90 THE GAZETTE OF INDIA : EXTRAORDINARY [PART II—S EC.

3(i)]

cup formation with suitable rain caps. The relief valves of such tankers shall be replaced with new valves every
ten years or whenever found defective during operation or periodic testing, whichever is earlier.

(3) Shut-off, emergency shut-off valves and excess flow valves-

(i) all liquid and vapour connections on vessels, except those for relief valves, plugged openings, and
those where the connection is not greater than 1.4 mm diameter opening shall have shut-off valves located as
close to the vessel as practicable;

(ii) all liquid and vapour connections on vessels, except those for relief valves, and drainage connections of
small diameter, shall have an emergency shut off valve such as, an excess flow valve, an automatically operated
valve or remotely controlled valve. The emergency shut off valve shall be in addition to the shut-off valve
referred to in clause (i) unless the emergency shut off valve is a remotely controlled valve which can be operated
from a safe area and shall be of a type which shall not fail:

Provided that the emergency shut-off valves is not required in cases where the connection to a vessel is not
greater than 3 mm diameter for liquid and 8 mm diameter for vapour, or for vessels meant for storage of non-
corrosive, non-flammable or non-toxic gas;

(iii) where the emergency shut off valve is of the excess flow type, it shall operate at a designated
differential pressure and flow rate for size and service as approved by the Chief Controller and its closing rate of
flow shall be below the rate which is likely to result from a fracture of the line it is protecting, calculated under
the most adverse weather conditions likely to be experienced. Excess flow valves shall have a rated flow
capacity sufficiently above normal flow requirement to prevent valve chatter;

(iv) compressed gas road tankers used for flammable, toxic and corrosive compressed gases shall be
provided with internal valve having dual function comprising of primary shut off valve and excess flow valve of
appropriate rating in liquid and vapour line. Internal valve shall have a spring-loaded fusible link in its actuation
lever to shut off in case of fire beneath. Further, the internal valve shall have a shear section and be designed
such that in the event of accident, the lower section of the valve is sheared off, the valve seat (soft seat–which
ensures zero leakage) remains inside the tank and is closed by self-stored energy (spring).

(v) for static vessels, operational fitness examination of excess flow valves shall be carried out during
periodic hydraulic test under rule 19 to check physical condition of the parts and its proper operations. For
compressed gas tankers operational fitness examination of excess flow valves/internal valves shall be done once
in a year. Closing flow rate testing of excess flow valves/internal valves of compressed gas tankers shall be
done during the periodic hydraulic test. The excess flow valves/internal valves shall be repaired/replaced by a
new ones if found defective on examination or during operation.

(4) Liquid level gauging device-

(i) a vessel used for liquefiable gas or dissolved gas shall be equipped with a liquid level gauging device
to afford ready determination of the amount of liquid in the vessel at any time;

(ii) all liquid level indicators shall be suitable for operation at the design pressure of the vessel;

(iii) every vessel shall, in addition, be equipped with a fixed maximum level indicating device depending
upon the liquefiable gas or dissolved gas filled in the vessel;

(iv) gauging devices that require bleeding of the contents of the vessel such as a rotary tube, fixed tube and
slip tube shall be designed in such a manner that the same cannot be completely withdrawn in normal gauging
operations.

(5) Pressure gauge.– Every vessel shall be provided with at least one pressure gauge.

19. Periodic testing of pressure vessels in service.—(1) (a) Except specifically otherwise provided in this rule, all
vessels shall be hydraulically tested by a competent person at a pressure marked on the vessel at intervals of not
more than five years after the date of first test, provided that in the case of vessels, containing corrosive or toxic
gases, the periodic test shall be done at an interval of two years. Internal inspection along with residual thickness
measurement shall be carried out during the periodic testing.
 II (i) 91
(b) Vessels of more than 100 KL water capacity meant for flammable, corrosive and toxic gases shall also be
subjected to Non Destructive Test for weld inspection in addition to hydraulic test referred in clause (a).

(2) In case of vessels which are so designed, constructed or supported that they cannot be safely filled with
water or liquids for hydraulic testing or which are used in services where traces of water cannot be tolerated, the
Chief Controller may permit pneumatic testing along with non-destructive tests instead of hydraulic testing, as
per procedure laid down in vessel fabrication code; after satisfying himself about the adequacy of the safety
precautions undertaken.

