<< Back Home Next >>

OISD – RP -158
First Edition (July, 1997)
Amended edition, August,2000
FOR RESTRICTED
CIRCULATION ONLY

RECOMMENDED PRACTICES ON

STORAGE AND HANDLING OF BULK

LIQUEFIED PETROLEUM GAS (LPG)

Prepared by

COMMITTEE ON STORAGE AND HANDLING OF

BULK LIQUEFIED PETROLEUM GAS (LPG)

OIL INDUSTRY SAFETY DIRECTORATE

7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI - 110 001.
 NOTE

OISD publications are prepared for use in the oil and gas
industry under the Ministry of Petroleum and Natural Gas.
These are the property of Ministry of Petroleum and Natural
Gas and shall not be reproduced or copied or loaned or
exhibited to others without written consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of the data contained in these documents, OISD
hereby expressly disclaims any liability or responsibility for
loss or damage resulting from their use.

These documents are intended only to supplement and not

to replace the prevailing statutory requirements.

Note 2 in superscript indicates the

modification/changes/addition based on the
amendments approved in the 18th Safety Council
meeting held in August,2000.
 FOREWORD

Oil Industry in India is more than 100 years old. Over the years, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design, operating and
maintenance practices was hardly in existence at a national level. This lack of
uniformity, coupled with feed back from some serious accidents that occurred in
the recent past in India and abroad, emphasised the need for the industry to
review the existing state-of-the-art in designing, operating and maintaining oil
and gas installations.

With this in view, the Ministry of Petroleum & Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD), staffed
from within the industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence, standardising and
upgrading the existing standards to ensure safer operations. Accordingly, OISD
constituted a number of functional committees comprising of experts nominated
from the industry to draw up standards and guidelines on various subjects.

The present document has been prepared by the Functional Committee on

Recommended Practices on Storage and Handling of Bulk Liquefied Petroleum
Gas (LPG). This document has been prepared based on the accumulated
knowledge and experience of the industry members and various national and
international codes and practices.

This document will be reviewed periodically for improvements based on the new
experiences and better understanding. Suggestions from industry members may
be addressed to:

The Member Coordinator

Committee on Recommended Practices on Storage and Handling
Of Bulk Liquefied Petroleum Gas (LPG)
OIL INDUSTRY SAFETY DIRECTORATE
7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI - 110 001.
 COMMITTEE ON

STORAGE AND HANDLING OF

BULK LIQUEFIED PETROLEUM GAS (LPG)

-----------------------------------------------------------------------------------------------------------------------------------
NAME ORGANISATION
---------------------------------------------------------------------------------------------------------------------------------

LEADER

Shri B.R.B.Mathur, Engineers India Limited, New Delhi

MEMBERS

Shri R.N.Das, Bharat Petroleum Corpn. Ltd., Mumbai

Shri E.Nandakumar, Cochin Refineries Limited, Cochin

Shri A.C.Agarwal, Indian Oil Corporn. Ltd., Faridabad

Shri S.C.Meshram, Indian Oil Corpn. Ltd.(M.D.), Mumbai

MEMBER-COORDINATOR

Shri S.N.Mathur, Oil Industry Safety Directorate, New Delhi

------------------------------------------------------------------------------------------------------------------------------------

(In addition to the above, several other experts from the industry contributed in the preparation, review
and finalisation of this document.)
 RECOMMENDED PRACTICES ON

STORAGE AND HANDLING OF BULK LIQUEFIED PETROLEUM GAS

INDEX

------------------------------------------------------------------------------------------------------------------
S.NO. CONTENT
-----------------------------------------------------------------------------------------------------------------

1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
4.0 PRESSURISED LPG STORAGE
4.1 APPLICABLE CODES & DESIGN PARAMETERS
4.2 LAYOUT
4.3 FOUNDATION & SUPPORTS
4.4 VESSEL ACCESSORIES
4.5 COMMISSIONING AND DECOMMISSIONING
4.6 INSPECTION & TESTING
4.7 PAINTING
4.8 INSULATION
5.0 ANCILLIARIES
5.1 PUMPS
5.2 COMPRESSORS
5.3 PIPING
5.4 VALVES
5.5 THERMAL PRESSURE RELIEF SYSTEM
5.6 FITTINGS
6.0 BULK HANDLING AND TRANSFER
6.1 BULK HANDLING FOR MOVEMENT BY ROAD
6.2 BULK HANDLING FOR MOVEMENT BY RAIL
6.3 BULK HANDLING FOR MOVEMENT BY SEA
7.0 SAMPLING AND DRAINING
7.1 SAMPLING
7.2 DRAINING
8.0 ODORISATION
8.1 SAFETY RELATED PROPERTIES OF
ETHYL MERCEPTAN
8.2 HANDLING OF ETHYL MERCAPTAN
8.3 EQUIPMENT FOR ETHYL MERCAPTAN SERVICE
------------------------------------------------------------------------------------------------------------------
S.NO. CONTENT
-----------------------------------------------------------------------------------------------------------------

8.4 DISPOSAL
9.0 ELECTRICAL AND INSTRUMENTATION
9.1 ELECTRICAL
9.2 INSTRUMENTATION
10.0 SAFETY AND FIRE PROTECTION
10.1 SAFETY
10.2 FIRE PROTECTION
11.0 REFERENCES
---------------------------------------------------------------------------------------------------------------------

ANNEXURES

A: LPG STORAGE VESSEL - P&I DIAGRAM

B: GENERAL ARRANGEMENT OF LPG TANK TRUCK (LORRY)

C: A TYPICAL LPG TRANSFER SYSTEM FOR

FILLING TANK TRUCK/WAGON

D: SAFE FILLING OF LPG VESSEL

E: SCHEMATIC DIAGRAM SHOWING TANK TRUCK

UNLOADING OPERATIONS

F: TYPICAL LPG TANK WAGON

G: SHIP/SHORE SAFETY CHECK LIST

TABLE

SAFETY RELATED PROPERTIES OF LPG

 RECOMMENDED PRACTICES ON STORAGE AND HANDLING

OF BULK LIQUEFIED PETROLEUM GAS (LPG)

1.0 INTRODUCTION (ii) Pressure Vessel

Liquefied Petroleum Gas, otherwise Pressure vessel (both static and mobile)
known as LP Gas or simply LPG, is means any closed metal container or
obtained by refining crude oil in tank of any shape, intended for storage
petroleum refineries and fractionating of LPG which is subjected to internal
natural gas available from oil and gas pressure and having water capacity of
fields. The product conforms to the more than one thousand litres.
requirements of IS : 4576 - 1978.
(a) Bullet
There has been a tremendous growth in
the use of LPG as domestic fuel as well A cylindrical pressure vessel with
as in industries. This rapid growth in hemispherical or dished ends, laid
demand of LPG has led to a substantial horizontally.
increase in the requirement of bulk
storage and handling facilities. Because (b) Horton Sphere
of its flammability and explosive nature,
LPG is a hazardous substance (Refer A spherical pressure vessel, supported
Table-I for safety related properties of vertically.
LPG ). The purpose of this standard is to
recognise the potential hazards of LPG (iii) Water Capacity
and recommend guidelines on safety
procedures and practices to be followed Maximum volume of water a vessel
in its storage and handling. will hold at 15 degree C.

2.0 SCOPE (iv) Filling Density

This document covers operation of Filling density means the ratio of weight
equipment and facilities connected with of liquefiable gas allowed in a pressure
storage and handling of LPG at Gas vessel to the weight of water that the
Processing Plants, Refineries and other vessel will hold at 15 degree C.
Bulk Handling installations. It also
includes some basic concepts for design Keeping in view the industry practice of
and construction of such facilities. It does leaving 5% free space in the vessel, the
not include the requirements associated above definition gets modified to:
with bottling and other marketing
functions or transportation of LPG by It is the ratio of the weight of liquefied
trunk pipelines. Also, unless otherwise petroleum gas introduced in the vessel,
indicated, it does not apply to so as to leave a free space of 5% by
refrigerated, underground and mounded volume at the reference temperature, to
storage of LPG. the weight of water the vessel will hold
at 15 degree C. Thus, the filling density
3.0 DEFINITIONS is numerically equal to 0.95 times the
density of LPG at the reference
(i) Bulk Storage temperature.

