEHICLE :
i)
Exhaust of vehicle, if effective spark arrestors are not provided.
ii)
Operation of non-FLP electrical switches such as vehicle ignition.
iii)
Spark from the loose contact on vehicle batteries.
iv)
Spark from exhaust of railway engine. the
v)
Excessive release of vapour beyond safe limit and fire due to outside source of ignition.
vi)
Lighting
vii)
Smoking.
13.2
ACTION EMERGENCY
DURING
13.2.1 Immediate action is the most important factor in emergency control because the first few seconds count, as LPG fires develop and spread very quickly unless prompt and efficient action is taken. In the event of fire/ gas leak within LPG Plant the following action shall be taken as quickly as possible: a)
Take immediate steps to stop LPG leakage/ fire and raise alarm simultaneously.
b)
Initiate action as per Fire Organisation Plan or Disaster Management Plan, based on gravity of the emergency.
c)
Stop all operations and ensure closure of all ROVs and isolation valves.
v)
Cinders from locomotives.
steam
(c)
OTHERS
d)
All out effort should be made to contain the spread of leakage/ fire.
i)
Landing of crackers (flying type ) in hazardous areas.
e)
Saving of human life shall get priority in comparison to stocks/ assets.
f)
Plant personnel without specific duties should assemble at the nominated place.
g)
All vehicles except those required for emergency use should be moved away from the operating
ii)
Chiselling/ hammering.
iii)
Spark from studed shoes, with steel button by friction against ground/ metal.
iv)
Lighted agarbatti in a truck.
area, in an orderly manner at prenominated route.
d)
Exercise care to ensure that static charge is not generated in LPG vapour cloud. For this purpose solid jets of water must be avoided, instead fog nozzles should be used.
h)
Electrical system except for control supplies, utilities, lighting and fire fighting system, should be isolated.
i)
If the feed to the fire cannot be cut off, the fire must be controlled and not extinguished.
e)
Fire fighters should towards a fire down possible.
j)
Start water spray system at areas involved in or exposed to fire risks.
f)
k)
In case of leakage of LPG without fire and inability to stop the flow, take all precautions to avoid source of ignition.
Cylinder fire should be approached using proper barricades/ protection to avoid direct hit from flying cylinders.
g)
If the only valve that can be used to stop the leakage is surrounded by fire, it may be possible to close it manually. The attempt should be directed by trained persons only. The person attempting the closure should be continuously protected by means of water spraying (through fog nozzles), fire entry suit, water jel blanket or any other approved equipment. The person must be equipped with a safety harness and manned life line.
h)
Any rapid increase in pressure or noise level of product discharged through safety relief valve of the vessel/ pipeline should be treated as a warning of over pressurisation. In such cases all personnel should be evacuated immediately.
i)
As in case of any emergency situation, it is of paramount importance to avoid endangering human life in the event of fire involving or seriously exposing LPG equipment or serious leakage of LPG without the fire.
l)
Block all roads in the adjacent area and enlist Police support for the purpose if warranted.
13.2.2 Fire Fighting Operations : a)
Enlist support of local fire brigade and neighbouring industries.
b)
If escaping vapour cannot be stopped, jets of water should be directed at the point of leakage to assist controlled release of vapour and in between water fog should be used for dilution and rapid dispersion of vapour cloud.
c)
Fire Fighting personnel working in or close to un-ignited vapour clouds or close to fire must wear protective clothing and equipment including safety harness and manned life line. They must be protected continuously by water sprays. Water protection for fire fighters should never be shut off even though the flames appear to have been extinguished until all personnel are safely out of the danger area.
advance wind if
13.2.3 Action in the event of LPG leakage without fire :
a)
Take basic action as detailed in 13.2.1 above.
b)
If escaping LPG is not on fire, close any valve which will stop the flow.
c)
In some cases like the leakage from a pressure vessel without a fire (such as leak from tank truck bullet or overturning) it may be desirable to move the vessel to some remote area such as block of isolated roadway or open field where it can be allowed to leak safely without a source of ignition nearby. However, if this is to be done, the vessel must be moved in an upright position. Never drag the vessel in a manner which might damage valve or pipeline. Any attempt to turn a vessel back upright to move it to some remote location should be done carefully to avoid damage to valve and pipelines. Take necessary actions as detailed in 13.2.2.
13.2.4 Action in the event of LPG fire a)
Take basic action as detailed in 13.2.1 above.
b)
Extinguishing Fires - A small fire at the point of leakage should be extinguished by enveloping with a water spray or a suitable smoothening agent such as carbon dioxide or dry chemical powder. However, it is again stressed that LPG fire should not; except in special circumstances explained earlier; be extinguished until the escape of product has been stopped.
c)
Fire fighting procedure - Fire fighting procedures would vary
depending upon various factors such as nature, sources, size, location, etc. of fire. Basic fire fighting techniques have been explained earlier in section 13.2.2. However, for the purpose of guidelines, fire fighting techniques for few common cases are as follows : (i) Cylinder Fire : If a filled cylinder is involved in fire, internal pressure may start rising and if not relieved the built up pressure could rise above 70 kgf/cm2g and ultimately rupture the container. Ignition of the escaping gas would aggravate the fire but the release of pressure would reduce the possibility of rupture of the container. No attempt should be made to extinguish the burning gas. Bus the container and other containers in the vicinity should be kept cool by water sprays until the contents of the container have burnt away. If the gas leakage does not ignite, the container should be approached from upwind (if in the open air) and be removed to a place of safety remote from sources of ignition. Cylinders not directly involved in the fire should be moved away from heat exposure, while applying cooling water sprays on cylinders directly involved. (ii)
Fire on storage vessel : If a pressure vessel is exposed to radiant heat from external fire, it should be kept cool by water sprays to prevent excessive pressure rise in the vessel. Cooling water sprays must be applied without delay to the heat affected area using fixed water sprinkler system or equivalent spray water coverage, through fixed monitors or other equipment. Cooling the
Water pressure in LPG vessels.
vessel with water sprays reduces the heat input to the vessel and thereby reduces the pressure, thus, reducing the rate of discharge from the relief valves. (iii)
If LPG vessel's SRVs have started blowing vapour, take no further action (apart from cooling) unless vessel pressure continues to rise.
Leakage of LPG burning at the outlet of a cylinder valve: Extinguish the fire by means of a portable fire extinguisher, or smoothening with a thick nonsynthetic cloth (preferably wet) or sand/ earth etc.
If fire enters LPG storage area, concentrate available cooling water on LPG vessels, most affected. Do not try to empty LPG vessels exposed to fire. They become more vulnerable to overheating as their liquid content decreases.
