1. Course Module No.5.3.

1
Area : LPG storage, bottling & distribution
Area Code : 300
Course Code : 301
Intended For : Fresh Entrant Officers and Supervisors.
Duration : 3 days
Objective : To provide knowledge on the hazards associated with LPG operations /
maintenance and safe way to perform job. To evoke correct and prompt
response in any emergency situation.

Course Content:
i) Characteristics of LPG and Associated Hazards.

ii) Safety Regulations (Statutory & In-company) and accident prevention.

iii) Safety Aspects in Design, Operation and Maintenance of LPG Plants / Cylinders and
Accessories.
iv) Fire Protection Facilities /Equipment.
v) Safety in Transportation of LPG in Bulk, Emergency Rescue Systems.
vi) Disaster Management Plan Emergency Procedure & Drills.
vii) Supervisor’s Role in Safety.
viii) Work Permit System
ix) Industrial First Aid
x) Electrical Safety
xi) Housekeeping
xii) Occupational Health Hazards.
xiii) Personal Protective Equipment.
 i) Characteristics of LPG and Associated Hazards.
LPG is a mixture of commercial butane and commercial propane having both saturated
and unsaturated hydrocarbons. LPG marketed in India is governed by Indian Standard
Code IS-4576-1999 (Refer Table 1 ) and the test methods by IS-1448 (1968 – reaffirmed
in 1997 ). LPG marketed in India for Automotive use is governed by IS: 14861 (2000)
[ Refer Table 2 ]

Commercial Butane also meets Indian Standard Code IS-4576 quality norms and can be
treated as LPG. LPG of mixtures 50% propane and 50% butane also meets Indian
Standard Code IS-4576 quality norms. It has been observed that Quality of LPG dealt in
India varies a lot depending on source of supply and number of constituents which
mainly consist of one or more of the following hydrocarbons:

a) Propane (C3H8)
b) Propylene (C3H6)
c) N-butane (C4H10)
d) Iso butane (C4H10)
e) Butylene (C4H8)

Currently LPG is being used for various applications like Cooking, Industrial applications
for heating, heat treatment, solvent & aerosol applications. LPG is also being used as
Automotive fuel. Specification of LPG used for cooking & Industrial applications is
governed by IS 4576 (1999) whereas LPG used for Automotive purpose is as per IS 14861
(2000)

1.1 `Specifications as per Indian Standards

IS 4576 specifications:

Table 1

REQUIREMENTS FOR LIQUIFIED PETROLEUM GASES

AS PER IS 4576 – 1999

Sr. Characteristics Requirement for Commercial Method of

No. Test Ref
Butane Butane – Propane
to:
Propane
Mixture

(1) (2) (3) (4) (5) (6)

i) Vapour pressure at 40 C in kPa, 520 1050 (Note 2) 1550 D 1267

gauge, Max (Note 1)

ii) Composition, liquid mole percentage D 2163

a) C2 Hydrocarbons - Report Report

 b) C3 Hydrocarbons Report Report 95.0 min.

c) C4 Hydrocarbons Report Report 4.0 max.

d) C5 Hydrocarbons and heavier 2.5 max. 2.5 max. 0.2 max.

e) Unsaturated hydrocarbons Report Report Report

OR

Volatility :

Evaporation Temp. in 0C for 95% by 2.0 2.0 -38.0 D 1837

vol. At 760 mm Hg pressure, Max.

iii) Total volatile sulphur ppm, Max. 150 150 150 D 2784

D 3246

iv) Copper Strip Corrosion at 38 0C for 1 Not Worse Not Worse than Not Worse D 1838
hour than No. 1 No. 1 than No. 1

v) Hydrogen Sulphide Pass Pass Pass D 2420

(Note 3)

vi) Free water content None None None Visual

1.2 PHYSICAL/CHEMICAL PROPERTIES & CHARACTERISTICS

1.2.1 COLOUR

LPG is colourless both in liquid and vapour phase therefore, they cannot be seen.
However, when LPG, in liquid form, is released from a container or a pipe it
vapourizes almost immediately. This produces a cooling of the surrounding air
and may cause water vapour in the air to condense, freeze and become visible. In
this way a LPG leak may be detected even though the gas itself is invisible.

1.2.2 Smell

LPG is, in general, odourless and cannot be detected by human senses. When
odourization of LPG is required Ethyl Mercaptan ( C2H6S) is added to a min of 20
ppm.

1.2.3 Taste
LPG is tasteless and non-toxic, therefore, the presence of LPG vapours in the
atmosphere cannot be sensed by taste.

1.2.4 COLD BURN

LPG in liquid form should not come in contact with surface of body. It is particularly
important that liqud propane or a product with relatively high vapour pressure be
avoided in the event that LPG in liquid form come in contact with the skin , the product
immediately vapourises. During this vapourisation process, heat will be absorbed
directly from the skin and flesh causing a freezing effect. The ultimate result of the
freezing is usually referred to as a cold burn. The results may be serious, therefore, if
the possibility of exposure to liquid LPG exists, suitable gloves and protective clothings
should be utilized.

1.2.5 TOXICITY

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 possesses mild anaesthetic properties.

1.2.6 VISCOSITY

LPG liquid has low viscosity of around 0.3 CS @ 45 deg. C and can leak when other
petroleum products normally cannot, thus demanding a very high integrity in the
pressurised system to avoid leakage. It is also a poor lubricant and leaks are therefore
likely to occur at pump seals and glands. In view of this a special attention to be given,
for example to the selection of mechanical seals for pumps and also seals at the
carousel centre column.

1.2.7 DENSITY

Density means Mass or weight per unit volume. Unit used is gm/cm3 or Kg/m3. Since
the density of the liquid varies slightly with temperature, the latter must be indicated
in an exact statement of density. Normally density is expressed at 15 degrees
centigrade or 60 degrees F.

Since the density of water is 1.0 gm/cm3, and the density of liquid LPG is about 0.5
gms/cm3, the latter is about half as heavy as water.

Temperature Range Density for Commercial Propane Density for Commercial

Butane

================= ============================
===========================

0-50 deg. centigrade 0.522 to 0.454 0.587 to 0.537

In an exact statement of density of the gas, it is necessary to indicate not only the
temperature but also the pressure.

The usual form is to state the density of 1 m3 of the gas at 0 degrees centigrade & 760
mm Of Hg (Normal atmospheric pressure), this being known as a normal cubic metres,
abbreviated to m3 (n).

Relative density is used to indicate the density of a gas in relation to that of air at the
same temperature & pressure. If the relative density is greater than unity, the gas is
heavier than air. LPG is about 1.5 to 2 times as heavy as air.

1.2.8 COEFFICIENT OF VOLUMETRIC EXPANSION

The coefficient, of volumetric expansion indicates the change in volume

per unit volume of liquid for each degree of temperature change.

Its value varies slightly with temperature, and the table therefore states the
coefficient for the two temperature ranges that may be encountered in practice.
The rate of expansion or contraction also varies depending upon the
composition of the product.
In the case of propane, the expansion rate between 0 °C and +40°C is
approximately 13.2%, whereas the expansion rate of butane for the same
temperature increase is approximately 8.0%.

In general, it may be said that the lower the density of the liquid the
greater the rate of expansion or contraction.

1.2.9 VOLUMETRIC EXPANSION OF LPG

Since the coefficient of volumetric expansion of LPG is about 100 times

that of steel it will be realized that this must be taken into account when
a container is being filled with LPG.

In consequence, a LPG container must only be filled to a certain volume in

order to leave a sufficient expansion volume, which varies with the
temperature and density of the liquid LPG.

1.2.10 MELTING OR FREEZING POINT

LPG can exist as a liquid over a wide range of temperature.

The lowest temperature is that at which the liquid assumes
the solid state. This is known as the melting point and is such
a low temperature that it is without practical interest.

1.2.11 CRITICAL TEMPERATURE

The highest temperature at which a substance can exist as a

liquid is known as the critical temperature. Above this
temperature the substance is gaseous, whatever pressure is
applied.

1.2.12 CRITICAL PRESSURE

To obtain the substance in liquid form at the critical

temperature a certain minimum pressure is required, this being
known as the critical pressure. At temperature below the
critical temperature the substance can exist either as a
gas or as a liquid.

When the substance exists as gas and liquid simultaneously

we say that there is a state of equilibrium between gas and
liquid. At any given temperature there will, under these
conditions, be a definite pressure.
1.2.13 BOILING POINT

The temperature at which the vapour pressure of a liquid

becomes equal to the external pressure is the boiling point.

This temperature differs for the liquid under different pressures.

The normal boiling point is the temperature at which the vapour pressure
reaches

760 mm of mercury or 1 atmosphere.

1.2.14 VAPOUR PRESSURE

Vapour pressure is the pressure developed over a liquid in a

closed container. The vapour pressure of LPG depends upon the
temperature of the liquid and the composition in terms of the primary
hydrocarbons present.

If liquid is heated in an open container the molecules (collectively called

vapour) move away from the liquid and the liquid is said to evaporate.

If, on the other hand, the liquid is in a closed container the motion of
the escaping molecules is confined to the vapour space above. As an
increasing number strike and re-enter the liquid, a point of equilibrium
is eventually reached when the rate of escape of molecules from the
liquid equals the rate of return to the liquid.

The pressure exerted by the escaping vapour at this point of

equilibrium is vapour pressure. The volume of liquid within a LPG
container does not effect the vapour pressure if product in liquid form
remains, after equilibrium has been reached. Considering an identical
product and identical temperatures, when equilibrium is reached in a
container with 5% liquid and 9.5% vapour, the vapour pressure will
be the same as that found in the same container with 85% liquid and
15% vapour.

From a practical standpoint, equilibrium will only be reached in

a container when vapours are not being withdrawn and the ambient
 temperature remains constant. Whenever product is being withdrawn
from the container it is anticipated that the internal pressure will be
depressed below the true vapour pressure which would be observed if
equilibrium did exist.

Vapour pressure is usually stated in kg/cm 2. This unit can be also

be written “at”, being then known as a technical atmosphere, to
distinguish it from the normal atmosphere, atm (1 atm = 1.033 at).

Since the vapour pressure is independent of the pressure of the air

or atmosphere it is usually stated as the "absolute" pressure, e.g. in
absolute technical atmosphere = ata. If LPG is to be obtained in
gaseous farm from a container the temperature must be such as to
give a vapour pressure at least as great as the pressure of the air.
Accordingly, vapour pressure can also be stated as overpressures in
relation to the normal pressure of the air, usually called 'gauge'
pressures.

1.2.15 LATENT HEAT OF VAPQURIZATION

The quantity of heat absorbed by a unit mass when changing from

the liquid to the gaseous phase while remaining at the same temperature. In
addition to the heat required to change or increase the temperature of a
liquid there is an additional heat requirement to cause actual vapourization.
This quantity of heat is referred to as the latent heat of vapourization.
The term is expressed in kilocalories per kilogram of the substance. The
temperature should also be stated since the value decreases somewhat with
an increase in temperature. -

As an example, the latent heat of vapourization of propane at -20° is 96

kcal/kg and at +20°C the value is 82 kcai/kg.

While LPG vapourization takes place, it takes latent heat from the body of the
container during change of phase from liquid to vapour. In case vapourization
rate is higher then the body temperature of the container is reduced resulting
in ice formation on the surface.

1.2.16 SPECIFIC HEAT

Specific heat is defined as the quantity of heat required to raise

unit mass of a material through a unit temperature interval.
Specific heat may also be expressed as the amount of heat required to warm
a sub.-stance in the solid, liquid or gaseous state,

Specific heat is expressed as the number of kilocalories required to

warm 1 kg of a substance through 1°C. Specific heat is dependent to a
degree upon the temperature of the substance. For gases, moreover, it is
necessary to indicate whether the pressure or the volume is constant.