Bulk storage shall mean provision of (v) Reference Temperature

storage facilities where more than 1000
litres of LPG is stored in a pressure This is the temperature at which the
vessel, e.g. Bullets and Horton Spheres density of liquid LPG is to be evaluated
(Refer SMPV Rules). for calculating the filling density. In India,
the reference temperature considered
 for LPG pressure vessels is 55 degree (vi) OISD-STD-144 on "LPG Bottling
C. Plant Operations" may be referred for
more information.
(vi) Vapour Pressure
4.2 LAYOUT
The vapour pressure is the pressure
exerted by the vapour in equilibrium with For general guidelines, reference shall be
the liquid in a closed container at a made to OISD Standard 118 on "Layouts
particular temperature. The vapour for Oil & Gas Installations" and OISD
pressure of LPG depends upon the Standard 144 on " LPG Bottling Plant
temperature of the liquid and the Operations". Salient features are given
composition of LPG. below:

4.0 PRESSURISED LPG STORAGE (i) Each above ground pressure vessel
shall be located in accordance with
LPG is stored in a pressure vessel. Refer the following :
Annexure-A for a LPG storage vessel P&I
diagram and Table 1 for safety related (a) A minimum safety distance shall
properties of LPG. be maintained as per OISD-STD-
118 on "Layouts for Oil and Gas
4.1 APPLICABLE CODES & DESIGN Installations".
PARAMETERS
(b) Vessel shall be in an open space.
(i) Bulk LPG storage facilities shall be Pumps shall be in open space or
installed in accordance with "The under an open shed.
Static & Mobile Pressure Vessels
(Unfired) Rules, 1981" as amended (c) Vessels shall not be installed one
from time to time. above the other.

(ii) Bulk LPG storage vessel shall be (d) Bullets shall be oriented so that
designed, constructed and tested in their longitudinal axes do not point
accordance with Bureau of Indian towards other vessels, vital
Standard Code IS : 2825 or any other process equipments, control
code approved by CCE. rooms, loading stations and
flammable liquid storage tanks.
(iii) The design pressure of vessel for
bulk LPG storage shall not be less (e) LPG storage installations shall be
than the vapour pressure of LPG in located in specially prepared
the vessel at 55 degree C. In case of industrial type fenced compound
propane storage, the design pressure having at least two exit gates.
shall not be less than the vapour However, if such storage is
pressure of propane in the vessel at situated inside a licensed area,
55 degree C. separate fencing is not required.
The number of storage vessels in
(iv) The design temperature of the vessel one group shall not exceed six.
shall be in line with the specifications The aggregate capacity of a
of LPG and statutory requirements. storage group shall be limited to
15,000 cu.m.
(v) The maximum quantity of LPG that
can be stored in a pressure vessel (f) In case, there are more than one
shall be governed by the filling group of storage vessels, the
density of LPG and shall be such that minimum safety distance between
the vessel shall not be more than two installations shall be the same
95% liquid full due to expansion of as the distance between the
the contents with rise in the vessel and the property line in
temperature to 55 degree C. (Refer accordance with OISD-STD-118
Annexure D) on "Layouts for Oil and Gas
Installations".
 (g) The top surface of the vessels 4.4 VESSEL ACCESSORIES
installed in a group shall be in the
same plane. (i) All fittings and accessories of the
storage vessel shall be conforming to
(h) Spheres and Bullets shall not be "Static & Mobile Pressure Vessels
grouped together and shall be (Unfired) Rules, 1981".
provided with separate piping
manifold so as to avoid overfilling (ii) Each storage vessel shall be provided
of a vessel due to gravitation from with the following :
the other.
Inspection manhole 1 No.
(ii) Because of the pronounced volatility of Pressure relief valves 2 Nos.
LPG, dykes usually are not necessary. Bottom nozzle for liquid
It is desirable for the grade to be inlet and outlet 1 No.
sloped away from the vessel to a safe Pressure gauge 1 No.
area in such a manner that the spills Liquid level indicator 2 Nos.
from one vessel does not pass Temperature measuring
through the adjoining vessel. device 1 No.
Vapour inlet and outlet nozzle 1 No.
A kerb wall shall be provided on three High level alarm switch 1 No.
sides of the vessel with a pit on the
fourth side. Refer OISD Standard 118 a) One number of Inspection manhole at the
on "Layouts for Oil & Gas Installations" top
for details. The area inside the
storage installation shall be kept free (b) Spheres and bullets shall have a single
from weeds and dry grass. nozzle at the bottom for inlet as well
as for outlet. The nozzle shall be full
4.3 FOUNDATION & SUPPORTS welded pipe, stress relieved along with
the vessel and shall extend minimum
(i) The materials, principles, methods three (3) metres from the shadow of the
and details of design and sphere / bullet. A fire safe remote
construction of foundation and operated (shutdown) valve (ROV) shall
supports should comply with be provided on this bottom nozzle at a
approved codes and specifications. distance of at least three (3) metres from
the shadow of sphere/bullet. The nozzle
(ii) The grade for the vessel shall pipe shall have a slope of 1.5 degrees.
preferably be elevated slightly above
the surrounding terrain to ensure There shall not be any other flanges,
complete drainage from beneath the manhole, instrument tapping on this
bottom of the vessel. nozzle upto the ROV or on sphere/bullet
bottom. In order to avoid stress on the
(iii) Suitable stairs, ladders, walkways nozzle due to relative settling of support
and platforms shall be provided and sphere, supporting the bottom nozzle
allowing easy access for from the vessel support legs should be
operation/maintenance of valves and considered. The top vapour zone of the
equipments. These structural items vessel shall be provided with nozzles for
shall be welded on the pad plates vapour outlet and re-circulation which
made of the same material as the shall also be provided with fire-safe
main equipment. Welding shall be ROVs (Refer OISD Standard 144).
done by qualified welder following
approved welding procedures. In a All the fittings shall be suitable for use at
group of storage vessels, inter- not less than the design pressure of the
connecting walkways with suitable sphere/bullet and for the temperature
guards shall be provided at the top. appropriate to the worst operating
conditions. The remote operated valves
(iv) Supporting structures shall be fire- on the sphere/bullet connected lines shall
proofed so as to support vessel and be fire-safe type. The flange joints of
pipes safely in line with OISD-STD- these valves shall either have spiral
144. wound metallic gasket or ring joints. Plain
asbestos sheet gasket shall not be used.
 Flange connections shall be a minimum (ii) Relief Valves shall be spring loaded.
of ANSI-300 lb flange class. All fittings Weight loaded relief valves shall not
shall be minimum 20 mm in length. be permitted.

(c) Bottom water draw off/drain valve (iii) Each safety relief valve (having 100%
relieving capacity) shall be set to start-
Two valves, with suitable distance piece to-discharge at a pressure not in
between them, shall be provided between excess of 110 percent of the design
ROV and the first isolation valve. The first pressure of the vessel and shall have
drain valve from the vessel should be of a total relieving capacity sufficient to
quick shut-off type valve while the second prevent the maximum pressure in the
valve should be throttle type (Globe Valve) vessel of more than 120 percent of the
Note 2
. The material for the drain pipe and design pressure.
related fittings shall be suitable for
cryogenic application. (iv) Each safety relief valve shall be
provided with isolation valve between
(d) Sampling Valve it and the vessel. Each valve shall be
of adequate capacity to allow full
Two valves with suitable distance piece required capacity flow through it.
between them shall be provided between Suitable provision to avoid accidental
ROV and the first isolation valve for closing of the isolation valve is
avoiding icing problem in the upstream recommended.
valve.
(v) Relief valves shall be fitted with
(e) Liquid level gauging device extended vent pipes having outlets at
least 3 meters above the top of the
The storage vessel shall have minimum vessel and atleast 3.5 meters above
two different types of level indicators and the ground level when not connected
one independent high level switch. One to flare system.
level indicator shall be float type and the
other may be differential pressure type in (vi) Relief valves shall be tested for
case of spheres. DP type level transmitter correct operation not less than once in
shall either be sealant filled type or LP a year or as per the statutory
side tubing heat traced. Magnetic float requirements and a record of such
type gauge is recommended for bullets in tests shall be maintained.
place of differential pressure type. High
level alarm shall be set at the level not (vii) For additional information, OISD
more than 85% of the volumetric capacity Standard 106 on "Pressure Relief and
of the vessel. Audio visual indication shall Disposal System" may be referred.
be at local panel and control room.
(i) Inside of bottom crown of sphere should be
(f) Pressure Gauge painted with anti-corrosive paint to protect it
from corrosion.
Minimum of one pressure gauge, duly
calibrated, shall be provided in the vapour 4.5 COMMISSIONING AND
space at the top. DECOMMISSIONING