Fix safety cap on the valve to prevent further leakage. After the fire is extinguished, if the leakage cannot be stopped the cylinder should be moved carefully to a safe location to vent out the contents under controlled conditions. (iv)
13.2.5 Fire Fighting Organisation Plan (a)
A plan of action for use in the event of a major LPG product leakage with a fire or risk of fire is essential. Such a plan must be carefully prepared for each plant. It should be fully understood by all LPG plant supervisory personnel and other personnel responsible for action as per plan. It shall be based on the following :
(i)
Plant personnel shall be fully trained for the specialized techniques necessary for combating LPG leakages and LPG fires.
(ii)
If leakage and/ or fire occurs, all personnel should use the equipment provided and to carry out their allotted tasks as detailed in the fire fighting organisation plan.
Fire of LPG vapour escaping from a damaged vessel fitting (flame not playing on vessel)
Allow fire to continue till exhaustion. Spray vessel with water to cool it, if vessel is being heated by radiation from the flame or if flame is endangering other plant equipment. Cool adjacent vessels and structures. (v)
Fire at Safety Relief Valves of vessels exposed to adjacent fire.
(vi) Fire in Oil storage area adjacent to LPG storage : Start water sprays only on those LPG vessels exposed to fire/ heat. Isolate affected vessels and run out fire water hoses in case hose stream cooling becomes necessary.
(iii) All personnel should be conversant with fire control equipment and also its location. (iv) LPG plant personnel should know the position and method of
operation of all Remove Operation valves (ROVs) in the plant. (v)
Plant personnel should be familiar with the standard recognition markings of fire control, first aid and all safety equipment, must know the location of emergency exits, and they should know the location of water hydrant points/ monitors and must be familiar with the sound of the emergency (fire) alarm.
(b) The Fire Fighting Organisation Plan together with layout of fire fighting and safety devices shall be displayed at prominent places and explained to all personnel. It shall include the following functions, expanded to suit the location facilities/ requirement:(i)
(ix) Preventing all sources of ignition in case of LPG leakage. (x) (xi)
Evacuation and mustering of personnel.
(xii)
Establishing an emergency firecontrol centre.
(xiii) Traffic control. (xiv)
Shutting off the LPG supply to any leakage point/ fire.
(iii)
Summoning the fire brigade/ police. Fire control, with first aid, fire fighting equipment.
(v)
LPG vapour dispersal.
(vi)
Operation of LPG vessel's fixed water sprinkler system, starting of fire pump (s) and application of water hose jets/ sprays for containing/ extinguishing fires.
(xvii)
(viii) Closing down all operations in the plant including closure of valves and stopping of pumps.
Display of fire brigade, ambulance, Police telephone numbers etc.
(xviii) All clear signal by competent person. Liaison with local fire brigade :
Close co-operation with the local fire authorities is essential and shall take the following form : (i)
(vii) Cooling of vessels/ cylinders and other equipment/ facilities.
Policing of affected areas.
(xvi) Any other specialised duties.
(c)
(iv)
Stations and duties of all personnel.
(xv)
Sounding the emergency (fire) alarm.
(ii)
Evacuation of vehicles.
The fire brigade should be made familiar with the layout of the plant and the location of important equipment/ facilities provided, and their method of use. Mock fire drills/ exercise jointly by plant personnel and local fire brigades shall be planned.
(ii) Fire fighting equipment at the plant shall be compatible with the fire brigade equipment, otherwise adapters shall be kept ready for hoses, hydrants etc.
(iii) The fire brigade shall be aware of the plant's fire fighting organisation plan and the views held at the plan regarding the most effective LPG fire control methods.
f)
Protective clothing, breathing apparatus and any other specialised safety equipment available shall be tried out during drills to train all concerned in their application.
(iv) In the event of an emergency/ fire, the plant manager and/ or his representative shall advise the Fire Officer about particular or potential hazards that may be present e.g. stocks of filled cylinders at that particular point of time.
g)
The local fire brigade should be encouraged to participate in fire drills periodically.
h)
Any shortcoming, noticed during the drill shall be rectified.
13.2.6 Disaster Management Plan : (d)
Fire Drills & Training : ON- SITE
a)
b)
c)
Drills for all Plant personnel, making use of the "Fire fighting Organisation Plan" and practicing the specialised techniques required for fighting LPG fires or dispensing/ diluting LPG vapour clouds shall be held minimum once in a month. The drills should cover various types of incidents, e.g. major spillage, LPG bulk lorry fire, cylinder fire etc. Extinguishers due for recharging/ due for hydrotesting shall be discharged during drills and replenished subsequently 50% (Min.) stock of refills as replenishment for FEs should be maintained.
d)
The fire pump should be run, sprinkler system activated, emergency systems tested, water hoses run out and spray/ set techniques practiced during drills.
e)
Fire alarms shall be sounded/ tested (neighbouring plants/ factories and the fire brigade shall be warned in advance of this test).
a)
It is basically a pre-plan to handle any emergency situation of a higher magnitude arising out of factors listed below:
(i)
Major fire/ explosions
(ii)
Uncontrollable leakage of LPG
(iii)
Lightning
(iv)
Heavy floods
(v)
Earthquakes/ land slides
(vi)
Sabotage/ terrorist outrage
(vii) War situation The objective of the plan shall be to reduce the probability of serious loss/ damage to general stock, plant and machinery, documents etc. utilizing combined resources of the location itself and the outside agencies. In order to have an effective organisation, preliminary meeting shall be conducted with the representatives from local fire services, police authorities, voluntary organisations like ambulance service/ Govt. medical service/ contractors and even Home Guards and defence
personnel. In the course of the meeting, there should be exchange of knowledge, training and plans for development of expertise and skills to gain knowledge about the plant layout/ facilities, potential of likely hazards/ risks, likely emergencies that may arise. This group should draw out modalities of the exercises in the given situation and arrive at an agreed action plan which should be updated from time to time and put to test in the form of periodical mock drills. (b) Due to varying risk potentials and also varying hazards at/ around each location `Disaster Management Plan' for each location shall be drawn up individually based on the outline given below: (i)
(ii)
Identify Disaster scenario i.e. the situation under which the plan would become operational. Plan for the worst possible scenario. Identify resources required from each of the outside agencies.
(iii) Establish outside agencies, role of each agency and obtain their commitment for rendering the assistance in crisis situation as per the agreed plan. (iv) Establish organogram for Disaster Management based on available manpower in various groups and identify the leader and alternative
leader for each for the groups and the role to be played by each team in various likely crisis situations. (v) Identify Disaster control room/ group. (vi) Furnish detailed data and drawings relevant for the crisis management. (vii)
Establish channel of communication at the local level to Statutory Authorities and higher authorities within the organisation.
(vii)
Mock drills to be conducted minimum once a year.
(ix) Modify the plan based on the experience gained through mock drills and try out the modified plan through subsequent mock drills. (x) The plan shall be updated as and when the changes recorded in the plan occur and communication sent to all concerned. (c) Communication organogram : As a part of Disaster Management Plan, communication organogram shall be drawn up giving flow of communication from the originating location to various local agencies and also to Statutory Authorities and upwards within the organisation to mobilise support and to consider alternatives for maintaining essential supplies.
