OISD 144 for LPG Plants

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Prepared by
Mohammed Asif Akram
Visakh LPG terminal
 Scope of std. OISD-144
Minimum safety requirements on
Design, layout, storage;
Operations;
Loading /unloading operation;
Inspection & maintenance;
Fire protection facilities;
Emergency planning;
Safety Audit systems
of LPG Installations

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 LPG PROPERTIES
• Colorless, but when leaked to atmosphere, whitish fog is formed due to
condensed water vapour
• Coefficient of expansion is around 0.00237 per C., which is 100 times
that of steel. Therefore high thermal stresses induce in Pipe due to
increase in temperature.
• This is considered during design of safety valves for vessels and pipelines.
• Stresses induced: At Liquid full condition-- per 1 oC, due to expansion of
the liquid, the container pressure will rise by approx. 14 to 15 kg./sq.cm.
• Auto-ignition temperature------- 410 to 580 oC.

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 FACILITIES FOR LPG PLANT
• Bulk Storage Facilities
• LPG Pump / LPG Compressor Facilities
• Cylinder Filling Facilities & QC equipment
• Cylinder Storage Facilities
• Water Storage Tanks / Fire Fighting facilities
• Tank Truck Gantry
• Tank Wagon Gantry
• Cylinder purging facilities
• Cylinder evacuation facilities
• Cylinder repair / hydro-testing facilities
• Electrical power supply
• Utilities (Air compressor, Service Water pump )
• Plant Building
• Office / Amenity block
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 LOCATION, LAYOUT AND SEPARATION DISTANCES
Following factors are to be considered while finalizing the location & layout of Bottling Plant:
• Location of residential quarters, other industries, railways, roads, water ways, overhead power lines, places of
public assemblies etc.
• Consider plan for emergency measures.
• Availability of water
• Availability of space for future extension of LPG facilities(with safety norms)
• Meteorological data of the location including predominant wind direction & velocity, high flood level,
temperatures etc.
• Separation distances as given in below Tables- I & II are the distances in plane between the nearest point on a
vessel other than the filling/ discharge line and a specified feature, e.g. adjacent vessel, site boundary etc.
• Atleast two side firefighting equipment to storage vessels
• Longitudinal axis of static vessels direction
• Storage vessels to be located preferably in downwind of potential ignition sources
• Storage vessels shall be laid out in single row in each group and shall not be located one above the other.

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SAFE SEPARATION DISTANCES IN LPG PLANTS
Table-I

1 2 3 4 5 6 7 8

1. LPG STORAGE VESSEL * T-II 30 30 50 30 15 60

2. BOUNDARY/ PROPERTY LINE T-II - 30 30 50 30 30 -

3. SHED LPG 30 30 15 30 50 30 30 60

4. TT GANTRY 30 30 30 50 50 30 30 60

5. TW GANTRY 50 50 50 50 50 50 30 60

6. LPG/ OTHER RAIL SPURS 30 30 30 50 50 50 30 60

7. PUMP HOUSE 15 30 15 30 30 30 - 60

8. FIRE PUMP HOUSE 60 ** 60 60 60 60 60 -

NOTE:
 Mounded storage to FF storage / Pump house is 30m.
 Mounded storage to any other LPG Shed is 15m
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 SAFETY DISTANCES FROM PROPERTY LINE
Table II

A/G storage vessels- Capacity of DISTANCE (M)

each vessel (M3)
10-20 15
20-40 20
40-350 30
350-450 40
Note: In Case of mounded
450-750 60 storage of any capacity the
requirement is only 15 m
750-3800 90
>3800 120

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 INSTALLATION LAYOUT
• Plant roads, walkways, doors and operating equipment shall be designed
as per the standard
• Permit access to be given from at least two directions.- Layout
• The access of mobile fire fighting equipment- atleast from 2 sides of
storage vessels.
• Longitudinal axis of static storage vessels (bullets) direction to be
designed as per the standard
• Storage vessels to be located preferably in downwind of potential ignition
sources at lower elevation.
• Storage vessels shall not be located one above the other, but in a single
row in each group.