(g) Temperature Gauge 4.5.1 COMMISSIONING

One temperature gauge shall be provided (a) The following inspections / checks shall be
in the liquid space at the bottom of the carried out :
vessel.
(i) Check that all foreign matters have
(h) Pressure relief valve been removed and the vessel interior
is cleaned before boxing it up.
(i) Minimum of two pressure relieving
valves shall be provided in the vapour (ii) Check that all relief valves have been
space at the vessel top in accordance installed after due testing and
with the design code of the vessel. calibration.
 is a hazard in releasing the purge
(iii) Check that all other fittings and water into drains. Immediate flushing
instruments are calibrated. with fresh water minimise this hazard.
Alternatively, the water may be
(iv) Check that valves are installed after released to a safe disposal system.
necessary inspection and removal of
blinds.
(v) Check that all safety facilities such as (b) For displacement purging with no
water sprays, fire protection mixing, the inert gas volume will
equipment etc. have been provided approximately be equal to that of the
and are in working condition. vessel. For dilution purging with
thorough mixing, the volume of inert
(vi) Ensure that pressure testing of the gas required will be about five times
vessel has been carried out as per the vessel volume. To inhibit mixing
appropriate code mentioned in para and thereby excessive consumption of
4.1 and a certificate to that effect purge gas, ensure that the densities of
from the approving authority is the purge gas and the gas to be
obtained. purged are widely different. Thus,
Carbon dioxide (SG: 1.52) is useful for
(b) Leak testing of the vessel and fittings shall removing air (SG: 1.00) and Nitrogen
be carried out with nitrogen, carbon (SG: 0.97) for removing propane (SG:
dioxide or water at a pressure of 7 1.52) or butane (SG:2.01).
kg/sq.cm. When using nitrogen/ carbon-
dioxide for leak testing, leak can be (c) In the case of an inert gas purged
located with soap and water. vessel, precautions should be taken
when entering the vessel for
(c) If nitrogen/carbon-dioxide is used for leak inspection and repair. Personnel
testing, it is sufficient to vent the vessel should be provided with breathing
and proceed with LPG filling operation apparatus or better, the vessel be air
ensuring a pressure of 1.5 kg per purged. The interior of the vessel shall
sq.cm.(g). be checked for breathable atmosphere
and to ensure that the LPG
(d) If water was used for leak testing, then concentration is below 5% of the LEL.
water can be displaced with LPG vapour, ( Refer OISD Standard 112 on Safe
fuel gas or natural gas prior to LPG filling Handling of Air-Hydrocarbon Mixtures
operation. and Pyrophoric Substances).
Preferably, a running air hose may be
(i) As water is displaced by equivalent provided during the initial period.
volume of LPG vapour/fuel gas/natural
gas, a constant watch on the pressure (d) When opening up a LPG storage
and level of water shall be maintained. vessel in which a stock containing
sulphur has been stored, deposits of
(ii) Care shall be taken to drain the pyrophoric iron sulphide may be
residual mixture of water and gas. found. They must be kept wet until
they are removed. If allowed to get
(iii) Similar care shall be taken when filling dried, these deposits may ignite
the vessel with LPG and venting the automatically in presence of air.( Refer
natural gas to a suitable flare/venting OISD Standard 112 on "Safe Handling
system. of Air-Hydrocarbon Mixtures and
Pyrophoric Substances").
4.5.2 DECOMMISSIONING
(e) During every hydro-testing, all nuts
The following inspections/checks shall be and bolts of manhole cover of
carried out : sphere/bullet should be replaced.

4.5.3 If air is required to be displaced from a

(a) Water purging has the disadvantage storage vessel during commissioning,
that it can dissolve about 150 parts then purging with inert gas like
per million (by wt.) of gas at ambient nitrogen or carbon dioxide is required
temperature and pressure. Thus, there to be carried out to lower the oxygen
 content of the vessel atmosphere to Storage vessels and their supports
less than two percent (2%) before shall suitably be painted externally to
admitting LPG. The residual oxygen prevent corrosion.
content of a vessel which is being
put into service or the residual 4.8 INSULATION
combustibles in one which is being
decommissioned, are limits which In order to protect the vessel from
must be scrupulously observed for the overheating during the initial period of
sake of safety. fire, it is recommended that the storage
facility be provided with fire proofing in
4.6 INSPECTION & TESTING line with OISD-STD-144.

(i) A pressure vessel shall be maintained 5.0 ANCILLIARIES

according to the requirements for
which it was designed or fabricated as 5.1 PUMPS
mentioned in para 4.1.
(i) Pumps may be centrifugal,
(ii) The reasons for inspection and testing reciprocating or other types, designed
are to determine the physical condition for handling of LPG and safely
of the vessel and the type, rate and withstand the maximum pressure
causes of deterioration. These which could be developed by the
informations shall be documented product and / or transfer equipment.
after each inspection. Such data will Pumps shall conform to API 610.
enable the management in
maintaining safety, enhancing (ii) Pumps shall be fitted with suitable
continuity of operation and predicting leak proof glands like mechanical
future repair/replacement seals. Glands fitted with double
requirements. mechanical seals are recommended.
(iii) Frequency of such inspection and
testing by a competent person at a (iii) Pumps shall have a by-pass valve and
pressure marked on the pressure other suitable protection against over
vessel shall be at intervals of not more pressure on the delivery side.
than five years.
(iv) Check valves shall be installed on the
(iv) For details on inspection and testing, delivery side of all centrifugal pumps.
refer OISD Standard 128 on
"Inspection of Unfired Pressure (v) The electrical motor drive and
Vessels". switchgear shall be of flame proof type
according to area classification as per
(v) Precautions shall be taken against fire OISD Standard-113 on "Classification
or explosion due to pyrophoric of Areas for Electrical Installations at
deposits in a vessel. (Refer OISD Hydrocarbon Processing and Handling
Standard 112 on Safe Handling of Air- Facilities". Belt drives shall be of the
Hydrocarbon Mixture & Pyrophoric anti-static type.
Substances).
5.2 COMPRESSORS
(vi) Vessel shall be isolated using blinds of
a suitable rating. It shall be drained, (i) Compressors shall be suitable for
purged, cleaned and gas tested before handling LPG and designed to safely
entering. withstand the maximum outlet
pressure to which these will be
(vii) Work shall be carried out only after subjected. Compressors shall conform
obtaining appropriate work to API 618 & API 619.
permit.(Refer OISD Standard 105 on
"Work Permit System"(Rev.I). (ii) A suitable size scrubber or liquid
knockout drum shall be installed
4.7 PAINTING upstream of the vapour compressor. It
shall be equipped with a gauge glass,
a drain and high liquid level shut down
 device. The drain shall be connected weld neck flanges should be used.
to a safe disposal system. Screwed flanges for sizes 50 mm or
smaller may be used. Steel flanges
should conform to the applicable
5.3 PIPING provisions of ANSI B 16.5.

(i) Piping shall conform to the provisions (ii) Steel screwed fittings and couplings
of ANSI B 31.3. shall conform to ANSI B 16.11. Steel
unions shall have ground metal to
(ii) Furnace butt welded or spiral welded metal seats. Gasket type unions shall
pipes shall not be used. not be used.

(iii) Only seamless pipes are to be (iii) Plugs shall be of steel. Cast iron or
used. brass plugs shall not be used.

(iv) Pipe joints should be welded as far as (iv) All flanges will be connected for
practicable with full penetration weld. bonding for electrical continuity.
Number of flanged or threaded joints
should be kept to a minimum. 6.0 BULK HANDLING AND TRANSFER

(v) Low point drains and high point vents 6.1 BULK HANDLING FOR MOVEMENT
shall be plugged or capped suitably. BY ROAD

(vi) Buried piping should be protected LPG is moved by road in tank trucks.
against physical damage and The tank truck shall be designed,
corrosion with suitable sleeves, constructed and tested in accordance
properly sealed at both the ends, at with the Static and Mobile Pressure
road crossings. Vessels (Unfired) Rules, 1981. A
sketch showing General arrangement
(vii) The design, material and construction of LPG Tank Truck is enclosed as
of hoses shall be suitable for LPG Annexure-B.
(Refer OISD Standard- 135 on
Inspection of Loading/ Unloading 6.1.1 FACILITIES
Hoses for Petroleum Products).
(a) Loading –
5.4 VALVES
Each loading station shall consist
Steel valves conforming to relevant API of the following :
standards shall be used. Cast iron valves
should not be used. (i) A filling line with an isolation valve
and excess flow check valve.
5.5 THERMAL PRESSURE RELIEF
SYSTEM (ii) A vapour return line with an isolation
valve connected back to the storage
Any equipment or section of pipeline in vessel from which the loading pump is
which liquid LPG may be trapped e.g. drawing LPG.
between shut off valves, should be
protected against excessive pressure (iii) Suitable loading arm/flexible hoses
developed by thermal expansion of the (Ref.OISD-STD-135 on Inspection of
contents by providing suitable thermal Loading/ Unloading Hoses for
pressure relief valve(s). If pressure Petroleum Products) shall be provided
relieving devices discharge to atmosphere, at the end of filling and vapour return
the discharge should be arranged in a safe lines for connecting to the tank truck
manner. vessel.

5.6 FITTINGS (iv) Weigh bridges of suitable capacity /

mass flow meters shall be provided
(i) Steel flanges and flanged fittings for custody transfer of product by
conforming to relevant API/ANSI weight.
specifications shall be used. Slip on or
 (v) A check valve shall be provided in the only slightly at first to allow release
vapour return line. of trapped pressure, if any.

A typical sketch of loading facilities is shown in

Annexure-C. 8. Do not expose hands, face or
clothing to liquid LPG. Always use
(b) Unloading - personal protective equipments
while making or breaking the
Unloading of LPG from tank truck is connections to avoid cold burns.
carried out with vapour compressors using
pressure differential method of liquid 9. Gas detection system shall be
transfer. The compressor shall be placed provided in line with OISD-STD-
at the unloading point with the following 144.
facilities:
10. The master switch shall be put off
(i) Vapour line with isolation valves immediately after parking the truck
in position. No electrical switch on
(ii) Product transfer line with isolation the truck shall be turned " on" or "
valves off" during the transfer operation.