(3)(a) Cryogenic pressure vessel and vessel for liquid Carbon Dioxide made of stainless steel shall be
periodically tested with pneumatic pressure at 1.1 times of maximum allowable working pressure.

(b) Carbon Dioxide storage and transport vessels made of carbon steel shall be subjected to hydraulic testing
(instead of pneumatic testing) at the marked test pressure as per design and fabrication code. It shall be ensured
that the vessel after testing is thoroughly dried of water and made moisture free before taking into service.

(4) The mounded and underground vessel shall be periodically inspected as specified in Schedule III.

(5)(a) Ammonia Horton sphere shall be subjected to first periodic inspection after two years of its installation
and the inspection shall consist of detailed Non-destructive Testing of the vessel.

(b) The second periodic inspection shall be carried out after three years of first inspection and shall involve
Non- destructive Testing and hydro testing of the sphere.

(c) Subsequent periodic inspection including Non-destructive Testing and hydro testing shall be carried out
every five years.

(d) If any major repair is carried out on a Horton sphere, the vessel shall be subjected to Non-destructive Testing
and hydro testing in accordance with original code of construction and procedure approved by Chief Controller
and the vessel shall be treated as a new vessel for subsequent periodic inspection as per the procedure noted
above.

(e) The Non-destructive Testing shall be as per the procedure approved by the Chief Controller.

(6) Notwithstanding anything mentioned in clause (a) of sub-rules (3), sub-rules (4) and (5) above; the Licensee
is at liberty to carry out Hydraulic Test as per the design code during the periodic inspection under rule 19.

(7) The competent person carrying out the test as required under sub-rule (1) to sub-rule (6) above shall issue
online certificate of test in the prescribed proforma along with the Annexures giving the details of NDT
inspections prescribed above.

20. Precautions to be observed in carrying out periodic test.—In carrying out the periodic test referred to in rule
19, the following precautions shall be observed, namely:-

(i) before the test is carried out, each pressure vessel shall be thoroughly cleaned and examined externally,
and as far as practicable, internally also for surface defects, corrosion and foreign matter. During the
process of cleaning and removal of sludge, if any, all due precautions shall be taken against fire or
explosion, if such sludge is of pyrophoric nature or contains spontaneously combustible chemicals;

(ii) evacuation or degassing of transport vessels used for flammable, toxic or corrosive gases shall be
carried out at a gas tanker degassing station or licensed premises equipped with degassing or
evacuation facilities approved by Chief Controller;
 II (i) 121
connections shall be identical to other piping. Non-metallic pipe, tubing or hose shall not be used for
permanent connection to storage vessels.
(xv) All gaskets shall be of flexi-metallic type.
(M) Management and Operation of Auto LPG Dispensing Stations:-
The company intends to operate Auto LPG dispensing station shall meet the following criteria for
considering recognition by the Chief Controller, it shall -
(i) Be a registered company.
(ii) Possess requisite rating under Auto LPG Control Order.
(iii) Possess a background of operating and managing a business activity.
(iv) Have sufficient in-house specialists well conversant with-
(a) Knowledge and experience in installation of auto LPG equipments, their operations, maintenance
& in training of personnel.
(b) Auto LPG regulations and the hazards associated.
(c) Codes of practice relating to setting up auto LPG stations.
(d) Number of such personnel engaged by the company shall be related to the stations proposed to be
put up by the company.
(v) Have professional administration and organization with clear levels of responsibility.
(vi) Take responsibility for the professional skills of its personnel.
(vii) Have a firm arrangement with auto LPG supplier for un-interrupted supply of LPG of Auto LPG
specification to the company stations.
(viii) Have a firm arrangement with installer for installation and maintenance of its stations. The period of
such arrangement should be specified.
(ix) Have a well laid out policy with regard to selection and management of its dealers or franchisees.
(x) Take responsibility of operations, periodic maintenance and breakdown maintenance in the stations
and enters into a legal agreement with its dealers in this respect.
(xi) Take responsibility in selection and training of Managers and operators of Auto LPG dispensing
station of its franchisees/dealers and enter into a legal agreement with its dealers in this respect.
(N) Emergency Plan:
Every Auto LPG dispensing station shall have a written emergency plan in place to control the hazards
from serious auto LPG leakage or fire. The plan must be drawn in consultation with local authorities i.e. fire
services. This plan should contains instructions for emergency shutdown of the station, warning to
customers and other people in the surrounding, calls for assistance, usage of fire fighting equipments among
others. The plan shall be tested from time to time for evaluation of its adequacy and shall be updated and
modified as required.
SCHEDULE III
[See rules 19(4), 21(9), 21(14) and 23(7)]
UNDERGROUND AND MOUNDED VESSELS
(Design, fabrication, installation, operation, maintenance and periodic inspections)
A. MOUNDED VESSELS INSTALLATION -
The Mounded vessel installations are categorised in the following categories:
(a) Category 1 : Upto 100 KL water capacity of each vessel
(b) Category 2 : Above 100 KL and upto 500 KL water capacity of each vessel
(c) Category 3 : Above 500 KL water capacity of each vessel
122 THE GAZETTE OF INDIA : EXTRAORDINARY [PART II—S EC. 3(i)]