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 Visakh
Visakh NewLPG terminal
LPG Plot
Terminal- plan
Plot planterminal Plot plan
Visakh LPG terminal Plot plan
 TYPES OF LPG STORAGE FACILITIES :
1. At ambient temperature under pressure
 Sphere / Bullet - Old technology
 Mounded Storage Vessels – Latest technology
 Under ground Storage Caverns –
eg: SALPG Cavern, VIZAG - Capacity 60000 MT

2. At atmospheric Pressure at low temperatures below boiling point

• Refrigerated storage

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 PRESSURE VESSELS- DESIGN PARAMETERS
 Marketing locations ASTM A 516 Gr. 70 or A 537 Cl. 1
 Refinery Storage – ASTM A 516 Gr. 60. Low stress material (presence of H2S can lead to stress
corrosion cracking)
 Design temperatures – 27OC to +55OC
 Design Pressure – min. 14.5 kg/sqcm vap. pres. of LPG at 55OC
 Corrosion allowance – 1.5 mm
 Stress relieving 100 % irrespective of thickness
 Radiography before and after Stress relieving
 Hydro-testing as per design code BS 5500, ASME Sec VIII Div. 2, IS 2825
 Stage-wise inspection by PESO approved TPI - Certificate of Control
 Liquid filling – Max. 85% of volumetric capacity

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 FITTINGS – PRESSURE VESSELS
 Single bottom nozzle for inlet as well as outlet
 Bottom Nozzle to be extended 3 m beyond the vessel shadow
 Bottom Nozzle - Slope of 1.5O for effective drainage support from sphere legs
 First valve from vessel to be Fire safe ROV
 Two independent level indicators
 High level alarm / switch for auto closure of ROVs
 Pressure switch for alarm / auto closure of ROVs
 Safety relief valves – 2 nos. Set at 110% of design pressure and enough relieving capacity for keeping
pressure under 120%
 Block valves prior to safety relief valves to be kept lock open

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 FITTINGS – PRESSURE VESSELS
 Discharge vents from SRVs to be connected to flare or to atmosphere at a
height of 3 m above SRVs
 Drains on discharge vents to prevent collection of rain water and also
such that discharge doesn’t impinge on vessel
 SRV capacity shall be based on fire condition and no credit can be taken
for fire proofing
 All flange joints to have metallic gaskets
 Emergency Shut down - Auto actuation of alarms / deluge systems and
tripping of critical equipment
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 LPG BULK LOADING/UNLOADING FACILITIES – RAIL
• Loading/unloading gantry shall be covered & located in a separate block shall not
be grouped with other petroleum products
• LPG TW loading/unloading shall be restricted to a max of half rake, less than 600
MT
• For full rake loading/ unloading, two separate rail gantries separated by distance
of 50 M shall be provided
• LPG loading/ unloading rail gantries shall have separate rail spur and be grouped
separately at least 50 M from other rail shunting facilities
• Loading/unloading arms to be provided with emergency release couplings

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TYPICAL LPG TANK WAGON

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 LPG BULK HANDLING FACILITIES – ROAD
• Each Gantry Limited to 8 bays; Inter-distances between gantries – 50m
• Trucks in drive-out position for quick exit.
• Excess flow check valves in loading gantries.
• Loading arms with Break-away couplings and Quick connect – disconnect
couplings are preferred.
• Loading arms provided with blow down or bleeder valves to vent loading
arm quantity
• Vapor return lines to prevent over pressurization of vessels during loading
operations
• Shut-off valve at discharge end of hose / Loading arm
• Discharge of static charges through continuity jumpers, earthing of pipelines,
pumps, other equipment including trucks - a critical factor in loading /
unloading operations

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 LPG PUMPING FACILITIES
• Positive gradients in suction lines from Vessels to avoid vapor locks.