(iii) Weigh bridge of suitable capacity 11. No repairs shall be made on the
truck while it is in the loading area.
A typical sketch of unloading facilities is
shown in Annexure-E. 12. New tank trucks vessels or vessels
received after repair shall be
6.1.2 SAFETY PRECAUTIONS purged before loading as
mentioned under the Item 4.5
1. Transfer of LPG to or from a tank "Commissioning and
truck requires special attention as Decommissioning".
accidental movement of vehicle
may cause rupture in the transfer 13. It is recommended that the
equipments. receiving vessel having a pressure
of less than 1 Kg/sq.cm.g should
2. No source of ignition must be not be filled. Such vessel should be
allowed in the area where product checked for oxygen
transfer operations are carried out. content/explosive mixture and
purged, if necessary.
3. Fire extinguishers shall be placed
near the tank trucks during transfer 14. Venting and purging of LPG during
operations. transfer operation normally should
not be carried out in open
4. The first operation after positioning atmosphere. It should be piped to a
the truck should be to provide suitable flare system. Where such
proper earthing. Earthing shall be facility does not exist, vent pipes
disconnected just before the shall be provided to carry the
release of the truck. vented product to a safe distance
5. Before removing plugs or caps, and released at a height not less
always crack open to allow for than three metres above the
release of trapped LPG and further highest point of any building, shed
to ensure that the valves are or structure within 15m radius.
effectively sealing. Snuffing steam facility may be
provided for the vent line.
6. Hoses should be handled with care
and inspected periodically (Refer 15. Filling/transfer operations should
OISD Standard 135 on Inspection be stopped immediately in the
of Loading / Unloading Hoses for event of -
Petroleum Products).
(i) Uncontrolled leakage
7. While disconnecting hoses/pipes, occurring
connections should be loosened (ii) A fire occurring in the vicinity
 (iii) Lightning and thunder storm
(20)Liquid / vapour line valves are in
good condition.

6.1.3 PROCEDURES FOR OPERATION 2. Move truck to the loading bay/weigh

bridge and record the weight of the empty
(a) LOADING OPERATIONS tank truck.

1. Check for following in a tank truck before 3. Stop the truck on a leveled ground and
accepting it for filling: place check blocks at front and rear
wheels.
(1) Two safety valves are provided on the
vessel. 4. Stop the engine and switch off all electrical
equipments.
(2) Fixed tube gauge is provided.
5. All persons should leave the driver's cabin.
(3) Excess flow valve is provided.
6. Make bonding connections of the vehicle
(4) Pressure gauge is provided. at specified point to the fixed grounding
system.
(5) Temperature gauge is provided.
7. Connect loading and vapour lines suitably
(6) Fire screen between cabin and vessel with the loading point. Crack open valves
is provided. on loading & vapour return lines and
inspect hoses & connections for leakage.
(7) 2 Nos. of10 Kgs. DCP Fire Loading should start only when the system
Extinguishers are provided. is leak free.

(8) Spark arrestors of approved 8. Start the loading pump.

quality are fitted.
9. The quantity loaded into the truck can be
(9) No leakage in exhaust silencer pipe determined by -
exists.
(i) Liquid level
(10)Manufacturer's name plate with date
of testing is fitted on the vessel. (ii) Weighment

(11)Valid Explosive Licence is available. (iii) Positive displacement meter

(12)Approved drawings of vessel are 10. Liquid level may be determined by roto-
available. gauge or fixed liquid level gauge.
Percentage volume to be filled should be
(13)Blind flanges/caps are provided on pre-determined (see Annexure-D and
vessel. Tables-2 & 3).

(14)Earthing cable is provided. 11. Where weigh bridge is used, it is

necessary to determine the density of the
(15)Bonding between vessel and chassis product being loaded to avoid excess
is satisfactory. filling in terms of volume. The weigh bridge
shall be periodically calibrated and
(16)Bonding between flanges in manifold stamped by Weights & Measures
is satisfactory. Authorities.

(17)Excess flow valve and control valve 12. Whether a gauging device is used or a
are available on water drain line. weigh bridge is employed for filling
operation - when the liquid content is
(18)Bonding point is available. approximately within 5% of the safe filling
level, the operator should position himself
(19)Third party inspection/test certificates so that he is in control of the shut off valve
for vessel/fittings are available.
 and starts to close the valve as the safe 8. Operations described under Item
filling level approaches. 14 in para 6.1.2 should now be
carried out.
13. When the filling operation is in progress,
the pressure within the tank truck vessel A filling line with excess flow check
should be observed to ensure that it does
not approach the start-to-discharge 6.2 BULK HANDLING FOR MOVEMENT
pressure of the relief valve. Filling rate BY RAIL
may be regulated as required.
LPG is moved in Tank Wagons by the
14. The couplings may then be removed and Railways. These wagons are designed
plugs/caps 4replaced on the tank truck by RDSO and are fitted with various
valves. Re-check tightness with soap devices as shown in Annexure F.
solution.
6.2.1 FACILITIES

(b) Unloading Operations (a) Loading

1. Operations described under Item 1 Each loading point shall consist of the
through 6 in para 6.1.3(a) should be following:
carried out.
(i) A filling line with excess flow
2. Liquid line and vapour line of the tank check valve and an isolation
truck should be connected to the valve.
respective hoses fixed to the
unloading point. (ii) A vapour line with a check valve
and an isolation valve to be
3. Test the connections for leaks by connected back to the vessel from
slightly opening the valves for which LPG is drawn.
pressurising. When satisfied, valves
on the tank truck and the receiving (iii) Flexible hoses to be connected
vessel should be opened. with the filling and the vapour
return lines.
4. Start the evacuation compressor.
Vapours will be sucked from the (iv) A check valve to the provided at
receiving vessel and will be the end of flexible hose with the
discharged into the vapour space of filling line.
the tank truck vessel creating pressure
differential thereby pushing the liquid A typical sketch of loading facility is
from the tank truck vessel to the shown in Annexure-C.
receiving vessel.
(b) Unloading
5. Care should be exercised to see that
the pressure created within the Unloading of LPG from tank
delivering vessel does not reach or wagons shall be done with the help
exceed the set pressure of the relief of compressor. The compressor is
valve. used to create a differential
pressure between the receiving
6. An authorised person of the company and discharging vessels by
should supervise the transfer withdrawing vapors from the
operation and respond immediately in receiving vessel and forcing it at
the event of an emergency. high pressure into the discharging
vessel thereby establishing a
7. After the liquid has been expelled, the smooth flow. The content of tank
vapour recovery operation may be wagons can be ascertained by
started. Care should be taken not to weighment on weigh bridge before
bring down the pressure of the and after emptying or, alternatively,
delivering vessel below 1.5 the quantity can be determined
Kg/cm.sq.g. based on wagon gauge readings
and differential in storage tank
 gauge readings before and after 3. The first operation after positioning
receipt, wherever physical the wagon shall be to provide for
weighment is not possible. proper earthing. Earthing shall be
disconnected just before the release
of the wagon.
6.2.2 SAFETY PRECAUTIONS
4. For connecting and disconnecting
1. Do not allow the locomotive to come hoses, it is advisable to use non-
on the weigh bridge due to its sparking type of tools.
capacity limitation.
5. After the wagons are placed on weigh
Sufficient number of dummy wagons bridge and before the loco is
may be used to avoid loco coming detached, the hand brakes on each
closer to the gantry. and every wagon should be applied.

2. In the event of leak : 6. Like-wise, before the wagons are

moved from the weigh bridge,
a) Stop the loading pump. release brakes on all the wagons.

b) Stop the movement of loco on 7. Do not use footwear with protruding

the adjoining rails. nails.

c) Switch off all internal 8. Ensure that the lower portion of

combustion engines that may flapper bridge at wagon side is fitted
be running in the nearby area. with rubber or wooden padding.

d) Stop hot jobs, if any, in the 9. Ensure that coir matting/rubber sheet
nearby area. is spread on the platform.

e) Stop all the vehicular traffic in 10. Ensure that electrical continuity of the
the vicinity. system is intact.

f) Start water monitors to form a 11. Ensure that all fittings on the wagons
blanket covering the leak and are checked physically.
the wagon/piping from which
LPG is coming out. 12. Hoses should be hydraulically tested
atleast twice a year (six monthly)
g) Call fire engine with crew to (Refer OISD-STD- 135 on "Inspection
standby till the emergency of Loading / Unloading Hoses for
exists. Petroleum Products").

h) Stop all the maintenance jobs 13. Excess flow check valve will stop the
in the area. flow of LPG in case the flow is in
excess due to accidental rupture of
i) Depressurise the system hoses etc. Close the isolation valve
before attending to the leak. at grade level.

j) Take immediate steps to 14. During the loading/unloading

decant the wagon, if the leak operation, the operator must be
is from wagon. present near the wagons.

k) Clear the area of all the 15. During unloading operation, after the
people except those who are liquid transfer is over, the wagon
required to meet the pressure shall not be reduced below
emergency situation. 1.5 Kg/sq.cm.(g).

l) Cut off power supply in the 6.2.3 OPERATING PROCEDURES

area where leak is detected.
(a) LOADING OPERATION
1. Place the wagon on weigh and gradually open the valve
bridge taking care to see that fully.
all the four wheels are
properly accommodated on 17. If everything is satisfactory,
the platform. Engage hand gradually throttle valve on
brakes. return line.

