OISD-GDN-169

First Edition
September, 1993
Amended Edition, September 2001

FOR RSTRICTED
CIRCULATION ONLY

OISD GUIDELINES

ON

SMALL LPG BOTTLINGS PLANTS

(DESIGN AND FIRE PROTECTION FACILITIES)

Prepared by:

COMMITTEE ON SMALL LPG BOTTLING PLANTS

OIL INDUSTRY SAFETY DIRECTORATE

26, KASTURBA GANDHI MARG,
2 ND FLOOR, “KAILASH”
NEW DELHI – 110001.
 NOTE

OIL INDUSTRY SAFETY DIRECTORATE (OISD) publications are prepared

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

Though every effort has been made to assure the accuracy and reliability of the
data contained in these documents, OISD hereby expressly disclaims and 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 3 in superscript indicates the

modification/changes/addition based on the amendments
approved in the 19th Safety Council meeting held in
September, 2001July, 1999
 FOREWORD

Oil Industry in India is more than 100 years old. Over years a variety of practices have been in vogue
because 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 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 Directorates (OISD) staffed from within the industry in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence, standardizing 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.

In pursuance to workshop held at OCC, New Delhi on 16.3.93, a committee was constituted by OISD to draw the
guidelines for small LPG Bottling Plants to facilitate private parties for importing/ storing, bottling and marketing of
LPG. These guidelines are developed based on the anticipated hazards of small LPG bottling plants. The essential
contributors for hazards are stated as below:

(i) Inventory of LPG Bulk/packed

(ii) Number of operational activities involved.

The recommendations made herein are applicable to bottling plants having a bulk inventory not exceeding
100 M. Tonnes of LPG with minimum two storage vessels and also bottling a total quantity not exceeding
20 M. Tonnes of LPG per shift of 8 hrs. For all the plants exceeding either of the above limits, OISD
Std.144 shall be applicable. While it is recognised that number of filling operations vary with the capacity
of the cylinders, it is essential that the net LPG contents in the cylinders is in the range of 10 - 20 Kg. Note 3

THE COORDINATOR
COMMITTEE ON
“SMALL LPG BOTTLING PLANTS”
OIL INDUSTRY SAFETY DIRECTORATE,
26, KASTURBA GANDHI MARG,
2ND FLOOR, “KAILASH”
NEW DELHI – 110001.
 OISD GUIDELINES ON
SMALL LPG BOTTLING PLANTS
(DESIGN AND FIRE PROTECTION FACILITIES)

SECTION DESCRIPTION

1.0 STATUTORY RULES AND REGULATIONS &

OTHER RECOMMENDED GUIDELINES

1.1 STATUTORY RULES AND REGULATIONS

(AS AMENDED/REVISED FROM TIME TO TIME)

1.2 RECOMMENDATION OF COMMITTEES

1.3 SALIENT FEATURES OF VARIOUS RULES/REGULATIONS

1.3
1.4 SUMMARY OF RECOMMENDATIONS OF SUDHA JOSHI
COMMITTEE-1987

2.0 PLANT LAYOUT : SCOPE

2.1 LOCATIONS & SAFTY DISTANCES

2.2 TYPE OF STORAGE VESSELS

2.3 LAYOUT

2.4 LPG BULK HANDLING FACILITIES

2.5 LPG BOTTLING FACILITIES

2.6 PROTECTION OF FACILITIES

2.7 UTILITIES

3.0 DESIGN CRITERIA

3.1 GENERAL

3.2 DESIGN BASIS

3.3 LPG STORAGE VESSELS

 3.4 SAFETY/SECURITY SYSTEM

3.5 OTHER EQUIPMENT/SYSTEM

4.0 SAFETY AND FIRE PROTECTION

4.1 INTRODUCTION

4.2 SCOPE

4.3 DESIGN CRITERIA

4.4 FIRE WATER SYSTEM

4.5 FIRE AID FIRE FIGHTING EQUIPMENT

4.6 FIRE/ALARM/COMMUNICATION SYSTEM

4.7 INSPECTION AND TESTING

4.8 MAKE UP WATER

ANNEXURES

SCOPE
This standard does not cover Mounded or Refrigerated Storage.
 STATUTORY RULES AND REGULATIONS

(d) Manufacture, Storage & Import of Hazardous

1.0 STATUTORY RULES/REGULATIONS AND Chemicals Rules – 1989.
OTHER RECOMMENDED GUIDELINES
(e) Guidelines for Environmental clearance of new
Construction and operation of LPG Bottling Plants, projects – 1981.
storage, transportation and distribution of LPG are
required to be carried out in accordance with various 1.2 RECOMMENDATION OF COMMITTEES
prevailing Statutory Rules and Regulations. This
section covers the features in brief w.r.t. following In addition to the above Statutory regulations, there
regulations which are in force. For complete details are various recommended guidelines emerging out of
with regard to the various provisions, original the various Committees set up by the Government of
notifications/ documents may be referred to. India from time to time for streamlining/improving
the safety standards of LPG Bottling/Distribution.
1.1 STATUTORY RULES/REGULATIONS (AS
AMENDED/REVISED FROM TIME TO (i) Vasudevan Committee – 1983, Ministry of
TIME) Energy (Deptt. Of Petroleum).

