TRAINING ON

LPG PLANT OPERATIONS-

RECIEPT OF LPG
BULK LPG RECEIPT
 TYPES OF BULK LPG RECEIPTS

 RECEIPT BY ROAD TANKERS

 RECEIPT BY RAIL TANK WAGONS

 PIPELINE RECEIPT

 COASTAL RECEIPT THROUGH SHIP

 RECEIPT BY ROAD TANKERS

 THE RECEIPT BY ROAD IS THROUGH TANK TRUCKS

OF CAPACITY RANGE 06 TO 18 MT

 THE TANKERS ARE ENGAGED THROUGH BULK

TRANSPORT CONTRACT AGREEMENT WITH BULK
LPG TRANSPORT CONTRACTORS

 THE ABOVE CONTRACTS ARE FINALISED BY

RESPECTIVE ZONAL OFFICES
TANK TRUCK GANTRY

Back….
 SAFETY OF ROAD TANKERS

 THE ROAD TANKERS ARE DESIGNED TO CARRY BULK

LPG & ARE APPROVED BY CCOE & ROAD
TRANSPORT AUTHORITIES
 THE CREW MEMBERS ARE ADEQUATELY TRAINED TO
ENSURE ENROUTE SAFETY
 THE DRIVING LICENCE OF THE T/T DRIVERS ARE
ENDORSED UNDER RULE 9 OF M V ACT
 BOTH THE LOADING LOCATION & BOTTLING PLANT
INSPECT THE TANKERS IN ROUTINE AS PER T/T
SAFETY CHECK LIST
 T/T SAFETY CHECK-LIST
 CHECK FOR VALIDITY OF STATUTORY LICENCES
 CHECK FOR AVAILABILITY OF CCOE APPROVED SPARK ARRESTOR
 CHECK FOR AVAILABILITY OF MINIMUM 02 NO. DCP FIRE
EXTINGUISHERS OF 10 KG CAPACITY
 CHECK FOR ANY LOOSE ELECTRICAL CONNECTIONS & WIRES
 CHECK FOR FUNCTIONING OF BATTERY CUT OFF SWITCH
 CHECK FOR ANY CORROSION OF BULLET
 CHECK FOR HEIGHT OF RIGID HEIGHT BARRIER
 CHECK FOR BONDINGS
 CHECK FOR FUNCTIONING OF EXCESS FLOW CHECK VALVE (EFCV)
 CHECK FOR AVAILABILITY OF FIRST AID & EMERGENCY KITS
 CHECK FOR AVAILABILITY OF TREM CARD & ROUTE CARD WITH CREW
MEMBERS
 CHECK FOR PROPER SIGNAGES & DISPLAY OF MANDATORY
INFORMATION ON TANK BODY
 CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION
CHECKS REQUIRED TO BE CARRIED OUT BEFORE ALLOWING ENTRY OF TT
INSIDE LICENCED AREA ON THE TANK TRUCK :
- Properly fitted spark arrestor of make and design approved by CCE, Nagpur.
- Proper Fittings i.e. SRV, EFCV, temperature & pressure gauges etc. as SMPV Rules &
OISD-STD-159.
- 2 nos. 10 kg. DCP extinguishers in easily accessible and removable position with Truck No.
date of checking and charging painted on it.
- Provision of quick closing manifold valve with lever indicating close and open status.
- No visible dent on the bullet.

ELECTRICALS :
- All junction boxes are properly sealed
- Any loose electrical wiring/ terminal
- Electrical wiring is insulated and provided with suitable over current protection.
- Truck is self starting
- Readily accessible master switch for switching off the engine is provided inside the cabin.
- Dipole wiring.

