SAFETY IN INSTALLATION AND MAINTENANCE OF LPG CYLINDERS MANIFOLD

1.0 INTRODUCTION

There are a number of LPG cylinders manifolded installations existing in Hotels, Hospitals, Nursing
Homes etc. Apart from a BIS code, there is no detailed code which can be followed by the Oil Industry
(through their approved contractors). In view of the potential hazards of such manifold installations, the
need was felt to develop a standard code of practice in addition to BIS code IS:6044 (Part I)-2018. In the
Liquefied Petroleum Gas trade, Commercial / Industrial cylinders installations relate to the larger type
catering/production arrangements such as Restaurants and Canteens located in Hotels, Hospitals,
Nursing Homes and Industrial Establishments such as Textiles, Baking, Glass factory etc.

2.0 SCOPE

The Standard:
Covers LPG cylinders (all types approved by CCE) connected through a manifold to commercial/
domestic, industrial burners where the end use of LPG is for Commercial cooking/ production/ Laboratory
purposes.
Supplements IS:6044 (part I) - 2018 on guidelines for packed cylinder installation. Items covered under
IS:6044 (part I) - 2018 are not being repeated and this standard may be referred in conjunction with IS:
6044 (Part I) - 2018.
Relates to safe practices in Design, erection, commissioning and maintenance of manifold installations.
However, detailed operational practices like handling emergencies etc. are not covered.
Oil industry is in the process of drawing out detailed specifications of the equipment’s used in the
manifolded LPG cylinders installations. All equipment’s used in these installations shall meet the above
specifications.

3.0 LAYOUT

3.1 General guidelines for manifolded LPG cylinders shall be followed from IS: 6044 (Part I) - 2018. The
additional safety measures need to be taken are as under:
3.2 The site for LPG cylinder manifold shall be located away from the user point. Installation shall be
slightly raised from the ground level. Cylinders shall not be installed below ground level in cellars or
basement. The cylinders shall be stored in dry, cool and well-ventilated room.
3.3 Cylinders installation should not be located close to steam pipes and boilers etc. to prevent cylinders
from getting affected due to radiant heat.
3.4 Cylinders shall not be installed at a place where they are likely to cause obstruction, suffer damage or
be exposed to conditions likely to affect safety.
3.5 The cylinder storage room shall be of fire - resistant construction. Flammable materials like wood and
plastic shall not be used.
3.6 Cylinders shall be located on a concrete or brick floor in case of outdoor installation. The cylinder shall
be installed in upright position with the valve pointing upwards.
3.7 Since LPG is heavier than air, ventilation shall be provided at floor level open to atmosphere. The
ventilators shall be provided with 2 layers copper or non – corroding metal wire mesh not less than 11 to
the linear centimeter.
3.8 Safety cap should be put on the cylinders which are empty.
3.9 The doors of the room where cylinders are installed shall open outwards.
3.10 Main shut-off valve (Plug or ball-type) on the pipeline emerging out of cylinder storage room shall be
located in such a manner that it just falls outside the storage room and shall be easily accessible at all
times. At the point of entry of each work place, the line shall have a quick shut off valve (plug or ball-type).
3.11 The main shut - off and quick shut-off valves are required in case the distance between the storage
room and the work place is more than 10 mars.
3.12 As per Statutory requirements no explosive license is required for multi cylinder installations.
However, consumers having unconnected filled cylinders with more than 100 kgs. LPG shall obtain
explosives license under Gas Cylinders Rules 1981.
3.13 The safety distance of packed installation shall conform to Rule 3.1.6. of IS:6044 (Part I) - 2018.
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3.14 Wherever the pipelines are passing through walls, slacks shall be provided so that the pipeline does
not get braised.
3.15 The storage room shall have caution signs such as “DANGER”, “HIGHLY INFLAMMABLE GAS
SHED”. “NO SMOKING” etc. painted in luminous red paint outside at a prominent place.
3.16 A minimum distance of 1 mt. shall be maintained between the cylinder installation and the surface
water drain, if any.

4.0 DESIGN CRITERIA OF INSTALLATION

4.1 In order to meet the larger requirement of commercial customers it is necessary to connect a number
of cylinders to a manifold so that the required quantity of gas at requisite pressure can be obtained. The
multi cylinder installations shall be designed as per IS:6044 (part I) - 2018.
4.1.1 It is required to visit the customer’s premises and select a suitable site for cylinder storage room as
per the layout considerations. In order to ascertain the requirement complete details shall be collected and
noted in the format as given in annexure - I.

4.2 REQUIREMENT OF CYLINDER BANK/BURNERS:

Multi- cylinder manifolds are mainly designed and used for cooking purpose. The LPG requirement of
customers desirous of converting from other fuels to LPG can be assessed based on the quantity of fuel
used, its calorific values and heat transferring efficiency.
4.2.1 In the case of absolutely new installations the requirement may be assessed alternatively by taking
normal consumption per person per day from 0.1 to 0.13 kg. depending upon the climatic conditions. For
existing as well as the new customers the no. of cylinders required to be in use may be assessed after
considering the burner consumption rate of LPG, % utilization during the usage and the natural
vaporisation capacity per cylinder.
4.2.2 Provision should also be made for 100% spare capacity for cylinders as calculated above.
4.2.3 While deciding at the size of the manifold it should preferably be designed for higher no. of cylinders
to accommodate for increase in consumption in future.
4.2.4 Size of the cylinder storage room shall depend upon the number of installed cylinders designed for
the layout of the manifold (parallel or linear) and the cylinder arrangement in the storage room (Standard
or staggered). Enough room shall be provided for easy access to each and every cylinder.

4.3 CONNECTION CRITERIA OF LPG CYLINDERS TO MANIFOLD:

4.3.1 All The cylinders at the customers’ premises shall always be connected to the manifold wherever the
installed cylinders at the premises are more than four. The cylinders should not be left unconnected or
stored elsewhere. Should there be requirement of additional cylinders which are to be kept loose, the
customer can store them within stipulations as provided for in Gas Cylinders Rules, 1981. However, such
cylinders should not be stored in manifolded room. Each arm of the manifold shall have a control valve. To
each arm of the cylinder manifold, cylinders shall be connected through a pigtail. For ‘SC’ type valve
cylinders it is necessary to use an adaptor to connect the cylinder pigtail. The distance between the
nipples on the manifold to which pigtails are attached, depends upon the type of cylinder arrangement
required i.e., standard or staggered. The staggered arrangement is to be used when availability of space
is limited.
4.3.2 The flexible hose/pigtail shall be in the same room and its length shall not exceed 2 M. Flexible
hose/ pigtail shall not pass through doors, windows, walls, ceiling (or) floors. The pigtails shall be
accessible for inspection.
4.4 LOCATION FOR MANIFOLDED INSTALLATIONS:

4.4.1 Manifolded installations upto 40 kgs LPG can be installed on any floor. Minimum floor area required
5 M2.
4.4.2 Manifold installations not exceeding 40 kgs. of LPG may be installed in doors on any floor within the
same workspace provided the minimum distance between two such installations are 3 M. The floor area
for each installation should be at least 5 M2 and the aggregate quantity of LPG in all such installations
does not exceed 200 kgs.
4.4.3 Manifolded installations not exceeding 80 kgs. of LPG may be installed indoors on any floor provided
the floor area is not less than 12 M2 for such installation.
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4.4.4 Manifolded installation not exceeding 80 kgs. of LPG may be installed indoors on any floor area
provided the minimum distance between the installations is 3 M, the proportion of such installations to
floor area is one installation per 12 M2 and the aggregate quantity of LPG in all such installations does not
exceed 200 kgs.
4.5 As per IS:6044 (Part I) - 2018, small manifold (i.e. Total capacity upto 320 kgs) can be accommodated
within the building. For bigger manifold (i.e. capacity 321 to 1000 kgs) a separate shed away from the
main building shall be provided keeping adequate safety distances. For manifold capacity requirement of
more than 1000 kgs, separate installations each not exceeding 1000 kgs. shall be provided.
4.6 The manifold (header) pipeline shall not have any joints to extend its length.