One kilocalorie is the quantity of heat required to raise the temperature of

1 kg of water through 1°C from 14.5 to 15.5°C As an example, propane
has a specific heat of 0.57 kcal
1.2.17 FLAMMABILITY

Flammability is defined by percentage by volume of the gas in mixture with air that forms a
flammable mixture at atmospheric pressure & ambient temperature. Flammability range is
difference between the minimum & maximum percentage by volume of the gas in mixture with
air .

In case of LPG, the flammability range is 1.8 % to 9.0 % with air.

The above indicates that in the event there is an insufficient supply of LPG vapour mixed with
air, the combination will not burn. Conversely, if an excessive amount of LPG vapour is mixed
in the atmosphere, combustion again can not be accomplished

1.2.18 AUTO IGNITION TEMPERATURE

Auto Ignition is the lowest temperature at which a material will ignite without an external
source of ignition. In case of LPG it is 410 to 580 degrees centigrade varying on account of
composition.

1.2.19 VOLATILITY

Volatility is the property of the substance to get converted into vapour phase from liquid phase
after absorbing latent heat of evaporation from surrounding at a certain pressure. In the case of
LPG , it is the temperature of residue LPG at balance quantity of 5 ml inside weathering tube of
100 ml capacity at atmospheric pressure. As per IS 4576 , the volatility of LPG can be of
maximum +2 Deg.C

1.3 COMBUSTION

Combustion may be defined as the oxidation of the product. In the context of LPG, combustion
is the combination of oxygen usually from air with LPG vapour to form carbon dioxide & water
vapour

As an example of the process, 0.4 volume of LPG when combined with 9.5 volume of air, after
combustion will produce 1.6 volume of water vapour, 1.2 volume of carbon dioxide and 7.5
volume of nitrogen.

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Flame temperature of LPG depends on the composition of the product. The maximum Flame
temperature of LPG attained is about 2000 degrees centigrade

The combustion reaction of LPG increases the volume of products in addition to the generation
of heat. LPG requires upto 50 times its own volume of air for complete combustion and at the
same time yields 3 or 4 times its own volume of carbon-dioxide yielding approx. 10,900 kcal to
16000 kcal heat per kg depending upon the composition.

Thus it is essential that adequate ventilation is provided when LPG is burnt in enclosed spaces
otherwise asphyxiation due to depletion of oxygen apart from the formation of carbon-dioxide
can occur.

Uncontrolled combustion also can lead to accidents and explosion.

1.5 FLAME PROPOGATION

Flame propagation is defined as the Flame velocity normal to the surface of the inner core of a
flame and is relative to the velocity of the unburned gases.

This property is one of the basis for Risk analysis of LPG facilities which influences site
selection & equipments layout, for efficient combustion of LPG for industrial /auto
application & mitigation measures to be adopted to ensure safety in case of any explosions

1.6 PRESENCE OF SULPHUR

LPG contain some volatile sulphur which generates sulphur oxide during combustion.
Presence of sulphur in LPG should be as minimum as possible. Free sulphur also reacts
with iron particle of vessel causing corrosion. As per IS-4576 sulphur content in LPG
should not exceed 150 PPM.

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Presence of the Sulphur in LPG will produce sulphur oxides ( Predominantly sulphur dioxide)
which inturn will produce acid which is highly corrosive in nature and may effect the
equipments in long term. In certain applications during combustion process, Sulphur oxides
will be a part of flue gas and will pollute environment. This may violate statuatory limits on
emission control set by Pollution Control Boards and hence the less presence of Sulphur in LPG
is desirable.

Presence of Hydrogen sulphide will generate sulphur and hydrogen ions. The sulphur inturn will
generate oxides and acids as explained above and leads to corrosion and environmental
pollution.

1.7 PYROFORIC IRON

Pyrophoric Iron sulphide is a highly inflammable compound formed due to the reaction of
sulphur and its compounds with the loose iron/ iron oxide on a ferrous surface. Thus the
pyrophoric Iron Sulphide can be controlled by totally eliminating highly corrosive hydrogen
sulphide, limiting the total volatile sulphur to 0.02% by mass reducing the loose iron oxide by
thoroughly cleaning the storage vessels internally during the outage.

Pyrophoric Iron Sulphide will not ignite spontaneously in a sphere/ cylinder containing a
concentration of vapour of gas as long as the concentration is above the upper flammable range
limit. When the contents of the vessels come in contact of air (during opening to atmosphere or
air entrapped condition) within or below the range, Pyrophoric iron sulphide will ignite
spontaneously, unless water or steam is used to cut the sulphur iron reaction. The most
effective extinguishing agent is water spray or fog. Similar type of precaution is warranted
while opening of LPG pump strainers and any location where loose iron oxide is expected.

1.9 EXPLOSION PROPERTIES OF LPG: ( PUVCE AND BLEVE'S PHENOMENA )

The hazards associated with the release to atmosphere of a boiling flammable liquid show
themselves disproportionately where large quantities are involved - they can give rise to two
phenomena which are highly hazardous ; (a) Unconfined Vapour Cloud Explosion (UVCE) and (b)
Boiling Liquid Expanding Vapour Explosion (BLEVE).

Vapour cloud can ignite and burn as deflagrations or fire balls causing lot of damage by
radiation starting secondary fires at some distance. Vapour cloud ignites and explodes causing
high over pressures and very heavy damage. The later is termed as `percussive unconfined
vapour cloud explosion' i.e. PUVCE in short. Even though large quantities of LPG emission is
necessary, only a fraction of this contributes to the percussive effect ( more reactive molecules
such as ethylene in much smaller quantities). Rare though PUVCE may be, their damage is large
and sometimes enormous.
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The boiling liquid expanding vapour explosion (BLEVE) is due to holding a pressurised flammable
liquid above its boiling point. This may result from inadequate vapour space for temperature
expansion of the contents or high temperature due to radiation heat from the adjacent vessel
fires or due to any mechanical damage. BLEVE even though not as serious as PUVCE, its
potential for spreading fire over a wide area makes them significant in terms of both life and
property damage.

Ejection of boiling liquid produces reaction rupturing the vessel causing the rocket
projectioning of dish ends. The released liquid flashes and atomizes immediately, often
resulting in a large fire ball. Although the fire ball lasts only a few seconds, its effect can be
devastating due to flame contact and thermal radiation.

ii) Safety Regulations (Statutory & In-company) and accident prevention.

IMPORTANT STATUTES APPICABLE TO LPG PLANTS / INSTALLATIONS.

2.0 GENERAL

LPG Bottling Plant / Installations can be termed as factories. Operations and administration of these
locations are governed by various applicable statutory guidelines. It is imperative that compliance to
the requirements of the applicable statutory guidelines to be ensured. Compliance of statutory
requirements plays important role towards safety , health and environment issues concerning not only
Corporation but Society as a whole.

Following are some of the important statutory Guidelines applicable to LPG Plants / Installaitons.

 Explosive Licences -Indian Explosive Act-1884

- Gas Cylinders Rules- 1981 amended in 2004.

- Static & Mobile Pressure Vessels ( Unfired ) Rules – 1981.

 Factory Licence - Factory Act-1948

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 Manufacture / Storage & Import of Hazardous Chemical Rules – 1989.

 Air Consent - Air (P&CP) ACT-1981

 Water Consent - Water (P&CP) ACT-1974

 Environment Act 1986

 Legal Metrology (W&M) Certification

- Standard W&M ACT-1976 & Rules 1987

- Standards W&M , Packaged Commodities Rules 1977.

 Contract Labour ( Regulation & Abolition ) Act, 1970

 Consent for commission of CPP –Indian Electricity Rules 1980 .

 Central Motor Vehicle Rules 1989 (Ammended 1993)

 Public Liability Insurance Policy.- PLI-1991

 ESIC Act -1948

 Employees Provident fund Act- 1952.

 Workmen’s \compensation Act - 1923

 Right to Information Act – 2005

 Minimum Wages Act 1948

 OISD Standards 144 & 105

 Vasudevan Committee ( MOP&C ) ,1983.

Page 14 of 92
  Sudha Joshi Committee – 1987.

These Acts be referred for any issues pertaining to LPG Plant / Installation Operations. Salient features
of these Acts required to be complied and useful for LPG Plant Operations are given below.

2.1 Explosive Licence -Indian Explosive Act-1884

Enforcement body : Petroleum & Explosives Safety Organisation

( PESO ) – Headed by The Chief Controller of Explosives .

Following three Explosive Licenses are required for LPG Bottling Plant :

I. License to store Bulk LPG in Storage Vessel (As per SMPV Rules)
II. License to Fill LPG in Cylinders (As per Gas Cylinder Rules)
III. License to Store Filled LPG Cylinders (As per Gas Cylinder Rules )

I. License to store Bulk LPG in Storage Vessel :

Applicable Rules : 49,50,54 & 55 of SMPV Rules,1981

Rule 49 : Gives details of Application for obtaining of License. Application for obtaining new license for
storage of Bulk LPG to be submitted as per Form III and renewal application to be made in Form I.

Rule 50 : Specifies the period of licence. Licence shall remain in force from 01 st Oct. to 30th Sept. . The
licence can be renewed for a maximum period of 03 years.

Rule 54 : Specifies the procedure for amendment of Licence

Rule 55 : Specifies the procedure for renewal of Licence

II. Licence to Fill LPG in cylinders :

Page 15 of 92
Applicable Rules 50,51,54 &55 of Gas Cylinder Rules 2004

Rule 50 : Specifies the conditions for Grant of licence

Rule 51 ; Gives the period for renewal of licence which can be maximum 10 years. The licence shall be
granted for the period ending 30th Sept

Rule 54 : Specifies procedure for amendment of Licence

Rule 55 : Specifies procedure for renewal of Licence which is applied for in Form E

III. Licence to Store filled LPG cylinders

Applicable Rules 50,51,54 & 55 of Gas Cylinder Rules 2004

Applicability of all rules is same for this licence as per licence to Fill LPG in cylinders except that the
renewal application to be made as per Form F

2.1.1 Important provisions of Gas Cylinder Rules 2004

Rule 9 : Labelling of Cylinders

Every cylinder shall be labeled with the name of Gas & the name and address of person by whom the
cylinder is filled

- Warnings to be attached with each LPG cylinder:

- Do not change the colour of cylinder
- Cylinder shall not be filled with any Gas other than the one it contains
- No Flammable material should be stored in the close vicinity of the cylinder or in the same
room
- No Oil or similar lubricant shall be used on the valves or the other fittings of the cylinders
- Next Test date to be prominently displayed

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Rule 35 : Retesting of cylinders (Refer schedule IV for fetails)

2.1.2 Important provisions of SMPV Rules 1981

Rule 19 : Gives the details on periodic testing of pressure vessels in service

Rule 33 : Gives the certificate of Safety by a competent person

2.2 FACTORY LICENSE : FACTORY ACT 1948

• Issued by BY CHIEF INSPECTOR OF FACTORIES.

• Renewal period : Every Year (Licence can be issued for more than 01 year )
• Approval of the Plan/Specification/Drawing for construction of factory by the Chief Factory
Inspector.
• Renewal fees depends upon Electrical load (HP) & Manpower ( Max. nos. of workers).
• Apply for renewal on or before the due date other wise we have to pay 25 % or more of renewal
fees.
• Submit Statement of Annual Return on or before 15th Jan. in DUPLICATE in form-21 under Rule-
107 of FA-1948.

Half yearly Return to Chief Inspector of Factory on or before 15th JUL in duplicate in FORM-22.

Muster Roll for all employees employed in a factory under Rule-110 in FORM-25.