TANK FITTINGS :
- No Leakage from any fittings or joints.
 CHECK LIST FOR BULK LPG TANK TRUCKS AT UNLOADING LOCATION

CHECKS REQUIRED TO BE CARRIED OUT BEFORE ISSUING

LOADING MEMO (DURING THE COURSE OF UNLOADING OPERTIONS)
- Height barrier provided as per specifications
- Fuel tank is protected by means of stout guard and fuel tank cap is locked.
- Paint of bullet is not peeling off.
- First aid kit is available.
- Internals of fire extinguishers in good condition
- Carries TREM CARD, instructions booklet detailing instructions on handling emergencies en rou
- Carries route map
- Has valid CCE licence and authenticated copy of drawing
- Carries RTO permits
- RLW-ULW> Licenced capacity
- HAZCHEM sign, name of contractor with address and telephone No. displayed prominently.
- Bullet has no sign of external corrosion.
TANK FITTINGS :
- Excess flow check valves are functioning.
- Liquid / vapour lines are adequately anchored and are well protected .
TANK TRUCK OPERATIONS
T/T HANDLING & UNLOADING PROCEDURE
 AS & WHEN THE T/T REPORTS AT THE PLANT, THE DETAILS OF SAME
TO BE NOTED IN REGISTER TO BE MAINTAINED AT THE PLANT MAIN
GATE
 TANK TRUCKS TO BE TAKEN INSIDE THE PLANT FOR DECANTATION IN
THE ORDER OF THEIR REPORTING AT THE PLANT GATE
 IT HAS TO BE ENSURED THAT 02 NO. CREW MEMBERS ARE AVAILABLE
WITH A TANK TRUCK & THEIR IDENTITY TO BE VERIFIED FROM THE I-
CARD ISSUED TO THEM BY THE RESPECTIVE TRANSPORTER
 NECESSARY T/T CREW ENTRY CARD TO BE ISSUED TO THE CREW
MEMBERS FROM THE PLANT GATE
 T/T TO BE WEIGHED AT THE PLANT WEIGHBRIDGE FOR GROSS WEIGHT
& WEIGHMENT TO BE SUPERVISED BY PLANT OFFICER . DETAILS TO
BE LOGGED IN THE REGISTER AND WEIGHBRIDGE SOFTWARE.
 THE TANK TRUCKS SHOULD BE PLACED ON THE UNLOADING POINTS
IN EASILY REMOVAL (DRIVE-OUT) POSITION AND WITHIN SPRINKLER
SPRAY AREA.
T/T HANDLING & UNLOADING PROCEDURE

 TANK TRUCK ENGINE TO BE KEPT IN OFF CONDITION & VEHICLE

SHOULD BE IN NEUTRAL GEAR WITH HAND BRAKE ON
 WHEEL CHOKES SHOULD BE PLACED PROPERLY TO AVOID ANY
MOVEMENT OF TANKERS DURING UNLOADING
 BATTERY CUT OFF SWITCH TO BE OPERATED FOR ISOLATION OF
VEHICLE ELECTRICAL SYSTEM
 DOUBLE EARTHING SHOULD BE PROVIDED TO TANKER BODY AT
APPROPRIATE POINTS (TO BULLET AS WELL AS THE CHASIS)
 DCP FIRE EXTINGUISHERS SHOULD BE KEPT IN READY TO OPERATE
CONDITION
 THE TANKER SHOULD BE CHECKED FOR ANY LEAKAGE ESPECIALLY
AT JOINTS & FITTINGS
 CREW MEMBERS SHOULD ALWAYS BE NEAR THE TANKER DURING
DECANTATION & PLANT OPERATOR HAS TO PHYSICALLY MONITOR THE
TOTAL OPERATION
 PICTORIAL VIEW OF BULK UNLOADING

NRV
LQ TFR CASE COMPRESSOR
VAP REC CASE BULLET

1
2 4
FWV 3
T/T GANTRY KOD
T/T HANDLING & UNLOADING PROCEDURE
 T/T SAFETY CHECKLIST TO BE COMPLETED AFTER COMPLETING ALL
THE INSPECTION POINTS AS SPECIFIED & A COPY OF SAME TO BE
HANDED OVER TO CREW MEMBERS WITH NECESSARY REMARKS FOR
LOADING LOCATION
 UNLOADING HOSES OR ARMS SHOULD BE PROPERLY CONNECTED TO
TANKER VALVES USING C-WRENCH & ONLY METALLIC GASKETS
SHOULD BE USED
 START COMPRESSORS AND CREATE DIFF. PRESSURE IN TT.
 PARAMETERS OF PRESSURE & LIQUID LPG LEVEL (THRU’
ROTOGAUGE) SHOULD BE MONITORED FOR THE TANKERS BEING
UNLOADED
 AFTER THE DECANTATION IS OVER, IT SHOULD BE ENSURED THAT
HOSES OR UNLOADING ARMS ARE REMOVED SAFELY
 AFTER REMOVAL OF EARTHING CONNECTORS & WHEEL CHOKES,
TANKERS SHOULD BE REMOVED FROM THE UNLOADING POINTS &
TAKEN TOWARDS PLANT WEIGH BRIDGE
 TARE WEIGHT OF EMPTY TANKER TO BE NOTED BY THE PLANT
OFFICER TO ARRIVE AT NET PRODUCT DELIVERED BY THE TANKER
 T/T HANDLING & UNLOADING
PROCEDURE(CONTD.)