CHAPTER 14 : SAFETY AUDIT 14.1 GENERAL: Safety audit is a well recognised tool to improve the effectiveness of safety programme and loss prevention measures by carrying out systematic and critical appraisal of potential safety hazards involving personnel, plants and equipments. For a structured and systematic safety audit of any plant/ facility, check lists are the most important prerequisite. Check lists should cover all the operational areas, major equipments, operating/ maintenance procedures, safety practices, fire prevention/ protection systems etc. Observations/ recommendations of safety audit team should be presented in the form of a formal report and action plan for corrective measures should be prepared and subsequently monitored for implementation.
14.2 TYPE OF SAFETY AUDIT AND PERIODICITY : In view of the high hazard potential of LPG, safety audits at frequent intervals by the teams/ personnel of various levels are advocated, Broad check lists for different recommended safety audits are given in the Annexure 10-I, II, III, IV. These check lists can be further supplemented and modified suitably to meet the specific requirements of individual plant. Recommended minimum safety audits at different levels, their frequencies and broad check lists to be used are indicated below :Daily audit essentially shall cover the compliance of recommended operating procedures/ safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis and corrective action be undertaken on priority wherever required.
General guidelines on safety audit methodologies and techniques are also given in OISD - GDN- 145. ----------------------------------------------------------------------------------------------------------------------------S.No. Type of Safety By Frequency Checklist Audit (Annexure) ----------------------------------------------------------------------------------------------------------------------------1 2 3 4 5 ----------------------------------------------------------------------------------------------------------------------------1. Inspection Safety LPG Plant Daily 14-I audit of LPG Installation Safety Officer 2. Electrical audit of Authorised Annual 14-II LPG Installation electrical Engineer 3. Detailed safety audit Multi disciplinary Annual 14-III of LPG Installation team of region/ HQ 4. Inspection and Personnel from Annual 14-IV maintenance audit of Inspection/ Maintenance LPG Installation 5. External safety audit OISD of LPG Installation --------------------------------------------------------------------------------------------------------------------------------
Daily audit essentially shall cover the compliance of recommended operating procedures/ safety practices. Reports of audit shall be reviewed by the Plant Manager on daily basis and corrective action be undertaken alongwith the target dates shall be done immediately. The compliance to other audit recommendations along with target schedules shall be monitored on monthly basis. Alternate, safety measures shall be taken till the recommendations are complied in totality. In case of external safety audit, following areas besides the points given in check list of Annexure 14- III shall be covered.
1.
Safety Organisation
2.
Security System
3.
Fire prevention/ protection system
4.
Preparedness to handle any emergency --Disaster control plan and mock drills.
5.
Skill level and training needs for HRD.
6.
Operating manual/ instructions, display of Do's/ Don'ts etc.
ANNEXURE 14- I DAILY SAFETY AUDIT - CHECKLIST FOR LPG BOTTLING PLANTS
LOCATION ______________ Audit/ Inspection by _________________ -------------------------------------------------------------------------------------------------------------------------------S.No. Item Observation* Action Plan Target Date Review date 1 2 3 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------A. SAFETY/ FIRE PROTECTION SYSTEM
A-01
Water level in static water tank is satisfactory.
Yes/No
A-02
Hydrant pressure maintained with jockey pump. Record Pressure.
Yes/No
A-03
Fire water pumps/engines
Yes/No
a) Are the batteries in good condition. b) Are the diesel tanks full c) Start one pump, record pressure developed. d) Whether auto start system working. A-04
Fire alarm/ communication system in working order.
Yes/No
A-05
Automatic Gas Detection system operating.
Yes/No
A-06
Vapour Extraction Unit operating
Yes/No
A-07
Any unsafe condition of Yes/No S&FP system observed (specify in brief under remarks column).
A-09
Regular surprise checks/ testing being done at gate/ at the plant.
Yes/No
A-10
Direction of wind (specify in remarks column by observing wind sock).
Yes/No
-------------------------------------------------------------------------------------------------------------------------------S.No. Item Observation* Action Plan Target Date Review date 1 2 3 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------A-11
Caution signs displayed at appropriate places.
Yes/No
A-12
Last fire drill in this area done on
-----------
B. BULK STORAGE AREA B-01
Whether water draining sampling done under constant supervision.
Yes/No
B-02
Earthing connection apparently sound.
Yes/No
a) Whether level instruments are working. b) High level alarm in working condition (test check). B-04
Portable fire extinguishers in position.
Yes/No
B-05
Water spray/ sprinkler system apparently O.K.
Yes/No
B-06
Housekeeping is in order
Yes/No
B-07
Gas detection system working
Yes/No
B-08
Any sign of LPG leakage
Yes / No
B-09
Any settlement of vessel observed
Yes / no
B-10
Condition of Water seal
Yes / no
B-11
ROVs on remote mode
Yes / no
B-12
Pressure and temperature gauge Functional
Yes/ no
B- 13
Bonding across flanges visible
Yes / no
B-14
Last fire drill in this area done on
-----------
C.
TANK WAGON UNLOADING
-------------------------------------------------------------------------------------------------------------------------------S.No. Item Observation* Action Plan Target Date Review date 1 2 3 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------C-01
Any visible sign of LPG leakage
Yes/No
C-02
Earthing connection apparently sound
Yes/No
C-03
a) Whether hose condition/ connections are proper
Yes/No
b) Are these properly plugged if not in use.
Yes/No
C-04
House keeping in order.
Yes/No
C-05
Portable fire extinguishers in position.
Yes/No
C-06
Water spray/ sprinkler system apparently O.K.
Yes/No
C-07
Housekeeping is in order
Yes/No
C-08
Condition of Water seal
Yes / no
C-09
Gas detectors functional
Yes/ no
C-10
ROVs on remote mode
Yes / no
C-11
Pressure and temperature gauge Functional
Yes/ no
C- 12
Bonding across flanges visible
Yes / no
C-13
Last fire drill in this area done on
-----------
D. BULK TRUCK UNLOADING --------------------------------------------------------------------------------------------------------------------------------
S.No. 1
Item 2
Observation* 3
Action Plan Target Date Review date 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------D-01
Are all vehicles allowed in licensed Yes/No area permanently fitted with CCE approved spark arrestors on exhaust pipe (Random check)
D-02
Is the vehicle engine and master switch being shut off during unloading bulk LPG (site check)
Yes/No
D-03
Are the earthing connection properly made before connecting hoses to tank trucks.
Yes/No
D-04
Rotogauge, Fixed level instrument in working order (Random check. Record TT No)
Yes/No
D-05
Any visible sign of LPG leakage
Yes/No
D-06
Random safety check of tank truck No.