• Provision for rapidly and positively stopping flow in emergencies

• Provision for auto-recirculation valves to avoid surges in pipelines
• Double mechanical seals for additional protection

• Liquid lines should have Thermal relief valves to relieve excessive pressures
developed in sections between block valves due to temperature rise
• Water draw-off from vessels should extend well beyond the shadow of the vessel
and should be provided with double block valves

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TYPICAL BOTTLING PUMP INSTALLATION

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 LPG BOTTLING FACILITIES
Bottling Facilities are provided in open sheds – for ventilation
RCC columns (unaffected by heat)
AC Sheets Roofing for effective ventilation.
Anti-static flooring and covering on columns up to 1.5m to avoid sparks.
3 shed concept for enhanced safety in operations. Filling, Storage and Cold repair
activities are segregated in different sheds.
Conveyors for avoiding manual handling of cylinders.
Conveyor & Equipment layout planned in such a manner to prevent trapping of
personnel.
Online evacuation of leaky cylinders.

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 LPG BOTTLING FACILITIES
 LPG cylinder filling machines & other related machines shall be provided in
sequential order
 A separate shed shall be provided for carrying out degassing of defective cylinders
 Filled cylinders to be stored in a separate shed
 Escape routes shall be specified and marked in LPG sheds for evacuation of
employees in emergency
 Sufficient no. of crossovers to avoid trapping of personnel in LPG sheds by
conveyors, cylinders and other facilities
 Sufficient no. of escape routes shall be provided

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 PROTECTION OF FACILITIES
• Properly laid out roads around various facilities
• Boundary wall at least 3 M high with 0.6 M barbed wire on top shall be provided
• Emergency exit with proper gate shall be provided in the earmarked zone
• Fireproofing of the column surface (spheres) or providing RCC pedestals (bullets)
• Fire water storage & Fire Engines for fire fighting for 4 hours
• Fire hydrant network with Hydrants and monitors @30m c/c
• Automatic sprinkler system
• Gas Detection System
• Green belt if provided should be segregated from hazardous area with a 1 M high
wall / chain link fencing. Alternatively, it shall be treated as a part of hazardous area

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 OISD -144 SAFETY CONSIDERATIONS
• Philosophy – Segregation of facilities to separate operations
• Inter distances – not designed for catastrophic conditions
• No cylinder trucks to come within 15m from LPG Sheds
• Storage vessels shall be located in downwind direction from potential ignition
sources and at lower level
• Longitudinal axis of bullets shall not be pointing towards any of LPG facility, FF shed,
buildings
• Top level of all vessels in a group shall be same. Max. of 6 bullets in one group
• Proper Soil investigation to be prevent settlement and consequent hazards
• Design of supports with provision for expansion and contraction of vessels

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 SAFETY SYSTEMS IN LPG PLANT

SAFETY SYSTEMS IN LPG PLANT

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 FIRE PROTECTION SYSTEMS

Gas Monitoring system

Vapour extraction system

Fire Water System

Heat detection System

Fire extinguishers

Fire Alarm/Communication system

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 SAFETY CONSIDERATIONS

GAS MONITORING SYSTEM

• Gas detectors placed at strategic locations and with audio-visual alarms.
• Manual Activation of sprinklers system in the event of Gas leak an option - Effective in
dispersing LPG vapor but can result in larger vapor cloud in case of liquid leak.
• Manual activation allows emergency to be evaluated.

VAPOUR EXTRACTION SYSTEM

• For removal of LPG from filling area. To be kept running as long as the filling operations are in
progress.
• Ducting location a critical factor for effective extraction.

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VAPOUR EXTRACTION SYSTEM

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 AUTOMATIC FIRE PROTECTION SYSTEM
• Designed for minimizing the damage once fire occurs

• Water is primary means of fire protection

• Vessel exposed to fire can fail due to inadequate pressure relief or failure of metal due to excessive metal temperature.

• Metal failure occur faster if the flames impinge on the portions of the vessel that are not internally wetted by the liquid.

• Vessel failure in this case can occur within few minutes if flame impinges on portion of metal not wetted by liquid inside

• Water application on vessels serve the following purposes:

- To reduce the volume of vapor to be vented by SRVs

- To prevent vessel failure due to excessive metal temperature

• Water application rates is that rate that is necessary to satisfy 2nd objective

• Adjacent areas to be cooled is decided basis the radiation from received fires without direct flame impingement from adjacent vessels
and the max temperature rise that can occur

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 FIRE PROTECTION FACILITIES
• All storage vessels, bulk loading facilities, pumphouses, sheds covered by
medium velocity water spray system.
• Heat Detectors (QB/EP detectors) for detection of fire for automatic
actuation of medium velocity water sprinkler system shall be provided.