 ANY VARIATION OF PHYSICAL WEIGHT OF BULK LPG RECEIVED VIS-À-

VIS DOCUMENT QUANITITY SHOULD BE NOTED IN THE LOG BOOK AND
WEIGH BRIDGE SOFTWARE.

 THE NECESSARY ACKNOWLDGEMENT OF RECEIPT SHOULD BE GIVEN

TO THE CREW MEMBERS BY THE PLANT OFFICER AFTER MARKING
SHORTAGES (IF ANY)

 DCP FIRE EXTINGUISHER OF THE TANK TRUCK IF OPERATED AT THE

PLANT FOR CHECKING, SHOULD BE REPLENISHED FOR DRY CHEMICAL
POWDER & REFILLED CO2 CARTRIDGE

 AT THE PLANT GATE, IN THE TANK TRUCK REGISTER, NECESSARY

ENTRY SHOULD BE MADE TOWARDS DECANTATION OF TANK TRUCK
WITH THE NOTING OF OUTGOING DETAILS OF THE SAME
LOADING/UNLOADING ARM
ERC
 RECEIPT BY RAIL WAGONS

THE RALWAY WAGONS FOR TRANSPORT OF LPG ARE :

- TG WAGONS (GENERALLY OF 13 TO 15 MT CAPACITY)

- RDSO WAGONS (GENERALLY OF 13 TO 15 MT CAPACITY)

- BTPGL WAGONS (GENERALLY OF 37.6 MT CAPACITY)

THE STANDARD RAKE SIZE FOR TG & RDSO WAGONS IS 72 NO.

WHEREAS THE SAME FOR BTPGL WAGONS IS 36 NO.

THE NORMAL QUANITY OF LPG DELIVERED BY ANY RAKE IS 1200

TO 1250 MT

RAIL RECEIPT AT HPCL IS AT BAHADURGARH, RAIPUR, JATNI,

HAZARWADI, CHERLPALLI & KHAPRI LPG PLANTS
TANK WAGON GANTRY
TANK WAGON GANTRY
 T/W HANDLING & UNLOADING
PROCEDURE
 THE T/W UNLOADING IS USUALLY CARRIED OUT BY THE
CONTRACTOR

 AFTER THE RAKE PLACEMENT ADVICE IS RECEIVED,

CONTRACTOR SHOULD REACH THE SITE ALONGWITH THE
LABOUR & ALL TOOLS / TACKLES

 THE RAKE PLACEMENT SHOULD BE ENSURED FROM POINT TO

POINT TO AVOID FOULING OF CONNECTIONS

 BRAKING FOR EACH WAGON TO BE ENSURED

 CONDITION OF WAGON SEALING & SLIP TUBE DIP READINGS

SHOULD BE TAKEN IN THE PRESENCE OF PLANT OFFICER
 T/W HANDLING & UNLOADING
PROCEDURE(CONTD.)
 IN CASE OF ANY DISCREPANCY IN CONDITION OF SEAL & DIP
READING, JOINT INSPECTION TO BE CARRIED OUT WITH
RAILWAY REPRESENTATIVES

 EACH & EVERY WAGON TO BE CHECKED FOR ANY LEAKAGE

ETC.