1. Design code for design and fabrication of the Vessel shall be as per BIS 2825, ASME Section VIII Div. 1 or
Div. 2 or PD 5500 or any other standard accepted by the Chief Controller. A single code shall be applied for
design, fabrication, inspection and testing. Specific considerations shall be given for internal pressure, internal
vacuum and external loading. Design pressure shall be adequate for vapour pressure at 55 deg C plus static
head. The design shall also include a minimum corrosion allowance of 1.5mm and stress relieving of
complete vessel irrespective of its thickness.
2. In case of LPG, design pressure shall be 14.5 Kg/sq. cm at top of the vessel & temperature of -27OC to +
55OC and the material selection in case of refinery installation shall be suitable for the traces of hydrogen
sulphide.
3. The installation shall conform to a recognized Indian or International standard accepted by the Chief Controller.
The vessels shall be placed horizontally and the central axis of the vessels shall be parallel to one another and
inter distance between the vessels, distance of boundary line of the installation shall be as per the Table 3. A
road/clear area of width (See Table A of this schedule) on three sides shall be provided around the mound for
moving and firefighting equipment. The facilities like pump house, compressors and firefighting equipments
shall be located at a distance from the edge of the vessels as per the Table A of this schedule.
4. The mounded pressure vessels installation shall be done on concrete or compacted sand base foundation. The
selection of the type of foundation shall have considerations for sufficient load bearing capacity, depending on
the site conditions and the soil mechanics. In case bottom nozzle has been provided for the vessel, an access
to the connection, like a tunnel opening of minimum 0.9 m X 1.2 m shall be provided. The bottom level of the
vessel shall be above the top of the inspection tunnel. The bottom connection shall be an integral part of the
vessel, and shall extend beyond the mound, and shall be at least 3 m from the edge of the Vessel. The bottom
outlet pipe connection shall have a slope of 1.5 deg at the end of which a remote operated valve shall be
provided.
5. The mound shall be of earth, sand or other non-combustible material of a thickness (as per Table A of this
schedule) of the cover for the vessel. The cover material shall be free from any abrasive particles that may
damage the anti-corrosive coating provided on the vessel. The mound shall provide adequate protection from
the thermal radiation, and shall be sufficiently robust to remain in place in the event of jet flame impingement.
The mound shall be protected from erosion, caving in from water seepage and provided with a protective hard
cover or lining. The mound and the top surface of the mound shall have proper facility to drain the rain water.
Reference points for the settlement of the vessel and the foundation shall be provided and monitoring of the
settlement if any shall be done on yearly basis.
6. The external surface of the vessels shall be suitably protected from corrosion by providing suitable external
coatings and cathodic protection. The design shall conform to NACE RP 169 or any other standard accepted
by the Chief Controller. The protected vessel shall be isolated from the unprotected structures and piping. The
calculated life of the cathodic protection shall not be less than 15 years, considering coating defect of
minimum 30% on vessel surface. The monitoring of the cathodic protection shall be on a yearly basis and
records maintained.
7. Vessels shall be provided with fire safe remote operated valves (ROVs) at the first flange on the liquid lines
and the closing time shall not exceed 30 seconds. Each vessel shall be provided with minimum two types of
level indicators of which one shall be electronic with High level switch and shall indicate a remote display of
the level at the fill point, one additional independent high level switch shall be provided for the Category 3
type of the vessel, two safety relief valves (SRVs), pressure and temperature measuring instruments. All the
safety fittings and instrumentation shall be provided on a dome or the manhole cover provided on the shell of
the vessel. There shall be adequate size of the manhole not less than 600 mm. Category 2 and 3 type of vessel
shall have at least two manholes each of size 600 mm provided on the vessel. The outlet of the SRVs may be
connected to a flare system where available or vented vertically up into the atmosphere with vent pipe not less
than 3 M from the top of the mound.
8. Provision shall be made for Gas leak detection system. Fire fighting facility shall be provided with fire hydrant
or monitor (See Table A of this schedule) in addition to the Water sprinklers to provide a water cover to the
exposed surfaces of the vessel and pipelines. Such hydrants and monitors shall not be located within the
distances specified in Table A from the exposed surface of vessel, fittings and pipelines. In addition
minimum 2 Nos. of fire extinguishers of capacity 75 Kgs. and shall be placed in an accessible position to
operate.
9. The mounded Vessels installation shall be inspected and certified by an inspector at every important stage of
construction, including the design and fabrication of the vessel, foundation, mound covering, cathodic
protection, NDT and hydraulic testing of vessels and piping and final certification of safety under Rule 33.
 II (i) 123
10. The vessel shall be subjected to internal inspection once in 5 years under Rule 19 and shall include the Non
Destructive Tests comprising of ultrasonic thickness measurement check evenly spread over the entire inner
surface including both dish ends and the openings, 100% wet fluorescent magnetic particle test of all weld
joints, ultrasonic flaw detection of welds not less than 25% of weld seams including all the T–joints of middle
circumferential seams and both dish ends weld seams & nozzle joints, liquid penetrant inspection of all the
fillet welds, nozzle joints, hardness test randomly on circumferential and longitudinal welds including parent
metal and nozzle welds from inside, heat affected zone and the weld beads on all the plates and joints.
Alternatively, other established NDT techniques such as acoustic emission testing may be used with prior
approval of Chief Controller. The vessel shall be tested pneumatically at a pressure of not more than the
design pressure held for 30 minutes.
11. The vessels shall be subject to hydraulic test pressure as per the design code in addition to the above non-
destructive tests once in 10 years, or when subjected to any repairs involving hot work. Settlement of the
vessel, if any, shall be measured during the first water fill.
12. The safety relief valves shall be inspected and tested under Rule 18 once in a year and the excess flow valves
and the remote operated valves shall be inspected and tested once in 5 years during the periodic test under
Rule 19.
TABLE A
Categories for Above Ground Covered with Earth (Mounded) Vessel