Yes/No
a) CCE licence available/ valid
Yes/No
b) Fittings as per CCE
Yes/No
c) 2 Nos. of fire extinguishers available in good condition/ easily accessible. (physical check)
Yes/No
d) Safety instruction booklet Yes/No TREMCARD available. Record any abnormality/discrepancies observed.
D-07
e) Wheel choke used
Yes/No
a) Portable extinguisher available in nominated places.
Yes/No
b) Sprinkler system in working condition.
Yes/No
D-08
House keeping in order
Yes/No
D-09
Bonding of flange connection given
Yes/No
D-10
Hose test date
Yes /No
D-11
Last fire drill in this area done on
-----------
E. PUMP HOUSE/ COMPRESSOR ROOM
-------------------------------------------------------------------------------------------------------------------------------S.No. Item Observation* Action Plan Target Date Review date 1 2 3 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------E-01 Electrical connections apparently sound
Yes/No
E-02 Earthing apparently proper
Yes/No
E-03 Gauges on pumps/compressor in working condition, record pressure.
Yes/No
E-04 Drain/ vent connection cap in position.
Yes/No
E-05 Safety guards in position
Yes/No
E-06 Abnormal vibration/ excessive noise.
Yes/No
E-07 Portable fire extinguisher in position
Yes/No
E-08 Any visible sign of LPG leak or any unsafe conditions observed (record under remarks column).
Yes/No
E-09 Housekeeping in order.
Yes/No
E-10 Gas detection system working.
Yes/No
E-11
-----------
Last fire drill in this area done on
F. FILLING SHED F-01 No ignition sources visible in operating areas or area in vicinity.
Yes/No
F-02 Are the LPG cylinders empty or empty or filled, properly loaded/ unloaded and handled to avoid impact, falling, horizontal rolling etc.
Yes/No
F-3 Are earthing connection on filling carousel properly made.
Yes/No
F-04 Are the cylinder chain conveyors adequately Yes/No lubricated to avoid metallic rubbing and friction. F-05 Water in test bath is clean and maintained upto the required level.
Yes/No
F-06 Any sign of leakage of unsafe condition Yes/No None of the filling guns or adapters used for cylinder filling/emptying are leaking. -------------------------------------------------------------------------------------------------------------------------------S.No. Item Observation* Action Plan Target Date Review date 1 2 3 4 5 6 (status) -------------------------------------------------------------------------------------------------------------------------------F-07 Are all the fire extinguishers available Yes/No in accessible location. F-08 All electrical connection apparently intact & safe.
Yes/No
F-09
Is the concentration level of gas checked Yes/No with explosimeter twice a day in the filling area in filled and empty cylinder area, pump/ compressor room. Record reading for sample check.
F-10
Sprinkler system in working condition
Yes/No
F-11
Housekeeping is in order.
Yes/No
F-12
Rotary equipment/ coupling etc
Yes/No
F-13
Gas detection system working.
Yes/No
F-14
CVT is functional
F-15
Last fire drill in the area
F-16
Vapour extraction system functional
Yes / no
F-17
Emergency trip at Carousel functional
Yes/ No
Yes/ No -----------
G.
CYLINDER STORAGE/ HANDLING
G-01
Are cylinders stacked properly in demarcated areas.
Yes/No
G-02
Any leaky overfilled cylinder kept at the end of the day. Record No. if any, of the leaky unevacuated cylinder.
Yes/No
G-03
Safety cap fixed on cylinders in stock.
Yes/No
G-04
Sprinklers functional
G-05
Cylinders loaded in to trucks through conveyors.
Yes/No
G-06
Rubber mats are used for unloading empty cylinders from tank trucks and are in good condition.
Yes/No
G-07
Last fire drill in the area
-----------
* Put specific observation wherever the conditions are not in line with specified requirement levels.
ANNEXURE 14 - II.
ELECTRICAL AUDIT OF LPG BOTTLING PLANTS LOCATION _____________
Dated ____________
AUDIT/ INSPECTION BY ______________________ -------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------A. ELECTRICAL SUBSTATION/ SWITCH ROOM
A-01 Is painted line diagram of power/ lighting distribution provided. A-02 Is the equipment easily accessible for operation, inspection & maintenance. A-03 MCC Panel condition : a) Doors okay and closed b) Dust/soot/ cobwebs not existed c) Lugs existing at each cable, termination not loose. d) Visual condition of switch contact fuse etc. O.K. e) Control wiring condition satisfactory. f) Jumper condition between bus and distribution okay. g) Grounding OK h) Alarm/ trip circuit working. A-04 Live parts of equipment made inaccessible by barriers/ shrouds. A-05 No temporary electrical connection existing. A-06 Condition of cable duct a) Cables are on rack b) Cable deck clear c) Sealing of duct d) Cable identification tags.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------A-07 Rubber mats (with ISI mark) existing are enough in number. A-08 Protective relays set at recommended values. A-09 All fuses are of proper type and rating as specified in single line diagram. A-10 Fire extinguishers are of proper type and are in working condition. A-11 Lighting condition OK (fixtures/ tubes/ wtiches etc.) A-12 Emergency lighting system in order. A-13 All energised equipment provided with caution boards. A-14 Condition of transformer : a) Grounding OK b) No oil leak c) Silica gel OK d) Oil level OK e) Terminal box earthing OK f) Oil/winding temp. OK g) Periodic oil quality test conducted. A-15 Whether location/type of transformer in conformity with area classification drawings. A-16 Housekeeping is good.
B. MOTORS IN PUMP HOUSE/ COMPRESSOR ROOM/ FILLING & STORAGE SHED ETC. B-01 Is double independent earthing connection for all motors provided. B-02 Is grounding wire OK (not loose). B-03 a) Is terminal box and gland OK Flame-proofness maintained and not tampered. b) Existing cable termination are proper B-04 a) Is push button earthed properly and flame proof condition not tampered. b) General condition of push button good. B-05 Ground resistance at motor/ push button measured and found okay.
B-06 No motor abnormality - Vibration/ bearing condition, faulty guard, fan condition, excessive noise, high body temperature. B-07 Existing preventive maintenance schedule OK. B-08 a) Earthing resistance test schedules/ records satisfactory. b) Earthing pit condition OK B-09 i) Carousel machine frame to filling gun earthing continuity maintained. ii) Carousel machine frame to central column earthing continuity OK. B-10 Conveyor system bonding and earthing maintained. B-11 First-aid chart for treating electrical shocks displayed prominently in MCC room. C. UNIT LIGHTING C-01 All lighting fixture flame proof as per area classification. C-02 Whether flame proof condition of fixtures ensured ? C-03 Whether proper earthing of fixture provided ? C-04 Condition of wiring good. C-05 Does water enter and accumulate in fixture distribution boxes etc ? C-06 Whether lighting DB, switches, MCB well maintained ? C-07 Any other unsafe point observed.
