Operational Manual

FOREWORD
LPG SBU has achieved tremendous growth in business line by adopting new technology in terms of its
bottling & other operations in last two decades. Currently, LPG Bottling Plants & Installations are
equipped with state of the art equipment which is in line with international standards. The other
applications of system improvement by implementing ERP & IT applications have been well assimilated
by LPG SBU.
In view of technological & other advances made by LPG SBU, it is imperative to have a updated reference
LPG operation manual for operational ease.
LPG SBU has taken the initiative and developed an operations manual with in-house expertise. This
manual fulfills LPG SBU’s requirement for a completely updated reference on all aspects of LPG
Operations. It should usher in better awareness and compliance to applicable standards across all LPG
installations & bottling plants.
I am confident that this manual will be a strong reinforcement to the efforts of LPG SBU in its march
towards operational excellence to achieve Customer delight.
I wish LPG SBU all the best in their initiatives and efforts to continuously improve the operational
efficiency and service quality.
S. Roy Choudhury,
Director – Marketing
March - 2006
PREFACE
The foundation of a sound marketing company rests on its backend infrastructure and its capabilities
to deliver the promises made to customers. A sound value chain, backed by a competent work force,
will enable HPCL to repeatedly deliver promises made to customers.
LPG SBU’s strength has always been its infrastructure. Be it automated bottling plants or state of the
art import facilities, LPG SBU has always steered ahead of competition thereby providing the cutting
edge in the marketplace.
Over a period of last two decades, there has been significant development in LPG business line.
There has also been increased emphasis by various statutory authorities like Environment Pollution
Control, Weights and Measures, Petroleum and Explosives Safety Organization, Transport Authorities
for improved safety and quality of installations, product and services. OISD has also revised their
standards for plant design, operations, safety and maintenance. Thus, currently adopted operating
practices, safety parameters have gone in for a sea change and are in line with best world-class
practices & procedures.
LPG SBU has also during this period endeavoured to upgrade the various LPG facilities with focus and
emphasis on increased automation, improved safety, quality and operational efficiency. The increased
use of IT and implementation of ERP has brought about a significant change in the way we do our
business. It thus became essential that the existing operation manual be replaced with new one in
line with current practices.
The operating personnel need to be well versed with various applicable statutes, National / International
standards and operating philosophy. This will promote HPCL’s objective of environment, health and
safety norms, quality product and innovative services to meet our objectives of social commitment
and customer delight.
View above, a comprehensive LPG Operations Manual has now been developed in-house considering
the entire gambit of LPG operations, supply and distribution. I am sure this manual will serve as a
ready reckoner to all our operating staff at all levels and guide them in various facets of LPG
Operations.
S V Sahni
Executive Director-LPG
March - 2006
INDEX
SECTIONS DESCRIPTION PAGE NOS.
1 Properties & Characteristics of LPG 1 - 39
2 Important statutes applicable to LPG Plants/Installations 2 - 20
3 Receipt & dispatch of Bulk LPG 3 - 77
4 Storage of Bulk LPG 4 - 48
5 LPG Terminals / Plant Operations 5 - 47
6 Bulk Stock Monitoring & Inventory Management 6 - 39
7 Design, Manufacturing & Maintenance of CVR 7 - 30
8 Fire Prevention & Safety 8 - 21
9 Appendix 1-9
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PROPERTIES & CHARACTERISTICS OF
LIQUIFIED PETROLEUM GAS
INDEX
CHAPTER DESCRIPTION PAGE NO.
1.0 General 1
1.1 Specification as per Indian Standards 4
1.2 Physical/Chemical properties & characteristics 9
1.3 Combustion 19
1.4 Solubility of water in LPG 20
1.5 Flame Propagation 20
1.6 Presence of sulphur 20
1.7 Pyroferic Iron 21
1.8 Presence of caustic soda (NAOH) residue 21
1.9 Explosion property of LPG 21
1.10 Testing procedures as per IS:1448 22
1.10.1 Testing procedure for odour of LPG (IS:1448) 23
1.10.2 Volatility of Liquified Petroleum Gas 24
1.10.3 Vapour presence of liquefied petroleum gases 28