(ii) Expert Committee Review of Safety and

(i) Gas Cylinder Rules – 1981 (Under Indian Operating Procedures in LPG facilities – 1986,
Explosives Act, 1884) Ministry of Petroleum & N.G. (Deptt. Of
Petroleum).
(ii) Static & Mobile Pressure Vessels (unfired)
Rules-1981 Under Indian Explosives Act 1884. (iii) Sudha Joshi Committee for better services to
L P G u s e r s – 1987, Ministry of Petroleum &
(iii) The Factories Act – 1948 (with latest Natural Gas (Deptt. Of Petroleum).
amendments)
For further details, the original documents may be
(iv) Electrical Installation under Indian Electricity referred to.
Rules – 1956.
1.3 SALIENT FEATURES OF VARIOUS
(v) (a) The Standards of Weight & Measures Rules- RULES/REGULATIONS
1987 Under Weight & Measures Act – 1976.
(The salient features from various statutory
(b) The Standards of Weight & Measures (Packed regulations are as at the time of preparation of the
Commodities Rules – 1977). guidelines. Any changes subsequently notified after
the publication of these guidelines shall also be
(vi) Liquefied Petroleum Gas (Regulation of Supply complied with)
and distribution order – 1993). (With latest
Revisions) (i) GAS CYLINDER RULES – 1981

(vii) The Motor Vehicles Act – 1988. These rules have been framed under the Indian
Explosives Act, 1884 to regulate the possession,
(viii) Environmental Regulations: delivery, storage, handling examination/testing of gas
cylinder limited upto capacity of 1000 litres.
(a) Water (Prevention & Control of
Pollution) Act-1974. Under these rules, prior approval from Chief
controller of Explosives is required to be taken before
(b) Air (Prevention & Control of Pollution) Act- constructing any new facility or altering the existing
1976. facility for filling cylinders and storage area etc.
Before commissioning/ operating of LPG filling plant
(c) Environment (Protection) Act – 1986. following licenses are required to be obtained from
CCE after furnishing the details in specified formats :
 CCE, Nagpur at least 30 days prior to expiry of the
License to import cylinders (form D) Application is current license.
to be submitted in form B (Under rules 57/61)
Inspection/hydrotesting of vessels is required to be
License to fill/possess cylinders (form E&F). carried out once in 5 years or as specified by a
Application is to be submitted in form C (under Competent Agency duly approved by CCE.
rules 57,61 and 62) Frequency of inspection/testing of safety valve is once
in a year.
Generally license for import of cylinders (Form D) is
valid upto one year (Maximum) whereas other (iii) FACTORIES A C T -1948 (AMENDED AS
licenses in Form E/F granted or reviewed remain in FACTORIES (AMENDMENT) ACT, 1987).
force till 31st March of the year subject to validity of
maximum 3 years. Application for renewal should The act aims at regulating working conditions in the
reach CCE, Nagpur at least 30 days prior to expiry of factories and lays down minimum requirements for
the current license. ensuring the safety health and welfare of the
workmen,. It is applicable to all
Cylinders should conform to specified design, fittings, establishments/factories employing more than 10
markings, identification colour and should have employees.
approval from CCE before use of the same.
As per the First schedule of the amended Act (1987),
Cylinders in use are required to be inspected and installations handling highly flammable liquids and
hydrostatically tested as specified in the BIS code gases come under Hazardous process/operations.
(IS:5845) or as per procedure/frequency approved by Salient provisions to be complied with rules framed
CCE. Rejected cylinders are to be destroyed by by the State Government under the Factories Act are
flattening/cutting into pieces. given below:

(ii) STATIC & MOBILE PRESSURE VESSELS - Approval of initial location or expansion of
(UNFIRED) RULED-1981 existing installation by the site appraisal
committee constituted by the State Government.
These rules in conjunction with Gas Cylinder Rules
have been framed under the Indian Explosives Act to - Approval of the plan, specification.drawings for
regulate the construction, fitment, storage, construction of the Factory.installation by the
loading/transport and inspection of unfired vessels in Chief Factory inspector and also
service of compressed gas like LPG with capacity registration.license for operating factory. License
exceeding 1000 litres. is to be renewed every year or as specified.

As per these rules it is obligatory to obtain approval - Disclosure of information by the occupier
and licenses from CCE prior to construction/alteration regarding hazards/danger including health
and commissioning/ operation of any LPG storage hazards and measures to overcome such hazards
vessel and allied facilities. Vessels are required to be to workmen and general public living in the
designed, constructed and tested in accordance with vicinity of the factory.
BIS-2825 as amended from time to time or such
code./standard as approved by CCE. - Declaration of written safety policy w.r.t. health
and safety of workmen.
APPLICATION/LICENSES UNDER THESE
RULES ARE: - Ensuring proper fencing/provision of safety
guards on equipment/machinery. Fire/ accident
License to store LPG Application is to be prevention facilities etc.
in bulk issued in Submitted in Form-1
Form-III (under rules 49, 54 & 55) - Examination/testing of machinery/vessels, tools/
Tackles etc. at specified frequency.
License to transport Application is to be
LPG in bulk issued in Submitted in Form-1 - Maintenance of up-to-date Disaster Management
Form – IV. (under rules 49 & 54) Plan.

- Specific responsibility of the occupier in relation

The licenses will remain in force till 31st of March of to :
the year and are generally valid for the period of 3
years (max). Application for renewal must reach
 (a) Maintenance of health records of persons equipment is imported, the same shall have
likely to be exposed to harmful toxic certification of appropriate authority of the country
substances. where it is manufactured in accordance with
recommendations of international organisation of
(b) Deployment of qualified persons to handle Legal Meterology. Such models shall be tested, if
hazardous substances/ equipment. required, and shall be duly certified by the Indian
authorities to verify the accuracy.
(c) Appointment of Safety Officer.
VERIFICATION/ STAMPING
(iv) STATUTORY REQUIREMENTS OF
ELECTRICAL INSTALLATIONS (UNDER Weighing equipment shall require re-verification by
INDIAN ELECTRICITY RULES, 1956) the designated Inspector at prescribed intervals.
Certificates in prescribed intervals. Certificates in
For supply of power, license is required from the prescribed form shall be obtained or stamping
designated authority of the State Government indicating there in the particulars of verified
after submitting the application with details of measures shall be made. Test weights used for
premises drawing/maps of the proposed area of regular checking the accuracy of weighting equipment
supply, electrical installation, nature and amount shall also require stamping of Weights & Measures.
of supply etc.