D. MAST LIGHTS (AREA LIGHTING) D-01 Whether grounding of mast OK ? D-02 Condition of junction boxes, switch board, fuses etc. OK D-03 Approach to electrical installation and ladder good and safe. D-04 Condition of flood lights : a) Is gasket present ? b) Is glass cover in good condition ? c)
Is control gear condition OK
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------D-05 Is earthing electrode of mast OK and its connection with mast proper ?
E. TANKAGE AREA, PIPELINES, LOADING/ UNLOADING GANTRY E-01 Are LPG pipelines provided with flange earth jumper connection for electrical continuity? E-02 Are earthing provision on LPG storage vessel well maintained ? E-03 Condition of grounding electrode OK E-04 Continuity of location, hoses maintained. E-05 Grounding resistance at inlet of grounding connection checked/ date (for vessels etc.) E-06 Connection of earth-bonding of railway track OK.
F. GENERAL F-01 a) Area classification drawings duly approved by CCE, Nagpur? b) Conditions if any, specified by CCE for electrical substation, switch room etc. and their compliance. F-02 Certificate in respect of FLP for each electrical equipment- records maintained. F-03 Earthing network diagram available and site checks done from time to time. F-04 Records for electrical testing/ checks maintained upto date. F-05 Work permit system is effective and records are maintained.
Note : For developing a detailed check list refer OISD-GDN-145-09 document on safety audit check list for electrical system.
ANNEXURE 14- III
DETAILED SAFETY AUDIT OF LPG BOTTLING PLANTS LOCATION _____________
Dated ____________
AUDIT/ INSPECTION BY ______________________
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------A. BULK STORAGE AREA A-01 Area under the sphere is having concrete pavement with proper slope leading to shallow sumps. A-02 a) Water drain chamber provided away from shadow of sphere. b) Double valves on water drain line provided: the first one (near to chamber) of quick shut off type and the other are throttle type (Globe valve). c) Safety instructions for draining operations displayed prominently and water draining is done under supervision. A-03 a) Relief valves provided with isolation valves. b) Isolation valves in locked open condition. A-04 Last safety valve test done as per statutory requirement and record maintained. A-05 Remote operated valves provided on liquid inlet/outlet lines with push buttons/ indication control and located at safe distance. A-06 Two independent level instruments and high level alarm provided in storage vessels and are in working condition. A-07 All leg supports of Horton spheres/ vessels encased in concrete with fire proof coating/ motor. A-08 a) Sprinkler system provided on all vessels and are in working condition. b) Deluge valve is remote operated and is located at safe distance from storage vessels. A-09 Gas detection system provided and in good working condition (To be checked). A-10 a) All flame-proof electrical fittings provided. b) Earthing connections properly maintained.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------A-11 Statutory inspection/ hydro test records maintained.
B. PUMPS/ COMPRESSORS AREA
B-01 a) All electrical motors/ push buttons properly earthed and flame proofness maintained. b) Flame proof light fittings provided. c) Earthing resistance test conducted periodically and record maintained. B-02 Venting through high rise vents or flare systems only. B-03 a) No leakage from mechanical seals. b) Double seal provided to minimise chances of leakage. c) No abnormal sound and vibration from motor and bearings condition OK. d) Coupling guards in position. B-04 Drain points/ vent points/ sample points capped when not in use. B-05 Operating instructions Do's and Don'ts displayed. B-06 Long range monitors/ fixed water spray with proper throw/ sprinkler system installed and in good condition.
C.
CYLINDER FILLING/ STORAGE AREA
C-01 LPG bottling facilities located at safe distance from other facilities with minimum ingress to trucking traffic. C-02 Facilities provided for positioning of trucks 15 m away from storage shed for receipt/ loading of cylinders. C-03 Transfer of cylinders from truck to conveyor. - Telescopic conveyor - Trolley use C-04 Proper purging facilities provided for new/ retested/ reconditioned cylinders C-05 a) Inspection/ visual checks followed for spurious/ defective cylinders and record maintained. b) Segregated storage marked for i) Spurious
ii) Hot repairs iii) 5/7 years testing due cylinders iv) Other defects C-06 Gross weight filling : - Auto cut off after completion of filling C-07 Hoses are of approved quality and periodically tested. C-08 Vapour extraction system provided for carousel and system is working satisfactorily. C-09 100% weight checking facilities provided and in use. C-10 Accuracy of check scales being checked daily and records maintained. C-11 CVT checks done for `O' ring defects. C-12 Check facilities provided for valve seat leakage and working satisfactorily. - CVT with verifier - Electronic C-13 Proper facilities/ correction conveyor loops are provided for defective cylinders (`O' ring & weight correction). C-14 Bung leak/ body leak check are done through in-line water bath with caps in position. C-15 Capping/ Pilfer proof sealing facilities provided. - Aluminium foil - PVC sealing C-16 Neck label being put - Plastic - Paper C-17 Quality control checks (SQC) carried out/ records maintained. C-18 Proper facilities provided for evacuation of defective cylinders and working satisfactorily. C-19 Cold repairs facilities evacuation for evacuated depressurized cylinders. -
Valve removal/ replacement by use of torque wrench with proper settings.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------- PTFE tape/ paste or other suitable sealing compound used. C-20 Movement of cylinders for cold repairs through floor conveyors/ use of trolleys. C-21 Mastic flooring provided on the floor storage area to avoid accidental sparks. C-22 a) Cylinders stacked in vertical position b) Stacking discipline with small lots of 4 rows and 25 cylinder lengths followed, a minimum access path of 1M maintenance on both sides of 4 rows. C-23 Cylinders are inspected for leakage with explosimeter or portable leak detector. C-24 Sprinkler system provided in the storage shed and in working condition. D. BULK LPG UNLOADING FACILITIES D-01 Whether the location and layout of the facilities meet statutory distances/ design guidelines. D-02 Effective earthing system provided and working satisfactorily. D-03 a) Hoses used are of approved quality standard. b) They are periodically tested and replaced after prolonged use. D-04 Hose contents after unloading are released to high vent located at safe distance. D-05 Blocked hoses/ pipelines provided with TSVs. D-06 a) Sprinkler system provided on the railway siding/ tank truck loading/ unloading area are and working satisfactorily. b) Fire hydrant/ long range monitors provided. D-07 Remote operated valves provided on liquid loading headers. D-08 a) Weigh bridge provided on liquid loading headers. b) Calibration certificate obtained from Weights & Measures Authorities available. D-09 a) Vehicles are properly checked for any sign of leak, proper fittings and other valid documents. b) 2 Nos. of fire extinguishers (DCP type). c) Explosive licence, safety certificate, fitness certificate. d) Proper earthing cable with clamps. D-10 Loading/ unloading procedures along with safety precautions prominently displayed.