2. Ask loco to move away and 18. Keep a check on the weigh
exhibit caution sign at suitable scale readings. As soon as it
distance away from the shows the required weight of
wagons on both ends. LPG to be filled, close the
LPG isolation valve near the
3. Switch off loco engine, if weigh scale.
parked nearby.
19. Close the wagon filling and
4. Note down wagon numbers vapour return lines valves and
and placement time. also valves on filling and
vapour return lines at the
5. Take loading advice. loading point.

6. Note the time of receipt of 20. Recheck final weight and

advice. record it. It shall be ensured
that final gross weight should
7. Connect earthing lugs to the not exceed the permissible
wagons. axle load of the wagon.

8. Lower the flapper bridge 21. Open the valve on flare line
slowly on the wagon. connection to both feed line
and vapour return line. Thus,
9. Open the lid of the wagon. the hoses are depressurised.
Then, close the flare line
10. Take the tare weight reading connection valves.
and set the pointer of the
scale to zero. Compare this 22. Disconnect the filling and
with the marked tare weight vapour return line hose
on the wagon. connections from the wagon.
Replace and tighten the plugs
11. Connect the filling hose and on filling and vapour return
vapour return line hose to the lines.
wagon. Ensure that the flare
connection valves are closed. 23. Close the top cover of the
wagon and seal it properly.
12. Ensure that the header is Remove earthing connections.
charged with LPG and the
bulk loading pump is running. 24. Prepare the gate pass.

13. Open the tanker filling line 25. Release the hand brake of the
valve and vapour return line wagon.
valve.
26. Release all the wagons on the
14. Open the LPG isolation valve, loading points in the lot.
located near the weigh scale.
(b) Unloading Operations
15. Check the system for leaks.
1. Ascertain that the liquid discharge
16. Open the valve on the vapour valve and the vapour valve within
return line. Now slowly open the tank wagon cover are in the
the valve on the filling line. closed position.
Increase the valve opening
2. Open the port covers in the side of 10. Recheck the lines and
the domeshell, if exist. Unscrew connections to make sure that
the plugs in the outlets of the they are connected correctly.
vapour valve and the liquid valves
using a box wrench. This must be 11. After the liquid and vapour lines
done slowly. have been secured and tested,
both liquid education valves
3. If there is any sound of escaping should be opened slowly and
vapour or if there seems to be completely. Then, open all other
pressure behind the plugs, the valves in the liquid line working
pressure must be allowed to from the tank wagon to the
relieve itself past the threads storage tank.
before the plugs are entirely
disengaged. 12. Open the storage tank filling valve
slowly, be careful not to open this
4. If the vapour discharge continues valve too far if the tank wagon
or if there is evidence of a liquid pressure is in excess of the
discharge, the valves should be storage tank pressure or the tank
retightened. wagon excess flow check valves
may get closed.
5. With the plugs removed, screw
pipe nipples into the outlets of the 13. If the tank wagon pressure is
valves after first having applied a higher than that in the storage
modest quantity of sealant to the tank, do not open the valves in
male threads, keeping the sealant vapour line or operate the
away from the end of the thread. compressor. When the rate of
Tighten nipples with a pipe liquid flow drops to an
wrench. unsatisfactory level with the
storage tank filling valve wide
6. Connect the two liquid transfer open, open the vapour valves
unloading swing arms or hoses to between the tank wagon and the
the nipples attached to the liquid storage tank.
discharge valves. Connect the
vapour or equalizing swing arm or 14. At this point, make sure that the
hose to the nipple attached to the control valves at the compressor
vapour valve. In most of the are in a position which allow the
cases, these connections will be compressor to draw vapours from
made by means of either a ground the storage tank and force it into
joint union or a hose coupling. the tank wagon, then start the
compressor.
7. In the event, a ground joint union
is used, no gasket will be required. 15. When the tank wagon is held at a
If a hose coupling is employed, pressure of 2.0 to 2.5 Kg/sq.cm.
ensure that the appropriate gasket above the storage tank pressure,
is in place. Make sure that they the tank wagon should be emptied
are secured tightly by appropriate into the storage vessel.
means.
16. A flow of gas instead of liquid
8. After the vapour and liquid hoses through the sight-flow glass in the
have been connected and before unloading line indicates that the
any valve is opened, the valves on wagon is empty of liquid. Recheck
the tank wagon are crack opened this by opening the sample valve
in order to apply pressure to the in the tank wagon dome.
hoses as a test for leaks.
17. When the tank wagon is emptied
9. If any leak appears, the valve of all liquid, stop the compressor
should be immediately closed and and close the liquid valves
corrective measures applied. beginning at the storage tank and
progressing to the tank wagon.
18. If the facilities are so arranged that it is removed from the siding
vapours may be removed from the promptly.
tank wagon, the pipeline at the
compressor should be arranged 28. Gauge the storage tanks, within
so that the compressor will draw the plant, which have received the
vapour from the tank wagon and LPG to determine that the liquid
force it into the storage tank. The level is appropriate.
sequence of piping line-up during
unloading liquid LPG and vapour 29. In the event of LPG received on
LPG is shown in Annexure - E. weight basis, the tank wagon may
require weighing following the
19. In this operation, the vapour completion of the unloading
should be discharged below the operation.
surface of the liquid in the storage
tank to hasten the liquefaction 6.2.4 DEGASSING OF SICK/LEAKY TANK
and, in turn, help prevent WAGONS
excessive pressure in the storage
tank. (a) Recommended Procedure

20. Restart the compressor and when In the degassing system

the tank wagon pressure is recommended for LPG wagons,
reduced to about 1.5 - 2.0 Kg/ vacuum cycle purging technique
sq.cm., stop the compressor and should be followed as outlined
close all the valves in the vapour below :
line.
- Vessel should be evacuated
21. After bleeding off the pressure in repeatedly by a vacuum pump.
the hoses, disconnect both the
liquid and vapour lines. Replace - Vapour should be discharged
all the plugs in the tank wagon through high rise vent, keeping the
valves and the unloading fittings. steam on.

22. Recheck sample valve, gauging - Maximum possible vapours should

device and thermometer well to be sucked out in first step
determine that they have been depending on the capacity of
returned to their original condition vacuum pump/compressor. As per
and are closed tight. Lower the RDSO, vessel can sustain the full
dome cover carefully and lock it in vacuum also.
place with the locking pin or
secure by appropriate means. - Between the two vacuum cycles,
nitrogen/inert gas should be used for
23. Remove bonding connections. breaking the vacuum.

24. Reverse or remove and replace - Cycle should be repeated till

the "Flammable" placard with the LPG concentration is found
"Dangerous - Empty" placard, if below the end point of LPG (for
applicable. butane, it is 4% by volume when
purging is done by nitrogen).
25. Remove the "Stop - Tank Wagon Periodically, samples should be
Connected" sign and wheel drawn from suitable location and
blocks. analysed for LPG concentration.

26. Any defect observed in the tank - Finally the vessel should be flushed
wagon should be noted on the with air to displace the nitrogen.
appropriate forms and routed in Barrel should be tested finally with
accordance with acceptable explosive meter to ensure that
procedure. hydrocarbon concentration is below
10% of LEL.
27. Notify the railways in writing about
release of wagon and ensure that (b) Alternate Procedure
 code for existing ships carrying liquefied
Alternately, wagons may be gases in bulk covers ships built before
degassed by steaming or filling with the application date of the new ship
water. However, it should be code. Put together these codes are
ensured that wagon is made water known as the IMO gas codes. The
free after degassing. international code for the construction
and equipment of ships carrying
6.3 BULK HANDLING FOR MOVEMENT liquefied gases in bulk, with the short
BY SEA title of the International Gas Carrier
(IGC) code, applies to ships contracted
Transportation of LPG in bulk by tankers on or after July 1, 1986. With its revised
may be carried out under fully- and clarified wording, this IGC code
pressurised, semi-pressurised (semi- includes all the updated requirements of
refrigerated) or fully refrigerated at the previous gas codes for new ships.
atmospheric pressure conditions. The ISG code has been incorporated
into the 1974 Safety of Life at Sea
Pressurised Ships (SOLAS) Convention and in 1986
became mandatory for all Flags whose
The cargo is carried in a number of governments are signatories to the
cylindrical pressure vessels (or cargo SOLAS Convention.
tanks) capable of withstanding the
maximum pressure likely to be met in Some of the factors to be taken into
service (usually 17 bars). consideration, which effect the design
and construction of ships carrying gas,
Semi-Refrigerated Ships are :

The pressure of the cargo is very much (a) Types of cargo to be carried
reduced by lowering its temperature to
about 0 deg.C by the process of (b) Condition of the carriage (i.e. fully
refrigeration and tanks containing the pressurised, semi-refrigerated or fully
cargo need not be so strong as those of refrigerated)
pressurised ships. The tanks are
thermally insulated. (c) Type of trade, which in turn,
determines the degree of cargo
Fully Refrigerated Ships handling flexibility required by the
tanker.
The cargo is carried at atmospheric
pressure and the cargo tanks are "box- (d) Terminal facilities available when
shaped" as opposed to cylindrical/ loading or discharging the vessel.
spherical in case of pressurised/semi-
refrigerated tankers for better utilisation (e) Cargo containment systems (IMO
of ship's space. code identifies five different types).