The installation must be inspected and approved by SITE INSPECTION

Electrical Inspector of the State Government before
commissioning. Subsequent inspection / testing shall Weights & Measure Authorities within their area of
be required at intervals not exceeding five years or as jurisdiction can visit the premises for inspection,
specified. Only licensed contractors/agencies holding testing of any measuring equipment in use apart from
the certificate of competency should be engaged for checking the relevant records/documents.
any installation work.
(b) THE STANDARDS OF WEIGHTS &
All earthing system in the installation shall require to MEASURES (PACKAGED COMMODITIES)
be tested for resistance during the dry season not less RULES, 1977& AMENDMENT RULES 1992
than once a year or as specified by the authorities
record of every earth test shall be maintained by the - LPG shall be marketed/sold on weight basis in
occupier incharge of the installation and shall be packaged form i.e. cylinders of approved design.
produced as required before the inspector or
authorised officer. - Declaration shall be required on every cylinder
about name/address of Manufacturer/packer
Suitable fire extinguishers for dealing with electrical common or generic name of the commodity, net
fire like CO2, DCP type extinguishers should be quantity in terms of standard weight,
placed in electrical installations. size/dimensional details of the containers etc.

NOTE: - Maximum permissible error on net quantities

declared by weight or by volume shall be as
(i) For appropriate area classification, guidelines, below:
contained in IS:5572 (Part-I) 1978 should be
followed. DECLARED MAXIMUM PERMISSIBLE
QUANTITY ERROR IN EXCESS OR
(ii) For selection of electrical equipment, guidelines gm or ml IN DEEFICIENCY AS % OF :
contained in IS:5571-1979 & IS:9570-1980 as
revised from time to time should be followed. Declared quantity gm or ml

(v) (a) STANDARDS OF WEIGHTS & 1000–10,000 1.5% -

MEASURES ACT – 1976 (WEIGHTS &
MEASURES RULES-1987) 10,000-15,000 - 150

Approval/certification of measuring Appliances: More than–15,000 1.0% -

Weighing equipment like weigh scales, weigh bridges

etc. before installation shall have approval and (VI) THE LIQUEFIED PETROLEUM GAS
certification by the Regional Director/designated (Regulation of Supply & Distribution of
authority of Weights & Measures. In case, the Supply & Distribution) Order, 1993.
 - Registered laden weight/axle weight as per
This order was brought into force w.e.f. August 1993 notification for particular model should not
by the Ministry of Petroleum & Natural Gas. Salient exceed the permissible value.
features are out lined below:
- Use “TREMCARD” or other safety guidelines
- No person shall be granted by a Govt. Oil issued for particular hazardous commodity a s
company more than one gas connection and the prescribed by Central/State Government
same shall not be used for purposes other than authorities. This covers specified arrangement of
cooking unless specified by a general or special maintenance/ repairs, emergency handling
order. procedures in case of road accidents.

- No transporter or delivery person shall deliver LPG - Certificate of fitness/age limit as specified in
gas either in Cylinders or bulk to any person rules of Central/State Government.
other than the consumer for whom the LPG is
meant for. (vii) ENVIRONMENTAL REGULATIONS

- The weight of the liquefied petroleum gas (a) WATER (PREVENTION AND CONTROL OF
contained in a cylinder shall not vary by a POLLUTION) ACT, 1974
difference of 1.5% or maximum permissible limit
to the net weight of the respective cylinder as Under the main provision of this Act:
indicated on it by the Govt. oil company.
Prior consent of State Pollution Control Board
- No person shall – supply or sell filled or empty by applying in prescribed format is require for :
cylinders, gas cylinder valves and pressure
regulators to any person other than a Govt. oil - Establishing any industry, operation or process or
company or parallel marketeer. any treatment and disposal system or any
extension or addition thereto which is likely to
- Unless authorized by a Govt. oil company or a discharge sewage or effluent into a stream or on
parallel marketeer, supply or sell empty cylinder, land. Using any new or altered outlet for
gas cylinder valve and pressure regulator to any discharge of sewage or effluent.
person other than a consumer.
Application for renewal of consent, which is generally
- Posses filled or empty cylinder, gas cylinder valid for one year should be made at least one month
valve or pressure regulator unless he is a in advance.
consumer and the same has been supplied by a
distributor a Govt. oil company or a parallel Occupier has to ensure the compliance of the
marketeer.. directions or stipulations laid down by the Board
while granting the consent. Returns for the amount of
- Schedule ‘B’ of the above order lays down the water consumed along with payment of cess must be
guidelines with respect to cylinder size, shape, submitted in manner as prescribed in the Water
design and weight for the parallel marketing (Prevention & Control of Pollution) Cess Act – 1977.
system in addition to those for Gas cylinder valve
and pressure regulator. (B) AIR (PREVENTION & CONTROL OF
POLLUTION) ACT – 1981
- (vii) THE MOTOR VEHICLES ACT – 1988
The objective of this act is to provide for prevention,
- Some relevant features w.r.t.. safety provisions control and abatement of air pollution (*) caused by
in the Motor Vehicle Act – 1988 are as below: any operation or process.