--------------------------------------------------------------------------------------------------------------------------------
S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------E. SAFETY/ FIRE PROTECTION SYSTEM E-01 Fire organisation chart prepared, updated and displayed. E-02 Contingency plan updated for tackling major emergencies. E-03 Important telephone Nos. of State Fire Services, Police, District Admn./ other offices etc. displayed. E-04 Are fire emergency mock drills conducted periodically and records maintained. E-05 Work permit system for repairs/ hot jobs etc. followed and records maintained. E-06 a) Fire water network (layout displayed) - above ground/ under ground - corrosion protection - material of construction b) Pressure at farthest end and flow c) Condition of hydrants, long range monitors. Maintenance and inspection schedules followed and records maintained. d) Provision of sprinkler system and testing schedules for checking : - Adequate water distribution : spray nozzle are clean. - Defective nozzles to be identified for replacement. - Deluge valve operation satisfactory. e) Strainers provided at inlet of deluge/ sprinkler water supply main piping. Strainers are cleaned periodically and records maintained. E-07 Fire Water Pumps : - Adequacy of capacity, nos. discharge pressure etc. - Auto starting (system security logic) provided. - Working jockey pump operating parameters maintained. E-08 Static water storage tank - capacity and adequacy -------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------- Source of water supply and rate of replenishment.
E-09 a) Fire vehicles well maintained. b) Mutual aid scheme with neighbouring industries/ district authorities existing. E-10 a) Fire extinguishers - type, make, capacity, location, provision of tamper seals on retainer clips. b) Maintenance procedures/ records of fire extinguishers. E-11 a) Fire alarm and communication system working satisfactorily. b) Testing schedule/ maintenance. E-12 Protective clothing : - Availability of special fire fighting suits (Aluminised suits) - Breathing apparatus & its upkeep - Water jel blankets. - Use of nylon clothes prohibited. E-13 Automatic Gas Detection System : - Working satisfactorily - Regularly tested. E-14 No smoking cautions/ signs in Hindi/ English local languages displayed at prominent places. E-15 First aid facilities maintained. E-16 a) Emergency lighting system provided in strategic locations and system working satisfactorily. b) Flame-proof torches available F. MANPOWER AND TRAINING F-01 Supervisory/ managerial cadre staff fully trained in all aspects of LPG plant operations, Disaster control/ emergency handling. F-02 Safety officer available in each shift and his detailed responsibility/ accountability is drawn.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------F-03 Training programmes are organised periodically in LPG operations;
fire fighting/ emergency handling etc. for a) Regular staff b) Contractor workmen c) Security staff d) Tank truck operators/ drivers F-04 All activities are effectively supervised with available manpower. F-05 a) Operating manuals and standing instructions provided to working personnel. b) Small handy safety booklets distributed to all including contractor employees in English/ Hindi/ Local language. F-06 Important Do's and Don'ts displayed prominently in operation areas.
G. GENERAL G-01 a) Plant approach/ access roads well maintained and at least two emergency exits are there. b) Fencing/ wall around the plant is in proper condition. c) Segregated parking area for LPG trucks outside the plant. d) Adequate escape route available for operational facilities. G-02 a) Strict security checks employed for compliance to safety regulations. b) Spot checks being done. G-03 a) Valid CCE licences available for : - Storage of LPG - Storage of LPG cylinders - Filling of LPG cylinders - Storage of HSD in tanks for running DG sets/ fire water engines. - Layout plan approved by CCE(layout plan updated and approved by CCE). G-04 Accident records maintained and updated.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------G-06 Hot work permit/ clearance issued - proper procedures followed and documents maintained. G-07 Following manual/ documents available:
a) LPG operating manual. b) Safety and Fire Prevention manual c) Emergency/ disaster control plan d) Operation/ Inspection manual of equipment supplied by vendors. e) Gas Cylinders Rules, 1981, SMPV Rules 1981 and other relevant BIS Standards with latest amendments. G-08 a) Records of periodic testing of hoses/ replacement. b) Testing records of Pn relief valves/ pop action valves. c) Inspection records of underground pipelines etc. d) Weights & Measures certificates. G-09 Updated P&I Diagrams, drawing of layout and other facilities available. G-10 Records of "Daily Safety Audits" reviewed. Corrective action taken. G-11 General housekeeping standards : area/ facility wise. G-12 Pipeline colour code system maintained.
ANNEXURE 14- IV
INSPECTION & MAINTENANCE SYSTEM AUDIT LOCAL _______________
DATED: _________
AUDIT/ INSPECTION BY ________________ -------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------A. GENERAL A-01 Whether standard system of inspection/ maintenance schedule developed and followed and records maintained. A-02 Whether equipment documents supplied by vendors are readily available and recommended maintenance procedures are strictly adhered to. A-03 Whether spare parts for different equipment/ machinery are maintained. A-04 Whether data card/ history records of static and rotary equipment are maintained (as per OISD Std.127/28). A-05 Whether proper work permit system is followed for maintenance jobs and records maintained. A-06 Whether personnel protective equipment such as hand gloves, safety shoes, safety helmet etc. provided to the concerned workmen and their use is ensured (OISD Std.-155). A-07 Fire fighting equipment and portable fire extinguishers periodically checked / tested as per maintenance schedules & records maintained (OISD Std.-142). A-08 Fire alarm/ communication system scheduled testing & maintenance ensured. A-09 Whether Explosimeters are periodically checked and calibrated. A-10 Whether continuous monitoring devices are periodically checked and calibrated. A-11 Whether exhaust fans and other ventilation devices are properly maintained and regularly used. A-12 Whether inspection/ testing of pressure vessels carried out periodically as per statutory requirements and records maintained.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 --------------------------------------------------------------------------------------------------------------------------------
B. BULK STORAGE HANDLING FACILITIES B-01 Whether design of pressure storage vessels conform to relevant BIS/BS/ASME code with standard engineering practices. All required fittings/ instruments/ safety valves have been provided. B-02 Whether inspection/ test certificate at the time of original fabrication available and subsequent inspection/ hydraulic test carried out as per SMPV Rules 1981 of CCE and records maintained. Guidelines of OISD Standard-128 followed for detailed inspection of pressure vessels. B-03 Annual inspection and testing of safety valves carried out at proper set pressure and records maintained. B-04 All instruments, level indicators, pressure and temperature gauges, ROVs are maintained in working condition following daily scheduled checks, periodic calibration and preventing maintenance schedule. B-05 Regular operation checks are carried out on pumps/ compressors (condition of bearings/ mechanical seal/ abnormal sound etc. as per OISD STD-119, 120). B-06 Preventive maintenance and servicing schedules for pumps and compressors for daily/ weekly/ monthly/ yearly are checked and records maintained. B-07 Gas detection system is checked and calibrated periodically. Audio visual alarm/ security logic system maintained in working condition. B-08 Fire water system & sprinkler spray system checked/ tested periodically and maintenance jobs carried out and records maintained. B-09 LPG bullets/ spheres having fire proofing are periodically checked for cracks, spalling/ bulging and suspected area are further inspected for presence of corrosion etc. and corrective steps taken. B-10 Earthing connections are periodically checked and good electrical contact is maintained. Records of resistance testing as outlined in OISD Std-137 maintained. B-11 Foundation/ Anchor bolts, ladders, stairways, platforms/ structurals checked periodically for any corrosion/damage etc. B-12 Annual testing of chain pulley blocks and other tool tackles is carried out by certified agency. B-13 Weigh bridges calibration and certification done once in a year.