5.0 SPECIFICATIONS FOR EQUIPMENTS, APPLIANCES AND ACCESSORIES

5.1 GENERAL:
5.1.1 For safe efficient performance of any LPG installation, all equipment’s, appliances and accessories
shall conform to the laid down standards and specifications. For quality control more and more items are
being covered by BIS. In case of BIS covered items, items approved by BIS only shall be used. In case
any component is not covered by BIS Standard, then the same shall have Oil Industry’s approval.
5.1.2 A list of such approved manufacturers for various components can be had from the concerned oil
company.
5.1.3 Major components of LPG installation are briefly described below:

5.2 PRESSURE REGULATORS:

5.2.1 Pressure Regulators are devices used to regulate the delivery pressure to the appliances for safe
operation. Adequate attention should be given to the Pressure Regulator selection and it must be chosen
with due care. It shall have sufficient capacity to handle the volume of the gas required to supply
maximum demand. The different types of pressure regulators presently available are:
➢ low pressure regulators with high volume.
➢ high pressure regulators with fixed outlet pressure.
➢ high pressure regulators with variable outlet pressures.
5.2.2 All high-pressure regulators to be used in LPG installations shall be of approved type. Only oil
industry approved high pressure regulators shall be used.
5.2.3 If the regulator selection is not proper the appliance performance will be affected by pressure
fluctuations and will induce a slow pulsation in line pressure causing appliance flame to vary.

5.3 GAS PIPES:

5.3.1 Copper, steel and mild steel tubes to be used in LPG service shall be as specified in IS:6044 (Part I)
- 2018.
5.3.2 Steel pipes, cold steel drawn seamless or electric resistance welded (ERW) conforming to IS:3601
shall only be used.
5.3.3 Copper tubes shall be solid drawn with outside diameter of 10, 12, 20 mm as suitable conforming to
IS:2501.

5.4 VALVES:
5.4.1 The following types of valves are normally used in the LPG installations:
i. Needle control valves
ii. Fire Safe valves
iii. Quick shut-off valves
iv. Main shut-off valves
5.4.2 The valves designed to work on LPG shall only be used. Materials used in these valves should not
be affected by LPG. Type of valves to be used on LPG service should be of proper pressure rating and
meet oil industry specifications since BIS or equivalent standards are presently not available.
5.4.3 Cast iron and aluminium valves shall not be used.

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5.5 BURNERS:
5.5.1 The burners used in commercial installations are normally high-pressure burners. These burners
work at a pressure of 0.315 kg/cm2 (4.5 PSIG) and above. Of the various models currently in use, from
types which find the maximum applications are outlined below:

5.5.2 T-TYPE BURNERS OR TORCH BURNERS

These give a concentrated flame and are good for water heating and deep frying. The vessels used in this
type of burners should preferably have concave bottom.
5.5.3 These are vertical burners and height can be varied.
5.5.4 There are mainly two sizes in this type of burners i.e. T22 and T35 with consumption of 1 kg/hr and
1.6 kg/hr LPG respectively. These burners are also called as T1 and T2. Higher capacity burners are also
available.

5.5.5 ‘M’ TYPE BURNERS

These have a spreading ring flame profile and are good for cooking purpose. These burners are referred
to as ‘M’ type burners.

5.5.6 ‘V’ RING OR ‘L’ BURNERS

These are long burners used horizontally and named ‘V’ burners due to their shape. These burners are
used for heating long, broad containers mussel ovens etc. The burner flame impinges on the bottom of the
vessel or plate at an angle of 45 degrees. The burner shall be so chosen such that the flame does not
enter beyond the circumference of bottom plate of vessel.

5.5.7 CANTEEN BURNERS

5.5.7.1 These burners are low pressure appliances widely used in commercial installations. These are
similar to the domestic burner but of larger size.
5.5.7.2 Canteen burners shall conform to IS:5517 - 1969.
5.5.7.3 High pressure canteen burners as may be required by end users can be custom - built and used.
The heat efficiency of all the burners mentioned above should be a minimum of 40% when tests are
conducted as per BIS Standard No. IS:5117-1969.

5.6 CYLINDERS MANIFOLD:

5.6.1 Cylinder manifold is very important because of the fact that it is subjected to full cylinder pressure
at all times. The fabrication/ welding of the manifold should be of the best available quality. All such
manifolds shall be designed to a pressure equivalent to the maximum possible cylinder pressure
(assessed at 65-degree C) of LPG i.e. at 16.87 kgf/cm2. The test pressure should be 1.5 times the
maximum pressure (assessed at 65-degree C) i.e. 25.35 kgf/cm2.
5.6.2 The control valve (‘F’ type) used in the cylinder manifold arm shall be of the type used for LPG
cylinders. Valves manufactured by approved valve manufacturers of oil industry shall only be used in
manifold.
5.6.3 All joints in the manifold should be welded (except for valve fixation) and be easily accessible for
inspection/ repairs etc.
5.6.4 Each manifold arm shall be fabricated out of a single length of pipe. Joints to lengthen the arm, are
not permitted.

5.7 CYLINDER PIGTAILS:

Normally copper pigtails are used to connect cylinders to the manifold. However, flexible reinforced
synthetic rubber pipes are also being used. The quality of braided synthetic rubber tubes shall be such
that it is least affected by LPG. The reinforcement i.e. braiding should be able to withstand the same
pressure as that of cylinder manifold. The design and test criteria shall be same as that of cylinder
manifold. Test pressure shall not be less than 25.35 /cm2. The free nut at the end shall be of noncorrosive
metal.

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5.8 ADAPTOR:
This device is used to connect the pigtails to the cylinder valves (self-closing) of the LPG cylinders. This
device shall have non-return device and shall have prior approval of the oil industry.

5.9 NEEDLE CONTROL VALVE:

These are normally used to control the flow of gas to the burners. These valves should be of approved type
of oil industry.

5.10 PRESSURE GAUGE:

A good quality pressure gauge with a range of 0-3 kgf/cm2 (0-40 PSI) shall be provided in the pipeline
after the first stage pressure regulator. The joint at which pressure gauge is fixed shall be thoroughly
checked for leakage. Similar type of pressure gauges shall be provided in the pipelines after II stage
regulation.

5.11 EXCESS FLOW VALVE:

The excess flow check valve shall be provided on each arm of the manifold to ensure stoppage of LPG
supplies in case of heavy leakage/damage to the pipeline in the downstream facilities. The capacity of the
excess flow valve shall be 50% more than the maximum designed flow rate required through the manifold.

5.12 PIPING TUBING AND FITTINGS:

Proper record of suppliers of equipment’s, its installation and Standard used shall be maintained.