Maintenance of Inspection Book in FORM-35 under Rule-112

Notice for change of Manager under Rule-15A in FORM-2A within 7days from the date of change.

Notice of Accident to Inspector & Chief Inspector of FACTORY within 12 hrs in FORM-18 under Rule-
103, with a copy to SDM, SHO & Relative of the injured.

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 • Hoist & lift shall be examined once in six month by competent persons.

Competent PERSON must have a valid authorization from the Chief Inspector Of Factory of
CONCERNED state only

2.3 Air (Prevention & Control of Pollution) Act-1981

• Air consent is required under Section-21/22.

• Application for renewal of consent shall be made 30 days before the date of expiry of consent.
• Maintain LOG book for running of all air pollution control devices
• Height of the stack of DG need to be specified
• Test reports by competent authorities for Ambient air quality and Stack emission to be submitted
during renewal of license.
• Submit On-site & Off- Site Emergency Plan.
• Comply Public liability Insurance Rule-1991
• Submit Environmental Statement along with renewal of consent.
• Comply Noise Pollution Rule-2000.

2.4 Water (Prevention & Control of Pollution) Act-1974

• Prior consent is required from concerned SPCB for discharge of effluent under Sect-25/26 of
above Act.
• Application for renewal of consent shall be made 30 days before the date of expiry of consent
along with required consent fees.
• Test reports by competent authorities for Effluent quality to be submitted during renewal of
license

2.4.1 REQUIREMENT OF EFFLUENT TREATMENT PLANT (ETP)

In case effluent sample does not meet the specified norms, ETP has to be installed for treatment for
effluent. The sludge generated has to be disposed as per the following procedure:

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a) Sludge from LPG Bullets / Sphere testing and mandatory testing of cylinders

i. The sludge is to be weathered for evaporation of oil and water

ii. Sample of sludge to be tested through a reputed chemical laboratory for ascertaining lead and
cobalt content.
iii. The relative dry sludge without lead or cobalt should be disposed off in a land filling.
iv. Dry sludge containing lead or cobalt should be embedded in concrete blocks preferably of 1 cft size
or as per the quantity of sludge and these blocks are to be finally buried in the ground . The
following precautions to be taken for burying the sludge.
 Selection of location within plant premises, preferably away from water resources.
 Fencing around the territory to prevent people or live stock
 Excavation of land fill to a depth of 2 m depending upon water table
 Covering the land fill with the soil from the excavated area

b) Sludge formed at painting booth

This is a heavy solid and must be collected in a container and should be buried to a depth of 2 m
depending upon the water table away from human settlement, water resources or agricultural fields.

2.5 `LEGAL METROLOGY PROVISIONS

2.5.1 Standards of Weights & Measures Act 1976 & Rules 1987)

• Every weights or measure used or intended to be used in any transaction shall be verified or re-
verified as prescribed by Controller of Weights & Measures ( Sect-24).
• Every weights or measures should be present for verification at the office of Inspector on or
before due date.
• For Every weights or measures which cannot be moved from its location, it shall be reported to
Inspector at least 30 days in advance for verification.
• The certificate of verification to be exhibited UNDER Sect-25 at a place where weights or
measures are used

• Maximum permissible ERROR on NET Quantities declared by weights or by volume. Under

“THE SECOND SCHEDULE See Rule-2(i)(ii), TABLE-1

• 1-10 kg +/- 1.5 %

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 • 10-15 kg +/-150 gms
• More than 15 kg +/-1.0 %
• Dead weight required for verification of WB is 25% of maximum load

Sampling & permissible error is as per Schedule 9

2.5.2 Packaged Commodities Rules 1977

Declaration to be made on each Package ( Rule 6)

- Name & Address of the manufacturer

- Common generic Name
- Net Quantity
- Month & Year of the Manufacture
- Retail Sale Price of the Package
-
Declaration to be made for Whole sale packages ( Rule 29)

- Name & Address of the Manufacturer

- Identity of the commodity
- Total number of retail package in whole sale packages
Exemption in respect of certain Packages (Rule 34)

Registration of Manufacturer ,packers & Importers.( Rule 35 )

- Name of the firm

- Name of the applicant
- Complete Address of the Party/Importer.

2.6 Contract Labour ( Regulation & Abolition ) Act, 1970 :

a. Applicability :

i. To every establishment in which 20 or more workmen are employed or were

employed on any day of the proceeding twelve months as contract labour.
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 ii. To every contractor who employs or who employed on any day of the proceeding
twelve months twenty or more workmen

Provided that the appropriate government may, after giving not less than two months notice of its
intention so to do, by notification in the Official Gazette, apply the provisions of this Act to any
establishment or contractor employing such number of workmen less than twenty as may be specified in
the notification.

b. Important Terminology Related to This ACT (Given in Section 2)

 Appropriate Government
 Contract Labour
 Contractor
 Controlled Industry
 Establishment
 Principle Employer
 Wages
 Workmen

c. Compliance to be Made

 Registration of Establishment for employing contract labour (Refer Section 6, 7,8 & 9)
 Licensing of Contractors (Refer Section 11,12,13 & 14)
 Welfare & Health of Contract Labour (Refer Section 16,17,18 & 19)
 Responsibility of Payment of Wages (Refer Section 21)
 Registers & Records to be maintained (Refer Section 29)
 Returns as per Section 82
 Registration of Establishment to be made as per Form I and Certificate of Registration to be issued
as per Form II.
 Notice of commencement & completion of contract work ( As per Form VI B) Notice to be
submitted by principle employer (In our case Plant Manager/Occupier) to the office of LEO.
 Principle Employer has to give a certificate in Form V to the contractor employing more than
specified number of contract labour.
 The contractor has to apply in Form IV to obtain labour license, and license is issued in Form VI
 Renewal of license under Form VII
 The principal employer has to maintain Register of Contractors as per Form XII
 Annual Return to be submitted by Principle Employer (Form No. XXV) by 15 th. Feb of next year.

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  The principal employer has to ensure that the following registers are to be maintained by the
contractor:

o Muster roll in Form XVI

o Register of Wages in Form XVII
o Register of Deductions
o Register of Advances in Form XXII
o Register of Overtime in Form XXIII
o Register of Fines in Form XXI
o Employment card in Form XIV
o Wage slip as per Form XIX
o Half yearly return in Form XXIV

 The following information is to be displayed prominently in Plant in local language

o Name of address of the licensing authority

o Plant working hour and break time details
o Applicable minimum wages under unskilled, semi skilled and skilled categories
o Wage distribution date and wage period

2.7 CENTRAL MOTOR VEHICLE RULE 9 ( 1993 ) :

Any person driving a goods carrying a goods carriage carrying goods of dangerous or hazardous nature to
human life shall in addition to being the holder of a driving license to drive a transport vehicle, also has the
ability to read and write at least one Indian Language out of those ( Specified in the VIII Schedule of the
Constitution ) and English and also possess a certificate of having successfully passed a course consisting of
following syllabus and periodicity with the transport of such goods.

Period of Training = 3 days

Place of Training at any Institute recognized by the State Govt. Syllabus

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2.8 PUBLIC LIABILITY INSURANCE ACT ( 1991 )

Public Liability Insurance act ( 1991) Is valid for one year basis financial year effective 1 st april to 31st march.

As per the act, Insurance is to be obtained by HPCL for protecting the interest of the affected people and
to give immediate relief in case of accidents involving operations , transportation or handling of OIL
products.

Policy covers all operations of the ensured for all locations within Geographically limit including
refineries / road transportations / pipelines.

Policy Covers accident involving fortuitous , sudden or unintentional occurrence.

Maximum aggregate liability shall not exceed s 5 Crs for an accident and Rs 15 Crs in aggregate for more
than One Accident.

Any Claim Under this act is to be forwarded through the District Collector

Time Barred for Claim under this act is 5 years

On Occurrence of accidents, same shall be brought immediately to the notice of concerned District
Magistrate by HPCL.

FIR has to be lodged by the victims or affected person for furhet claim.

Claim application is to be made to the DM by the Victim / Relatives as per Form-1 of this ACT.

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2.9 EMPLOYEE STATE INSURANCE ACT ( 1948) :

This is a piece of social welfare legislation enacted primarily with the objecvtive to provide dcetial benefits
to employees in case of sickness, maternity , employment injuries and also to make provisions for certain
other matters .

This ACT applies to the employess, contract labours falling within the wage limit specified in the ACT from
time to time. Further, this ACT will be applicable if the factory falls within the area classification by ESIC
(Employees State Insurance Corporation) .

The contribution to be paid ESIC by the employee and the employer as per provisions of the ACT.
Employees are issued ESIC Card to get treatment for their self and family members in the nominated ESIC
hospitals.

In case of accidents or incidents, the act specifies accidents benefits / disebalement benfits , treatment
expenses etc.

2.10 Employees Provident fund Act- 1952.

Any person employed by or through a contractor in or in connection with the work of the establishment is
also an employee unless otherwise covered under the act and will be thus eligible to get the benefit of the
schemes framed under the act. Thus the employees engaged through the contractor will be liable to be
covered under the provisions of Employees Provident Fund Act.

Contractor has to obtain a separate identification code for the employees rendering services on contract
basis. On termination of the services, the amount can be withdrawn or continued with the new
contractor.

2.11 Workmen’s Compensation Act - 1923

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The act deals with the liability of demand of compensation as per provision of the act to a contract labour
for personal injury caused by accident arising out of and in course of employment.

The principal employer shall be liable to pay any workman employed in the execution of the work any
compensation which he would have been liable to pay if that workman had been immediately employed
by him.

2.12 Right to Information Act – 2005

Salient features of the act

o Statutory provisions made for Right to Information

o All citizens possesses the Right to Information
o Information includes any mode of information in any form of record, document, email, circular,
press release, contract, sample or electronic data etc.
o Information can be obtained within 30 days of date of request in a normal case
o If information is a matter of life or liberty of a person, it can be obtained within 48 hours from the
time of request.
o Every pubic authority is under obligation to provide information on written request by electronic
means
o Certain information are prohibited.
o Restriction made for third party information
o Appeal against the decisions of the central information commission or state information
commissions can be made to an official who is senior in rank
o Penalty for refusal to receive an application for information or not providing information is Rs
250/- per day but total amount of penalty should not exceed Rs. 25000/-
o Central Information commission and State information commission are to be instituted by the
central government and state governments.
o No court can entertain any suit , application or other proceedings in respect of any order made
under the act.

2.13 MIMIMUM WAGES ACT ( 1948 ) :

Act provides that the principal employer will ensure that the worker engaged thru the contractor will be
paid wages not less than minimum range as specified in that.

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The minimum wage rates are specified for different categories of jobs and skills of labour required to be
employed by the factory / establishments.

Act also specifies minimum wages will be applicable basis appropriate Governments for the establishment
i.e. in case of HPC minimum wages specified for Central Government will apply.

However, higher of the minimum wages notified by the sate / Central Government notifications shall be
payable .