Pressure ships usually range from very (f) Materials of construction (Fully
small capacity upto 2000 cum. capacity. refrigerated LPG cargoes must have
The capacity of semi-refrigerated ships tanks capable of withstanding
usually ranges from 1000 to 15000 temperatures down to (-)55 degree
cu.m. Fully-refrigerated tankers could be C. Alloy steels such as fully killed fine
made very much larger and for any grain carbon manganese steel,
given size, much lighter. sometimes alloyed with 0.5% Nickel
are used.)

6.3.1 CARGO CARRIER DESIGN & (g) Tank insulation (for refrigerated
CONSTRUCTION cargo)

International Maritime Organisation (h) Tanker layout and safety features

(IMO) code for the construction and
equipment of ships carrying liquefied (i) Survival capability and tank location
gases in bulk, covers ships contracted
on or after October 31, 1976. The IMO
 As specified by IMO codes, gas carriers a guide tube. The liquid level is read
are required to undergo five different off the tape through a gas-tight
types of survey and have the certificates window at the top of and outside the
of fitness issued or endorsed. The tank.
certificate of fitness signifies that a
minimum standard of constructional f) Two sets of purge lines at the top
safety has been achieved. In order for a and bottom of the tank. These are
tanker to comply with code throughout used to distribute inert gas or vapour
its life time, it must be subjected to re- for gas-freeing or gassing-up of the
inspection to maintain its validity. cargo tanks.

6.3.2 FACILITIES IN THE TANKER g) A vapour line for withdrawal of

vapour to the compressor.
The cargo handling equipments in a
tanker usually comprise of : h) Sample tubes.

Cargo pumps (submersible and booster)

Safety Devices
Compressors
(a) Atleast two safety valves in each
Condensers cargo tank

Heat Exchangers (b) High and Low level alarms

Vapourisers
(c) Overfill alarm. When actuated, this
Cargo heaters will shuttle main loading valve and
sound an alarm.
The deep well pump supplies liquid to
the booster pump to send the product However, the design of the tankers with
ashore. In pressurised ship, liquid is regard to provision of facilities,
withdrawn by pressurising the tank equipments, accessories and safety
through vapour compression from other features must be in accordance with the
tanks. All semi and fully-refrigerated IMO requirements.
tankers are provided with cargo heaters The electrical equipments of all gas
to enable the vessels to discharge into tankers are subject to the requirements
pressure storage ashore and a booster of the Flag Administration, the
pump if the discharge pressure is Classification Society and of IMO. The
significantly above 9 bars. Each cargo certified safe electrical equipment found
tank is provided with the following on gas tankers are :
equipments:
(i)Intrinsically safe
a) Two cargo pumps, one each on
either side of the longitudinal bulk (iii) Flameproof
head.
(iv) Pressurised or purged
b) Liquid discharge line from the tank
dome, connected to the main liquid (v) Increased safety
line.
6.3.3 TRANSFER PIPEWORK
c) All emergency pump trunk way.]
The following facilities on transfer piping
d) A liquid loading line connected to the between Terminal and Shore tanks
main liquid line. should be provided:

e) Two liquid level indicating devices (a) ROVs at both the ends of transfer
one on each side. These usually line.(Additional ROV at critical
consist of a float attached to a self locations in the pipe line route.)
winding tape which moves up and
down, either on guide wires or inside
 (b) Relief valves on liquid line to surge (c) Nitrogen cylinders with attendant
vessel with an audible alarm system facilities for hose purging/testing
connected to high safe venting and alternate supply to ROVs and
system other instruments.

(c) Physical protection against impact to (d) The following agents may be
vent/drain pipes incorporated in terminal fire
control system :
(d) Protection of pipeline against
corrosion, particularly when the (i) Water
pipeline passes under public road (ii) Foam
way, which is likely to be water- (iii) Dry chemical powder
logged
6.3.6 UNLOADING OPERATIONS
(e) Pipe work passing public road way
be designed to acceptable public It is essential that the ship and terminal
highway authority standard in terms operators are familiar with the basic
of roadway axle weights characteristics of each other's facilities,
are aware of the precise division of
6.3.4 TERMINAL FACILITIES responsibilities and are able to
communicate effectively during the time
Transfer of LPG from ship to terminal they are together involved in the joint
and vice versa is accomplished using operation of cargo handling.
hoses or loading arms. If terminal
authorities supply the cargo transfer 6.3.7 COMMUNICATION
hoses, it is recommended that NFPA
section 59 regulation 4.5 be followed Reliable and effective communications,
and complied with. However, if the irrespective of whether they are directly
hoses are ship hoses, these should between the tanker and the terminal or
conform to section 5 of IMO (IGC). indirectly via third party, are pre-
requisites of safe and efficient cargo
Provision of vapour return facility operations before the tanker comes
depends on economics, transfer rates, alongside and during the period of cargo
distance of jetty from storage tanks, operations and until the tanker departs.
product pressures and temperatures etc. Terminal communication should be
compatible with tanker's system.
In case of pressurised gas transfer, it is
observed that the pumping rate falls off
gradually due to back pressure of the 6.3.8 PRE-CARGO TRANSFER
shore tank. A suitable vapour recovery DISCUSSIONS
system or reliqifaction of the gas from
the receiving tank is well considered. Before any cargo transfer operation is
commenced, it is imperative that the
6.3.5 ANCILIARY EQUIPMENTS intended procedures are thoroughly
discussed and a meeting held between
(a) These include pipe work, valves, the responsible personnel from the
relief valves, rotating equipment tanker and the terminal. The purpose of
(pumps, compressors), the meeting is primarily to make both
exchangers, instrumentation, gas sides fully conversant with the
detection systems etc. characteristics of the tanker and shore
cargo handling systems, the envisaged
(b) Transfer line inerting facilities such operational and safety procedures and
as inert gas generation combined requirements and the parameters to be
with water base foam generator adhered to during the transfer.
and pipeline pig system or water
storage with corrosion inhibitor The content of the meeting will depend
chemical dosing transfer and on a wide variety of circumstances but
supply facilities. the following broad outlines form the
basis of such meetings :
 (a) The names and roles of terminal
and ship personnel who will be (i) Trim correction - to make allowance
responsible for cargo transfer for the liquid level indicating
operations may be noted. devices not centrally located.

(b) The terminal representatives shall (ii) Shrinkage factor - for correction of
check that pre-arrival instructions to volume at 15 deg.C.
the ship on cargo, cargo disposition
and cargo conditioning have been (iii) Low sounding trim corrections to
carried out. They also shall check allow for the wedge shaped
that all necessary tanker volume.
equipments inspection and tests
have been performed. Volume at Corrected
15 Deg.C = Volume X VRF
(c) Similarly, the tanker's officers shall Quantity at Volume at
satisfy themselves that the relevant 15 Deg. C = 15 Deg. C X Density
terminal equipment and inspection at 15 Deg. C
checks have been carried out
satisfactorily. (VRF is ascertained by ASTM-IP Table
- 54).
(d) Terminal representatives and
customs and/or independent 7.0 SAMPLING AND DRAINING
surveyors, where necessary, will be
informed of the cargo tank data e.g. 7.1 SAMPLING
temperature, pressure, whether
free of cargo, liquid heel or arrival (a) Standard for Sampling and
dip, composition of tank vapour Testing of LPG
and quantity of cargo on board.
Sampling of LPG for different
6.3.9 SHIP/SHORE SAFETY CHECKLIST analytical tests shall be carried out
in accordance with the guidelines
Checklist for Ship/Shore safety is given given in IS 1448.
in Annexure -G.
(b) Safety During Sampling
6.3.10 DISCONNECTION OF HOSE/
UNLOADING ARM In handling LPG samples, the
following safety precautions shall
On completion of unloading operation be followed :
the tanker discharge pipeline need to be
purged to push liquid LPG to the (i) Special sampling bombs shall
receiving tank. Purging may be done by be used for LPG sampling.
LPG vapour, inert gas or water as per The coefficient of thermal
the design of the system. However, expansion of LPG is
before disconnecting hoses or unloading sufficiently high to develop
arm, it is to be ensured that there is no very high pressure on heating.
liquid LPG left between the tanker main Arrangement of rupture disc or
valve and shore isolation valve. Product any other suitable safety relief
from this length of pipeline is to be safely device may be incorporated in
vented. the sampling bomb.