6.0 INSTALLATION OF PIPING AND APPLIANCES

6.1 In fabrication of LPG installation general guidelines shall be drawn from code of practice for LPG
storage installation IS: 6044 (Part I)-2018.
6.2 Those responsible for the installation of LPG equipment and piping etc. should understand the
characteristics of LPG very clearly and shall be trained in proper handling, installing and maintaining
installations.
6.3 Detailed drawings giving specifications of the equipment used and layout of the entire installation must
be approved by concerned Oil Co. before undertaking work.
6.4 The route of pipeline which is spelt out very clearly in the approved drawing, shall not deviate while
laying down the pipelines. If need be the original drawings can be got revised duly approved by Oil Cos.
6.5 All pipelines must be either welded or brazed so as to ensure that no leakage can take place even at
pressures much higher than the working pressures. Use of threading and jointing the pipeline through
jointing compound shall not be resorted to.
6.6 The welding/brazing of the pipeline joints shall be done by a trained and qualified welder.
6.7 If the pipeline diameter is more than 50 mm, it should be welded and/or flanged. Smaller diameter
pipelines should only be welded/brazed.
6.8 The piping joints shall not be placed embedded in floors in inaccessible places. Wherever it cannot be
helped, welding and prior pressure testing of pipeline shall be done. Wherever the pipes are buried they
shall not have any flange joints in the buried portion.
6.9 Joints other than welded, if any, are to be so placed that they shall be readily accessible, so that
leakage tests can be conducted without any difficulty.
6.10 Piping both embedded in floor and above ground shall be protected against physical damage and
corrosion. These shall be covered with bituminous wrap coating at the buried portion for LPG.
6.11 Cast iron and aluminum pipe fittings shall not be used.
6.12 All materials including non-metallic parts for valves, seals, gaskets and diaphragms shall be resistant
to the action of the LPG under the service conditions to which they are subjected.
6.13 Plugs shall be solid steel plugs or steel ball plugs. Cast iron or brass plugs shall not be used.
6.14 Copper or brass pipe or tubing shall be seamless and shall only be used. for sizes 12.5 mm and
under.
6.15 The pipeline connecting the storage shed to the main installation should preferably be brought
overhead without creating any hazard for the people/vehicles passing through the same. In case of any
foreseen hazard the pipeline can be laid embedded in the ground.
6.16 Quick shut-off valves designed to work on LPG, shall only be used for mainline for shut-off
operations. The jointing compound shall be of Industry approved type.
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6.17 No heating devices of any nature are permitted to be installed in the storage shed. Similarly,
pipelines location shall be such so as to avoid any over heating/cooling at any length of the pipeline.
6.18 The single stage pipeline network (down the range of first stage pressure regulator) from the storage
shed onward should work at pressure very close to the working pressure of the appliances. Under no
circumstances, the pressure of the pipelines should exceed 22 PSI (1.5 kg/cm2). This should be obtained
by double stage regulation of pressure, if necessary. A typical layout of installation is given in Annexure III.
6.19 Water spray of 10 liters PM/M2 on LPG manifold (with connected LPG cylinders) may be considered
depending on installation size.
6.20 Whenever cylinders are taken out of manifold after closing the isolating valve, the idle ends of
adaptor end shall be plugged with dummy valves (if new cylinders are not fixed) to avoid leakage from
adaptor end to atmosphere.

7.0 PRE-COMMISSIONING CHECKS

7.1 Every multi-cylinder installation essentially consists of the following:
1. Cylinders
2. Manifold
3. Valves
4. Pigtails
5. Regulators
6. Burners
It shall be ensured that all the above equipment’s conforms to an approved layout drawing and other
specifications as mentioned in the foregoing sections.

8.0 MAINTENANCE OF CYLINDER’S MANIFOLD

Maintenance of the cylinders manifold and the equipment’s shall be undertaken regularly and the
periodicity of the maintenance shall be as under:
8.1 PERIODICITY:
i. Valves: All the valves i.e. needle valves; manifold control valves emergency valve shall be checked
once in a year.
ii. Piping and manifold: It should be checked once a year visually. pneumatic testing of pipe lines once in
5 years.
iii. HP & LP Regulators once a year for its accurate throttled pressure.
iv. The burners shall be regularly cleaned.
v. Pigtails shall be checked every time empty cylinder is replaced by a filled cylinder and replaced in
case of any physical damage.

8.2 INSPECTING AUTHORITY:

i. All the manifold installations shall be che ked once in six months by the dealers authorised mechanic
and record maintained at the installation location.
ii. The installation shall be checked once in a year by the concerned Oil company Sales Officer of the
area or by any authorised representatives of the Oil Co. Major installations shall also be inspected by
Senior Officials of the Oil Co.
iii. The inspection shall be carried out as per the check list attached. (Annexure II)

9.0 SAFE OPERATING PRACTICES AND LEAK TESTING

9.1 All the safety precautions outlined in the Gas Cylinder Rule 1981 shall be complied with.
9.1.1 Storage of Cylinders
i. The storage of cylinders is governed by the Gas Cylinders Rules - 1981 and the appropriate safety
distances as given in the rule should be complied with.
ii. Cylinders shall be stored in a cool, dry, well ventilated place under cover, away from boilers open
flames, steam pipes or any potential sources of heat and such place of storage shall be easily
accessible.
iii. The storage room or shed shall be of fire-resistant construction.
iv. LPG filled cylinders must never be stacked in horizontal position.

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 v. Cylinders containing flammable gases shall be kept separated from each other and from cylinders
containing other types of gases by an adequate distance or by a suitable partition wall.
vi. Cylinders shall not be stored under conditions which will cause them to corrode.
vii. Cylinders shall not be stored along with any combustible material.
viii. Unconnected cylinders shall be kept away from the LPG cylinder manifold.
ix. All electric meters, distribution boards, switches, fuses, plugs and sockets, electric fixed lamps,
portable hand lamps and motors shall be of flame-proof construction.

9.1.2 HANDLING AND USE

I) Cylinders shall be adequately supported during handling.
ii) Trolleys and cradles of adequate strength shall as far as possible be used when moving the cylinders.
Use of high-powered magnets for lifting the cylinders and chains for slinging the cylinders shall not be
permitted. Valve or any other fitting on the cylinder should not be lubricated.
iii) The cylinders shall be handled carefully and not be allowed to fall upon one another or otherwise
subjected to any undue shock.
iv) Sliding, dropping or playing with cylinders is prohibited.
v) Liquefied Petroleum Gas cylinders shall always be kept in an upright position and shall be so placed
that they cannot be knocked over.
vi) Open flames, lights, lighting of fires, welding and smoking shall be prohibited in close proximity.
Cylinder should not be lifted with magnets and chains should not be used for slinging.

9.2 LEAK TESTING:

9.2.1 CRITERIA FOR LEAK TESTING
i) It shall be ensured that the manifold provided has been subjected to the test pressure of 25.35 kgf/cm2
(360 psig) at least for a minimum period of 1 hour inspected by the Oil Industry approved contractor.
ii) It shall be ensured that the fire extinguisher and sand buckets are provided and installations are
ADEQUATELY PROTECTED FROM WEATHER CONDITIONS.
9.2.2 DETECTION OF GAS LEAKAGES
Gas leakage can be easily detected by its characteristic smell and more positively located by soap
solution only.
9.2.3 For pinpointing the source of leakage only soap solution shall be used. A NAKED FLAME MUST
NEVER BE USED because there is risk of causing fire accident.
9.2.4 SOURCE OF LEAKAGES
A. Cylinders:
i. Welded seams.
ii. The cylinder/valve connection bung joint.
iii. Cylinder valve
B. Check leakage from Pressure Regulator at:
i. Near the joints.
ii. In the pressure regulator itself.
iii. Check leakage from the piping and manifold
iv. Regulator and the appliance inlet nozzle.
v. Check leakage from burners and appliances
vi. All threaded connections.
vii. The appliances itself.
9.3 ACTION TO BE TAKEN WHEN LEAKAGE IS DETECTED
i. Leakage of cylinder: Any cylinder which develops a leak should be promptly removed to an isolated
open place away from any source of ignition.
ii. In case of leakages of piping, appliances or pressure regulators, close the valves and isolate the part,
disconnect the cylinders and place the safety cap on the valve of the cylinder. NEVER repair the
appliance or any other part of system when in use

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LPG GAS CYLINDER AND EQUIPMENT MAINTENANCE

Record the compliance plate certificate details of every cylinder and all equipment delivered to the homes
and businesses of our customers.
It's part of our dedication to the safety of our employees, customers and their communities.
Like electricity and Natural Gas, LPG is considered a dangerous good, and as such needs to be treated
with the utmost respect.
A safety and compliance program that is unparalleled amongst its competitors and well in excess of
regulatory requirements should be implemented.
Monitor the details and location of every cylinder and use this to conduct regular safety audits, programmed
maintenance and replacements where necessary.
State of the Art Emergency Shut Down systems OPSO and UPSO should be installed.
Comprehensive daily and weekly routine safety checks
A maintenance program well beyond industry standards and requirements

FIRE EXTINGUISHERS:
Number of Fire Capacity in
Sr No. Capacity of LPG Installations Type
Extinguisher kg
For installations with LPG 40 kg to
i) 2 Dry powder 10
200 kg
For installations with LPG more
ii) 3 Dry powder 10
than 200 kg and up to 320 kg
For installations with LPG more
iii) 4 Dry powder 10
than 320 kg and up to 1000 kg
For installations with LPG more 2 numbers for each
iv) Dry powder 10
than 1000 kg additional 1000 kg
NOTE — For electrical installation 1 No. carbon dioxide (CO2 ) (4.5 kg capacity) fire extinguisher shall
be provided.