{IS:1448 (P:71) – 1979}
1.10.4 Specific gravity test – Hydrometer test 30
1.10.5 Copper corrosion test 31
1.10.6 Hydrogen sulphide test 33
1.10.7 Dryness test 34
1.10.8 Composition test – Gas Chromatograph (ASTM D 2163) 36

1
1.0 GENERAL
LPG is the generic name for predominant mixture of propare & butane having both saturated
and unsaturated hydrocarbons.
Commercial Propane predominantly consists of hydrocarbons containing three carbon atoms,

mainly propane (C3H8).
Commercial Butane predominantly consists of hydrocarbons containing four carbon atoms, mainly
n- and iso-butanes (C4H10).
They have the special property of becoming liquid at atmospheric temperature if moderately
compressed, and reverting to gases when the pressure is sufficiently reduced. Advantage is
taken of this property to transport and store these products in the liquid state, in which they are
roughly 250 times as dense as they are when gases.
Butane is usually supplied to customers in cylinders. Propane can be supplied in cylinders or in

bulk for storage in tanks at the customer’s premises.
LPG marketed in India is governed by Indian Standard Code IS-4576-1999 (Refer Table 1) and the
test methods by IS-1448 (1968 – reaffirmed in 1997). LPG marketed in India for Automotive use
is governed by IS: 14861 (2000) [Refer Table 2]
Commercial Butane also meets Indian Standard Code IS-4576 quality norms and can be treated
as LPG. LPG of mixtures 50% propane and 50% butane also meets Indian Standard Code IS-4576
quality norms. It has been observed that Quality of LPG dealt in India varies a lot depending on
source of supply and number of constituents which mainly consist of one or more of the following
hydrocarbons:
a) Propane (C3H8)
b) Propylene (C3H6)
c) N-butane (C4H10)
d) Iso butane (C4H10)
e) Butylene (C4H8)
However small quantities of one or more of the following hydrocarbons may also be present
a) Ethane (C2H6)
b) Ethylene (C2H4)
c) Pentane (C5H12)
d) Pentene (C5H10)
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At present, in India there are 17 fractionators, 18 refineries & 5 import locations on Industry
basis where LPG is produced/imported for marketing. Composition of propane & butane varies
from location to location. In fractionators & refineries generally propane percentage will be
higher whereas imported LPG basically constitutes major portion of Butane. Thus quality of LPG
& its calorific value varies from source to source.
As per the supply demand scenario of the country, availability of LPG is surplus to the requirement
at Western part of the country whereas major shortfall is in the North. Import locations are
mostly situated in the South & South East. Due to above fact, product flows from West to North
& Imports are being concentrated in South & East.
Thus any specific requirement of Product quality for a particular application to be decided basis above
fact.
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LPG is the most convenient form of gaseous fuel in comparison to similar category of fuels like
CNG, LNG due to its basic inherent properties. LPG can be stored & handled for any kind of
application as a saturated mixture of liquid & vapour at ambient temperature at any place in the
country. LNG & CNG which are nothing but Methane stored & handled in different form i.e. in
liquid & gaseous form (by compressing). Huge energy is required to maintain the LNG at its
boiling point of -259 degrees centigrade. Similarly CNG has to be compressed at a pressure of
200-250 kg/cm2 to make it available at delivery point. Thus storage & carrying cost of CNG/LNG
is very high in comparison to LPG.
As regards to calorific value, LPG has a calorific value of 11000-16000 Kcal/kg whereas CNG &
LNG have calorific value of around 18000 KCal/Kg.
Currently LPG is being used for various applications like Cooking, Industrial applications for
heating, heat treatment, metal cutting, solvent & aerosol applications. LPG is also being used as
Automotive fuel. Specification of LPG used for cooking & Industrial applications is governed by
IS 4576 (1999) whereas LPG used for Automotive purpose is as per IS 14861 (2000).
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1.1 SPECIFICATIONS AS PER INDIAN STANDARDS :
IS 4576 specifications:
Table 1
REQUIREMENTS FOR LIQUIFIED PETROLEUM GASES
AS PER IS 4576 – 1999
Requirement for Commercial
Sr. Characteristics Butane Butane – Propane Method of Test