-------------------------------------------------------------------------------------------------------------------------------S.No. ITEM DESCRIPTION AUDITORS REMARKS 1 2 3 -------------------------------------------------------------------------------------------------------------------------------C. CYLINDER FILLING C-01 LPG filling carousel - Drive unit, central column, running rails, etc. are daily checked, scheduled maintenance (weekly, monthly, quarterly, annual) are carried out and records maintained. C-02 Introduction/ Ejection devices and filling machines are checked daily and scheduled maintenance/ overhaul work carried out. C-03 Checking of pin travel done regularly and records maintained. C-04 Check scales are well maintained and calibrations carried out on daily basis with standard weights. C-05 Calibration of CVT/DCVT detectors being done regularly and maintenance schedule followed.
15.0 REFERENCES 15.1 BIS CODES PERTAINING TO LPG OPERATIONS -------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:2-1960
-
RULES FOR ROUNDING OFF NUMERICAL VALUES
IS:5-1978
-
COLOURS FOR READY MIXED PAINTS & ENAMELS
IS:1196-1978
-
CODE OF PRACTICE FOR LAYING BITUMEN MASTIC FLOORING
IS:1432-1959
-
GENERAL REQUIREMENTS FOR WEIGHING INSTRUMENTS
IS:1435-1991
-
PLATFORM WEIGHING MACHINE
IS:1436-1991
-
WEIGHBRIDGES
IS:1437-1967
-
AUTOMATIC WEIGHING MACHINES
IS:1448(P:70-1968)
-
RESIDUE IN LPG
IS:1448(P:71-1979)
-
VAPOUR PRESSURE OF LPG
IS:1448(P:72-1968)
-
VOLATILITY OF LPG
IS:1448(P:73-1968)
-
HYDROGEN SULPHIDE IN LPG
IS:1448(P:74-1968)
-
DRYNESS OF LPG
IS:1448(P:75-1968)
-
ODOUR OF LPG
IS:1448(P:76-1968)
-
DENSITY OF LPG
IS:1448(P:111-1983)
-
ANALYSIS OF LPG AND PROPYLENE CONCENTRATES BY GAS CHROMATOGRAPHY
IS:2148-1981
-
FLAMEPROOF ENCLOSURES FOR ELECTRICAL APPRATUS
IS:2206
-
FLAME PROOF ELECTRIC LIGHT FITTINGS
IS:2206(PART 1)-1984
-
WELL GLASS AND BULKHEAD TYPES
IS:2206(PART 2)-1976
-
FITTINGS USING GLASS TUBES
IS:2808-1964
-
METHOD FOR COMPUTATION OF CAPACITY TABLES FOR PRESSURIZED STORAGE TANKS
-------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:2825-1969
-
CODE FOR UNFIRED PRESSURE VESSELS
IS:2827-1976
-
METHODS FOR CALIBRATION OF PRESSURIZED STORAGE TANKS
IS:3196(PART 1)-1992
-
WELDED LOW CARBON STEEL GAS CYLINDER EXCEEDING 5 LITRE WATER CAPACITY FOR LOW PRESSURE LIQUEFIABLE GASES CYLINDERS FOR LPG.
IS:3465-1966
-
JOINTING COMPOUND FOR USE IN LPG APPLIANCES AND INSTALLATIONS
IS:3710-1978
-
FILLING RATIOS FOR LOW PRESSURE LIQUEFIABLE GAS.
IS:4093-1981
-
NON-REFILLABLE LPG CONTAINERS
IS:4246-1984
-
SPECIFICATION FOR DOMESTIC GAS STOVES FOR USE WITH LIQUEFIED PETROLEUM GASES
IS:4379-1981
-
IDENTIFICATION OF CONTENTS OF INDUSTRIAL GAS CYLINDERS
IS:4576-1978
-
SPECIFICATION FOR LIQUEFIED PETROLEUM GASES
IS:4784-1968
-
LOW PRESSURE REGULATORS FOR USE WITH BUTANE GASES
IS:4785-1968
-
LOW PRESSURE REGULATORS FOR USE WITH PROPANE GAS
IS:4786-1968
-
VARIABLE HIGH PRESSURE REGULATORS FOR USE WITH LPG
IS:4991-1968
-
CRITERIA FOR BLAST RESISTANT DESIGN OF STRUCTURES FOR EXPLOSIONS ABOVE
IS:5116-1985
-
GENERAL REQUIREMENT FOR DOMESTIC AND COMMERCIAL EQUIPMENT FOR USE WITH LPG
IS:5571-1979
-
GUIDE FOR SELECTION OF ELECTRICAL EQUIPMENT FOR HAZARDOUS AREAS
IS:5572
-
CLASSIFICATION OF HAZARDOUS AREAS (OTHER THAN MINES) FOR ELECTRICAL INSTALLATIONS
GROUND
-------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:5572(PART 1)-1978
-
AREAS HAVING FLAMMABLE GASES AND VAPOURS
IS:5844-1970
-
RECOMMENDATIONS FOR HYDROSTATIC STRETCH TESTING OF COMPRESSED GAS CYLINDERS
IS:5845-1984
-
CODE OF PRACTICE FOR VISUAL INSPECTION OF LOW PRESSURE WELDED STEEL GAS CYLINDERS IN USE
IS:5903-1970
-
RECOMMENDATIONS FOR SAFETY DEVICES FOR GAS CYLINDERS
IS:6044
-
CODE OF PRACTICE FOR LPG TORAGE INSTALLATIONS
IS:6044(PART 1)-1971
-
COMMERCIAL AND INDUSTRIAL CYLINDER INSTALLATIONS
IS:6044(PART 2)-1972
-
INDUSTRIAL, COMMERCIAL AND DOMESTIC BULK STORAGE INSTALLATIONS
IS:6539-1972
-
INSTRINSICALLY SAFE MAGNETO TELEPHONES FOR USE IN HAZARDOUS ATMOSPHERES
IS:6665-1972
-
CODE OF PRACTICE FOR INDUSTRIAL LIGHTING
IS:7142-1974
-
WELDED LOW CARBON STEEL GAS CYLINDER FOR LOW PRESSURE LIQUEFIABLE GASES, NOT EXCEEDING 5 LT WATER CAPACITY
IS:7145-1973
-
TECHNICAL SUPPLY CONDITION FOR TORQUE WRENCHES
IS:7241-1981
-
GLOSSARY OF TERMS USED IN GAS CYLINDER TECHNOLOGY
IS:8198(PART 5)-1984
-
CODE OF PRACTICE FOR STEEL CYLINDERS FOR COMPRESSED GASES ; LIQUEFIED PETROLEUM GAS (LPG)
IS:8374-1977
-
SPECIFICATION FOR BITUMEN MASTIC, ANTI STATIC ELECTRICALLY CONDUCTING GRADE
IS:8451-1984
-
CODE OF PRACTICE FOR VISUAL INSPECTION OF HIGH PRESSURE GAS CYLINDERS