REQUIREMENTS OF LIQUID OFF TAKE VALVE MULTI CYLINDER INSTALLATION

A-1 GENERAL
a) The liquid withdrawal or liquid off take (LOT) valve (see IS 16484) multi cylinder installation shall meet
the requirements given in IS 6044 (Part 2) and this standard.
b) The cylinder and valve used for liquid off take shall be approved by statutory authority.
c) For any additional cylinders which are to be kept loose, the customer can store them within
stipulations as provided for in Gas Cylinders Rules, 2016.
d) The manifold and the LOT valve installation shall be certified by the officer of the distributing company
or third party inspection agency recognized by distribution company prior to commissioning.
A-2 LAYOUT

a) The site for LPG cylinder manifold shall be located away from the furnace, any source radiating heat
like steam pipes and boilers, etc, to prevent cylinders from getting affected due to radiant heat.
b) The area where this installation is provided shall:
1) be a segregated area with all round fencing as per 5.1.13c) and plain cement flooring/paver block in
the open space inside the fenced area. The plain cement flooring / paver block shall be raised by
minimum 100 mm from the natural ground; and
2) have mastic flooring inside the shed, raised by minimum 100 mm from plain cement flooring/ paver
block. The cylinders shall be stored in dry, cool and well ventilated shed.
c) The cylinder installation area and the area where vaporizer is installed shall be a covered shed with
sides open for ventilation. Flammable materials like wood and plastic shall not be stored in this area.
Flame proof (FLP) light fitting approved by the Statutory Authority for lighting with armoured
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aluminium/copper PVC extruded cable with fire retardant properties conforming to relevant Indian
Standards shall be provided.
d) The cylinder shall be installed in upright position with the valve pointing upwards.
e) The cylinder installation should be so located so as to facilitate the following:
1) Full and empty cylinders can be easily changed, disconnected and removed quickly at the time of
normal operation or emergency.
2) It is easy to operate and maintain the valve provided between the manifold and the cylinder.
3) Manifold maintenance is easier.
4) Cylinders shall not be installed below ground level in cellars or basement or at a place where they are
likely to cause obstruction, suffer damage or be exposed to conditions likely to affect safety.
f) Since LPG is heavier than air, proper ventilation shall be provided at floor level open to atmosphere.
g) Main shut-off valve (Plug or ball-type) on the pipeline emerging out of cylinder installation area shall be
located in such a manner that it just falls outside the cylinder installation area and shall be easily
accessible at all times. At the point of entry of each work place, the line shall have a quick shut-off valve
(plug or ball-type).
h) Wherever the pipelines are passing through walls, slacks shall be provided so that the pipeline does
not get a braised.
j) A minimum distance of 1 m shall be maintained between the cylinder installation and the surface water
drain, if any.

A-3 INSTALLATION

Following provisions, in addition to requirements given in IS 6044 (Part 2), and this standard are to be
made for LOT valve installation:
a) A safety valve, thermal relief valve, excess flow check valve and non-return valve shall be provided on
liquid line as shown in Fig. 1 (for illustration). SRVs may be inter-connected through a common vent flow
which shall be at a height of minimum 1.5 m above eaves end of the shed.
b) The safety relief valves shall be as per IS 12992 (Part 1) and have adequate capacity.
c) The vent of the safety valve/thermal relief valve shall be at a height of minimum 1.5 m above eaves
end of the shed. It shall be adequately supported. A thermal relief valve is required to be provided
between two isolation valves in the liquid pipeline.
d) The name plate shall be provided on the piping manifold assembly containing the following information:
1) Name of the owner;
2) Type of installation;
3) Installation date;
4) Date of test and test pressure, in kg/cm2 ; and
5) Manufacturer’s identification symbol.
e) The typical installation layout, piping and distance is provided in Fig. 1 to Fig. 6 as directional
guidelines for installation up to 8 000 kg capacity. Any modifications and changes shall be as accepted by
the distribution company.

Fig. 1 Typical illustration for installation and piping layout for 20 × 20 LPG LOT cylinder installation
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Fig. 2 Typical illustration for installation layout and distance for 20 × 20 LPG LOT cylinders.

A-4 PIPE AND PIPE FITTINGS FOR PIPING MANIFOLD AND HEADER UP TO PRV

a) The pipe fittings used shall be forged fittings of SCH 80, as per specifications approved by the
distributing company.
b) All fittings of less than 50 NB shall also be forged fittings of 300 class rating.
c) The pipe used for liquid line that is upto vapourizer shall be seamless steel pipes as per specifications
accepted by distribution company. Pipes of below 50 NB shall be of SCH 80 and pipes of 50 NB and
above shall be of SCH 40. Copper tubing manifolds shall not be allowed. The pipe used for vapour service
(after vapouriser) shall be as specified in 8.
d) No screwed connection shall be allowed. In case, due to any reason screwed connection is used, the
pipe used shall be of SCH 80 only.
e) The valves, sight flow indicator, thermal relief valve, NRV, etc, shall be of 300 class rating. Only cast
steel ball valves with fire safe feature shall be used.
f) All flanges used shall be of carbon steel, SA105, 300 class rating with dimensional standard as per
specifications approved by distribution company. No screwed connections should be provided except for
the special fitting as specified in 4.4.
g) All weld joints provided on the line shall be accessible and shall be hydro-tested for 25 kgf/cm2
pressure. The welding shall be fusion welding.
h) Only metallic/spiral wound metallic gaskets shall be used for liquid line that is up to vapourizer and also
down stream of vapourizer.
j) Each arm of the manifold shall have a control valve. To each arm of the cylinder manifold, cylinders shall
be connected through a pigtail. A check valve and an isolation valve shall be provided with each cylinder
pigtail connection to protect the system from back flow of LPG in event of any flexible pigtail rupture. The
distance between two pigtail connections on manifold shall be minimum 300 mm.
k) Cylinder manifold is subjected to full cylinder pressure at all times. The fabrication/welding of the
manifold should be of the best available quality. All such manifolds shall be designed to a pressure
equivalent to the maximum developed cylinder pressure (assessed at 65°C) of LPG that is 16.87 kgf/cm2 .
The test pressure should be 1.5 times the maximum pressure (assessed at 65°C) that is 25 kgf/cm2 for a
period of 2 min.
l) Painting — Piping manifolds and the supporting structure shall be painted with two coats of red oxide
primer and with two coats of first quality synthetic enamel paint. The colour of the LPG lines shall be as
per IS 2379.
10
A-5 VAPOURIZER

a) The vapourizer used shall be approved by statutory authority. Vapourizers may be low pressure steam
heated, hot water heated, electrically heated type or heater less. In case electrical vapourizer is used, it
shall have FLP connections.
b) A minimum distance of 2 m of vapourizer from cylinder installation shall be maintained.
c) The vapourizers shall be provided with suitable automatic means to prevent liquid LPG passing from
the vapourizer to gas discharge piping.

A-6 FLEXIBLE HOSE

a) The hoses connecting cylinder with manifold shall be in line with IS 6044 (Part 2), and shall be used for
connecting the cylinder to manifold. The hoses shall be as per IS 9573 (Part 1) The hoses shall be hydro
tested at 25 kg/cm2 pressure once in six months.
b) The design, material and construction of hoses shall be suitable for grade of LPG. Currently, it is
envisaged that LPG as per IS 4576, shall be supplied.
c) The flexible hoses should have electrical continuity of 0.75 Ω/m.
d) All flexible hoses used before first stage PRV and after second stage PRV shall be tested at 3.5 MPa
(35 kgf/cm2 ) during initial manufacture and should be designed to withstand a minimum bursting pressure
off our times the maximum working pressure.
e) The flexible hose/pigtail shall be in the same room and its length shall not exceed 2 m. Flexible hose/
pigtail shall not pass through doors, windows, walls, ceiling (or) floors. The pigtails shall be accessible for
inspection.
f) In case the ambient temperature exceeds 52°C, flexible hose shall not be used.
g) The flexible hose shall not be twisted, looped or kinked. It should not be subject to any external
pressure.
h) The hose shall be tested half yearly and proper records of testing, etc, shall be maintained.