2.14 Vasudevan Committee ( MOP&C ) ,1983.

Ministry of Petroleum & Chemicals had set up a high level committee in May, 1983 headed by Shri R.
Vasudevan, the then Joint Secretary, Deptt. of Petroleum to review all safety and operational
procedures adopted in LPG filling plants, transportation of LPG by rail/ road, and in the distribution/
delivery of LPG cylinders. Several recommendations for improvements in operations/ systems were
made by the committee for adoption/ implementation by the oil industry. Gist of key points pertaining
to the recommendations are given below :

2.14.1 LPG BOTTLING PLANT

i) Location - Should not adjoin residential areas

ii) Size - Desirable to restrict to 25000 MTPA on 2 shift basis.

i) Layout - Provision of 80 M wide green belt beyond perimeter wall, access roads etc.

ii) Cylinder Filling - 100% cross checking of weighments on manual scale.

iii) Cylinder Testing - Use of compact valve tester, water bath check for leaks.

iv) Cylinder Handling - Conveyor system, loading/ unloading at 15 M distance from shed.

v) Evacuation of leaky cylinders - Use of proper evacuation system and recovery of LPG, gas freeing
prior to repairs/ replacements of valve.
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vi) Cylinder Storage - Vertical stacking in small lots with min. separation distance of 1 metre
segregated storage for empty and filled cylinders, mastic flooring in the shed.

vii) Other Safety features/ practices - Fail-safe shut-off valves, extraction of gas/ air mixtures,
adequate communication facilities etc. One designated Safety Officer for each plant.

viii) Manpower & Training - LPG plants to be headed by Sr. Officers. Structured training/ refresher
courses for staff and officers on LPG operations, emergency handling etc. No contract labour on
shop floor for LPG operations.

ix) Fire Prevention/ Fire Fighting - Strict security check prevention of smoking, Gas detection/ alarms,
automatic Fire Water deluge/ sprinkler system. Automatic starting of Fire Water Pumps, fire drills
etc.

2.14.2 CYLINDERS/ VALVES/ REGULATORS

Standardisation and strict quality control in manufacture of cylinder and fittings, industry inspection
system for quality assurance etc.

2.14.3 TRANSPORTATION OF LPG :

i) Bulk by Rail - LPG movement in bulk rake of 68 wagons, unloading/ loading in lot of 34 (500 MT)
wagons. Provision of remote operated water sprinklers at Gantries.

ii) Bulk by Road - Safety training of Driver/ Attendant, special safety precautions during loading/
unloading LPG.

iii) Cylinders by Road - Vertifical stacking, gradual switchover to palletisation.

2.14.4 LPG DISTRIBUTION :

i) Distributor's godown - Properly designed distributor godowns with mastic covered flooring, fire
fighting equipment etc.

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ii) Delivery Equipment - Standardisation approach with cage design, use of 3 wheeler scooters/
delivery van.

iii) Training of delivery boys/ mechanics - suitable training programme by oil companies with
certification scheme.

iv) Customer Education - Audio Visual aids/ films on TV , booklets on LPG safety emergency complaint
cells etc.

v) Control and Supervision - System of periodic inspection to oversee and control the working of the
distributors by oil companies.

2.15 SUDHA JOSHI COMMITTEE - 1987 :

Ministry of Petroleum & Natural Gas in 1986 had set up a committee headed by Mrs. Sudha Joshi, the then
M.P. and Marketing Directors of Oil Companies as members with a view to provide better services to LPG
users with due regard to safety.

Brief summary of important recommendations w.r.t. safety aspects are outlined below :

-Streamlining of registration/ release of LPG connections, issuing booklet like ration card to each consumer
etc.

 Use of auto-driven vehicles to be encouraged for delivery of refills.

 Consumers to use only BIS marked hot plates.

 Distributors to check weight of at least 10% of cylinders before accepting deliveries. Oil
companies to ensure pre-delivery checks by the Distributors.

 Caging of trucks carrying filled LPG cylinders.

 - Oil companies to use only aluminium/ PVC seals with different colour code of filling plant
embossed.

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 Periodic safety inspection of equipment at consumer premises.

 Regular training of delivery boys by the oil companies.

 Emergency and complaint cells to be operated by oil companies in LPG marketed towns.

 Consumer education in LPG SAFETY THROUGH TV media and curriculam to high school.

 - Oil companies to strengthen the inspection system of LPG bottling plants and working of the
Distributors.

 Establishment of more bottling plants near the consuming centre to the extent possible.

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iii) Fire Fighting Facilities /Equipment & their Application.

LPG Bottling Plants are generally located away from populated areas in view of
hazardous nature of product. With the passage of time these plants get surrounded by

settlements/ residential localities in the absence of any statutory regulations prohibiting

their construction.

Due to large quantities of highly inflammable product stored in the Bottling Plants these
pose safety risk to the plant as well as to the surrounding environment. Therefore, it is
very much essential that elaborate in-built Fire Protection Facilities are installed at the
LPG Bottling Plants.

8.1 Fire Protection system

a. Portable Fire Extinguishers / Equipments to fight small / approaching fire

b. Fire Fighting system with Automatic Operation to fight Emergency involving
major fire

Specific norms of various types of fire extinguishers and equipments to be kept at plant
has been stipulated in the OISD 144.

In case of fire fighting system detailed design and operating parameters has been
defined.

Provisions for fire fighting facilities for plants construction as per OISD 144 is different
from plant constructed as per OISD 169. Majority of plants are as per OISD 144 . Details
of Fire fighting facilities as per OISD 144 are as below.

8.2 DESIGN CRITERIA FOR FIRE FIGHTING SYSTEM

i) Facilities shall be preferably designed on the basis of plant area , LPG handled,
Inhibition around the plant and availability of Auxiliary source of water and other
facilities near the plant.

ii) The single largest fire risk shall be considered.

iii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump Houses,
Bulk Lorry and Tank Wagon Gantries shall be fully covered by medium velocity water
spray system.

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iv) Fire Protection Facilities shall have fire fighting access, means of escape in case of fire
and also segregation of facilities so that the adjacent facilities are not endangered
during the fire. The layout shall permit access from at least two directions.

v) Detection of fire for automatic actuation of medium velocity water sprinkler system
shall be provided at all critical places like LPG Bulk Storage, Tank Truck/ Tank Wagon
Gantry, near Carousal, LPG pump/ Compressor House, Evacuation, Valve Change
Shed etc.

8.3 FIRE WATER SYSTEM

Water is used for fire extinguishment, fire control, cooling of vessels/ equipment and
exposure protection of equipment and personnel from heat radiation.

8.3.1 COMPONENTS OF FIRE WATER SYSTEM

The main components of the system are :

- Fire Water Storage

- Fire Water Pumps

- Fire Hydrant/ Monitor distribution piping network.

- Water Sprinkler/ Deluge system.

8.3.2 FLOW RATE DESIGN

The Fire Water pumping requirement shall be calculated based on minimum spray
density as under :

Storage Vessels - 10.2 LPM/Sq.M

LPG Shed - 10.2 LPM/Sq.M

LPG Pump/compressor - 20.4 LPM/Sq.M.

House

LPG Loading racks - 10.2 LPM/Sq.M.

a) Storage Vessels

In case of Bulk Storage of LPG, automatic detection of heat for automatic actuation of
medium velocity (MV) sprinkler system having remote/ local operated deluge valve with

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spray density of 10.2 LPM/Sq.M. of surface area shall be provided. For water flow
calculations adjoining vessels within distance of R+30 Mts. (Where R is the Radius of the
LPG vessel and 30 Mts. shall be measured from the periphery of the LPG vessel), water
density for cooling shall be considered at the rate of 10.2 LPM/Sq.M. surface area.

b) Sheds

MV sprinkler system having remote operated deluge valve and at critical places like near
carousal, evacuation, valve change shed, automatic detection of heat for automatic
operation of sprinkler system with spray density 10.2 LPM/Sq.M. shall be provided. The
shed has to be divided into suitable number of zones, each served by independent
deluge system. The adjacent zones are required to be operative around the zone under
fire and the same shall be considered as a single risk. (Note 1)

c) LPG Pump House

MV sprinkler system with automatic heat detection having remote/ local operated
Deluge valve with spray density of Max. 20.4 LPM/Sq.M shall be provided. (Note 1)

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 7 bays shall be considered
as single risk area. (Note 1)

e) Tank Wagon Gantry

MV sprinkler system with automatic heat detection having remote/ local operated
deluge valve with effective spray density of 10.2 LPM/Sq.M shall be provided. A
minimum of one gantry (600 MTs) shall be considered as single risk. The spray system
shall cover tank wagons surface on either side of tank wagon gantry as well as the
associated LPG pipelines in the gantry.

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.

8.3.3 FIRE WATER SYSTEM DESIGN

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i) The Fire Water pressure system shall be designed for a minimum residual pressure of
7.0 kgs/ Sq.cm 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 30 M centre to centre. 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.

8.3.4 FIRE WATER STORAGE

i) Water for the hydrant service shall be stored in any easily accessible surface of
underground concrete reservoir or above ground tank of steel or concrete. However,
above ground tanks shall be preferred in view of the availability of flooded suction
condition for easy start of fire water engines. The effective storage capacity shall be
not less than 4 Hrs. aggregate working capacity of Fire Water pumps.

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.

8.3.5 FIRE WATER PUMPS

i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head. These pumps preferably should have a flooded suction.

ii) There shall be jockey pump of capacity so designed to achieve a pressure of 7

kg./cm2 at the farthest end of the hydrant system . The system pressure has to be
maintained at 7 kg/cm2g with the help of Jockey Pump operating automatically.

The Jockey Pump shall be quick auto start-stop type with the help of pressure
switches.

A standby jockey pump shall be provided if the number of hydrant points are more
than 100.

iii) The fire water pump(s) including the stand by pump(s) shall be of diesel engine driven
type. The pumps shall be capable of discharging 150% of its rated discharge at a

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 minimum of 65% of the rated head. Each engine shall have an independent fuel tank
of suitable size for 6 Hrs. continuous running.

iv) No. of stand by pumps shall be provided as per following criteria :

a) Minimum 1 no.

b) 50% upto 4 Nos. of Main pumps.

c) For 4 and above, minimum 2 Nos.

v) Fire water pump house/ Fire water tanks or reservoir shall be located atleast 60 M
(minimum) away from LPG facilities.

vi) Fire water pumps shall be exclusively used for Fire Fighting purpose only.

8.3.6 FIRE HYDRANT NETWORK

i) Fire hydrant ring main should be normally laid above ground. Following precautions
should be taken if fire water ring main laid above ground:

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.

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 shall 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.

iii) If Fire water ring main laid underground the following precautions shall be taken :

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a) The Ring main shall have at least one meter earth cushion in open ground and 1.2
meters cushion under the road crossings.

b) The Ring main shall be provided with protection against soil corrosion by suitable
coatings/ wrappings.

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 rate. Design flow
rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.

v) The fire water network shall be kept pressurised to a pressure of about 7 kg/sq.cm.g
with the help of one or more Jockey pumps.

vi) Hydrants/ monitors shall be located bearing in mind the fire hazards at different
sections of the premises to be protected and to give most effective service.

vii) Hydrant/ monitors shall be provided for every 30 meters in case of hazardous areas
and may be spaced 45 meters in other areas.

viii) Connections for fire water monitors shall be provided with independent isolation
valves.

ix) Hose boxes with 2 nos. hoses and a nozzle shall be provided between the hydrant
points.

x) Considering radiation levels in the event of a fire hydrants/ Monitors/ Control valves
shall be located at a safe distance (minimum distance of 15 mts.) and from hazardous
equipment/ buildings.

xi) 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.

8.3.7 MATERIAL SPECIFICATIONS

All the materials used in fire water system using fresh water shall be of approved type as
indicated below.

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In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally.

i) Pipes CS as per IS:3589/IS:1239

ii) Isolation Valves Cast iron/ Cast Steel

iii) Deluge valves Cast iron/ Cast steel

iv) Hydrant

Standpost C.S.

Outlet valves Gunmetal/ Aluminium

v) Monitors C.S.

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.

viii) Water monitor and hose box shall be painted "Luminous Yellow'.