- Grant of drivving license for transport vehicles - Under the main provision of this Act prior
used for hazardous goods like LPG and other consent of the State Pollution Control Board is
petroleum products is restricted. The person required regarding discharge or emission of air
must have some minimum educational pollutants for operation of an industry as
qualification as prescribed by Central/State specified in schedule which includes Petroleum
Government apart from other conditions like Industry.
medical fitness, driving competence certificate, - Strict compliance with standards/conditions laid
minimum driving experience etc. down by the board or specified in the consent
order must be ensured.
- Application for renewal of consent must be Firstly, No objection Certificate (NOC) has to be
submitted at least one month prior to expiry of obtained from concerned State Pollution Control
the ccurrent consent order which is generally Board by submitting application in the prescribed
valid for one year. form alongwith detailed project report.

- (*) : Air Pollution means presence in the Final clearance from environmental angle is to be
atmosphere, of any solid, liquid or gaseous obtained from DOEn. Government of India. The
substances including noise in such following documents will have to be submitted for
concentration/intensity that may be injurious to obtaining clearance :
human being or other living creatures or plant or
property or environment. - Detailed Project Report (PDR)

Several rules for the specific areas have been/are in - Response to questionnaire (Prepared by DOEn).
the process of being notified under this Act. This also
includes issuance of various standards for effluent - Detailed environmental Impact Assessment (EIA)
water, atmospheric emissions/air quality, Report.
storage/handling of hazardous chemicals, solid,
waster - Environmental Management Plan.

(c) ENVIRONMENT (PROTECTION) ACT-1986 - Risk Analysis Study Reports.

The Water Act-1974 and Air Act-1 9 8 1 d e a l - Disaster management Plan – M a s t e r

specifically with water and air pollution while this act Rehabilitation Plan, duly approved by State
deals with environment as a whole including Government (Where required).
prevention of hazards to human beings, other living
creatures, soil, plants and property. - Green Belt Development Plan.

This act empowers Central/State Government to take - Safety Manual/Code.

all such measures, it may deem fit for protecting and
improving the quality of environment. The Department of Environment, after considering
these documents and presentation by the industry
(c) ENVIRONMENTAL CLEARANCE FOR member will give clearance with/without special
NEW LPG BOTTLING PLANTS conditions to be complied with. A six monthly report
on the progress of the facilities being provided for
(i) GUIDELINES FOR SITING INDUSTRY pollution control is to be submitted to DOEn, till the
completion of the report.
Ministry of Environment have laid down certain
guidelines for Siting of Industries which includes Finally, before commissioning of the plant, consent
LPG installation . While selecting a site, enough care has to be obtained from the State Pollution Control
should be taken to minimise the adverse impact of the Board for the discharge of liquid effluent and
neighborhood and natural life sustaining systems. atmospheric emission under Water (Prevention and
Control of Pollution) Act, 1974 and (Air Prevention
Letter of intent of the industry can be converted to the and Control of Pollution) Act-1976.
Industrial License only after the following conditions
are fulfilled : 1.4 SUMMARY OF RECOMMENDATIONS OF
SUDHA JOSHI COMMITTEE – 1987
The State Director of Industry confrms that the site of
the project has been approved from the environmental Ministry of Petroleum & Chemicals had set up a
angle by the concerned state authorities. committee headed by Mrs. Sudha Joshi, the then M.P.
and Marketing Directors of Oil Companies with a
- The Project Authorities commit to State and view to provide better services to LPG users with due
Central Governments to install the appropriate regard to safety.
equipment and implement the measures
prescribed for prevention and control of Brief summary of important recommendations w.r.t.
environmental pollution. safety aspects are outlined below :

(ii) PROCEDURE FOR OBTAINING - Streamlining of registration/release of LPG

ENVIRONMENTAL CLEARANCE connections, issuing booklet like ration card to
each consumer etc.
- Use of auto-driven vehicles to be encouraged for
delivery of refills.

- Consumers to use only BIS marked hot plates.

- Distributors to check weight of at least 10% of

cylinders before accepting deliveries Oil
companies to ensure predelivery checks by the
Distributors.

- Caging of trucks carrying filled LPG cylinders.

- Oil companies to use only aluminium/PVC seals

with different colour code of filling plant
embossed.

- Periodic safety inspection of equipment at

consumer premises.

- Regular training of delivery boys by the Oil

companies.

- Emergency and complaint cells to be operated by

Oil companies in LPG marketed towns.

- Consumer education in LPG Safety through TV

media and curriculum of high school.

- Oil companies to strengthen the inspection

system of LPG Bottling Plants and working of
the distributors.
- Establishment of Mini Bottling Plants near the
consuming centre to the extent possible.
 PLANT LAYOUT

2.0 SCOPE : (h) Storage vessels shall be located downward

of processing units, important building and
The general layout principles of LPG facilities.
storage, bottling and bulk handling facilities
have been detailed in this chapter. The various (i) Storage vessels shall be laid out in single
facilities within LPG storage and bottling row within a group.
premises shall be located based on Table-I and
Table-II. (j) Storage vessels shall not be located one
above the other.
2.1 LOCATION & SAFETY DISTANCES
2.1.2 SAFETY DISTANCES:
2.1.1 LOCATION :
The safety distances as given in Table-I
While assessing the suitability of any site and Table-II are the distances in plane between
for location of LPG storage facilities, the the nearest point on a vessel other than the
following aspects shall be considered: filling/discharge line and a specified feature, e.g.
adjacent vessel, site boundary etc.
(a) In addition to the requirements for safety the
plant should be located in such a manner so 2.2 TYPE OF STORAGE VESSELS:
as not to be contignous to any industry
having open flame. Property line of the 2.2.1 H O R I Z O N T A L C Y L I N D R I C A L
plant shall be away from the central line of VESSELS:
the road/railways as per statutory
requirements and overhead high tension Horizontal bullets with the total volumetric
wire shall not traverse through the battery capacity upto 235 Cu. M. Note 3 shall be used for
limit of the plant. storing LPG.