A-7 SAFETY AND INSPECTION

a) The consumer has to be trained to use the LOT cylinder installation. A trained personnel who has
minimum qualification as diploma in engineering or a science graduate at supervisory level shall be
responsible for the installation from customer’s end. However for daily operation of connecting and
disconnecting the cylinders and for other operation a trained ITI technician is preferred.
b) Distributing company shall assist the consumer in organizing regular safety programmes, drills, etc, and
will also provide regular training on use of LPG.
c) Empty cylinders shall be placed in a safe place and proper safety cap shall be provided on the valve so
as to ensure that no leakage takes place.

A-8 MAINTENANCE OF CYLINDER MANIFOLD

Maintenance of the cylinders manifold and the equipments shall be undertaken regularly and the
periodicity of the maintenance shall be as under:

A-8.1.1 PERIODICITY OF CHECKS AND MAINTENANCE

a) Valves
1) All the valves that is safety valves, TRV shall be checked once a year.
2) All the other valves should be checked once a year for free and full range of movement, positive shut
off, mechanical damage, etc.
b) Piping and manifold
1) It should be checked once a year visually for corrosion, any physical damage. All supports of manifold
should also be checked for any corrosion, etc.
2) The manifold should be internally cleaned once a year and should be free from contaminants.
3) The strainer provided on the manifold should be cleaned at least once in a month.
4) Hydro testing of manifold and pneumatic testing of pipelines should be done once in 5 years.
c) Vapourizer shall be checked as per maintenance schedule.

11
d) The burners shall be regularly cleaned.
e) Pigtails shall be checked every time empty cylinder is replaced by a filled cylinder and replaced in case
of any physical damage.
f) The PRV should be checked once in a year for correct settings and performance as well as for corrosion
and mechanical damage.
g) The pressure gauges should be calibrated once in a year and proper records should be maintained.
The dial of the gauge should be clearly visible.

A-8.2 INSPECTION

a) All the manifold installations shall be checked once in six months by the authorized agency or the LPG
distributing company and record to be maintained at the installation location.
b) The installation shall be checked once in a year by the sales officer of the LPG distributing company or
by their authorized third party inspection agency.
c) The area of LOT installation should be free of any uncontrolled weed growth and accumulation of waste
products.

A-8.3 LEAK TESTING

a) It shall be ensured that the manifold provided has been subjected to the hydro test pressure of 25
kgf/cm2 atleast for a minimum period of 30 min and inspected by the authorized agency or the distribution
company.
b) It shall be ensured that the fire extinguishers and sand buckets are provided and installations are
adequately protected from weather conditions.
c) The gas piping system should be carefully tested for ensuring gas tightness.
d) Naked flames shall never be used for checking gas tightness of the installation.
e) Leak detection should be done using soap solution or similar material.
f) All defective pipes should be replaced and no repair should be carried out in-situ.

A-8.4 WARNING SIGNALS

a) Smoking or naked flames shall not be permitted within the Safety Zones of the installation. ‘NO
SMOKING’, ‘HIGHLY INFLAMMABLEGAS’, ‘DANGER’, boards shall be provided.
b) Sign boards, instruction boards for ‘DOs’ and ‘DONTs’ shall be provided.
c) Instruction board with emergency telephone numbers and important telephone numbers shall be
provided.
d) Instruction board prohibiting unauthorized entry shall be provided.
e) It shall be ensured that all signage are in place and are legible.

A-8.5 SOURCE OF LEAKAGES

a) Cylinders:
1) Welded seams;
2) The cylinder/valve connection bung joint; and
3) Cylinder valve.
b) Check Leakage from PRV at:
1) Near the joints;
2) In the prv itself;
3) Check leakage from the piping and manifold, prv;

A-8.6 ACTION TO BE TAKEN WHEN LEAKAGE IS DETECTED

a) Leakage of Cylinder — Any cylinder which develops a leak should be promptly removed to an isolated
open place away from any source of ignition.

12
b) In case of leakages of piping, appliances or pressure regulators, close the valves and isolate the part,
disconnect the cylinders and place the safety cap on the valve of the cylinder. Never repair the appliance
or any other part of system when in use.
c) The matter should be immediately reported to the in charge and the officer of distribution company.

A-9 EARTHING AND ELECTRICAL PROTECTION

a) The cylinder manifold installation, the vapourizer installation and the downstream installation shall be
earthed at two places. Two earth pits as per IS 3043, shall be provided and the earthing resistance should
not exceed 1Ω.
b) The system should be tested for electrical continuity and resistance to earth.
c) The earthing resistance shall be checked twice a year once during the summer season and once during
winter and records for same shall be maintained.
d) Only flame proof electrical fittings approved by statutory authority shall be used in the area segregated
for LOT installation. These shall be earthed at two points:
1) Only flame proof hand torches shall be used; and
2) Copper jumpers shall be provided at flange.

INSTRUMENTS IN LPG SYSTEM

1. Pressure Reducing Station (PRS) or Gas Train @ 1st Stage & 2nd Stage:
➢ In order to ensure a sufficient degree of safety & reliability of gas supply, gas pressure reducing station
(PRS) are used. It is recommended to use Twin / Dual stream Pressure Reducing Station, so that in
case of working line failure / under maintenance the stand by line can take over the supply function.
➢ A gas train consists of Filter, Slam-shut off valve, pressure regulator, safety relief valve and flame
arrestor. Filter helps to remove the dust / dirt particles in the gas which may damage the regulator
parts.
➢ The slam shut off valve normally remains open. In case the outlet pressure of the regulator exceeds the
permissible limits, the slam shut off valve senses it through the impulse line & instantly shuts off the
supply to the downstream system. The safety relief valve is provided for additional safety.
➢ It is to be set at higher pressure than the slam shut off valve pressure so that the safety relief valve will
operate only when slam shut off valve fails to operate.
➢ The outlet of the safety relief valve is vented well above the PRS.

2. Filters:
➢ Filter must be fitted prior to the regulators on the upstream side, to ensure that only clean / dust free
gas is entering the regulator. The presence of dust / dirt in pipeline results in malfunctioning of the
regulator because of damage caused to the regulator seat and rubber sealing pad.
➢ The movement of the linkage is restricted due to the deposition of dust / dirt on the moving parts and
affects performance of the regulator. Hence the use of filter is strongly recommended.

3. Pressure regulator
➢ Pressure regulator are devices used to regulate the delivery pressure to the appliances for safe
operation
➢ Adequate attention should be given to the pressure regulator selection and it must be chosen with due
care
➢ It shall have sufficient capacity to handle the volume of the gas required to supply maximum demand
➢ The different types of pressure regulators are available
1) Low pressure regulator with high volume
2) High pressure regulator with fixed outlet pressure
3) High pressure regulator with variable outlet pressure
4) Pressure regulator has adjustable pressure outlet
5) Pressure reducer has fixed pressure outlet.

➢ All high-pressure regulators to be used in LPG installation shall be approved type

➢ Only oil industry approved high pressure regulator shall be used

13
➢ If the regulator selection not proper the appliance performance will be affected by pressure fluctuation
and will induce a slow pulsation in line pressure causing appliance flame to vary

4. Over Pressure Shut off Valve (Slam Shut-off Valve):

➢ Slam Shut-off valve is installed immediately after the filter & prior to the pressure regulator.
➢ It normally remains open, in case the outlet pressure of the regulator exceeds the permissible limits, the
slam shut off valve senses it through the impulse line & immediately shut off the flow to downstream.
➢ When the regulator is repaired or reset, the slam shut off valve is to be opened manually by pulling the
knob.
➢ Once the flow starts through the slam off valve it will remain open till the outlet pressure of the regulator
is within limits.

5. Safety Relief Valve:

➢ Safety relief devices remain closed during normal service operation & have been designed to
automatically release a certain gas flow out of the pressurized line through the safety relief valve, as
soon as the pressure within the section to be protected will have risen to the pre-set pressure.
➢ Safety relief valve closes automatically as soon as the pressure decreases below the set limit.