 CONNECTIONS SHOULD BE MADE PROPERLY USING LPG HOSES

OR UNLOADING ARMS

 AFTER THE START OF UNLOADING PROCESS, REGULAR

MONITORING OF WAGONS SHOULD BE ENSURED

 AFTER DECANTATION OF LIQUID LPG IN A PARTICULAR WAGON,

CORRESPONDING LIQUID LPG VALVE TO BE CLOSED
 T/W HANDLING & UNLOADING
PROCEDURE(CONTD.)
AFTER DECANTATION OF LIQUID LPG IN ALL
WAGONS, FOUR WAY VALVE SHOULD BE
CHANGED FOR STARTING VAPOUR RECOVERY

AFTER THE TOTAL PROCESS IS COMPLETE,

CONNECTIONS SHOULD BE SAFELY REMOVED

RELEASE NOTE IN STANDARD FORMAT SHOULD

BE HANDED OVER TO RAILWAY AUTHORITIES
LPG LOADING
OPERATIONS
 LOADING OPERATION
• At the Entry Gate, Registration of the Tank Truck shall be done on the basis of
checklist cum loading advise from unloading location
• Place the tare-weighed truck in the gantry and adjust the position of the truck to
facilitate easy connection of loading arms / hoses
• The truck should switch off its main battery switch and the hand brake or air brake
has to be applied.
• Connect the earthing clamps to the tank truck
• Connect the loading arms / hoses - both liquid and vapour by fixing bolts or
coupling. Use Metallic Gaskets and fix all nut bolts while making flange connection
• Keep the DCP fire extinguisher of the truck in ready to use position.
• Open the valves on the liquid and vapour lines before the respective loading arms/
hoses.
• Crack open the ball valves and check for leakage in the flange connections.
• If there is leakage, close the valve immediately and vent out the product between
the loading arm valve and truck valve by opening the ½ “ vent valve. Arrange to
arrest the leakage by retightening of bolts/coupling.
 LOADING OPERATION
• First open the truck valves and then open the vapour loading arm valve slowly to
make the vapour line through. The liquid loading arm ball valve is kept as the
controlling valve.
• The crew of the truck should be available near the loading arms throughout the
loading operation.
• Tank trucks are usually loaded by means of pumps
• The liquid may be discharged into the liquid space or the vapour space of the truck
tank.
• A vapour equalizer line is usually connected between the tank truck vapour space
and the vapour system of the plant to avoid excessive pressure building up in the
truck tank.
• The quantity loaded in the truck can be determined by liquid level, weighment,
positive displacement meter, mass flow meter.
• The quantity of LPG filled shall be lower of the quantity approved by CCOE or
RLW of the tank truck.
 LOADING OPERATION
• Liquid level may be determined by rotogauge or fixed liquid level gauge.
Percentage volume to be filled shall not exceed 85 %.
• After the loading is completed close all the valves of the truck and the loading
arms.
• Vent out the product between the truck valves and ball valves of loading arms
through the vent valves, which are connected to the vent lines. After venting is
completed close the vent valves and disconnect the loading arms.
• Remove the earthling clamps.
• Ask the truck crew to take the truck out of the gantry slowly for gross weighment.
• After gross weighment, if it is found that TT is short loaded, it is sent back to the
gantry for filling the short quantity. In case it is overloaded, it goes to Bay
for decanting the excess quantity.