8.3.8 MEDIUM VELOCITY SPRAY SPRINKLER SYSTEM

i) Medium velocity sprinkler system based on heat and other detection shall be
employed.

ii) Quartzoid Bulb protection can be provided in open areas or in the sheds. The
Quartzoid Bulbs are designed to blow at 79 deg. centigrade (max.) and Quartzoid
Bulb network shall be maintained with plant air at a pressure of about 3.5
kgs/sq.cm.g through a restriction orifice and is such that the discharge of air through
one Quartzoid Bulb will depressurise the down stream side of the restriction orifice.

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iii) The Electro pneumatic (E.P) heat detectors can be provided in the sheds and they
work on the following principle :

a) Rate of rise - 10 deg. C/ of temp. Minute.

b) At 79 deg. C(max.)

The EP detectors are divided into groups and alternate detectors are connected in
one circuit. Two detectors from two different groups shall function/ operate for
actuation of sprinkler system.

iv) The actuation of detectors shall initiate the following :

a) Opening of deluge valve.

b) Audio-visual alarm at the fire pump house/ control panel.

c) Fire siren.

d) The diesel pump will start based on their set pressure to supplement/ to maintain the
fire water pressure in the ring main.

ROV's of Fire-safe type shall be provided.

The following areas shall be covered with the medium velocity spray system in the
LPG Bottling Plants :

a) LPG Storage Area :

Automatic detection of heat for automatic actuation of MV sprinkler system having

remote/ local operated deluge valve shall be provided.

b) Tank Wagon Loading/ Unloading Area :

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MV sprinkler system having remote/ local operated deluge valves shall be provided.
Tank wagon loading/ unloading area shall be divided into six zones and one deluge
valve shall cover 12 LPG tank wagons at a time (60 Meters long on each spur).

c) Tank Lorry Loading/ Unloading Area :

Detection of heat for automatic actuation of MV sprinkler system having remote/ local
operated deluge valve shall be provided. One deluge valve shall be provided for a
maximum of 4 bays.

d) LPG Sheds:

MV sprinkler system having remote/ local operated deluge valve and at critical places
like carousal, evacuation, valve change shed, automatic detection of heat for automatic
operation of sprinkler system shall be provided.

e) LPG Pump/Compressor House :

Based on heat detection automatic MV sprinkler system having remote/ local operated
deluge valves shall be provided.

8.4 FIRST AID FIRE FIGHTING EQUIPMENT

8.4.1 PORTABLE FIRE EXTINGUISHERS

i) Portable fire extinguishers shall be located at convenient locations and shall at all
times be readily accessible and clearly visible.

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 Portable Fire Extinguisher

LPG Storage 2 Nos. 10 kg DCP

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 Vessel(Each) extinguisher.

LPG cylinder 2 Nos. 10 kg DCP sheds extinguisher per 200

Sq.M.Area.

LPG Pump 2 Nos. 10 kg. DCP houses extinguisher per 50 Sq.m.

Area.

Tank Truck loading/ 1 No. 10 kg. DCP loading gantries Extinguisher in each bay.

Tank Wagon loading/ 1 No. 10 kg DCP

unloading gantries Extinguisher for every 15/20 meters of gantry.

Other Pump Houses 2 Nos. 10 kg DCPExtinguisher

Office/Canteen/ At least 2 Nos. 10 kg.

Stores DCP extinguishers in each building

MCC/DG Room/HT At least 2 nos. 4.5 Room KG Co2

extinguishers in each room or for floor area
of about 100 Sq.m.

& 4 sand buckets & a stand shall be

provided in MCC/DG Room.

v) 100% spre CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher
Capacities) shall be stored in the LPG plant.

8.4.2 WHEELED/ MOBILE FIRE FIGHTING EQUIPMENT

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.

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ii) The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based or
Sodium Bicarbonate as per IS:4308. Nitrogen/ Carbon Dioxide shall be used as
expellent gas.

iii) Considering the large area, and no. of operations involved in Mega LPG Plants,
special fire fighting facilities like DCP fire tenders should preferably be provided.

iv) A trolley with suitable first aid fire protective accessories shall be readily available in
the LPG plant.

8.5 HOSES, NOZZLES AND ACCESSOREIS

i) Reinforced rubber lined hoses (63mm) conforming to IS:636 (type A or B) shall be

provided.

ii) The hoses shall be of 15 Meters standard length and shall be provided with Gun
metal/ Aluminium alloy male & female couplings of instantaneous pattern.

iii) 50% 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 :

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1. Fire hoses 100% of no. of hydrant points.

2. Safety helmets As required ( Min.

10 Nos.) 1 no. for each.

3. Hose Boxes alternate hydrant point.

4. Stretcher with Min. 2 Nos. each

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.

8. Low tem. protective Min. 2 sets

clothing for LPG

emergency.

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 9. Explosimeter Min. 2 Nos.

10. Fire proximity suit Min. 1 No. (Note 3)

11. Deleted Note 3

12. Resuscitator Min. 2 Nos.

13. Red/Green Flags As required

14. Self contained Min. 1 No.

breathing apparatus

with one spare cyl.

(Cap. 30 minutes)

15. Water jet blankets Min. 2 nos.

16. Gas detectors Min. 2 Nos.

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.

8.6 FIRE/ ALARM/ COMMUNICATION SYSTEM

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8.6.1 FIRE ALARM SYSTEM

i) Sufficient No. of Manual call points shall be provided in the plant.

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 walling 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.

8.7 COMMUNICATION SYSTEM

i) Communication system like telephone/ PA or paging or walkie-talkie shall be

provided.

ii) In the hazardous areas flame-proof telephones shall be provided.

iii) Wherever possible Hot line connection between City Fire Brigade/ near by major
Industries shall be provided.

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iv) Plant shall have a ` Mutual Aid' arrangement with near by industries.

8.8 SPECIAL FIRE PROTECTION

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

The unwetted (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 fighting
measures like starting of pumps, organising people, opening of valves etc. This will also
take care of automation failure wherever it is provided.

The fireproofing of LPG storage vessel should be decided based on the risk analysis
keeping in view local considerations, availability of water and societal risk.

Since the risk of BLEVE get reduced to insignificant level with the provision of mounded
storage, all new facilities for storage of LPG/ Propane should preferably be of mounded
type.

Fire proofing provided on the vessel and supporting legs shall be adequate to protect
the shell material from overheating and consequent failure. The material provided for fire
proofing purpose shall be good enough to provide this protection for the initial 30-60
minutes. Based on this it is recommended to provide the minimum rating for fire
proofing as follows :

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LPG storage vessel & connected 1 hour

lines upto the fire safe ROVs

Supporting legs of all above 2 hour

Before fire-proofing application, protected metal surfaces shall be prepared through

such means as sand-blasting and corrosion-protective primers. Particular attention shall
be given to the top junction of the fire-proofing with the protected metal to prevent
water ingress.

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.

8.9 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.

(a) FIRE WATER PUMPS

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i) Every Pump shall be in test run for atleast 10 min. 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.

(b) 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.

ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion.

iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/
operation and lubricated once in a month.

(c ) 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) The sprinkler system in the sheds shall be tested by closing the outlet of the deluge
valve for correct remote operation once in a quarter.

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iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.

(d) 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.

(e) MAKE UP WATER :

Facilities to make up water during fire fighting shall be provided.

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Page 48 of 92
8.10 CHANGES IN FIRE FIGHTING FACILITIES REQUIREMENTS PLANTS CONSTRUCTED
AS PER OISD 169 WHEN COMPARED TO OISD 144

8.10.1 FLOW RATE DESIGN

(i) The fire water pumping requirement shall be calculated based on spray density as
given below :

LPG Storage Vessels 10 LPM/Sq M.

(R + 15)

LPG Shed 10 LPM/Sq. M.

LPG Unloading Gantry 10 LPM/Sq. M.

(ii) (a) LPG STORAGE VESSELS:

Fixed water system with manually operated isolation valve located at a safe distance of

15 meters shall be provided. For water flow calculations adjoining vessels within

distance of R + 15 Mts. (Where R is the radius of the LPG Vessels) shall be considered.

(ii) WATER REQUIREMENT :

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 72 Cu. M

per hour for operating 2 hydrant points.

8.10.2 FIRE WATER STORAGE :

(i) Water for the hydrant service shall be stored preferably in above ground tanks for
availing the advantage of flooded suction to enable easy start of fire water pump. The
effective storage capacity shall be for two hours aggregate working capacity of fire
water pumps

8.10.3 FIRE WATER PUMPS:

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(i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head.
(ii) Atleast one fire water pump shall be of diesel engine driven type.
(iii) Pumps shall be capable of discharging 150% of its rated discharge at a minimum of
65% of the rated head.
(iv) Fire water pumps shall be exclusively used for fire fighting purposes only.

No. of fire water pumps of appropriate capacity

shall be provided as per the following criteria :

(a) Normal operation - 1 No.

(b) Stand –By - 1 No.

8.11 SYSTEM OF AUTO MATIC FIRE FIGHTING SYSTEM

The fire water hydrant system is to be maintained in pressurized condition with water
pressure of 7 Kg/cm2 at Farthest end. Fire Fighting system is provided with Jockey
pump to keep the system in pressurized condition in Auto mode through pressure
switch.

Jockey pump is generally set to operate at minimum of 7 kg/cm2 and cut off pressure
at 8 kg/cm2 or more based on the pipeline network. A standby jockey pump is also to
be maintained.

Principle of Operation of Fire Fighting System in Auto Mode: In case jockey pump fails
to maintain pressure due to opening of outlets from the hydrant network, Fire Engines
are set logically with set pressure as below .

First Engine will start immediately on dropping the pressure below 7 Kg/cm2. In case
the Engine is able to maintain the pressure at 7 Kg/cm2 , next pump will not start. In
case the pump is not able to maintain the pressure, then subsequent pumps will start
one by one till it maintains the hydrant pressure of 7 Kg/cm2. Standby pumps shall not
be kept in Auto mode as long as the main pumps are in working order.

The operation of soundness of auto system shall be checked regularly by opening

bypass line / or by opening any of the major risk area.

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Fire water network operates in Auto mode basis signal it receives from area under
emergency either through communication as below

1. Breaking of Quartzoid Bulb

2. Manual opening of Air pressure switch
3. Pressing the manual call point
4. Opening of any outlets of pressurized hydrant network

In any of above case, logic shall be such that solenoid valve at the DV station gets
deactivated opening the sprinkler line.

After the Emergency is over, the effected Deluge valve shall be isolated by opening the
water balancing line which balances the inlet pressure and pressure of the deluge valve
thereby closing the deluge valve. Then reset the Fire Fighting panel alarm system and
reset the deluge valve at field.

8.12 GAS MONITORING SYSTEM

8.12.1 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 continous detection system with warning annunciation to alert the plant
personnel to take corrective action. The Gas Monitoring system is to 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 lef open, gasket leaks, hose pinholes, valves
gland leakage, drain point left partially open, TSV’s relief discharge in manifold area,
filling / evacuation hoses leakage.

8.12.2 APPLICATION:

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 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

The detection control equipment should be provided in the control room for
continous monitoring even during power failure.

(A) DETECTORS:

Amongst the various methods of detection available, the following proven systems for
LPG can be considered.

i) Catalytic detectors
ii) Infra-red detectors

(B) CONTROL SYSTEMS

a. 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
b. 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
c. The control equipment should have data logging facilities to provide print
outs of the history of the events with date and time of leakages
d. The control equipment should be able to generate at least two alarms at
different levels of LEL concentration of gas.
e. 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

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(C) 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.