6. Flame Arrestor:
➢ Flame arrestors are used to arrest the flame from reaching the highly dense area of fuel, in case of
backfire & thus avoid accident & explosions.

7. Pressure Gauge;
➢ A good quality pressure gauge with a suitable range shall be provided in the pipeline after the first
stage PRV.
➢ The joint at which pressure gauge is fixed shall be thoroughly checked for leakage.
➢ Millibar pressure gauges (0-500 mili-bar) shall be provided in the pipelines after second stage PRV.

8. Excess Flow check Valve

➢ The excess flow check valve shall be provided on each arm of the manifold to ensure stoppage of LPG
supplies in case of heavy leakage/damage to the pipeline in the downstream facilities.
➢ The capacity of the excess flow check valve shall be +10/-20percent of designed flow rate.

9. Gas Leak Detection in LPG Bank Area:

➢ A gas detector is a device that detects the presence of gases in an area, often as part of a safety
system.
➢ This type of equipment is used to detect a gas leak and interface with a control system so that the flow
of the gas can be automatically shut down.
➢ The gas detector system will sound an alarm to operators in the area where the leak is occurring, giving
them the opportunity to address the situation.

10. Vaporiser
➢ The vaporiser used shall be approved by statutory authority. Vaporisers may be low pressure steam
heated, hot water heated, electrically heated type or heater less. In case electrical vaporiser is used, it
shall have FLP connections.
➢ A minimum distance of 2 m of vaporiser from cylinder installation shall be maintained.
➢ The vaporisers shall be provided with suitable automatic means to prevent liquid LPG passing from the
vaporiser to gas discharge piping.
➢ Only for bulk installation vaporiser must be approved by CCOE for LOT no approval is required

11. Earthing and Electrical Protection

➢ The cylinder manifold installation, the vaporiser installation and the downstream installation shall be
earthed at two places.
➢ Two earth pits as per IS 3043 shall be provided and the earthing resistance should not exceed 1ohm.
➢ The system should be tested for electrical continuity and resistance to earth.
14
➢ The earthing resistance shall be checked twice a year once during the summer season and once
during winter and records for same shall be maintained.
➢ Only flame proof electrical fittings approved by statutory authority shall be used in the area segregated
for LOT installation. These shall be earthed at two points.
➢ Only flame proof hand torches shall be used.
➢ Copper jumpers shall be provided at flange for earthing connectivity.

HANDLING AND USE OF CYLINDER

➢ Cylinder shall be adequately supported during handling
➢ Trolleys and cradles of adequate strength shall, as far as possible, be used when moving the cylinder
➢ The cylinder shall be handled carefully and not allowed to fall upon one another or otherwise subjected
to any undue shock
➢ Sliding, dropping or playing with cylinder is prohibited
➢ LPG cylinders and cylinder contain liquefiable gases shall always be kept in an upright position and
shall be so placed that they cannot be knocked over down
➢ Cylinders used in horizontal position shall be so secured that they cannot roll
➢ Open flames, lighting of fire, lights, welding and smoking shall be prohibited on close proximity to any
cylinder containing flammable gases except those whole in use for welding, cutting and heating
➢ Working places shall not be classified as storage places for the purpose of licensing

PROCEDURE FOR CHANGING THE CYLINDERS

➢ Close the isolation ball vales of the hose of the cylinder to be replaced
➢ Depressurise the hose by allowing LPG bleeding by loosening the joints
➢ Check the flexible hose for any crack by twist and kinks etc and replace it if necessary
➢ Do not repair any damaged part
➢ Replace the empty cylinder by filled cylinder and refit the flexible hose on the same after the deflating
airlock in hose
➢ Check the flexible hose connection for leakage due to cracks after opening the isolation valve
➢ Cap the empty cylinder and store it in cool dry place as it is still filled with gas vapour, leakage of same
can also cause fire
➢ The operator shall wear cotton clothes only, use of synthetic clothes may generate static charge and
should therefore be avoided
➢ Operator shall use cotton / rubber hand gloves to prevent the skin from cold burn in case of any
accident LPG leakage.

STORAGE OF CYLINDER
➢ Cylinder shall be stored in a cool, dry, well ventilated place under cover, away from boiler, open flames,
steam pipes or any potential sources of heat and such place of storage shall be easily accessible
➢ The storage room or shed shall be of fire resistance construction
➢ Thin wall cylinders such as liquefied petroleum gas cylinder and dissolved gas cylinder shall not be
stacked in a horizontal position
➢ Cylinders containing flammable gases and toxic gases shall be kept separated from each other and
from cylinder containing other types of gases by an adequate distance or by a suitable partition wall
➢ Cylinder shall not be stored under condition which will cause them corrode
➢ Cylinder shall not be stored along with any combustible material
➢ Empty cylinder shall be segregated from the filled once and care shall be taken that all the valves are
tightly shut

OPERATING PROCEDURE OF WATER BATH TYPE VAPORISER

➢ Switch on the vaporiser
➢ Ensure the sufficient water in vaporiser
➢ If water level is low top up the water
➢ The solenoid valve on the inlet of the vaporiser will open when the vaporiser temperature reaches 50-
60-degree Celsius
➢ Normally the solenoid valve opening temperature set at 55 degree
➢ Open inlet liquid LPG line to vaporiser after the water temperature reaches at temp 55 degree Celsius

15
➢ Open the vaporiser outlet valve from vaporiser to pressure regulating system
➢ Keep the valve on upstream and downstream of pressure regulating system in open condition for flow
of LPG to user point
➢ Monitor LPG pressure, upstream and downstream of the pressure regulating system and the water
temperature in the LPG vaporiser
➢ The water temperature should not drop
➢ The LPG pressure, upstream and downstream of vaporiser and pressure control valve should be
maintained at constant value
➢ There should not be any fluctuations in LPG pressure, irrespective of the flow
➢ The high temperature of cut of heater should be set at 85-degree Celsius maximum
➢ Replace the water of vaporiser every week
➢ Use soft water only

LPG GAS EMERGENCY PROCEDURES

➢ Check the entire system for ANY indication of gas leak, such as smell or hiss
➢ Test with soapy water solution, which will bubble at any point where gas escapes
➢ Never use a match, flame or plain water to test for a leak, or use portable leak tester
➢ If the leak has been indoors, fully ventilate the room before further use of appliance
➢ Do not interfere with any part of a fixed installation
Leak Detected - Not on Fire
➢ If possible, stop the leak by shutting the cylinder valve
➢ Ventilate the area thoroughly until the air is clear
➢ If it’s not possible to stop the leak, remove the cylinder carefully to a safe outdoor location
➢ Keep the leak uppermost so that only vapour and not liquid escapes
➢ Keep hands and face clear of any stream of escaping liquid and where possible, wear thermally
insulated gloves
➢ If the cylinder cannot be removed, disperse gas with fine water spray and provide maximum ventilation
➢ Keep possible ignition sources at least 20 metres away until cylinder is empty
➢ These sources could include open fires, non-flameproof electrical appliances, camera flash
➢ telephone, radio, vehicle engines, and any other equipment that can generate a spark
Leaking Cylinder or Appliance - On Fire
➢ If the valve is undamaged and it’s safe to do so, close it and let the fire go out. Do not use again until
inspected.
➢ If the valve cannot be closed, call the fire brigade, maintenance team or gas dealer, advising location,
that it is LPG and cylinder size.
➢ Keep cylinder cool by water hose but DO NOT attempt to extinguish flame.
➢ Unburnt gases in confined space may explode if reignited.
➢ Keep clear and await assistance.
➢ If there is any possibility of cylinder(s) being engulfed by fire, evacuate the adjacent area. Avoid
Cylinder Exposure to Excessive Heat.
➢ Remove from heat source if safe and possible to do so

IF YOU SMELL GAS:

➢ Ensure that BURNER KNOBS/VALVES are in CLOSED position.
➢ Extinguish all fires and flames.
➢ Do not light a match.
➢ Switch OFF the pressure REGULATOR by turning the knob CLOCKWISE TO THE ‘OFF’ POSITION.
➢ Open all doors and windows.
➢ If gas smell persists; call your Gas Distributor or the Emergency Service Cell.
➢ Do not operate electrical switches, DETACH the regulator. Fix the Safety cap on the valve. Remove the
cylinder to a safe and ventilated place.
➢ Do not bring any naked flame or fire near the cylinder.