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 FIRE WATER SYSTEM AND FIRE WATER PUMPS

 Fire water system designed to meet highest fire water flow requirement of a single largest risk + 288 Cu.M/Hr.
for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
 Fire water pumps – 50% standby (min. 2)
 Closed loop fire Hydrant network /Monitor distribution piping network.
 Water Sprinkler/ Deluge system.
 Line pressure maintained with Jockey pumps so maintain residual pressure of 7kg/cm2 at the farthest point
 All LPG Facilities provided with Automatic Sprinkler system actuated by QB network (790C) and deluge valves
 All LPG sheds / Vessels – 10.2 lpm /sqm;
 LPG pumphouse/compressor – 20.4 lpm/sqm
 Hydrants and monitors shall not be installed within 15m of the facility to be protected

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 FIRE WATER SYSTEM AND FIRE WATER PUMPS

• Hydrants/ monitors spaced at intervals not exceeding 30 M

• Centrifugal type fire water pumps shall have a flooded suction,
alternatively suitable arrangement for auto priming shall be provided.
• The system pressure has to be maintained at 7 kg/cm2 at the farthest
end of the hydrant system with the help of Jockey Pump operating
automatically and actuated by pressure switches.

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 AUTO FIRE FIGHTING SYSTEM

Break glass / Blowing of QB actuates the following :

1. Deluge valves in fire zone as well as adjacent zones open up
2. Fire engines will start in the pre - set sequence
3. Audio visual alarm starts in local/main control panels
4. Fire siren starts wailing sound
5. Immediate closure of all ROVs on LPG lines
6. LPG pumps, compressors will trip (main power trips)

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FIRE FIGHTING SYSTEM

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FIRE FIGHTING SYSTEM IN ACTION

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FIRE FIGHTING SYSTEM IN ACTION

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BOTTLING OPERATIONS-
PICTORIAL VIEW
 PICTORIAL
PICTORIAL VIEW
VIEW OF BOTTLING
OF BOTTLING OPERATION
OPERATION

PI as per IS 13258
Cap opening & TW writing op Washing unit

CWS ELD OLD

Carousel – O ring replace Unloading

Bottling Op Adjustment scale & retest Platform

Test Bath

To valve changing shed Evacuation unit

Hot air
Sealing unit

To loading/stacking shed
BOTTLING OPERATIONS
 BOTTLING OPERATIONS

• Receipt of LPG cylinders

• Filling & despatch of LPG Cylinders
• Handling &storage of LPG cylinders
• Auxiliary Operations

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 FILLING OF CYLINDERS
• All cylinders shall be filled on gross weight basis on filling machine in
accordance with the Standards of Weights & Measures (Packaged
Commodities) Rules 1977 and Amendment Rules, 1992
• Cylinder shall be counter weighed with check scale for accuracy of weight
• The filling pressure should not exceed maximum working pressure of
cylinder i.e. 16.9 kg/cm2 at 65 deg.C.

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 QUALITY CONTROL CHECKS ON FILLED CYLS

SQC - on 2 % of Total Cyls Filled

Weight of Filled Cyls. – Variation + 100 Gms with Zero on Negative Side
 No leakage from the Valve: By Manual CVT
 Presence of O-Ring and No Leakage due to cut gasket
 Condition of PVC Seal
 Cyls. not due for Hydro testing
 No visible damages and Proper Look of Cyl

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 QUALITY CONTROL CHECKS ON FILLED CYLS AND DESPATCH

• Cylinder shall be counter weighed with check scale for accuracy

• All under-filled/ over-filled cylinders should be corrected on correction
scale.
• check for `O" ring condition and for valve leak by means of Compact valve
Tester (CVT) or electronic leak detector(ELD). Limit is 0.5 gm/hr
• check for body leak and bung leak by dipping in water test bath or by an
established electronic leak detection system.
• Capping to be done prior to dipping in test bath water.
• processed further for PVC seal or Aluminium sealing.
• Dispatch
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 HANDLING & STORAGE OF LPG

• Governed by Gas Cylinders Rules, 1981.