Category Water Clear Distance of Minimum Independent Minimum Manhole

No. Capacity Width facilities thickness of high level numbers of
of each around such as the earth gauges and minimu
vessel Mound pump cover requirement location of m sizes
(M) room, Fire 600 mm
(KL) vapouriser (M) Hydrant/M
etc. from onitor
the edge of
the vessel
(M)
1. Upto 100 3 4.5 0.5 No 1 No.
KL
15 M 1 no.
2. Above 100 3.5 9 0.7 Yes 2 Nos.
KL-Upto
500KL 15 M 2 nos.
Above 500 As per
3. KL 3.5 15 0.7 Yes OISD I50 2 nos.

B. UNDERGROUND PRESSURE VESSEL INSTALLATION FOR INDUSTRIAL USE AND AUTO LPG
DISPENSING STATIONS (ALDS)
1. Design code for design and fabrication of the vessel shall be as per BIS-2825, ASME Section VIII Div.1 or Div.
2 or PD 5500 or any other standard accepted by the Chief Controller. A single code shall be applied for design,
fabrication, and inspection & testing. Specific considerations shall be given for internal pressure and external
loading. Design pressure shall be adequate for vapour pressure at 55 deg C plus static head.
2. The design shall also include a corrosion allowance of 1.5mm and stress relieving of complete vessel
irrespective of its thickness.
3. The underground vessels shall be placed within a concrete or brick masonry pit with a distance of 1 mtr between
the walls of the pit and the vessel and inter distance between the vessels. Soil cover of at least 500 mm shall be
provided over the top surface of the vessel. The vessels shall be installed on a firm RCC foundation and
anchored adequately to prevent the floatation of the vessel due to up-lift force of buoyancy in case of a worst
scenario of no load of the product and overburden. The designer/fabricator of the vessel shall furnish for prior
approval in addition to mechanical design documents and drawings, the civil design drawings and documents
and calculations duly vetted by an inspection agency to substantiate that the foundation, securing and anchoring