(D) 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
of the wind direction

iii) The detectors especially the catalytic type should be positioned very close to the
potential source of leakage to avoid poisioning 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 pre-poritioned.

v) The minium detectors facilities-wise are given below:

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 Storage vessels ( above ground ) – 1 No. top and 1 No. near bottom ROV

LPG Pump house 1 No. in pump hose and1 No. in manifold

Filled cylinder shed – 1 No

Valve change shed – 1 No

8.13 The safe Operating Practices to be followed at LPG Plants / Installations -

 Hot Work & Cold Work to be carried out with proper Work Permit system as per
OISD -105

 Plant Should ensure closure of the permit on completion of job and maintain records
for future reference

 Identity card should be issued to all the contractor employees by the contractor
authorizing their entry to the Work area

 Safety shoes, hand gloves, helmets etc. and other related protective equipments shall
be used while carrying out the specified job.

 Specific care shall be taken while working at heights and entry to a vessel .

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 Explosimeter to be used to ensure that the working araea is free from LPG before
commencing any hot work.

 Authorised anad Qualified Electricians to be allowed to work in electrical Installations.

 Earthling of all electrical equipments to be checked for its connectivity and earth
resistance on regular intervals.

 Welding Job shall not be carried out in explosive area unless or otherwise it is
unavoidable. However, In case it is to be carried out , specific permission must be
taken from the location incharge .

 Protective equipments shall be used while carrying out weldings.

 Floor area in all the operating sheds shall be maintained clean and free from foreign
materials like soap solution, oil spillage, cotton waste etc.

 Cylinder handling shall be carried out on the conveyor . No rolling of cylinder should
be allowed. In case it is not possible for handle the cylinders ( due to its shape &
Size ) in conveyors then mechanized trolleys / puller or pusher to be used to handle
such cylinders.

 Maintain the speed of carrousel at its optimum i.e. 66 to 72 seconds per revolution.

 Use proper Non sparking tools and tackles for M&R jobs involving LPG equipments.

 Use proper earthings while loading / Unlaoding tank truck / tank wagons .

 Use recommended tools for connection and disconnection of loading / Unloading

Hoses/ arms.

 Ensure the evacuation of valves in defective cylinders at the Day end.

 No defective cylinders shall be left uncapped whether it is filled or empty.

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 Stacking of cylinders shall be made as per VSCR recommendations with identified
lots.

 De-pressurize the defective cylinders before opening the valves for replacement.

 Use Torque wrench for fixing valve in the cylinders with allowable torque.

 Maintain standard weights at Check scale and at weigh bridge.

 Ensure the operation of vapour extraction system during operating period.

 Vapour extraction system should be inter-locked with the operation of the carrousel.

 Ensure proper setting of relays for all motors connected with conveyors, compressors
, pumps etc.

 Ensure use of recommended Oil, Greases for use in mechanical equipments and chain
conveyor.

 Trained operator should carry out connection and disconnection of tank trucks hoses
/ arms and supervise the loading / unloading operation.

 Ensure working condition of ELD, OLD on daily basis thru test cylinders.

 Ensure use of rubber mats while loading / unloading of cylinders at the platform
from the trucks and in front of electrical panels.

 Water draining operation shall be supervised by an Officer.

 Highest level of House keeping of the Filling shed to be ensured.

 There should be no LPG Leakages from Filling guns, LPG valves etc.
 Double earthing of carousel & other equipments should be properly maintained for
effectiveness
 Hand Gloves should be used during manual handling works
 To ensure regular routine check up equipments etc.
 Any near miss must be considered as warning.
 Fire fighting equipment to be ready all the time for fighting any untoward incident.

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 Medical facilities to be kept ready.

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iv) Safety in Transportation of LPG in Bulk, Emergency Rescue
Systems/Analysis of Accidents. Disaster Management Plan
Emergency Procedures & Drills

28.0 ERDMP for Road Transportation.

The road transport of Petroleum products has significant presence and needs
special attention. Complete details of treatment for handling emergency
arising out of road transportations have been provided below:

28.1 Resource mobilisation for road transport emergency

Resource mobilisation for road transport emergency shall be as per the

Schedule-VIII.

(a) In order to handle Emergencies, which may arise due to incident

involving Petroleum Product Transportation, it is required that a
comprehensive Emergency Management Plan is readily available
with the industry as well as with other related authorities all along
the routes. The ERDMP should be clearly understood by its users
so that the emergencies can be handled in a systematic manner
with minimum response time in accordance with the prescribed
procedure.

(b) Copies of the ERDMP shall be made available by the Industry to all
the field locations i.e.Plants, Installations, POL Depots, Terminals /
Installations, Refineries, Gas Processing Plants, Dispatch units of
etc., the concerned District Administration, Police Stations and Fire
Brigades en-route and within vicinity of specified tank truck routes,
oil industry sales personnel of concerned area as may be required.

(c) Location specific availability of Emergency Response Vehicle shall

be mentioned in the ERDMP.

28.2 TREM Card (Specific to Road Transportation)

TREM Card format including sample as per details shown in

Schedule-IX and Route Map shall be provided to the Tank Truck
Crew which should be referred in case of an emergency.

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28.3 Role of External Agencies for road transportation emergency

It is expected that the following roles shall be performed by various

agencies:

28.3.1 Fire Brigade

On receipt of information from any source on incident of tank truck,

fire brigade may contact nearest installation and police station. After
assessing the situation, it may:

(a) rush fire tender to the incident site with all necessary fire fighting
equipments;
(b) prepare a contingency plan for removal of tank truck, if not
leaking, in consultation with installation personnel;
(c) dispersal of vapours by water spray away from inhabited area, in
case of leakage. Extinguish the fire, in case leakage source cannot
be stopped;
(d) allow the fire to burn under controlled conditions if isolation is
not possible in case of gaseous fuels;
(e) save human lives and salvage material from incident affected
truck;
(f) liaise with fire brigade in the adjoining town for additional help, if
necessary;
(g) arrange water through muni
(h) cipal water tanker or any other source;
In addition to the above, the Schedule-V shall be followed.

28.3.2 Role of Police

On receipt of information, police may take the following actions as per

Schedule-V derived from the National Disaster Management Guidelines

Chemical Disasters (Industrial), April, 2007. However, the following

points may also be taken care by the police authority:

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 (a) stop the traffic from both ends of the road.
(b) warn the people living in adjacent area for stopping all fire,
smoking, evacuation to safe places, if necessary.
(c) contact nearest district police headquarters and giving the
situation report.
(d) evacuate personnel from the area, if required.
(e) extend help in removal of injured personnel to the nearest
first-aid centre /hospital, contacting highway patrol,
completing legal formalities in case of any casualty.

In addition to the above, the shall be followed

28.3.3 District Administration

On receipt of information, District Administration may take the

following actions as per Schedule-V derived from the National Disaster
Management Guidelines Chemical Disasters (Industrial), April, 2007.
However,

On receipt of information, following actions should be taken care

(a) to keep watch on the overall situation.

(b) rush ambulance to the incident site if casualties are reported.
(c) direct cranes or any other such equipment to carry out rescue
operations.
(d) issue warning messages to people through public address
system, if any evacuation is required.
(e) arrange emergency vehicles for evacuation purposes.

(f) give direction to hospitals having burns injury ward for readiness
to receive patient in case of incident involving fire.

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 (g) provide basic amenities, e.g., water, electricity, food and shelter
to the affected people as required.

In addition to the above, the Schedule-V shall be followed.

Resource Mobilisation for Road Transportation Emergencies

A. In-Plant Resources

Following items should be available at the Plant in adequate quantity / nos.

Mechanical Equipment:

1. Gaskets (Carbon Asbestos Filled)

2. Studs and bolts.
3. Teflon tapes.
4. ½” / ¾” crowbar (1 m long)
5. Spade / blind flange
6. Rope (Manila / Jute)
7. Spark arrestors.
8. 1” tapered wooden pegs.
9. Chopper
10. Spare fan belt for tank lorry with P.T.O. unit
11. Wind sock
12. M-Seal / epoxy-base cold-welding compound.
13. Wooden slippers
14. Teflon-taped spanners, wrenches
15. Spark-proof wrenches, hammer and tools.
16. Barricading masts and ropes / tapes
17. hoses
18. Chain pulley blocks and stay pipes
19. Small valve keys for operating valves in the tank truck

Electrical Equipment :

1. Gas Explosi-meter

2. Flame-proof torches

3. Earthing wires (10 m long) with crocodile clips

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Personnel Protective Equipment :

1. Gloves:

i) Rubber gloves

ii) Low Temperature Gloves

iii) Industrial gloves (with leather lining)

iv) Canvas gloves

2. Face shields

3. Ear muff / ear plugs

Other Safety Items:

1. 1 roll of gunny / hessian cloth (about 10 mts. long)

2. First aid box (containing water gel compounds)

3. Soap

4. Blanket.

5. Water Gel Blanket

6. Breathing Apparatus (With spare filled cylinder and Canister gas masks)

7. Fire proximity suit

Fire Fighting Equipment :

1. Portable Dry Chemical Powder Fire Extinguishers

2. Fire-water Hoses

3. Triple Purpose diffuser nozzle for use with fire hoses.

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Communication Equipment :

1. Hand operated sirens

2. Whistles

3. Megaphone, Mobile Phones, VHF sets.

Traffic Control Equipment :

1. Red lights (Battery operated) - for traffic diversion

2. Area maps

3. Diversion Boards

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.
b) Careful selection and correct use of equipment.
c) Observance of safety and security regulations.
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 supervision and alertness.

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 firefighting
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 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.

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13.1.3 CHECK FOR LPG LEAKAGE AT FOLLOWING LOCATIONS
a) Through water drain valve while draining.
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 swivel joints of body arms.
g) Leakage from the filling guns.
h) Escape of liquid/ vapour LPG during maintenance/ repairs.

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.
v) Cinders from the steam locomotives.

(c) OTHERS
i) Landing of crackers (flying type ) in hazardous areas.
ii) Chiselling/ hammering.
iii) Spark from studed shoes, with steel button by friction against ground/ metal.
iv) Lighted agarbatti in a truck.
v) Excessive release of vapour beyond safe limit and fire due to outside source of
ignition.

vi) Lighting
vii) Smoking.

13.2 ACTION DURING EMERGENCY

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:

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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.
d) All out effort should be made to contain the spread of leakage/ fire.
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 area, in an orderly manner at pre-nominated route.
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.
j) Start water spray system at areas involved in or exposed to fire risks.
k) In case of leakage of LPG without fire and inability to stop the flow, take all
precautions to avoid source of ignition.
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.
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. e)
Fire fighters should advance towards a fire down wind if possible.
f) 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.

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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.

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/cm 2g 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 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.

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(iii) 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 non-synthetic cloth
(preferably wet) or sand/ earth etc.
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) 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.
Water pressure in LPG vessels.
If LPG vessel's SRVs have started blowing vapour, take no further action (apart from
cooling) unless vessel pressure continues to rise.
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.

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.
(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) Sounding the emergency (fire) alarm.

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(ii) Shutting off the LPG supply to any leakage point/ fire.
(iii) Summoning the fire brigade/ police.
(iv) 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.
(vii) Cooling of vessels/ cylinders and other equipment/ facilities.
(viii) Closing down all operations in the plant including closure of valves and stopping of
pumps.
(ix) Preventing all sources of ignition in case of LPG leakage.
(x) Evacuation of vehicles.
(xi) Evacuation and mustering of personnel.
(xii) Establishing an emergency fire-control centre.
(xiii) Traffic control.
(xiv) Stations and duties of all personnel.
(xv) Policing of affected areas.
(xvi) Any other specialised duties.
(xvii) Display of fire brigade, ambulance, Police telephone numbers etc.
(xviii) All clear signal by competent person.

(c) Liaison with local fire brigade :

Close co-operation with the local fire authorities is essential and shall take the following
form :
(i) 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.
(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.