Note : In case the location is not provided with loading arms and LPG hoses are still in
use, the term loading arm to be read as LPG hose.
 APPROVALS AND STATUTORY
REQUIREMENTS FOR TANK TRUCKS
• ‘License to Transport Compressed Gas in a Vehicle’ in Form IV as per SMPV Rule 49
and 50 of Indian Explosives Act 1884 (4 of 1884) issued by Chief Controller of
Explosives.
• ‘Certificate of Fitness’ in Form 38 as per Rule 62(1) of Central Motor Vehicles Rules
1989 and ‘Certificate of Registration’ in Form 23 as per Rule 48 of CMV Rules 1989
issued by R.T.O.\
• ‘Certificate of Half Yearly Examination of Road Tankers for Compressed Gases’ as per
rule 44(2) of SMPV(U) Rules 1981 issued by Competent Authority certified by CCOE.
• ‘Certificate of Yearly Test of Safety valve and Excess Flow valve’ as per rule 18 of
SMPV (U) Rules 1981 issued by Competent Authority certified by CCOE.
• Monthly servicing certificate of DCP Fire Extinguisher .
• Driving licence which should specifically mention that the driver is certified to drive
vehicles carrying hazardous chemicals as per CMV Rule 9, 1993.
• ‘Safety Check List for Road Tankers’ pertaining to the truck issued by the unloading
location.
 SAFETY PRECAUTIONS DURING
LOADING / UNLOADING OPERATIONS
• Transfer of LPG to or from a tank truck requires special attention as accidental
movement of vehicle may cause rupture in the transfer equipments.
• No source of ignition must be allowed in the area where product transfer operations are
carried out.
• Fire extinguishers shall be placed near the tank trucks during transfer operations.
• The first operation after positioning the truck should be to provide proper earthing.
Earthing shall be disconnected just before the release of the truck.
• Before removing plugs or caps, always crack open to allow for release of trapped LPG
and further to ensure that the valves are effectively sealing.
• Hoses should be handled with care and inspected periodically (Refer OISD Standard
135 on Inspection of Loading / Unloading Hoses for Petroleum Products).
• While disconnecting hoses/pipes, connections should be loosened only slightly at first
to allow release of trapped pressure, if any.
• Do not expose hands, face or clothing to liquid LPG. Always use personal protective
equipments while making or breaking the connections to avoid cold burns.
 SAFETY PRECAUTIONS DURING
LOADING / UNLOADING OPERATIONS
• Gas detection system shall be provided in line with OISD-STD-144.
• The master switch shall be put off immediately after parking the truck in position. No
electrical switch on the truck shall be turned " on" or " off" during the transfer
operation.
• No repairs shall be made on the truck while it is in the loading area.
• New tank trucks vessels or vessels received after repair shall be purged before
loading.
• It is recommended that the receiving vessel having a pressure of less than 1 Kg/sqcm
should not be filled. Such vessel should be checked for oxygen content/explosive
mixture and purged, if necessary.
• Venting and purging of LPG during transfer operation normally should not be carried
out in open atmosphere. It should be piped to a suitable flare system. Where such
facility does not exist, vent pipes shall be provided to carry the vented product to a
safe distance and released at a height not less than three metres above the highest
point of any building, shed or structure within 15m radius. Snuffing steam facility
may be provided for the vent line.
 SAFETY PRECAUTIONS DURING
LOADING / UNLOADING OPERATIONS

• Filling/transfer operations should be stopped immediately

in the event of –

- Uncontrolled leakage occurring

- A fire occurring in the vicinity
- Lightning and thunder storm
PIPELINE RECEIPT
 PIPELINE RECEIPT REQUIRES TRANSFER OF BULK
LPG FROM MOTHER STATION OR MAIN LPG
TERMINAL TO THE LPG PLANT
 THE PRODUCT TRANSFER IS DONE THROUGH
PUMPING SINCE NO VAPOUR RECOVERY IS
INVOLVED
 STORAGE TANKS WHICH ARE TO RECEIVE THE
PIPELINE TRANSFER PRODUCT ARE TO BE LINED
UP & ADEQUATE ULLAGE SHOULD BE ENSURED TO
RECEIVE THE PRODUCT
 PRODUCT IS RECEIVED THROUGH PIPELINE
TRANSFER IN HPCL AT AJMER, LONI, VISAKH,
USAR, MAHUL, ANKLESHWAR, MANGALORE,
KONDAPALLI & CHERLAPALLI PLANTS

PIPELINE RECEIPT
 PIPE LINE RECEIPT
 LOCATIONS HAVING PIPE LINE RECEIPT
FROM REFINERY :
 MANGALORE
 VISAKH
 MAHUL
 LOCATIONS HAVING PIPE LINE RECEIPT
FROM CROSS COUNTRY PIPE LINE (GAIL) :
 AJMER
 USSAR
 ANKLESHWAR
 LONI
 KONDAPALLI
 CHERLAPALLI
PIPELINE TRANSFER
 PIPE LINE RECEIPTS
Based on the stock availability at the Refinery /
Mother station or Main LPG Terminal and
product requirement, PLT is planned.
If the product samples pass the QC tests, Joint
Flow meter readings are taken at both ends.
The supply line is made through upto the
Refinery / Mother station or Main LPG
Terminal battery limit.
A sphere / bullet with sufficient ullage is lined
up in the receiving location.
 PIPE LINE RECEIPTS

 Isolation gate valve of the pertinent area is closed.