No. Propane Ref to:
Mixture
(1) (2) (3) (4) (5) (6)
i) Vapour pressure at 40 C in 520 1050 (Note 2) 1550 D 1267

kPa, gauge, Max (Note1)
ii) Composition, liquid mole D 2163

percentage
a) C2 Hydrocarbons - Report Report
b) C3 Hydrocarbons Report Report 95.0 min.
c) C4 Hydrocarbons Report Report 4.0 max.
d)C5 Hydrocarbons and 2.5 max. 2.5 max. 0.2 max.
heavier
e)Unsaturated hydrocarbons Report Report Report
OR
Volatility :
Evaporation Temp. in 0C for 2.0 2.0 -38.0 D 1837
95% by vol. At 760 mm Hg
pressure, Max. D 2784
iii) Total volatile sulphur ppm, 150 150 150 D 3246
Max.
iv) Copper Strip Corrosion at Not Worse than Not Worse than Not Worse than D 1838
38 0C for 1 hour No. 1 No. 1 No. 1 D 2420
v) Hydrogen Sulphide Pass Pass Pass (Note 3)
vi) Free water content None None None Visual
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IS 14861:2000
Table 2
Requirements for Liquefied Petroleum Gases for Automotive Purpose
( Clause 4 )
Sr. No. Characteristics Requirement Method of Test

Ref to”
(1) (2) (3) (4)
i) Vapour pressure at 40 0C. ISO 4256
kPa gauge (Note 1 ).
- Min 520 ( Note 2 )
- Max 1050
ii) C5 Hydrocarbons and 2.0 ASTM D 2163
heavier, mole percent, Max
iii) Dienes (as 1:3 Butadiene), Max 0.5 ISO 7941
iv) Total volatile sulphur 150 ASTM D 3246
(After stenching) ppm, Max
v) Copper strip corrosion at Class I ISO 6251
40 0C for 1 hour, Max
vi) Hydrogen sulphide Pass the test ISO 8819
Max
vii) Evaporation residue, mg/kg, 100 ISO 13757
viii) Free water content Nil ASTM E 700
( Note 3)
ix) Motor octane number ( MON), 88 ISO 7941
Min + Annex A
x) Odour Unpleasant & ( Notes 4 & 5)
distinctive down to
20% lower
explosive limit (LEL)
NOTES
1. Vapour pressure may be determined at any other temperature and converted to 40 0C by means
of suitable vapour pressure-temperature graph. The same can also be determined by analyzing the
gas by means of a gas chromatograph and then using the composition, the vapour pressure can be
calculated at 40 0C from the standard values of vapour pressures at various temperatures.
2. In winter, the gauge vapour pressure requirement shall be minimum 700 kPa at 40 0C. Winter period
shall be from 1st November to 15th February.
3. The water content shall be determined at the Refinery first dispatching location.
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4. Product shall contain 20 ppm, Min, ethyl mercaptan at the first dispatching location to ensure the
detection of leakage by odour.
5. 5ml Doctor Solution + 8 ml Iso-Octane + Pinch of Flower Sulphur in 25 ml stoppered cylinder.

Shake and add 2 ml LPG (Aq). Shake slowly by releasing pressure. Odour is adequate if sulphur turns
yellowish brown.
IS 1448 [ P : 75 ], Odour test method is also acceptable as an alternate method.
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Table 3
Comparison of ‘Auto-LPG’ and ‘Domestic/Industrial-LPG’ Standards
Sl.No. Requirement Auto LPG- IS 14861-2000 Domestic LPG

IS 4576-1999
Characteristics Test Method Characteristics
1 Vapor Pressure Vapor Pressure (Kpa- 1050 max
520 to 1050 IS 4256
(Kpa-g) at 40 0C g) at 40 0C
2 Pentanes
2.0 ASTM D 2163 C5 mole% max 2.5
(mole% max)
3 Dienes (as 1-3
0.5 ISO 7941 Dienes(as 1:3 Not
Butadiene)
butadiene) mole% Required
(mole% max)
max
4 Total volatile Sulphur 150 ASTM D 3246 Total volatile sulphur 150
after stanching after stanching ppm
(ppm-max) max
Copper strip corrosion Class I ISO 6251 Copper strip Not worse
5 (at 40 deg C for corrosion (at 38 deg than no 1
1 hour - max) C for 1 hour - max)
6 Evaporation residue 100 ISO 13757 Evaporation residue, Not
(mg/kg max) Mg/kg Max Required
Hydrogen sulphide Pass the test ISO 8819 Hydrogen sulphide Pass the
7
test
Free Water content Nil ASTM E 700 Free Water content Nil
8
9 Motor Octane Number 88 ISO 7941 Motor Octane Not