(d) Fire Drills & Training :

a) 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.
b) The drills should cover various types of incidents, e.g. major spillage, LPG bulk lorry
fire, cylinder fire etc.
c) 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.

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e) Fire alarms shall be sounded/ tested (neighbouring plants/ factories and the fire
brigade shall be warned in advance of this test).
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.
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 :

ON- SITE
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) Identify Disaster scenario i.e. the situation under which the plan would become
operational. Plan for the worst possible scenario.
(ii) 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.

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(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.

viii) Work Permit System

 REFER OISD-STD-105 ON WORK PERMIT SYSTEMS.

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  THREE TYPES OF PERMIT -:

 HOT WORK

 COLD WORK

 ELECTRICAL JOBS

 ALL WORK TO BE CARRIED OUT WITH PROPER AUTHORIZATION IN

PRESCRIBED FORMATS LIKE HOT WORK, COLD WORK AND ELECTRICAL
WORK.

 LOCATION OF WORK TO BE INSPECTED ON REGULAR BASIS.

 RECORDS TO BE MAINTAINED FOR EVERY ACTIVITY UNDERTAKEN.

 MAINTENANCE IN LINE WITH OISD STANDARDS.

TYPES OF WORK PERMITS

 COLD WORK PERMIT (YELLOW COLOUR)

 HOT WORK PERMIT (RED COLOUR)

 ELECTRICAL WORK PERMIT (BLUE COLOUR)

HOT WORK PERMIT SYSTEM

 HOT WORK PERMIT

 ISSUED BY LOCATION – INCHARGE

 NON ROUTINE JOBS

 JOBS WHICH RESULTS IN FIRE/EXPLOSION

 WELDING / BURNING / BRAZING / SOLDERING

 GRINDING / EXCAVATION

 ENTRY INTO CONFINED SPACE

 CLEANING OF SCEPTIC TANK

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  EARTH RESISTANCE / CONTINUITY

COLD WORK PERMIT

 ISSUED BY LOCATION INCHARGE

 JOBS NOT PRODUCING SUFFICIENT HEAT TO IGNITE A FLAMABLE

HYDROCARBON MIXTURE OR A FLAMABLE SUBSTANCE.

 SAFETY RELIEF VALVE

 SPRINKLER NOZZLE CLEANING

 FIRE ENGINE

 GRASS CUTTING

 PAINTING OF P/Ls

GUIDELINES

 ISSUED BY LOCATION INCHARGE

 ISSUED TO OFFICER SUPERVISING THE JOB.

 CHECK LIST TO BE FILLED

 NORMALLY ISSUED FOR SINGLE SHIFT. EXTENSION AFTER INSPECTION

OF THE SITE.

 COMPLETION TIME & DATE TO BE RECORDED AND THE PERMIT BE

RETURNED TO ISSUING AUTHORITY.

 SAFETY OFFICER TO INSPECT THE SITE.

 OISD STD. 137 TO BE FOLLOWED.

ELECTRICAL WORK PERMIT

 RELATED TO POWER SUPPLY / CUT OFF

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  WORKING ON ELECTRICAL CIRCUITS OR ELECTRICALLY POWERED
EQUIPMENT

 ELECTRICAL SUPPLY TO BE TURNED OFF.

 TO BE TAGGED

RESPONSIBILITIES - ISSUER

 ENSURING SAFETY TO PERFORM THE WORK

 ALL FORMS TO BE FILLED

 MAKE THE EMPLOYEE AWARE OF THE REQUIREMENT

 AREA TO BE INSPECTED

 WORKING CONDITIONS

RESPONSIBILITIES - RECEIVER

 ALL CONDITIONS TO BE COMPLIED

 ENSURING IMPLEMENTATION OF THE GUIDELINES

 START WORK IF OPERATING CONDITIONS ARE NOT CONDUCIVE.

 PRESENCE OF FIRE EQUIPMENT

 CLOTHING OF WORKERS

 FINAL INSPECTION AFTER THE WORK

 NOTIFY ISSUER ON COMPLETION OF WORK.

vi) Electrical Safety

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6.13 SELECTION OF ELECTRICAL EQUIPMENT

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., OISDSTD– 113,
OISD-RP-149, NEC – 1985, IS:2148, IS:5571, 5572, IS: 13408, Petroleum Rules, 2002 shall
be referred.

6.14 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
water pumps, fire alarm stations etc.
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.
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.

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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 Installation Earthing

i. All electrical equipment shall be suitably earthed. Earthing system shall cover the
following:
􀂾 Equipment earthing for personnel safety.
􀂾 System neutral earthing, and
􀂾 Protection against Static and Lightning discharges.
The earthing system shall have an earthing network with required number of earth
electrodes connected to it. The following shall be earthed:
• System neutral

• 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.
• Steel structures, loading platform etc.
• Cable trays and racks, lighting mast and poles.
• Spheres, Bullets etc.
• Electrical equipment fencing (e.g. transformer, yard etc.)
• Cable shields and armour.
• Flexible earth provision for wagon, truck.
ii. 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.
iii. Where installed, lightning protection shall be provided as per the requirements of
IS:2309.
iv. The resistance values of an earthing system to the general mass of earth should be as
below:
􀂾 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.
􀂾 10 Ohms in the case of all non-current 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.

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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.

STATIC ELECTRICITY

 PHENAMENON OF ELECTRIFICATION OF MATERIALS THROUGH

PHYSICAL CONTRACT ON SEPERATION AND THE VARIOUS EFFECTS
THAT RESULT FROM THE POSITIVE AND NEGATIVE CHARGES SO
FORMED.

 BOTH MATERIALS REMAINED CHARGED IF THEY ARE WELL INSULATED

ELECTFICALLY.

 CAN BE PREVENT STATIC ELECTRICITY ?

 NO, BECAUSE ITS INTRINSIC ORIGINS ARE PRESENT AT EVERY

INTERFACE.

 GENERATION OF ELECTRIC CHARGE, USUALLY OCCURS WHENEVER A

LIQUID (HYDRO CARBON) FLOW PAST A SOLID OR ANOTHER LIQUID.

 STATIC ELECTRICITY IS GENERATED BY THE SEPERATION OF LIKE OR

UNLIKE BODIES.

 ELECTRO STATIC CHARGES, POSITIVE AND NEGATIVE, ALWAYS OCCUR

IN PAIR AND ARE DEVELOPED WHEN ANY TWO BODIES THAT HAVE
BEEN IN CONTACT ARE SEPERATED.

 THE RATE OF ELECTRO STATIC GENERATION IN A PIPELINE OR HOSE

INCREASES WITH INCREASING LENGTH OF PIPE OR HOSE TO A
MAXIMUM LIMITING VALUE.

 THE MAXIMUM LIMITING VALUE IS RELATED TO LIQUID VELOCITY AND

THE CONDUCTIVITY AND WILL BE GREATER FOR HIGH VELOCITIES OF
LIQUID FLOW THAN FOR LOW VELOCITIES.

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  THE AMOUNT OF ELECTRO STATIC CHARGE ACCUMULATION ON AN
INSULATED BODY DEPENDS UPON :

 RATE AT WHICH THE STATIC CHARGE IS BEING GENERATED.

 THE RESISTANCE OF PATHS BY WHICH THE CHARGE LEAKS OF

(DISSIPATES).

 ELECTRO STATIC CHARGES CONSTANTLY LEAK FROM A CHARGED BODY

BECAUSE THEY ARE ALWAYS UNDER THE ATTRACTION OF AN EQUAL
BUT OPPOSITE CHARGE. BECAUSE OF THIS MOST STATIC PARTS ARE
PRODUCED WHILE THE GENERATING MECHANISM IS ACTIVE.

GENERATION OF SPARKS

 A SPARK CAN BE DESCRIBED AS THE PASSAGE OF AN ELECTRIC CHARGE

ACROSS A GAP BETWEEN TWO POINTS NOT PREVIOUSLY IN CONTACT.

 ELECTROSTATIC DISCHARGES ARE USUALLY SPARKS.

SOURCES OF STATIC ELECTRICITY

 NON CONDUCTIVE POWER TRANSMISSION BELTS OR CONVEYOR BELTS

IN MOTION.

 MOVING VEHICLES

 HYDRO CARBON LIQUIDS FLOWING AT HIGH VELOCITIES IN PIPES /

NOZZLES, ETC.

 SPLASH LOADING OF HYDRO CARBON LIQUIDS

 AGITATION / MIXING & BLENDING

BONDING

 SPARKING BETWEEN TWO CONDUCTIVE BODIES CAN BE PREVENTED BY

AN ELECTRICAL BOND ATTACHED TO BOTH BODIES.

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  THE BOND PREVENTS A DIFFERENCE IN POTENTIAL ACROSS THE GAP AS
IT PROVIDES A CONDUCTIVE PATH FOR STATIC CHARGES.

 BOLTED CONNECTIONS WITHIN THE BOND WIRE OR AT THE BOND

WIRE TERMINALS ARE ADEQUATE FOR STATIC DISSIPATION.

GROUNDING

 EARTH MAY BE USED AS PART OF THE GROUNDING SYSTEM.

 GROUNDING OF A CONTAINER OR TANK CANNOT PREVENT THE

ACCUMULATION OF CHARGES ON THE SURFACE OF A LIQUID IN THE
CONTAINER.

vii) Responsibility of Supervisors in implementing Safety

Regulations.

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THE PURPOSE OF EFFECTIVE SAFETY MANAGEMENT SYSTEM:

 TO PREVENT ACCIDENTS AND TO ELIMINATE/MITIGATE THEIR

CONSEQUENCES.

 APPLICATION OF MANAGEMENT CONTROL FOR TACKLING THE RISKS

ASSOCIATED WITH HANDLING OF PETROLEUM PRODUCTS/HAZARDOUS
SUBSTANCES.

 MAKE AWARE OF VARIOUS SAFETY PRACTICES WHICH NEED TO BE

PRACTICED AND TRAINING GIVEN TO ALL EMPLOYEES.

 MAKE AWARE OF THE VARIOUS OISD STANDARDS AND NORMS

CONNECTED WITH SAFETY IN POL MARKETING LOCATIONS.

 IDENTIFY AREAS OF DETAILED TRAINING REQUIRED TO EMPLOYEES

HANDLING HAZARDOUS SUBSTANCES.

 MANAGING SAFETY PRACTICES SHOULD COVER ALL ASPECTS OF THE

PLANT AND FACILITIES TO PREVENT LOSS OF LIFE & PROPERTY AND TO
PROTECT ENVIRONMENT.

 OBJECTIVE IS TO HAVE A STANDARDIZED SYSTEM OF PROCEDURES

WHICH WOULD CONTINUE TO BE FOLLOWED BY ONE AND ALL UNLESS
A CHANGE IN THE SYSTEM IS DULY AUTHORIZED BY A COMPETENT
PERSON.

 OISD STD/GDN ON VARIOUS TOPICS ARE AVAILABLE FOR USE IN OIL

INDUSTRY.

THE BASIC ELEMENTS OF SAFETY SYSTEM CONSISTS OF :

1. SAFETY POLICY

2. SAFETY COMMITTEES

3. EMPLOYEE PARTICIPATION

4. PROCESS/OPERATION SAFETY INFORMATION

5. PROCESS/ OPERATION HAZARD ANALYSIS

6. OPERATING PROCEDURES

7. TRAINING

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 8. CONTRACTORS

9. PRE-START SAFETY REVIEW

10. MECHANICAL INTEGRITY

11. WORK PERMIT SYSTEM

12. INCIDENT INVESTIGATION ANALYSIS

13. EMERGENCY PLANNING AND RESPONSE

14. INTERNAL AUDIT & COMPLIANCE

15. OCCUPATIONAL HEALTH

16. ON THE JOB SAFETY

17. CUSTOMERS AND PRODUCTS

18. ROAD TRANSPORTATION

SAFETY POLICY

 WE HAVE A SAFETY, HEALTH AND ENVIRONMENT POLICY APPROVED BY

THE BOARD OF DIRECTORS.