At this lined up position, PLT will be controlled
by the MOV which is kept closed.
 The valve at Refinery / Mother station or Main
LPG Terminal battery limit is opened and the line
is allowed to fill under gravity upto MOV of the
receiving vessel.
 Once the line is filled and the gauges of supply
sphere stabilize, the receipt line of the receiving
sphere / bullet is made through by opening the
MOV.
 Once the product starts flowing, Supply location
is advised to start the pumps.
 PIPE LINE RECEIPTS
 Hourly figures of the pumped quantity, flow rate,
pressure and temperature are recorded from the
flow meter.
 Quantity pumped and quantity received are
exchanged and noted by the supply and receiving
locations.
 In case of large variation between the quantity
despatched and the quantity received, the PLT is
stopped and the pipelines are checked for any
leakages or improper lining up of the supply and
receiving spheres.
 PIPE LINE RECEIPTS
 Pumping is stopped once the planned quantity
has been delivered.

 After the pumping is stopped the closing Flow

Meter readings at both ends are taken and
recorded.

 Necessary documentation (Outturn / Joint

Certification) is prepared and signed by both
locations).
 SAFETY DURING PIPE LINE RECEIPTS
 It should be ensured that the sphere is properly lined up.
 Ensure that appropriate isolation valves are closed.
 Monitor pressure, flow rate / quantity and temperature
constantly to ensure that the flow is with in safe limits.
 Ensure continuous communication is maintained with
supply location.
 The Line from MOV at battery limit to the bullet / sphere
is kept through for a few hours after PLT is over, so that
the pressure is stabilised in the pipeline and Bullet /
Sphere.
LPG TANK TRUCKS:

REQUIREMENTS OF SAFETY FOR

DESIGN/FABRICATION AND
FITTINGS
LPG TANK TRUCKS: REQUIREMENTS OF
SAFETY FOR DESIGN/FABRICATION AND
FITTINGS

 All LPG tank trucks should meet the requirements

of the Motor Vehicle Acts and Regulations and
Static & Mobile Pressure Vessels (Unfired) Rules,
1981 as amended from time to time.
 VESSEL DESIGN

• DESIGN PRESSURE:

 Vapour pressure of LPG conforming to IS:4576 at a

maximum anticipated service temperature of 55 °C to
be considered.

 Providing an allowance of minimum 5% as per code

requirements the minimum design pressure shall be
14.5 kg/sq.cm.
 VESSEL DESIGN

• Design Temperature:
The design temperature of the vessel shall be 55 °C.

• Vessel Design Code:

Vessel shall be designed, fabricated and tested in
accordance with requirements of Class I pressure vessels
conforming to IS:2825 - 1969 (Latest Edition) BS-5500,
ASME SEC. VIII or equivalent codes accepted by
Statutory Authority.
 VESSEL DESIGN

Vessel Plate Thickness:

The nominal thinkness of the plate material used in

fabrication should not be less than the sum of
minimum calculated thickness as per the fabrication
Code and Corrosion Allowance (CA), if necessary
and in addition, adequate thinning allowance in case
of formed heads.

For mobile vessels (for which CA may not be

necessary) an allowance of at least 0.5 mm. shall be
included in place of CA to safeguard against wear
and tear
• Connecting Joints/Nozzles and Manhole:
Connecting joints / nozzles and manhole shall be
constructed without any flange joints.

• Baffle Plates:
Every vessel over 5 cu.m water capacity shall be fitted
with baffle plates to minimise the surge, the design of
which should facilitate complete internal inspection.

• Painting:
External surface shall be sand blasted and painted with
two coats of red-oxide primer and two coats of enamel
paint of the colour stipulated by HPCL , in
Transportation agreement.
• Marking:
• Vessel Identification Plate:
Each vessel shall have a non-corrosive metal plate permanently
affixed by brazing or welding on the rear dished end in a place
readily accessible for inspection and maintained legibly.