PRECAUTIONS
➢ In case of accidents, even minor ones it is important for workers to raise an alarm or a siren.
➢ In case customers detect leaks they will need to immediately close isolation valves and stop using
16
➢ In case there is a valve leakage directly from the cylinder, users will have to ensure that they put the
safety cap and then carry the cylinder out to an open space.
The Don’ts that you should not
➢ Don't keep cylinders in a horizontal position. Always keep the cylinder in upright position Don’t heat the
cylinder directly or indirectly
➢ Check the cylinder for any leakage from ‘O’ ring and valve before connecting Don’t keep unconnected
cylinders
➢ Turn off the valve when cylinder is not in use
➢ Restrict entry to authorized persons only
➢ Don’t store any extra material in the LPG shed
➢ Keep the area clean
➢ Don’t allow battery operated instruments inside the LPG shed
➢ Don’t use any non-flame proof electrical items inside the LPG shed
➢ No smoking in the LPG shed or area
➢ No naked flame anywhere inside the LPG shed or area
➢ In case of a fire, customers must only use a D.C.P type of a fire extinguisher or call the fire station.
➢ In case leakage cannot be controlled, the fire department must be notified.

SAFETY TIPS ON USING THE LPG INSTALLATION

➢ Everyone involved in handling and using LPG should be given training on basic LPG product
knowledge and safe handling to increase safety awareness and avoid bad practices which can result in
accidents. Below are some safety tips consumers should be aware of.
➢ LPG is stored under pressure and any small gaps and pinholes can cause LPG to leak out. Pipes must
never be stepped on or used to hang kitchen equipment or other objects that may create undue force
on it.
➢ The boiling point of LPG is low and any contact with bare skin can cause cold burns. People handling
liquid LPG i.e. during bulk delivery should wear proper personal protection equipment (PPE) that
includes suitable gloves, long sleeves and eye goggles.
➢ LPG can be detected by means of its ‘rotten egg’ odour. It is odorised in such a concentration that
even the presence of a small amount of LPG is discernible by smell. Gas valves should be closed
immediately once LPG is detected by smell and all ignition sources should be put out.
➢ Use leak detection fluid or soapy water to check for leaks on the piping system. Apply on all joints and
hoses and check for bubbles which indicate a source of leak. Never use naked flames.
➢ When appliances are disconnected from the gas piping for servicing or, removed to clean the area, the
connection should be checked for vapour tightness when they are reconnected.
➢ Cooking utensils should match the burners used. A burner whose flame exceeds the base of a pan
throws away heat and wastes LPG.
➢ Appliance gas valves should always be closed when the appliance is not being used. When LPG will
not be used for an extended period of time, the main gas valve and LPG container valves should be
shutoff for safety reasons.
➢ When using appliance without a spark igniter, the lighter or match must be lighted before opening the
appliance gas valve to avoid accumulation of LPG vapour which could cause a flash fire.
➢ Never leave the cooking appliance unattended with the flame on.
➢ Keep the cooking area well ventilated to dispose of products of combustion and ensure sufficient
supply of air for combustion.
➢ Some kitchens may be equipped with an exhaust fan which needs to be turned on before cooking
begins. Cylinders should always be used in the upright position.
➢ Never shake the cylinder or turn it upside down to draw out residual LPG. This may result in heavy
ends clogging the valve and/or regulator.

17
 MONTHLY CHECK LIST FOR MAINTENANCE OF VOT/LOT/450 KG INSTALLATIONS
SR.NO DESCRIPTION FUNCTIONING
YES (√) NO (×)
GAS BANK
MANIFOLD SYSTEM
MANIFOLD BALL VALVES
NON-RETURN VALVES
A
HOSE PIPES
ADAPTORS
PRESSURE GAUGES
NEEDLE CONTROL VALVES
ACTION TO BE TAKEN
VAPOURIZER UNIT IF PRESENT
TEMPERATURE GAUGE
WATER LEVEL INDICATOR
SAFETY RELIEF VALVE
INLET / OUTLET BALL VALVES
B
PRESSURE SWITCH
SOLENOID VALVE
ACTION TO BE TAKEN
Y STRAINERS / LIQUID DIRT TRAPS
C
GAS FLOW GLASS
ACTION TO BE TAKEN
REGULATING STATION (STAGE-1)
FILTER
REGULATOR
SLAM-SHUT OFF VALVE
D BALL VALVES
HOSE PIPES
SAFETY RELIEF VALVE
PRESSURE GAUGES
NEEDLE CONTROL VALVES
ACTION TO BE TAKEN
REGULATING STATION (STAGE-2) IF PRESENT
FILTER
REGULATOR
E BALL VALVES
HOSE PIPES
PRESSURE GAUGES
NEEDLE CONTROL VALVES
ACTION TO BE TAKEN
PIPELINE AND JOINTS
FLANGED JOINTS
F WELEDED JOINTS
SUPPORTS & CLAMPS
PAINTING
ACTION TO BE TAKEN

18
 LOT VALVE MULTI CYLINDER INSTALLATION INSPECTION

1. NAME OF CONSUMER
_________________________________________________________________________

2) ADDRESS
____________________________________________________________________________

3) PHONE NO.: EMAIL :

4) TYPE OF ESTABLISHMENT:

5) DATE OF INSPECTION LAST DATE OF INSPECTION VALIDITY

6) PURPOSE FOR WHICH LPG IS PROPOSED TO BE USED. (COMPLETE PROCESS FOR

WHICH LPG IS USED SHALL BE EXPLAINED. ATTACH SEPARATE SHEET IF NECESSARY)

7) INSTALLATION DETAILS

A) NO. OF CYLINDER IN EACH MANIFOLD

B) NO. OF MANIFOLD IN EACH BANK

C) SIZE OF CYL. _____ KGS EACH. TOTAL QUANTITY IN KGS.

8) MAXIMUM CONSUMPTION RATE IN KG/HR

9) WHETHER SEGREGATED AREA PROVIDED FOR CYLINDER BANK INSTALLATION.

YES / NO

10) WHETHER THE LAYOUT IS AS PER APPROVED DRAWING: YES / NO

A) IF NO WHAT ARE THE DEVIATIONS:

11) WHETHER ANY EXCLUSIVE ENTRY AND SEPARATE EXIT PROVIDED

SIZE ____MTR X ____MTR.

12) WHETHER ANY INSTRUCTIONS BOARDS, LIKE “NO SMOKING”, “RESTRICTED ENTRY”,
“DO’S & DON’TS” ETC. PROVIDED (GIVE DETAILS OF BOARDS)
YES / NO

13) BOARD WITH INSTALLER NAME AND EMERGENCY CONTACT NOS. PROVIDED
YES / NO

14) CYLINDER LOCATION: TO BE INSTALLED OUTSIDE BUILDING / PLANT AREA ONLY.

A) DRAWING BY INSTALLER ATTACHED? YES / NO

B) FLOORING TYPE _____________ ROOFING TYPE ______________

FENCING TYPE _______________

C) MINIMUM DISTANCE OF AS PER DRAWING YES / NO

D) SAFETY DISTANCE MAINTAINED FOR INSTALLATION SURROUNDINGS PROVIDED.

YES / NO

19
 E) BRICK WALL FOR SAFETY DISTANCE PROVIDED? YES / NO

F) RAISED PLATFORM DIMENSIONS ____________ X ____________ X ___________ HT.