 COPY OF THIS POLICY SHOULD BE AVAILABLE AT ALL LOCATIONS AND

SHOULD BE MADE AVAILABLE TO ALL EMPLOYEES IN A LANGUAGE
EASILY UNDERSTOOD BY THEM.

 IT SHOULD BE DISPLAYED AT VARIOUS LOCATIONS WITHIN THE

DEPOT/TERMINAL.

 EMPLOYEES SHOULD BE MADE AWARE OF THE CONTENTS OF THE

POLICY AT VARIOUS FORUMS AND REFRESHED ON A REGULAR BASIS.

SAFETY COMMITTEE

 SAFETY COMMITTEE SHOULD BE DULY CONSTITUTED AT EACH

LOCATION BY A NOTIFICATION.

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  PROPER REPRESENTATION FROM WORKMEN TO BE ENSURED AS PER
FACTORY ACT AND SHOULD MEET ONCE IN A QUARTER.

 ALL DELIBERATIONS SHOULD BE RECORDED AND IMPLEMENTED IN A

TIME BOUND PROGRAM.

 THE NAME OF THE MEMBERS SHOULD BE DISPLAYED.

EMPLOYEE PARTICIPATION

 SAFETY SUGGESTION SCHEMES, QUIZ, COMPETITIONS TO BE

CONDUCTED TO ENHANCE PARTICIPATION OF EMPLOYEES.

 EMPLOYEES TO BE ENCOURAGED IN SAFETY TALKS ABOUT OPERATION

OF THE PLANT INCLUDING SAFETY AND HEALTH HAZARDS.

 EMPLOYEES TO BE ON TRAINED IN USE OF PERSONAL PROTECTIVE

EQUIPMENTS AND WORK PERMIT SYSTEMS.

 WRITTEN INFORMATION ABOUT PROCESS, CHEMICALS INCLUDING

MSDS SHOULD BE MADE AVAILABLE TO THE EMPLOYEES.

 PARTICIPATION THROUGH SAFETY COMMITTEE

OPERATING TECHNOLOGY

 PROPER WRITTEN PROCEDURES FOR OPERATIONS

 UPDATED P&ID DIAGRAMS

 SAFE OPERATING LIMITS LIKE PRESSURE, TEMPERATURE, FLOW RATE

ETC.

 HAZOP STUDY - RECOMMENDATIONS NEEDS IMPLEMENTATION

 COMMUNICATION TO THE EMPLOYEES ABOUT THE ANALYSIS REPORTS

FOR AWARENESS

 DESIGN DATA INCLUDING DESIGN SPECIFICATIONS, CODES,

STANDARDS FOR THE EQUIPMENTS USED SHOULD BE DOCUMENTED

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OPERATING PROCEDURES

 DESCRIBED TASK TO BE PERFORMED, DATA TO BE RECORDED AND

OPERATING CONDITION TO BE MAINTAINED.

 OPERATIVE INSTRUCTION SHOULD BE SPECIFIC TO THE

PLANT/FACILITY.

 OPERATING PROCEDURES SHOULD PROVIDE SPECIFIC INFORMATION

ON STARTUP NORMAL OPERATIONS, TEMPORARY OPERATIONS,
EMERGENCY OPERATIONS AND SHUT DOWN ETC.

 MANUAL SHOULD BE MADE AVAILABLE TO ALL EMPLOYEES.

 MANUAL SHOULD BE UPDATED AS OFTEN AS NECESSARY.

MECHANICAL INTEGRITY

 PROPER PRE-STARTUP INSPECTION OF EQUIPMENTS AND ITS

DOCUMENTATION AS PER CODES. FOR E.G.TANKS, PIPELINES, JOINTS,
PUMPS, DG’S.

 OVERALL MAINTENANCE PLAN SHOULD BE DRAWN IN LINE WITH OISD

STANDARDS / MANUFACTURERS RECOMMENDATION.

 MAINTENANCE/ INSPECTION TO BE ENSURED ON A REGULAR BASIS

AND DOCUMENTED

 EQUIPMENT DATA SHEETS SHOULD BE MAINTAINED ALONG WITH

HISTORY CARDS OF VARIOUS MAINTENANCE ACTIVITIES CARRIED OUT.

 RELEVANT OISD STANDARDS AND GUIDELINES SHOULD BE USED FOR

DEVELOPING INSPECTION AND MAINTENANCE SYSTEMS.

viii) Safety Audit

14.1 GENERAL:

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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.
General guidelines on safety audit methodologies and techniques are also given in
OISD - GDN- 145.

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.

-----------------------------------------------------------------------------------------------------------------------------
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.

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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.

ix) Personal Protective Equipment

v) The following accessories/ first aid items shall be provided in the plant :
1. Fire hoses Two nos. for each Hose Box

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2. Safety helmets 1 no. for each person. (min. 10 nos.)
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
8. Low tem. protective Min. 2 sets clothing for LPG emergency.
10. Fire proximity suit Min. 1 No.
11. Resuscitator Min. 2 No.
12. Red/Green Flags As reqd
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.

x) Housekeeping

 Maintenance of the location.

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  Up keeping of all equipments

 Untidy & pilling up of dangerous ` material.

 Scrap & excess material .

 Material stuffed in a corner .

 Blocked pathway .

Item that are no longer need should be disposed .

MACHINERY & EQUIPMENT

• Cleanliness & no undesired material

• NO unnecessary dripping of oil/ grease

• Proper guards provided

STOCK & MATERIAL

• Properly pilled & arranged

• Safe & orderly loading

• TOOLS

• *Properly stored

• *Free of oil & grease when stored

• *Safe working condition of tools

• AISLES

• *Provided for work place, FE & PPE s

• *Safe & free of obstruction

• *Clear marking

FLOORS

• Safe surface & suitable to work

• Clean , dry & free of oil / grease

BUILDING

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 • Clean walls and windows

• Clean & efficient lighting system

• Clean stairs with adequate no of hand rails

• Clean & well lit platform

GROUND

• Good Order

• Free of refuse and unnecessary material

CONSERVATION OF NATURAL RESOURCE

• Water

• Electricity

House Keeping :-

a) Maintenance of the locations

b) Upkeep of all equipments

c) Stacking materials in an orderly manner.

d) Record Keeping.

e) Stacking scrap material / crush cylinder

f) Day to Day Cleaning operations

HOUSE KEEPING PRACTICES

PRINCIPLE OF GOOD HOUSE KEEPING

RESPONSIBILITY OF HOUSE KEEPING

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 GOOD HOUSE KEEPING INCLUDES

• Proper Layout & Equipments

• Correct material Handling & storage

• Cleanliness and orderliness.

WASTE MANAGEMENT

xi) Industrial First Aid

FIRST AID:

Aim of First Aid :

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· Preserve life - the overriding aim of all medical care, including first aid, is to save
lives

· Prevent further harm - also sometimes called prevent the condition from
worsening,or danger of further injury, this covers both external factors, such as
moving a patient away from any cause of harm, and applying first aid techniques to
prevent worsening of the condition, such as applying pressure to stop a bleed
becoming dangerous.

· Promote recovery - first aid also involves trying to start the recovery process from
the illness or injury, and in some cases might involve completing a treatment, such as
in the case of applying a plaster to a small wound

 Disposable gloves.

 Tweezers - for removing foreign objects such as splinters or bee stings.

 Scissors - for cutting tape or bandages.

 Safety pins for securing bandages and pinning slings.

 Cotton buds - for cleaning small wounds or removing obvious foreign objects.

 Sterile saline for washing eyes.

 Sterile eye pads - as a temporary dressing and cover for injured eyes.

 Cling film - for applying over serious burns to keep air out. This helps relieve
pain and prevents infection. As it won't stick to the burn, it can also be easily
removed later by medical staff treating the burn.

 Triangular bandages - for use as a sling for an injured arm or shoulder, or as a

scalp bandage.

 Sterile saline or alcohol-free wipes to clean wounds.

 Cotton gauze or gauze swabs for cleaning/drying/covering wounds.

 Fabric or waterproof plasters.

 Sterile dressings that won't stick to weeping wounds, eg Melolin.

 Permeable adhesive tape, eg Micropore, for holding dressings in place.

 Gauze bandages.

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  Crepe bandages for holding dressings in place or supporting sprains and
strains.

 Antiseptic cream or lotion.

 Calamine lotion: for controlling itching due to insect bites etc.,

 Antacid : Indigestion

 Constipation : Laxative

 Diarrhoea : Loperamide , rehydration medicine

 sore throat : cough syrup

 Fever : Paracetamol tablets

 Pain relievers: Bruefen

 FOR COLD BURN : USE PLENTY OF WATER FOR COOLING/ WASHING/

BURNOL.

 LPG SPLASH IN TO EYES : EYE WASH WITH WATER

 GUIDDYNESS : GLUCOSE WATER

 SCRATCHES : CLEAN WITH HYDROJEN PEROXIDE & APPLY BETADINE

OINMENT OR NEUBASULF POWDER

 FRACTURE : IMMOBILISE THE CONCERN PART OF BODY/ CONSULT DOCTOR

 BURN : WATER / ANTISEPTIC OINMENT

 FEVER / HEADACHE: PARACETOMOL

HANDLING EMERGENCIES

In the event of an incident, following 4 steps should be taken :

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STEP 1. In case the TT crew is in a position to act, they should inform the nearest LPG
Installation first otherwise contact the nearest Depot / Terminal of any oil company.
The TT crew should also inform the nearest Police Post and Fire Brigade.

STEP 2 In case, phone facility is not available in the vicinity, TT crew should send the
message through any other means such as any other truck / TT or any volunteer to
the nearest Bottling Plant, Retail Outlet, Oil Installation of any Oil Company, Police
Post and Fire Brigade, (All Retail Outlets, Oil Installations, Fire Brigade & Police
Station should be provided with telephone nos. of the nearest LPG Installation).

STEP 3 In case the message is received first by Police Post or Fire Brigade or Depot /
Installation of any Oil company, they should inform the nearest Bottling Plant of any
company.

STEP 4 While conveying the information to LPG Installation by TT Crew, Fire Brigade,
Police Post, Depot / Installation as may be the case, the following information should
be collected and relayed :

a) Location of incident, milestone no., Highway No., nearest village / town and any
other easily identifiable landmark.

b) Registration No. of TT, name of the Transporter. c) Date and time of incident. d) TT
empty or full and the quantity. e) Proceeding from/ on way to.

f : Any casualty or injury.

g: Any leakage or fire and its source.

h : Position of TT after the incident on road.

i : Safety Precautions taken.

j : Help required (tools & tackles, i.e., jacks etc., crane, transfer of product, towing of
vehicle, fire tender, fire fighting equipment, ambulance etc).

k : However, to minimize the delay whatever information is readily available should

be quickly relayed followed by detailed information as above.

Documentary proof of such intimation to be kept ready.

x) Occupational Health Hazards

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 OCCUPATIONAL HEALTH
 REFER OISD-GDN-166 FOR GUIDELINES ON OCCUPATIONAL HEALTH
MONITORING IN OIL AND GAS INDUSTRY.
 STRUCTURE OCCUPATIONAL HEALTH MONITORING SYSTEM FOR
PROTECTION OF HUMAN HEALTH FROM ANY POSSIBLE ADVERSE
CONSEQUENCES OF EXPOSURE TO THE HAZARDS IN THE
OCCUPATIONAL ENVIRONMENT.

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