6.3.11 CALCULATING THE QUANTITY (ii) Sampling bombs shall be

OF LIQUID ON BOARD inspected periodically and
tested hydrostatically at
Before commencement of tanker regular intervals. Record of
discharge operation, tank readings for such inspection/test shall be
temperature, pressure liquid level etc. maintained.
are jointly agreed by the shore and tank
representatives. The corrections applied (iii) Necessary caution must be
to assess the quantity of cargo on board exercised to eliminate rough
are : handling of sampling bombs.
 (iv) Discharge of LPG from (ii) Water in the system, which is
sampling bomb can cause subjected to freezing temperatures,
static electricity. Sample may prevent the operation of
bombs must, therefore, be internals of valves, which in turn,
earthed effectively before and may obstruct transfer of product by
during discharge of sample. formation of ice-block.

(v) Sampling normally involves (iii) Ice formation may also lead to
venting product into the regular freeze up by plugging the
atmosphere. Therefore, orifice and stopping flow of gas.
absence of source of ignition Additives like methanol or propylene
must always be confirmed glucol may be added to LPG to
before and during sampling of prevent water deposition and/or
LPG. hydrate formation.

(vi) LPG samples shall be 2. Safety during Water Draining

collected only in
open/ventilated areas and the In view of the effects of water in LPG as
person taking the sample shall above, regular checking of storage
stand on the windward side. vessels for presence of water and its
draining is essential. Following
(vii) Liquid LPG coming in contact precautions shall be followed in carrying
with skin produces very out water draining operation :
severe burns due to frost bite.
The sampler, therefore, must (i) While draining water from storage
wear protective goggles, hand vessels, it shall be ensured that two
gloves, shoes etc. while taking valves are provided on the drains
samples. connection with a suitable distance
piece between them.
(viii) Samples, after
collection, shall be properly (ii) In the draining assembly, the valve
labeled. nearer to the vessel shall be opened
first and draining controlled by
(ix) Sampling of LPG should gradually opening the valve farther
preferably be done in bombs from the vessel. On completion of
with provision of pre-charge at draining operation, the valves shall be
one end. This will not only closed in the reverse sequence.
eliminate the possibility of
undesirable presence of air in (iii) It shall be ensured that the drain outlet
the bomb, which may become is at a safe distance from the vessel
a safety hazard, but also so that accidental ignition of any
minimises flashing of sample escaping vapour would not expose the
during collection, thereby vessel to flame impingement.
providing a truly
representative sample. (iv) It is important not to attempt removal
of the entire quantity of water as
7.2 DRAINING considerable liquid LPG may escape
in the process. At the first sign of
1. Effects of Water in LPG system appearance of LPG, the operation
shall be stopped. Escape of LPG may
Presence of water in LPG is detrimental lead to formation of ice block at the
as it may lead to following undesirable valve seat, preventing closure of
situations : valve. This will result in escape of
uncontrolled vapour to the atmosphere
(i) If water in the product is in sufficient causing a very serious hazard.
quantity, it may cause rust and
corrosion to the vessel which may 8.0 ODORISATION
not otherwise be affected by the
product in any way.
 LPG is an odourless gas, heavier than
air. Any leakage developed from a A useful device for transfer of ethyl
source of LPG can go undetected, mercaptan from a drum consists of a
thereby creating a grave safety dip pipe assembly equipped with
hazard. Therefore, if LPG is to be mercaptan tight bung or fittings. The
distributed as a utility gas to the dip pipe should reach the bottom of the
consumers, it shall be odorised by drum if the drum is not kept tilted. An
addition of a warning agent of such inert gas is used to apply pressure on
characteristics that it is detectable by the drum to force out mercaptan
a distinct odour down to a through the dip pipe. The system shall
concentration in air of not over one have a suitable relief valve to avoid
fifth of the lower limit of flammability. accidental rupture of the drum due to
high pressure built up. Alternately, a
Ethyl mercaptan is the commonly suitable pump may be used for
used odorant for LPG because of its transferring ethyl mercaptan from a
distinctive smell. The assessment of drum into a dosing vessel.
odour level and the amount of ethyl
mercaptan to be dosed are 8.3 EQUIPMENT FOR ETHYL
determined as per the guidelines MERCAPTAN SERVICE
given in IS 1448 (P : 75) - 1968.
1. Material of Construction of Ethyl
8.1 SOME SAFETY RELATED Mercaptan containers
PROPERTIES OF ETHYL
MERCAPTAN Stainless steel and copper free steel
alloys are the preferred materials of
Ethyl mercaptan is extremely construction of equipment for
flammable. It causes irritation. mercaptan service. Aluminium is also
Prolonged inhalation may cause acceptable provided the pressure rating
nausea and headache; may of aluminium is sufficient to meet the
temporarily desensitize olfactory actual requirement.
system (smelling sensation).
Iron or carbon steel is less acceptable
The properties of ethyl mercaptan are as there is the hazard of formation of
furnished below : iron-sulphur complexes which are
pyrophoric. They can be used if proper
Boiling Point = 36.2 deg.C steps are taken to suitably condition
Explosive Limits = 2.8 to 18.2% them.
Flash Point = Less than 27 Deg.C Copper or copper bearing alloys shall
Auto ignition not be used for mercaptan service as
temperature = 299 deg.C
Threshold Limit
mercaptan readily attacks and
Valve (TLV) = 0.5 ppm contaminates them.

Vapour Pressure 2. Pumps for Mercaptan service

at 37.8 deg.C = 1.12 Kg/cm sq.(abs)
Because of the odour of mecaptan, only
hermetically sealed pumps shall be used.
Personal protective equipments like
hand gloves, aprons and respiratory 3. Piping and Fittings
protection shall be used when working
with ethyl mercaptan. (i) Seamless stainless steel piping is
recommended for mercaptan.
8.2 HANDLING ETHYL MERCAPTAN Threaded fittings can be used
provided they meet the service
Vapour pressure of ethyl mercaptan requirement ratings. A fluoroplastic
increases rather rapidly with tape sealant is recommended.
temperature. It is, therefore,
recommended that the drums (ii) Flexible connections shall be
containing ethyl mercaptan be kept seamless stainless steel with pipe
cool and away from direct exposure to nipples welded to each end or
heat/sunlight before they are opened.
 fluoroplastic tube with neoprene 9.1 ELECTRICAL
cover.
(i) Electrical installation, equipment
(iii) Relief valves shall be full nozzle, and wiring shall conform to
disc type, closed bonnet carbon "Classification of Areas for
steel body with 304 stainless steel Electrical Installations at
trim and stainless or aluminized Hydrocarbon Processing &
steel spring. Handling Facilities" - OISD-STD-
113.
(iv) For transfer valves, stainless steel
ball valves with fluoroplastic seats (ii) All motors, in addition to the control
and 316 stainless steel trim or their gears at MCC, shall have local
equivalent are recommended. start/stop facilities.

(v) Rigid connection should be welded (iii) Motor terminal boxes should be
or flanged joint type. sealed with cold setting plastic
compound.
(vi) Fluoroplastics and asbestos are
satisfactory material for gasketing. (iv) Although LPG storage vessels do
not require lightening protection,
(vii) For pressure gauges, stainless steel ground rods shall be provided for
diaphragm type is recommended vessels supported on non-
with stainless steel socket and tip. conductive foundations. Similar
ground rods shall be provided for
8.4 DISPOSAL loading/unloading gantries.

(i) Drum Disposal (v) Transfer facilities at

loading/unloading gantries shall be
Initially, it shall be ensured that the grounded and bonded as a
drums are emptied of mercaptan as protection against static charges
completely as possible. The empty (Refer OISD-RP-110 on Static
drums then can be washed with Electricity).
water and detergent, followed by
wash with a 5% bleach solution. (vi) Work permit shall be obtained
After again washing with copious before carrying out any
amount of water, the drums will be maintenance work (Refer OISD-
ready for disposal. STD-105: WORK PERMIT
SYSTEM).
(ii) Treatment of Leaks and Spills
9.2 INSTRUMENTATION
Leaks and spills of mercaptan can
be treated with commercially Following instruments shall be fitted :
available masking agents A. Storage Vessel
(e.g.Aldor and Neutroleum Alpha
etc.) to make them odourless. (i) Pressure gauge - at the top of the
Large mercaptan spills shall be vessel in vapour
covered with sand or activated space with remote
carbon or any other absorbing indication/alarm.
material, which are then buried or
incinerated. The area over the spill (ii) Temperature -One in the liquid
should then be washed with space gauge at the
ordinary household bleach solution bottom.
and then thoroughly with water. Dry
bleaching powder should never be (iii) Pressure - 2 Nos.
used in treating mercaptan spills. A (Minimum)relief
violent reaction could occur. valves

9.0 ELECTRICAL AND (iv) Liquid level - 2 Nos. (minimum)

INSTRUMENTATION gauges
(v) Quick closing emergency shut-off
valves on inlet/outlet and vapour (i) Fire protection facilities shall be
return line - valves should be provided as per OISD Standards
interlocked for emergency operation 116 or 117 as the case May be.
manually from a safe distance and
automatically through control panel. (ii) Fire protection facilities shall be
designed to fight two major fires at
(vi) High liquid level switch (Float type) - two locations simultaneously.
Alarm, connected to control room for
annunciation. (iii) Water spray system shall be
provided in storage vessels,
(vii) Liquid level transmitter and indicator - loading / unloading gantries and
Local and remote, connected to LPG transfer pump/compressor
control room for indication. areas as per NFPA 15. Such
system shall be automatically
(viii) High temperature switch - Alarm, to actuated by temperature
control room for annunciation. responsive device and also shall
have provision for manual
B. Handling and Storage Area operation.