• Nature of defects in cylinders: body leak, bung leak, bulge, fire ravaged or
spurious cylinders, valve leak
• All cylinders shall be clearly identified, with markers, to their nature of
defects and shall be kept capped during storage.
• Mastic Flooring is provided for Cyl Storage
• Stacking of cylinders shall be done in lots of 4 rows and 25 cylinders
length (spacing provided as shown in the figure)

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 STACKING ARRANGEMENT OF CYLINDERS

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 AUXILIARY OPERATIONS

valve removal and valve fixing: The valve of cylinders with bung / valve leak shall be replaced as per the
procedure
Purging of cylinders: New cylinders and cylinders degassed for repairs shall be purged of air prior to be
taken up for refilling with LPG as per the procedure
Degassing of Cylinders :
Cylinders shall be evacuated and de- pressurised to near atmospheric pressure.
Then filled with water fully allowed to over flow. Thereafter, cylinders shall be emptied out of water and
checked with explosimeter for degassing.
Not more than 6 cylinders shall be degassed at a time.

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INSPECTION AND MAINTENANCE
 MAINTENANCE & INSPECTION OF EQUIPMENT

• All Maintenance/ Inspection jobs shall be carried out in line with OISD
Standard ; OISD-STD-105 on "Work Permit System".
• Electrical maintenance / inspection, provisions of OISD-STD-137 shall be
adhered to.
• PPEs- Hand gloves, Safety shoes, Helmets, Safety belts, Safety goggles
etc. shall be used (OISD- STD-155).
• a preventive maintenance schedule: must be worked out mentioning the
periodicity i.e. daily, weekly, monthly, half yearly and yearly schedules.

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 INSPECTION &MAINTENANCE OF PRESSURE VESSELS
&STORAGE FACILITIES
Inspection of Pressure Vessels: OISD128
• WFMPT- Wet Fluoroscent Magnetic Particle Testing- most reliable test
method for detecting micro-cracks experienced in the lower half
portions of LPG vessels- ultrasonic testing
• Inspection of valves and fittings : API598
For fire safe valves:
• Low pressure seat test
• No leakage shall be permitted
• Fire-safe test shall be carried out as per API : 607.

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 INSPECTION &MAINTENANCE OF PIPELINES
• Inspection and thickness data of newly constructed pipelines- with in 2
yrs of their commissioning to function as base for establishment of
corrosion rates.
• External inspection of LPG pipelines- once in three years which shall
include both visual inspection and ultrasonic thickness readings taken
externally.
• Comprehensive inspection of LPG pipelines- once in 6 years
• Visual inspection
• Hammer test
• Ultrasonic thickness measurement
• Dye penetration test or Magnetic particle test
• Hydrotest

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 MAINTENANCE OF HOSES, STRAINERS AND FILTERS
INSPECTION &MAINTENANCE OF HOSE AND FLEXIBLE CONNECTION:
• OISD135 - Inspection of Loading and Unloading Hoses for petroleum products
• LPG hoses shall be inspected & tested at maximum interval of 4 months
• LPG hoses shall be discarded after 3 years of service or earlier
INSPECTION &MAINTENANCE OF STRAINERS AND FILTERS :
• Air filters Weekly
• Strainers on evacuation Weekly line
• Pump Suction Quarterly
• Up stream of filling carousel Quarterly
• up stream of PD-Meter Quarterly

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 INSPECTION &MAINTENANCE OF SAFETY RELIEF VALVES

• OISD132- Inspection of Pressure Relieving Devices

• Safety Relief valves shall be tested once in a year
• On stream visual inspection: at least once in every 6 months

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 INSPECTION &MAINTENANCE- ELECTRICAL EQUIPMENT

• Preventive maintenance as per schedules laid down in OISD137.