(b) Adequate availability of water from a nearby 2.3 LAYOUT :

reliable source should be ensured.
The following aspects shall be considered while
(c) The topographical nature of the site with establishing layout of LPG storage vessels.
special reference to its effect on the disposal
of LPG, in the even of its escape, if any, 2.3.1 LPG STORAGE FACILITIES :
shall be considered.
(a) GRADING :
(d) The access for mobile fire fighting
equipment to the storage vessels under all Area below the storage vessels
foreseen circumstances, preferably from two (Bullets) shall be free from vegetation, property
sides and upward prevailing wind direction graded with the slope of 1.100 (towards one
js an important parameter. side) away from the pipeline manifold.

(e) For any expansion beyond the specified (b) PIPING :

limit, all provision under OISD-144 shall be
applicable. (i) Piping manifold shall be away from the
shadow of the vessel.
(f) Predominant direction of wind and velocity
shall be considered. (ii) Spring loaded quick closing valve with
fusible link or Rov to facilitate
(g) Longitudinal axis of horizontal vessels immediate closure in the event of
(Bullets) shall not point towards other emergency, if any, shall be provided in
vessels, vital process equipment and other the LPG liquid line of each vessel
facilities. between excess flow check valve
(EFCV) and pipeline manifold.
 2.5.2 Bottling section shed (Refer Annexure-I)
(c) SURFACE DRAINAGE shall be of single story having asbestos
roofing and open from all
In order to prevent the escape of spillage sides for adequate ventilation to ensure
into the main drainage system, surface water quick dessipation of LPG Vapour in the
from the storage area and from the manifold event of leakage, if any, RCC roofing
area shall be directed to the main drainage shall not be used. Anti-static mastic
through a water seal designed to avoid the flooring conforming to IS-8374 shall be
spread of hydrocarbon. provided in the LPG filling shed/cylinder
storage shed to avoid frictional sparks.
(d) GROUPING : Anti-static mastic coating up to 1.5 meters
height from bottom of the supporting
Vessels shall be arranged in a group and columns in the shed shall be provided.
total volumetric capacity of the group shall
be ,limited to 235 Cu. M. N o t e 3 . Inter- 2.5.3 Stacking area for empty and filled
distances as specified in Table-I and Table- cylinders shall be marked specifically.
II shall be maintained. Cylinders shall always be stacked
vertically in two lines. For details of
Top surfaces of all the vessels installed in a cylinders stacking pattern refer Annexure-
group shall be on the same plane so that the II. Plant should have one shed each for
safety blowout from them do not affect each filling and storing of filled./empty
other. cylinders.

2.4 LPG BULK HANDLING FACILITIES : 2.5.4 Valve changing operation should be
carried out in a demarcated place within
2.4.1 LPG tank lorry loading/unloading gantry the filling shed itself.
shall be located in a separate block and
shall not be grouped with other petroleum 2.5.5 Cylinder storage shall be kept on or above
products. grade and never below grade in celler or
basement.
2.4.2 Space for turning with a minimum radius
of 20 meters for tank lorries shall be 2.5.6 Filled cylinders shall not be stored in the
provided commensurate with the vicinity of cylinders containing other
capacities of the tank trucks. gasses or hazardous substances.

2.4.3 LPG tank lorries upto the maximum of 2 2.5.7 Escape routes shall be specified in LPG
Nos, at a time should only be taken for sheds for evacuation of employees in
unloading. emergency.

2.4.4 Adequate permanent protection for TLD

pipeline island shall be provided. The 2.5.8 There shall not be any trapping of
minimum width of such pipeline island personnel in LPG sheds by conveyours,
shall be 1 metre. cylinders and other facilities. If such
trapping cannot be eliminated, it should be
kept to the minimum. In such places
2.5 LPG BOTTLIG FACILITIES : sufficient arrangements for escape routes
to be provided.
2.5.1 LPG Bottling facilities should be located a
a safe distance from other facilities with 2.5.9 Adequate lighting shall be provided in the
minimum ingress of trucking traffic and cylinder filling area.
downward wind direction with respect to
bulk storage. 2.5.10 Water drains from cylinder filling areas to
out side drainage system shall be provided
There shall not be any deep ditches in the with water seals (near the plant boundary)
surrounding area to avoid settling of LPG.
2.6 PROTECTION OF FACILITIES :
2.7 UTILITIES
2.6.1 There shall be road all around the various
facilities within the bottling plant areas for Utilities consisting of Fire Water Pumps,
accessibility of fire fighting operations. Admin. Building, Motor Control Center, DG
Room, Air Compressors, Dryers etc. shall be
2.6.2 There shall be proper industry type separated from other LPG facilities and to
boundary wall all around the Bottling be located as per the area classification as
Plant. specified in Table-I.
 TABLE – I

INTERDISTANCES FOR LPG FACILITIES

1 2 3 4 5

1. LPG STORAGE VESSEL 2 T-11 T-II 15 T-II

2. BOUNDARY/PROPERTY
LINE/GROUP OF BLDGS.
NOT ASSOCIATED WITH
LPG PLANTS. T-II - 15 15 -

3. LPG SHED T-II 15 15 15 30

4. TANK TRUCK GANTRY 15 15 15 NA 30

5. FIRE WATER PUMP T-II * 30 30 -

HOUSE

NOTES: 1. ALL DIMENSIONS ARE IN MTS.

2. NOTATION

T-II : REFER TABLE II

* : ANY DISTANCE FOR OPERATIONAL CONVENIENCE

3. MAXIMUM PACKED STORAGE LIMITED TO 20000 KGS.

TABLE – II

INTERDISTANCES BETWEEN LPG STORAGE VESSELS, FILLING SHED, STORAGE SHED

AND BOUNDARY/PROPERTY LINE/GROUP OF BUILDINGS.