Explosive Gas - Remote (iv) Adequate number of portable fire

Detectors Annunciation extinguishers of dry chemical type
with two levels shall be provided at strategic
of alarm at pre- points.
determined LEL
(v) Gas detection and alarm system
shall be provided.
(ii) Fire alarm
(vi) Fire drills shall be conducted at
regular intervals and the
C. Transfer System observations recorded.

(i) Pressure gauges - At suction and delivery 11.0 REFERENCES

side of pumps and
compressors. 1. IS:4576-1978 Specifications for
Liquefied Petroleum Gases.
(ii) Excess flow check valves
2. IS:3710-1978 Filling ratios for Low
(iii) Thermal relief valves Pressure Liquefied Gases.

(v) High pressure switch - alarm and 3. The Static and Mobile Pressure
shutdown Vessels (Unfired) Rules – 1981.

10.0 SAFETY AND FIRE PROTECTION 4. Liquefied Petroleum Gases – by

nd
A.F. Williams & W.L. Lom, 2
10.1 SAFETY Edition. Eillis Horwood Ltd.,
England.
(i) Safety precautions/regulatory
signs and signs prohibiting 5. IS:2825-1969 Indian Standard
smoking/naked lights shall be Code for Unfired Pressure
displayed generously. Vessels.
th
(ii) No vehicular traffic will be 6. API Standard 25, 4 Edition,
permitted inside the storage and December 1978 – Design and
handling area. When required, Construction of LP Gas
vehicles fitted with approved spark Installations.
arrestors shall only be allowed
with valid vehicle entry permit. 7. Code of Practice for LPG Storage
Installations (Part II) IS:6044 (Part
10.2 FIRE PROTECTION II) – 1972.
8. IS:1893 – 1975 Criteria for 15. NFPA 59 – LP Gases at Utility
earthquake resistant design of Gas Plants, 1979.
structures.
16. API RP 510 – January 1979 –
9. IS:456-1978 – Code of Practice Maintenance Inspection, Rating
for Plain and reinforced concrete. and Repair of Pressure Vessel.

10. IS:800 – 1962 – Code of Practice 17. Guide for Inspection of Refinery
for use of Structural Steel in Equipment – Chapter VI, Pressure
rd
General Building Construction. Vessels – 3 Edition 1976, API
Publication.
11. IS:875 – 1964 – Code of Practice
for Structural Safety of Buildings : 18. NFPA 58 – Storage and Handling
Loading Standards. of Liquefied Petroleum Gases
1979.
12. IS:2911 – Code of Practice for
Design and Construction of Pile 19. OISD – STD – 105 on Work
Foundation. Permit System.

13. ASME Boiler and Pressure Vessel 20. OISD – STD- 106 on Pressure
Code Sect. VIII Division 1 Relief and Disposal System.
American Society of Mech.
Engineers., New York (1977). 21. OISD- STD – 112 on Safe
Handling of Air – Hydro – Carbon
14. IS:1448 – Method of Test of Mixtures and Pyrophoric
Petroleum and its Products. Substances.

a) IS : 1448 (P:119) – 1960 22. OISD-STD-116 on Fire Protection

Doctor Test. Facilities for Petroleum Refineries
and Oil Gas Processing Plants.
b) (P:70) - 1968 Residue in
LPG. 23. OISD-STD-117 on Fire Protection
Facilities for Petroleum Depots
c) (P:71) - 1979 Vapour and Terminals.
Pressure of LPG.
24. OISD-STD-118 on Layouts for Oil
d) (P:72) - 1968 Volatility of and Gas Installations.
LPG.
25. OISD-STD-128 on Inspection of
e) (P:73) – 1968 Hydrogen Unfired Pressure Vessels.
Sulphide in LPG.
26. OISD-STD-135 on Inspection of
f) (P:74) – 1968 Dryness of Loading/Unloading Hoses for
LPG Petroleum Products.

g) (P:75) – 1968 Odour of LPG 27. OISD-STD-144 on Liquefied

Petroleum Gas (LPG) Bottling
h) (P:76) – 1968 Density of Plant Operations.
LPG.
 ANNEXURE-D

SAFE FILLING OF LPG VESSEL

LPG has relatively high coefficient of expansion. If sufficient vapour space is not left in the
vessel, pressure inside the vessel would shoot up rapidly once the vessel becomes liquid full. Hence
care is exercised in limiting the filling of storage vessel to the filling density of LPG. The filling density
is defined so as to leave a guaranteed free space of five percent at the reference temperature of 55
degree C. As per Static and Mobile Pressure Vessels (unfired) Rules - 1981, the design pressure of a
vessel shall not be less than the vapour pressure of the gas in the vessel at 55 degree C.

The following information are required to work out the safe filling capacity of a storage vessel.

i) Water capacity of the vessel (WC)

ii) Density of liquid LPG

iii) Filling density (FD)

iv) Ullage factor (U)

WC x U x Density of LPG at 55 degree C

FD = --------------------------------------------------------
WC
= U x Density of LPG at 55 degree C

a) Safe maximum quantity of LPG that can be filled by weight - FDxWC

b) Safe maximum quantity of LPG at 15 degree C that can be filled by volume percent of water
capacity

FD x 100
= ----------------------------------------
Density of LPG at 15 degree C

c) Safe maximum quantity of LPG at t degree C that can be filled by volume percent of water capacity

FD x 100
= -------------------------------------------
Density of LPG at t degree C

FD x 100
= --- ----------------------------------------
Density of LPG as 15 degree C x VRF

Where : FD = Filling density

WC = Water capacity in ltrs. at 15 degree C

(may be taken as total weight of water in Kg.)

VRF = Volume reduction factor for density of LPG at

t degree C as per ASTM Table 54.
 ANNEXURE-G

LIQUEFIED GAS-CARGO TRANSFER CHECK LIST

(Items to be checked before cargo transfer begins)

SHIP:_________________________________________DATE:______________

PORT &BERTH:_________________________________TIME:______________

S.NO CHECK POINT FOR SHIP FOR SHORE

1. Has information on cargo and ship-

shore connection been supplied ?

2. Is the agreed ship-shore communic -

ation system operative ?

3. Are fire and other emergency

procedures agreed ?

4. Are local regulations being

observed ?

5. Has safe access been provided and

warning notices posted ?

6. Are moorings secure and agreement

reached on the use of tension
winches ?

7. Are emergency towing-off wires

correctly positioned ?

8. Is the ship ready to move under its

own power ?

9. Are smoking restrictions in force

and notices posted ?

10. Are naked light restrictions being

observed ?

11. Are portable electrical equipment

cables disconnected ?

12. Are all hand torches and portable

R/T sets of approved type ?

13. Are ship's main transmitting

aerials and radar switched off
and earthed ?
Counted....
S.NO CHECK POINT FOR SHIP FOR SHORE

14. Some doors and ports have to be

closed : are they actually shut ?

15. Are all air conditioning intakes

correctly trimmed and window type
units closed ?

16. Is the water main ready for

immediate use ?

17. Is the water spray system ready

for immediate use ?

18. Are dry powder and all other fire

fighting appliances correctly
positioned and ready for immediate
use ?

19. Is necessary protective clothing

available or being worn ?

20. Are void spaces properly inerted ?

21. Is the required ventilation

equipment in operation ?

22. Is the cargo system set for the

operation ?

23. Are all remote control valves in

working order ?

24. Are cargo tank relief valves

correctly set and in good order ?

25. Are the required cargo pumps and

compressors in good order ?

26. Is reliquefaction or boil-off

control equipment in good order ?

27. Is gas detection equipment set for

the cargo, calibrated and in good
order ?

28. Are cargo system gauges and alarms

correctly set and in good order ?

29. Are scuppers plugged and suitable

drip trays in position ?
Contd...
S.NO CHECK POINT FOR SHIP FOR SHORE

30. Are cargo and bunker hoses in good

condition and properly rigged, have
certificates being checked ?

31. Are unused bunker connections

blanked and bunker tank lids
closed ?

32. Are unused cargo connections

(including inert gas line)securely
blanked ?

33. Are automatic shutdown systems

working properly ?

34. Does shore know the closing rate

of ship's automatic valve at
operating temperature ; does ship
have a similar details of shore
system ?

35. Are all personnel (including

supernumeraries and new arrivals)
aware that cargo transfer is to
begin ?

36. Have all personnel been allocated

emergency stations ?

37. Are non-essential personnel clear

of the cargo area ?

38. Are those directly involved aware

of the agreed cargo transfer
sequence ?
============================================================================
REMARKS :

We have checked with each other the items on the above check list and have satisfied ourselves that
the entries we have made are correct to the best of our knowledge.

CHECKED BY______________________ _______________________

(For Ship) (For Terminal)
<< Back Home Next >>