• Valves and Accessories:

LPG pipes, fittings and other equipments mounted on the vessel
shall be suitable for LPG service i.e. corresponding to Vapour
Pressure of LPG at 55 °C. and shall be capable of withstanding
the most severe combined stresses set up by the following:
 a) Maximum vapour pressure of the product in
service.
 b) Superimposed pumping pressure.
 c) The shock loading during transport movements.
• Fittings:

• LPG tank truck is provided with the following

openings/nozzles:

 Safety Relief valves (Two Nos).

 Excess flow check valves in the liquid and vapour lines.
 Pressure gauge (Provided in the vapour space of the vessel)
 Temperature gauge (Provided in the liquid space)
 Rotogauge (to measure the percentage of liquid in the vessel.
 Manhole with cover.
 Drain point at the bottom.
 Liquid/Vapour manifold.
 Safety Relief Valve:

• There shall be minimum two safety relief valves

with each one sized to suit the full relieving capacity of
the vessel. The design and operation of Safety Relief
Valves shall conform to the provision of SMPV rules as
amended from time to time.
• SRV shall be so installed that it does not project
out of the top surface of the vessel. If necessary, recessed
cup formation on vessel shall be made to house the SRV.

• The safety relief valves shall be installed at the top

surface around the central portion of the vessel
 Liquid / Vapour Connections:

• 1 no. 50 mm size liquid inlet / outlet and 1 no. 40

mm size vapour connection shall be provided at the
bottom of the vessel.

• The vapour line shall extend internally with a

clearance of 50 mm from the top of the vessel
surface.
Internal Valve with Excess Flow Check Valve

• Internal valves with EFCV of appropriate

ratings shall be installed on LPG liquid and vapour
line
 Liquid Level Gauging Device - Roto Gauge

• The vessel shall be equipped with a liquid level

gauging device for ready determination of liquid level in the
vessel at any time. The liquid level gauging device shall be
of the direct level gauge type with zero leakage of product to
atmosphere. The design shall be such that the unit
encompasses a tough, durable steel shock absorber to
prevent transfer of any vibrations sustained in transit.

• This liquid level gauging device shall be located on

the shell near the midpoint /top upper half of the vessel in a
recessed cup formation.

• To avoid damage to this liquid level gauging device,

a suitable hinged cover shall be provided.
 Pressure Gauge & Temperature Gauge

• 1 No. dial type (100 MM) glycerine filled pressure

gauge with EFCV shall be provided on the rear dished end in
the vapour space. This shall be protected by 10 mm thickness
U-type shield metal plate.

• The range of the pressure gauge shall be from zero to

21 kg/sq. cm (min.) gauge.

• 1 No. Dial type temperature gauge to be provided.

• Drain:

Suitable drain of maximum 25 mm NPT plug to be

provided on the bottom side of vessel with proper
shield.

• Manholes:

1 no. manhole of size as per IS 2825 or code followed

for design and fabrication of vessel shall be provided
on the rear dished end.
• Protection of Fittings:

All valves, fittings, safety relief devices and other

accessories to the vessel proper shall be protected
against such damage as could be caused by collision
with other vehicles or objects and due to
overturning.
 Filling Capacity

• The maximum quantity of LPG filled into any tank

shall be such that the vessel shall not become liquid full due to
the expansion of LPG and shall leave a vapour space
equivalent to 5% or as stipulated by Statutory authority of its
volume with the rise of temperature of its contents to a
maximum of 55 °C.

• The RLW of the vehicle shall not exceed the authorised

Registered Weight of the vehicle by the concerned transport
authority or chassis manufacturer, whichever is less. The Pay
Load filled should not exceed the licensed capacity as
permitted by the R.T.O.
 VEHICLES
GENERAL SAFETY CONSIDERATIONS