CAPACITY OF EACH VESSEL DISTANCES

(CU. MTS. OF WATER) (MTS.)

10 – 20 15

20 – 40 20

41 – 235 Note 3 30
 DESIGN CRITERIA

3.0 DESIGN CRETERIA FOR LPG

BOTTLING PLANTS LPG loading/unloading facilities through tank
truck are recommended.
3.1 GENERAL
3.2.4 CYLINDER FILLIG FACILITEIS
The section descirbes the broad process
design and safety features required in a (A) FILLING MACHINES :
typical LPG Bottling Plant. For design
details about the plant layout reference (a) The filling machines should preferably be
should be made to section 2 of this standard. provided with auto cut-off system be ensure
that LPG supply is cut-off after filling the
3.2 DESIGN BASIS desired quantity of product.. The filling
pressure shall not exceed the design pressure
3.2.1 For safety reasons, the operation of of the cylinders.
facilities should be restricted to maximum
two shifts operation. Facilities to include (b) Filling machines shall not have weighment
the following : error more than +/-1% of the net LPG filled
in the cylinder.
(i) Stationary Filling Machines :
(c) It is recommended that in-line check weigh
For filling Cylinders. scales with a minimum graduation of 50
gms be installed and all cylinders after
(ii) Check Scale : filling should be counterchecked for correct
weight.
To countercheck the quantity of LPG
filled. 3.2.5 CYLINDER STORAGE

(iii) Compact Valve Tester : Maximum cylinder storage of filled cylinders

shall be restricted to a total of 20,000 Kgs.
To check valve/”O” Ring leakage.
3.3. LPG STORAGE VESSELS
(iv) Test Bath :
3.3.1 MECHANICAL DESIGN
To check the body./bung leak
cylinders. The mechanical design of storage vessel
shall be based on the following:
(v) Evacuation Rack :
(a) DESIGN CODE :
For evacuation of cylinders.
ASME SEC, VIII or IS-2825 or BS-5500 or
(vi) Purging Manifold : equivalent duly approved by CCE.

For purging of cylinders. Design shall take into account the Static and
Mobile Pressure Vessels (Unfired) Rules,
3.2.2 STORAGE CAPACITY 1981 also.

The maximum bulk storage (of all vessels) shall (b) Design Pressure : Vapour pressure of LPG
be restricted to 100 MT. at 55oC.

3.2.3 LPG LOADING/ UNLOADING 3.3.2 FITTINGS:

FACILITIES
 Bullets shall have a single nozzle at the
bottom for inlet as well as outlet. The nozzle 3.5 OTHER EQUIPMENT/ SYSTEM
shall be fully welded, stress relieved alongwith
the vessel and shall extend minimum 3 metres 3.5.1 BOTTLIG PUMPS
from the shadow of the bullet. Excess Flow
Check Valve (EFCV) shall be provided on this Two pumps including one stand-by shall
bottom nozzles to ensure immediate stoppage of be provided with suction and discharge
the flow of LPG in the event of downstream pressure gauge, a high point vent to safe
leakage rupture, if any. There shall not be any height/flare, suction strainer and
other manhole, instrument tapping on this nozzle mechanical seal shall be provided. Pumps
upto the EFCV. shall be designed to build a discharge
pressure to ensure 5 Kg/CM2 pressure
High level gauge should be provided to ensure above the vapour pressure at the operating
safe filling of vessels and slip tube or temperature at the filling machines.
Roto/Gauge/Rochester gauge should be provided
for gauging of the vessels. 3.5.2 LPG COMPRESSOR

All the fittings shall be suitable for use at not less Gear driven compressor shall preferably
than the design pressure and temperature be used. However belt driven
appropriate to the worst operating conditions of compressors can be used provided the
the bullet. belts used are anti static type and fire
resistant.
3.3.3 INSTRUMENTS
There shall be minimum of two
(i) The storage vessel shall have minimum 2 compressors including one as a standby.
different type of level indicators as stated
below: The operating parameters shall be decided
on a case to case basis. However, typical
(a) High Level Gauge. operating conditions may be as follows:

(b) Slip Tube Gauge/Roto Gauge/Rochester Suction Pressure : 10.0Kg/cm2 abs

Gauge. (max). during unloading.

(ii) Each vessel shall have atleast two safety 2-11.8kg/cm2 abs. During vapour
valves, each set at not more than 110% of recovery.
design pressure of the vessel and having
the relieving capacity adequate for limiting Discharge Pressure : 13.0 kg/cm2 abs.
the pressure build-up in the vessel not more During unloading 11.5 kg/cm2 abs.
than 120% of design pressure. The During vapour recovery.
relieving capacity shall be based on fire
condition. Compressor shall be provided with the
following features:
3.4 SAFETY/SECUTIRY SYSTEM
· Pressure gauges in suction and
The features of safety/security system for discharge.
the different areas in the LPG Bottling Plants
shall be as follows: · Temperature gauge in discharge.

(I) The hand operating/electrical siren should · Discharge safety valve and a vent
be provided to sound the alarm in case of valve, their outlets leading to cold
fire/emergency, if any. flare at a safe height outside the shed.

(ii) Manual push button should be provided at · Suction and discharge block valves
2-3 strategic locations to bring to halt all (lock open type).
the operational activities in the event of any
emergency. · Suction strainer.
 Cylinders shall be evacuated and
· Check valve in discharge. depressurised to near atmospheric
· A discharge to suction recycle valve pressure. The residual LPG in the
for achieving capacity turndown cylinder shall be cold flared in the
during startup. atmosphere at a vent outside the shed at
1.0 M height above the roof of the shed.
Besides these, other indications/protections can
also be provided along with those recommended 3.5.4 PURGING OF NEW CYLINDERS
by compressor vendor.
Proper facility shall be provided to
3.5.3 EVACUATION FACILITIES FOR disperse the air from newly/hydrotested
DEFECTIVE CYLINDEERS cylinders before commissioning.