• No Flame proof or intrinsically safe apparatus shall be opened until all
voltage has been cut off from said apparatus or wiring.
• Equipment enclosures and fittings shall be examined
• If at any time, there is a change in the area classification or in the
characteristics of the flammable material handled in the area or if the
equipment is relocated in the area, the area classification drawing should
be correspondingly revised.
• A system shall be established to record the results of all inspections and
the action taken to correct defects.

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 EMERGENCY PLANNING
1. Definition of Emergency
2. Objective of the plan
3. Identification and assessment of scenarios
4. Organization structure
5. Emergency handling procedures
6. Communication
7. Resources
8. Control Centre
9. Coordination with outside agencies / mutual aid

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 PERSONAL PROTECTIVE EQUIPMENT

• Safety helmets • Water Jel blankets

• Safety shoes • Safety Belts

• Eye Wash
• Low temperature gloves

• Safety Goggles
• Fire Proximity Suits
• Ear Plug/Muff
• Breathing Apparatus

• Resuscitators

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 MANDATORY TESTING OF CYLINDERS
Sequence of operations for the mandatory pressure testing of used LPG
Cylinders:

1. Segregation of cylinders due for Pressure testing

2. De-pressurisation
3. Recording of cylinder details.
4. Valve Removal for DPT cylinders.
5. Degassing.
6. External and internal inspection, internal cleaning.
7. Bung thread inspection by using L1 & L9 gauges.
8. Tare weight check.
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 MANDATORY TESTING OF CYLINDERS
10. Hydro testing at a pressure 2.45 MPa (25.35 kg/cm2).
11. Water draining, Internal drying and Inspection.
12. External Surface Cleaning.
13. Primer coating. Zinc Chromate red oxide Primer
14. Signal Red Synthetic Enamel Paint
15. Tare Weighing of cylinder
16. Punching of new test date and Identification mark of testing unit.
17. Incorporating French Blue band on cylinder shroud and screen painting of
new tare weight, net weight, next test date and safety slogans.
18. Valve Fixing
19. Pneumatic Test at 12.0 kg/cm2 & Air Release.
20. Record Keeping and Certification.
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SAFETY AUDIT
 SAFETY AUDIT IN LPG PLANTS
• It’s a well recognized tool to improve the effectiveness of safety programme
and loss prevention measures
• Implemented to carrying out systematic and critical appraisal of potential
safety hazards involving personnel, plants and equipments.
• Make Check lists – All operational areas, major equipments, operating/
maintenance procedures, safety practices, fire prevention/ protection systems
etc.
• Observations/ recommendations of safety audit team should be presented in
the form of a formal report and action plan for corrective measures should be
prepared and subsequently monitored for implementation.
• General guidelines on safety audit methodologies and techniques OISD 145.

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 SAFETY AUDIT IN LPG PLANTS
• It is recommended to do minimum safety audits at different levels, their
frequencies and broad check lists to be used
• Daily audit essentially shall cover the compliance of recommended
operating procedures/ safety practices. Reports of audit shall be
reviewed by the Plant Manager on daily basis and corrective action be
undertaken on priority wherever required.
• The compliance to other audit recommendations along with target
schedules shall be monitored on monthly basis.
• Alternate, safety measures shall be taken till the recommendations are
complied in totality.

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 TYPE OF SAFETY AUDIT AND PERIODICITY
Type of Safety By Frequency Checklist
Audit (Annexure)
1. Inspection Safety LPG Plant Daily 14-I

audit of LPG Installation Safety Officer

2. Electrical audit of Authorised Annual 14-II

LPG Installation electrical Engineer
3. Detailed safety audit Multi disciplinary Annual 14-III
of LPG Installation team of region/ HQ
4. Inspection and Personnel from Annual 14-IV
maintenance audit of Inspection/ Maintenance
LPG Installation
5. External safety audit OISD
of LPG Installation
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 NAME : MOHAMMED ASIF AKRAM
EMPLOYEE ID : 31966470
DESIGNATION : PROJECT ENGINEER
LOCATION : VISAKH LPG PROJECTS/
VISAKH NEW LPG TML
CREATED DATE: 22.04.2018

Thank you !
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