-------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:8737 VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF MORE THAN 5 LIT. WATER CAPACITY IS:8737(PART 1)-1979
-
VALVE FITTINGS FOR REPLACEMENT PURPOSES
IS:8737(PART 2)-1978
-
VALVE FITTINGS FOR NEWLY MANUFACTURED LPG CYLINDERS
IS:8776-1988
-
VALVE FITTINGS FOR USE WITH LIQUEFIED PETROLEUM GAS (LPG) CYL. UPTO AND INCLUDING 5 LIT WATER CAPACITY
IS:8790
-
GENERAL REQUIREMENTS OF POWERED INDUSTRIAL TRUCKS WORKING IN HAZARDOUS AREAS
IS:8790(PART 1)-1978
-
INTERNAL COMBUSTION ENGINES POWERED TRUCKS
IS:8790(PART 2)-1979
-
ELECTRIC BATTERY POWERED INDL. TRUCKS
IS:8867-1987
-
SATURATED VAPOUR PRESSURE AND TEST PRESSURE FOR LOW PRESSURE LIQUEFIABLE GASES CONTAINED IN GAS CYLINDERS
IS:8868-1988
-
PERIODICAL INSPECTION INTERVAL OF GAS CYLINDERS IN USE
IS:9121-1979
-
INSPECTION GAUGES FOR CHECKING TYPE 1 (SIZE 2) TAPER THREADS OF GAS CYLINDER VALVES, TAPER 1 IN 16
IS:9122-1979
-
INSPECTION GAUGES FOR CHECKING TYPE 2 TAPER THREADS OF GAS CYLINDER VALVES, TAPER 3 IN 25
IS:9199-1979
-
INSPECTION GAUGES FOR CHECKING TAPER THREADS OF GAS CYL. VALVES, TAPER 60 DEGREE INCLUDED ANGEL
IS:9200-1979
-
METHOD OF DISPOSALS OF UNSERVICEABLE COMPRESSED GAS CYLINDERS
IS:9281
-
ELECTRONIC WEIGHING SYSTEMS
IS:9281(PART 1)-1979
-
TERMS AND DEFINITIONS
IS:9281(PART 2)-1979
-
METHODS OF MEASUREMENTS
-------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:9281(PART 3)-1981
-
REQUIREMENTS
IS:9281(PART 4)-1983
-
CODE OF PRACTICE FOR USE & INSTALLATION
IS:9583-1981
-
EMERGENCY LIGHTING UNITS
IS:9639-1980
-
CODE OF PRACTICE FOR VISUAL INSPECTION OF LOW PRESSURE WELDED STEEL GAS CYLINDERS IN USE
IS:9777-1981
-
DATA SHEET FOR SELECTION OF WEIGHBRIDGES FOR BULK HANDLING EQUIPMENT
IS:9798-1981
-
LOW PRESSURE REGULATORS FOR USE WITH LPG
IS:9902-1982
-
RECOMMENDED PRACTICE FOR LEAK TESTING
IS:9975
-
`O' RINGS
IS:9975(PART 1)-1981
-
DIMENSIONS
IS:9975(PART 2)-1984
-
MATERIAL SELECTION & QUALITY ACCEPTANCE CRITERIA
IS:9975(PART 3)-1984
-
SEAL HOUSING DIMENSIONS AND TOLERENCES
IS:9975(PART 4)-1984
-
TERMINOLOGY AND DEFINITIONS OF TERMS
IS:10733-1983
-
ELECTRICALLY BONDED ROAD AND RAIL TANKER HOSE OF RUBBER, RESISTANT TO PETROLEUM PRODUCTS
IS:10908-1991
-
FLEXIBLE RUBBER TUBING FOR LPG
IS:11498-1985
-
LEVER TYPE DIA GAUGES
IS:12936-1990
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CODE FOR BASIC REQUIREMENTS FOR DELIVERY PERSONS ENGAGED IN THE DELIVERY OF LPG CYLINDERS
-------------------------------------------------------------------------------------------------------------------------------CODE NO. NAME -------------------------------------------------------------------------------------------------------------------------------IS:13258-1991 WELDED LOW CARBON STEEL CYLINDERS EXCEEDING 5 LT WATER CAPACITY FOR LOW PRESSURE LIQUEFIED PETROLEUM GAS CODE OF PRACTICE FOR INSPECTION AND RECONDITIONING OF USED LPG CYLINDERS IS:13432(PART 1)-1992
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GAS LEAK DETECTOR FOR USE WITH LOW PRESSURE LIQUEFIED PETROLEUM GAS BURNING APPLIANCES SPECIFICATION
PART I – MECHANICAL TYPE --------------------------------------------------------------------------------------------------------------------------------
ii.
The Static and Mobile Pressure Vessels (Unfired) Rules-1981
iii.
LPG (Regulation of use in Motor Vehicles) Order 2001
iv.
Gas Cylinder Rules, 2003
v.
API Standard 25 – Design and Construction of LP Gas Installations
vi.
ASME Boiler and Pressure Vessel Code Sect.VIII Division 1 American Society of Mech.Engrs., New York
vii.
NFPA 58
:
Storage and Handling of Liquefied Petroleum Gases
viii.
NEPA 59
:
LP Gases at Utility Gas Plants
ix.
OISD-STD-105
:
Work Permit System.
x.
OISD-STD-113
:
xi.
OISD-STD-135
Classification of Areas for Electrical Installations at Hydrocarbon processing and handling facilities
:
Inspection of Loading/Unloading Petroleum Products.
hoses
for
xii.
OISD-STD-144
:
Liquefied Petroleum Gas (LPG) Bottling Plant Operations
xiii.
OISD-STD-150
:
Design and Layout of Liquefied Petroleum Gas Mounded Storage Vessels
xiv.
OISD-STD-158
:
xv.
OISD-STD-159
:
Recommended Practices on Storage and Handling of Bulk Liquefied Petroleum Gas (LPG) LPG Tank Trucks Requirements of Safety on Design/ Fabrication & Fittings
xvi.
OISD-STD-179
:
Requirement of Safety for Compression, Storage, Handling & Refueling of Natural Gas for Use in Automotive Sector.
xvii.
ASME B - 31.3
:
Chemical Plant and Petroleum Refinery Piping
xviii. ASME B - 31.4
:
Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia and Alcohols
xix.
:
Specification for unfired fusion welded pressure vessels
PD-5500