Proper cylinder evacuation facility with 3.5.5 E L E C T R I C A L A R E A

cold flaring arrangement shall be provided CLASSIFICATION
to evacuate the defective cylinder before
undertaking cold repairing job. For electrical area classification refer to
IS-5571 and IS-5 5 7 2 ( P a r t -I).
 SAFETY AND FIRE PROTECTION
4.0 FIRE PROTECTION FACILITIES 4.4 FIRE WATER SYSTEM

4.1 INTRODUCTION : Water to be used for fire extinguishment/

fire control/cooling of vessels/equipment
LPG Bottling plants are general located and protection of equipment and
away from the populated areas in view of personnel from heat radiation.
hazardous nature of product. In the absence
of statutory regulations prohibiting their 4.4.1 COMPONENTS OF FIRE WATER
construction of residential/others civil SYSTEM
structures, they start mushrooming in and
around these plants and with the passage of The main components of the system are :
time these plants get surrounded by such
civil structures. (i) Fire water storage

A large quantity of highly inflammable (ii) Fire water pumps

product stored at the Bottling Plants pose
safety risk to the plant as well as to the (iii) Fire Hydrant/distribution piping network
surrounding environment. Therefore, it is
essential that adequate Fire Protection (iv) Water Sprinkler.
Facilities are installed at the LPG Bottling
Plants. 4.4.2 FLOW RATE DESIGN

4.2 SCOPE : (i) The fire water pumping requirement shall

be calculated based on spray density as
The standard lays down the minimum given below :
requirements of Fire Protection Facilities at
small LPG Bottling Plants. LPG Storage Vessels 10 LPM/Sq M.
(R + 15)
4.3 DESIGN CRITERIA
LPG Shed 10 LPM/Sq. M.
Following should be considered while
designing the Fire Protection Facilities: LPG Unloading Gantry 10 LPM/Sq. M.

(i) City fire water supply/facilities not available (ii) (a) LPG STORAGE VESSELS:
for these LPG Bottling plants.
Fixed water system with manually
(ii) One single largest fire risk situation shall be operated isolation valve located at a safe
considered. distance of 15 meters shall be provided.
For water flow calculations adjoining
(iii) All LPG storage vessels, cylinder vessels within distance of R + 15 Mts.
filling/storage shed, tank lorry loading (Where R is the radius of the LPG
gantry, LPG pump/compressor shall be Vessels) shall be considered.
covered by fixed water spray sprinkler
system. (b) SHED:

(iv) Fire protection facilities shall have fire Fixed water spray system with isolation
fighting access, means of escape in the event valve to be operated manually and placed
of fire. Whole area should be segregated at a safe distance of 15 meters from the
depending upon the risk involved and each shed shall be provided.
segregated area should have independent
system. (c) TANK LORRY GANTRY:

Layout shall permit access from at least two For tank lorry unloading gantry, fixed
directions. spray system with manual operating valve
 located at 15 meters distance from the
gantry shall be provided. (iii) Pumps shall be capable of discharging
150% of its rated discharge at a
(ii) WATER REQUIREMENT : minimum of 65% of the rated head.

The fire water system in the plant shall be (iv) Fire water pumps shall be exclusively
designed to meet the highest fire water used for fire fighting purposes only.
flow requirement of a single largest risk of
any of the above cases at a time plus 72 No. of fire water pumps of appropriate capacity
Cu. M per hour for operating 2 hydrant shall be provided as per the following criteria :
points.
(a) Normal operation - 1 No.
4.4.3 FIRE WATER SYSTEM DESIGN :
(b) Stand –By - 1 No.
(I) Fire water ring main always charged with
water (atmospheric pressure at a normal 4.4.6 FIRE HYDRANT NETWORK ;
condition) shall be provided all around
perimeter of the LPG plant facilities, with (i) Fire hydrant ring main should normally be
hydrants/monitors conveniently placed to laid above ground. Following precautions
combat the fire protection system. should be taken:

(ii) Fire water ring main shall be designed for (a) Pipe line should be laid at a height of 300
a minimum residual pressure of 7 mm to 400 mm above finished ground
Kg/cm2 quake at the farthest point of level.
application in the plant.
(b) The mains shall be supported at regular
(iii) Fire hydrant network shall be in closed intervals not exceeding 6 meters.
loops to ensure multidirectional flow in
the system,. Isolation of any section on the (c) The system for above ground portion shall
network without affecting the flow in the be analysed for flexibility against thermal
rest. The isolation valves shall be expansion and necessary expansion loops
conveniently located near the loop where called for, shall be provided.
junction for ease of operation.
(d) The portion of fire water hydrant above
4.4.4 4.4.4 FIRE WATER STORAGE : ground and within 15 M of the LPG
storage vessels shall be fire proofed.
(i) Water for the hydrant service shall be
stored preferably in above ground tanks (ii) However, the ring main shall be laid
for availing the advantage of flooded underground at the following places:
suction to enable easy start of fire water
pump. The effective storage capacity (a) road crossings.
shall be for two hours aggregate working
capacity of fire water pumps. (b) Place where above ground piping is likely to
cause obstruction to operation and vehicle
(ii) Storage tank/reservoir shall be 2 in Nos. movement.
Interconnected with suitable valve to
facilitate cleaning/repairs. (c) Place where above ground piping is likely to
get damaged mechanically particularly in
4.4.5 FIRE WATER PUMPS: the LPG storage area where water supply
lines are laid for feeding sprinkler deluge
(i) Centrifugal type fire water pumps shall be system.
installed to meet the designed fire water
flow rate and head. (iii) Fire water ring main laid underground the
following precautions shall be taken :
(ii) Atleast one fire water pump shall be of
diesel engine driven type.
(a) The ring main shall have at least one (ii) The maximum running distance to/ locate
meter earth cushion in open ground and an extinguisher in working areas shall not
1.2 meters cushion under the road exceed 15 meters.
crossings.
(iii) The top surface of the extinguishers shall
(b) The ring main shall be provided with not be more than 1.5 meter high.
protection against soil corrosion by
suitable coatings/wrappings. (iv) The fire extinguishers shall be provided at
various as under :
(c) In case of poor soil conditions it may be
necessary to provide concrete/masonry AREA PORTABLE FIRE
supports under the pipeline. EXTINGUISHER