15) POSITION OF CYLINDER TO FACILITATE

A) CHANGING AND QUICK REMOVAL YES / NO

B) ACCESS TO CONNECTION AND REGULATING DEVICE YES / NO

C) OPERATION OF CYLINDER VALVES YES / NO

D) CYLINDER INSTALLED UPRIGHT YES / NO

E) CYLINDER INSTALLED ON GROUND LEVEL YES / NO

F) CYLINDER NOT INSTALLED WHERE THEY MAY GET OVER HEATED (10 M AWAY)
NOT CLOSE TO OPEN FLAME ETC . YES / NO

G) CYLINDERS ARE NOT CAUSING AN OBSTRUCTION YES / NO

16) CYLINDERS MANIFOLD: CERTIFICATES REQUIRED

A) ALL JOINTS BETWEEN MANIFOLD HEADER AND CYLINDER CONNECTION

ARE READILY ACCESSIBLE YES / NO

B) ALL MATERIALS, FITTINGS ETC. USED IN CYLINDER MANIFOLD COMPLY

WITH BIS STIPULATION YES / NO

C) IN CASE OF PRESSURE REGULATOR AND AUTOMATIC CHANGE OVER,

DEVICE CONNECTED BY SEMI FLEXIBLE CONNECTORS AND ARE SUPPORTED?
YES / NO

D) HOSES AS PER BIS STANDARDS, ATTACH CERTIFICATES YES / NO

17) VAPORISER CERTIFICATES REQUIRED

A) MANUFACTURER’S NAME SERIAL NO.

B) MODEL TYPE.

C) MAXIMUM WORKING PRESSURE TEMPERATURE

D) VAPORISING CAPACITY IN KG/HR

E) YEAR OF MANUFACTURE

F) DATE OF TEST CERTIFICATE NO.

18) PRESSURE REDUCING SYSTEM: ALL CERTIFICATES REQUIRED

A) PRS COMPLIES TO BIS STIPULATION YES / NO

B) MANIFOLD FITTED WITH A RELIEF VALVE AND POSITIONED TO AVOID HAZARDS

YES / NO

20
 C) ALL CONTROL DEVICES ADEQUATELY SUPPORTED YES / NO

D) CALIBRATION, TESTING AND CERTIFICATION OF FIRST STAGE PRS DONE

YES / NO

E) MANUFACTURED BY:

F) DETAILS OF SECOND AND THIRD STAGE PRS WITH CERTIFICATIONS

YES / NO

19) PIPING, TUBING AND FITTINGS: CERTIFICATIONS REQUIRED

A) ALL PIPING, FITTINGS COMPLY BIS STIPULATION OR ARE APPROVED BY OIL COMPANY
YES / NO

B) CONDITION OF PIPELINE (CORROSION, PAINTING, COLOUR SCHEME ETC)

YES / NO

C) WHETHER FIRE SAFE BALL VALVES PROVIDED, MAKE AND CERTIFICATIONS DETAILS:
YES / NO
D) LAST DATE OF HYDROTEST / PNEUMATIC TEST:

E) CHIEF FIRE OFFICER AND FACTORY ACT RULE 13 CERTIFICATION ATTACHED?

YES / NO

20) FLEXIBLE HOSE /PIPING FOR UPSTREAM I.E. BEFORE VAPORISER & DOWNSTREAM
FACILITIES AFTER STAGE II REGULATION. CERTIFICATIONS REQUIRED

A) LENGTH OF HOSE DOES NOT EXCEED 2 M YES / NO

B) APPLIANCES CONNECTION, HOSE MAKE AND TYPE YES / NO

C) ALL PIPING AND JOINTS ACCESSIBLE FOR INSPECTION YES / NO

D) NOT TWISTED – LOOPED YES / NO

E) PIPING AND ELECTRIC WIRING ARE AT LEAST 60 MM AWAY AND PIPING IS

FIXED BELOW ELECTRIC WIRING YES / NO

G) TEST PRESSURE MENTIONED ON HOSE & AS PER CERTIFICATES:

H) MANUFACTURER OF HOSE TYPE USED:

I) DATE LAST TESTED TO BE DONE ONCE EVERY YEAR, MAX LIFE 5 YEARS.

21) LEAK TESTING: ALL NEW AND OLD INSTALLATIONS TO BE TESTED @ 1.5 TIMES OF
WORKING PRESSURE, COMPULSARY EVERY SIX MONTHS BY VISUAL INSPECTION AND
EVERY YEAR BY NITROGEN PNEUMATIC TEST. CERTIFICATION REQUIRED

A) NAKED FLAMES ARE NOT USED FOR CHECKING LEAKS OF THE INSTALLATION
YES / NO

B) SOAP SOLUTION IS USED TO DETECT LEAK YES / NO

C) DEFECTIVE PIPES OR FITTINGS REPLACED AND NOT REPAIRED YES / NO

D) CONSUMER KNOWS THE ACTION TO BE TAKEN IN CASE OF LEAKAGE YES / NO

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 E) CONSUMER KNOWS THE ACTION TO BE TAKEN IN CASE OF FIRE YES / NO

F) CONSUMER KNOWS THE ACTION TO BE TAKEN IN CASE OF DAMAGE /

FAILURE OF ANY PART OF INSTALLATION YES / NO

22) DETAILS OF FIRE EXTINGUISHER: CERTIFICATES REQUIRED

A) NO. OF FIRE EXTINGUISHERS DATE OF TESTING:

B) CAPACITY: TYPE:

C) MANUFACTURER’S NAME

D) PHYSICAL CONDITION OK? YES / NO NEXT DATE OF TESTING:

23) ELECTRICAL FIXTURES & EARTHING:

A) NO. OF EARTH PITS PROVIDED:

B) CONDITIONS OF EARTH PITS I.E. THE EARTH RESISTANCE, PHYSICAL CONDITION

C) WHETHER THE PIPE LINES, VAPORISERS ETC. PROPERLY EARTHED OR NOT

YES / NO

D) TYPE OF FIXTURES PROVIDED FLAME PROOF? YES / NO

E) DETAILS OF ELECTRICAL FIXTURE FOR INSTALLATION AND LEAK DETECTION

SYSTEM WITH DRAWING AND CERTIFICATION YES / NO

E) NAME OF INSTALLER CONTRACTOR AND PHONE NUMBER

G) WHETHER CONTINUITY JUMPERS PROVIDED IN CASE OF FLANGED CONNECTION

YES / NO

24) SAFETY RELIEF VALVE/ THERMAL RELIEF VALVES: CERTIFICATIONS REQUIRED

A) LOCATION

I) SR. NO MAKE AND PR TEST DT.

II) SR. NO MAKE AND PR TEST DT.

III) SR. NO MAKE AND PR TEST DT.

IV) SR. NO MAKE AND PR TEST DT.

B) WHETHER DESIGN CALCULATIONS APPROVED BY COMPETENT PERSON / OR

SALES OFFICER OF APPROVED BY OIL COMPANY YES / NO

C) NAME OF MANUFACTURER OF SAFETY VALVES:

E) NAME OF THIRD PARTY TESTING AGENCY FOR COMPLETE INSTALLATION:

PHONE NUMBER CERTIFICATE NO:

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25) TESTING DATE: PRESSURE: NITROGEN ONLY

CERTIFICATE DATE

26) TRIALS DATE: PRESSURE BY LPG

CERTIFICATE DATE

TOTAL BOQ OF MATERIAL WITH MAKE, PART DETAILS, AND MODEL NO., SPECIFICATIONS AND
TEST CERTIFICATES

TO BE ATTACHED ALONG WITH THIS. CERTIFICATES AS MENTIONED ABOVE FOR ALL

MATERIALS, TESTING, BIS

6044 & FACTORY ACT RULE 13

INSPECTION OFFICER SIGNATURE NAME

DATE

SIGNATURE OF CONSUMER NAME

DATE

OIL COMPANY STATE OFFICE NAME

DATE

GAS DISTRIBUTOR NAME

DATE

INSTALLER CONTRACTOR NAME

DATE

ASSESSMENT DONE BY:

NO OF BURNERS TOTAL KW CAPACITY OF ALL IN KGS_____LPG

CONSUMPTION MAX PER HR. PER DAY PER MONTH

PEAK LOAD: AVERAGE LOAD:

SUGGESTED MANIFOLD:

SIZE OF CYLINDERS:

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