1. Each tank truck shall be provided with at least one rear

robust bumper, designed to protect the vessel and piping in
the event of a rear-end collision and minimise the
possibility of any part of the colliding vehicle striking the
vessel.
2. Extension to chassis, if any shall not be more than 300 mm
and the extension piece shall not be welded to the chassis.
3. Whenever cabin height is less than the height of the vessel
and fittings on top of it, a height barrier shall be provided
all along the width of the cabin in the form of a cage either
50mm diameter pipe or 50 X 50 X 3 MM angle frame on
the top of vessel and within the height regulation of Road
Transport Authority
 VEHICLES
GENERAL SAFETY CONSIDERATIONS
• 4. The fuel tank to be protected from external blows by stout steel
guards.
• 5. Safety Equipments:
The vehicles shall carry the following:
a) A First Aid box.
b) 2 nos. 10 Kg DCP (ISI marked fire extinguishers (ISI marked).
c) Leather hand gloves and heat resistant hand gloves.
d) Safety Goggles
e) 2 nos. red flags
f) Emergency kit approved by CCOE.
g) TREM card.
In addition, each vehicle must carry non-metallic tools, wooden
plugs of appropriate size and sealing compound for any
emergency.
 VEHICLES
GENERAL SAFETY CONSIDERATIONS

• An emergency information board should be

displayed on the vehicle mentioning the important
telephone nos. of contractor, Oil company’s loading
base, attached Bottling Plants and easier contact
nos. in the event of accident.
 Design Safety Requirements - Electrical

• The Electrical System:

– The battery shall be mounted inside the cabin
within a metallic cover with openings in an easily
accessible position.
– A readily accessible cut-off switch of not less than
300 Amps rating.
– Electrical wiring shall be heavily insulated and be
adequate for maximum current loads to be carried.
– Have all junction boxes sealed.
– Normal/emergency lighting other than that
permitted by the Transport Authority shall not be
allowed.
 Design Safety Requirements - Electrical

• Earthing boss on the saddle of the vessel shall be

provided on both sides.
• The vehicle should carry minimum six reflector
cones having base of 12” dia and height of 2.5 feet.
These cones should be used for marking out the area
where truck is parked or in the event of an accident
segregating it from other portion of the road.
 PURGING

• After completion of hydro and pneumatic

tests, the bullet shall be purged safely by authorised
persons, and only then it should be taken for
Loading.
DEFECTIVE CYLINDERS
EVACUATION
 EVACUATION OF DEFECTIVE CYLINDERS

 THE DEFECTIVE (LEAKY) CYLINDERS SEGREGATED

AT ELD (VALVE LEAK & NECK LEAK) , AT TEST BATH
(BODY LEAK, NEC LEAK) ARE EVACUATED AT ON-
LINE EVACUATION UNIT
 THE CYLINDER ARE EVACUATED OF ALL THE LIQUID
LPG WHICH IS TRANSFERRED TO STORAGE TANKS
 VAPOUR PRESSURE IS ALSO REDUCED INSIDE
CYLINDERS UPTO 1.5 KG/CM2
 THE EVACUATED CYLINDERS ARE TRANSFERRED TO
CYLINDER REPAIR SHED FOR NECESSARY COLD
REPAIRS
 COMPRESSOR STAGE 1

P/G
P/G

VAPOUR VAPOUR

To Bullet

NRV

LIQUID LIQUID

Cylinders
NRV

FORCED EVACUATION SYSTEM

 COMPRESSOR STAGE 2

P/G
P/G

VAPOUR VAPOUR

To Bullet

NRV

LIQUID LIQUID

Cylinders
NRV

FORCED EVACUATION SYSTEM

PURGING OF LPG
CYLINDERS
 PURGING OF LPG CYLINDERS
Purging is the procedure to remove the air from the New, Hot repair and Pressure tested
cylinders and replace it with LPG before filling , which is a mandatory requirement as
per CCOE .It is done to avoid presence of Air - LPG Flammable mixture inside the
cylinder.

New cylinders and cylinders degassed for repairs shall be purged of air prior to be taken
up for refilling with LPG. Following safe procedure shall be observed for purging of
LPG cylinders :

• Connect the cylinder valve to vacuum pump and evacuate air so that the pressure in
cylinder is brought down to maximum 0.35 kg/cm 2 absolute.
• Inject LPG vapour in the cylinder so that pressure is minimum 1 kg/cm 2.
 PURGING
The evacuation facility shall consist of :

• Vacuum pump (water/ oil / air cooled type)

• Purging manifold
• Vacuum receiver fitted with vacuum gauge, vent and drain.
• LPG vapour header
• Purging adapters
• Vacuum pump with suction strainer
• Pressure regulator, relief valves
SCHEMATIC DIAGRAM
THANK YOU