(d) Fire water ring main shall be sized for LPG storage Vessels 2 Nos. 10 Kg. DCP.
120% of the design water rate. Design (each)
flow rates shall be distributed at nodal
flow rates shall be distributed at nodal LPG Cylinder Filling/ 2 Nos. 10 Kg. DCP
points to give the most realistic way of storage shed per 200 sq. M area
water requirements in an emergency.
Tank Truck loading/ 1 No. 10 Kg. DCP
(iv) Hydrants/monitors shall be located unloading gantries Fire Extinguisher in
bearing in mind the fire hazards at each Bay and 1 No.
different sections of the premises to be 50 Kg, Mobile DCP
protected and to give most effective Unit/gantry.
service.
Office/Canteen/Stores At least 2 Nos. 10 Kg,
(v) Connections for fire water monitors shall DCP Extinguishers in
be provided with independent isolation Each Bldg.
valves.
MCC/DG Room/HT Min 2 Nos, 4,5 kg. CO2
(vi) Hose boxes with 2 Nos, hoses and a Room/ Extinguishers in each
nozzle shall be provided by the side of the room /100 Sq. M area
each hydrant points. and 4 sand buckets
with a stand.
(vii) Considering radiation levels in the event
of a fire, Hydrant/Monitors/Control valves
shall be located at a safe distance from 100% spare CO2 cartridges and 50% spare Dry
hazardous equipments/buildings. Chemical Powder i.e. DCP shall always be
stored in the plant.
4.4.7 FIXED WATER SPRAY/SPRINKLER
SYSTEM: 4.5.2 MOBILE FIRE FIGHTING
EQUIPMENT :
Fixed water spray / sprinkler system shall
be installed in LPG storage area. Tank The Dry Chemical powder used in the
lorry unloading area, LPG shed and in the extinguishers shall be potassium/Urea based or
pump/compressor shed, if any. Sodium Bicarbonate as per IS:4308. The
expellent gas i.e. CO2 should be of food quality.
4.5 FIRE AID FIRE FIGHTING
EQUIPMENTS 4.5.3 HOSES, NOZZLES AND
ACCESSORIES :
4.5.1 PORTABLE FIRE EXTINGUISHERS
(i) Reinforced rubber lined hoses confirming
(i) Portable fire extinguishers (only ISI to IS:636 (Type A or B) shall be provided.
approved) shall be located at convenient
locations and shall at all times be readily (ii) The hoses of 15 meters standard length
accessible and clearly visible. shall be provided with gun metal/
 Aluminium allow male & female The fire fighting system shall be
couplings of instantaneous pattern. periodically tested for proper functioning
and logged for record and corrective
(iii) 50% spare hoses shall be stored in the actions. In addition to routine daily
LPG Plant. checks/maintenance periodic inspection
/testing shall be ensured.
(iv) In addition to the nozzles provided in the
hose boxes, 4 Nos. triple purpose nozzles 4.7.1 FIRE WATER PUMPS :
shall be provided.
(i) Every pump shall be subjected to test run
(v) Fire Hoses : 50% of no. of Hydrant for atleast 10 minutes minimum twice a
points. week.

(vi) Sand drums with scoops : 20 Nos. (ii) Once in a month each pump shall be
checked and tested and the shut-off
(vii) Hose boxes : 1 No. for each hydrant point pressure observed should be logged. Also
the pump performance shall be
(viii) First aid box : 2 Nos. each ascertained.

(ix) Explosimeter : 2 Nos.

4.7.2 FIRE WATER RING MAIN :
(x) Siren: 1 No.
(I) The ring main shall be inspected for any
(xi) Red/Green Flag : 1 No. each visual leaks, defects,. Damages and
corrosion.
(xii) Hand gloves :
(ii) All valves on the ring
(a) Leather lined asbestos hand gloves for main/hydrant/monitor valves shall be
cold working : 2 pairs. checked for leaks/operation and lubricated
once in a month.
(b) Rubber hand gloves : 2 pairs for MCC
room. 4.7.3 FIRE WATER SPRINKLER SYSTEM

4.6 FIRE/ALARM /COMMUNICATION (i) The sprinkler system in the sheds shall be
SYSTEM. tested once in a month.

(ii) The strainer provided in the fire water

4.6.1 FIRE ALARM SYSTEM : sprinkler records maintained. System shall
be cleaned once in a quarter and record
(i) Electricity operated Fire Siren shall be maintained.
audible to the farthest distance in the
plant. 4.7.4 FIRE WATER RESERVOIR :

(ii) Manually operated fire sirens shall also be In case of a reservoir the same shall be
provided at strategic places. cleaned once in 6 months or whenever
needed so that there shall not be any
4.7 INSPECTION AND TESTING : Foreign particles/fungus/vegetation in the
reservoir.
The fire protection equipment shall be
kept in good operating condition all the 4.8 MAKE UP WATER :
time.
Facilities to receive make up water during
fire fighting shall be provided.