(MON, min) Number(MON) Min Required
Unpleasant & Odor
10 Odour distinctive down Mercaptans ppm max 20
to 20% LEL
11 Volatility (Evaporation Volatility (Eva
temp in deg C for 95% Not Required poration temp in Deg 2.0
by volume, max) C for 95% by vol max)
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Table 4
COMPARISON BETWEEN LPG, LNG, NG AND CNG
Natural Gas when stored in cryogenic and liquid condition is called LNG, at Atmospheric pr. and Ambient
temp. is called NG, Compressed to 200 bar becomes CNG.
Parameter LPG LNG NG CNG
Operating temp Max 55 Deg C -168 Deg C Max 55 Deg C Max. 55 Deg C
Pressures Max 16 bar Atmospheric 10-12 bar 200-240 bar
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1.2 PHYSICAL/CHEMICAL PROPERTIES & CHARACTERISTICS
1.2.1 COLOUR
LPG is colourless both in liquid and vapour phase therefore, they cannot be seen. However, when
LPG, in liquid form, is released from a container or a pipe it vaporizes almost immediately. This
produces a cooling of the surrounding air and may cause water vapour in the air to condense,
freeze and become visible. In this way a LPG leak may be detected even though the gas itself is
invisible.
1.2.2 SMELL
LPG is, in general, odourless and cannot be detected by human senses. When odorization of LPG
is required, Ethyl Mercaptan ( C2H6S) is added to a min of 20 ppm.
1.2.3 TASTE
LPG is tasteless and non-toxic, therefore, the presence of LPG vapours in the atmosphere cannot
be sensed by taste.
1.2.4 COLD BURN
LPG in liquid form should not come in contact with surface of body. It is particularly important
that liquid propane or a product with relatively high vapour pressure be avoided in the event that
LPG in liquid form come in contact with the skin, the product immediately vapourises. During
this vapourisation process, heat will be absorbed directly from the skin and flesh causing a
freezing effect. The ultimate result of the freezing is usually referred to as a cold burn. The
results may be serious, therefore, if the possibility of exposure to liquid LPG exists, suitable
gloves and protective clothing’s should be used.
Note: This feature to be kept in mind to handle LPG accident, to carry out operations and M&R
jobs which exposes our body to LPG in liquid form.
1.2.5 TOXICITY
LPG even though slightly toxic, is not poisonous in vapour phase, but can, however, suffocate
when in large concentrations due to the fact that it displaces oxygen. In view of this the vapour
possesses mild anesthetic properties.
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1.2.6 VISCOSITY
LPG liquid has low viscosity of around 0.3 CS @ 45 deg. C and can leak when other petroleum
products normally cannot, thus demanding a very high integrity in the pressurized system to
avoid leakage. It is also a poor lubricant and leaks are therefore likely to occur at pump seals and
glands. In view of this a special attention to be given, for example to the selection of mechanical
seals for pumps and also seals at the carousel centre column.
1.2.7 DENSITY
Density means Mass or weight per unit volume. Unit used is gm/cm3 or Kg/m3. Since the density
of the liquid varies slightly with temperature, the latter must be indicated in an exact statement
of density. Normally density is expressed at 15 degrees centigrade or 60 degrees F.
Since the density of water is 1.0 gm/cm3, and the density of liquid LPG is about 0.5 gms/cm3,
the latter is about half as heavy as water.
Temperature Range Density for Commercial Propane Density for Commercial Butane
================= ============================ ===========================
0-50 deg. centigrade 0.522 to 0.454 0.587 to 0.537
In an exact statement of density of the gas, it is necessary to indicate not only the temperature
but also the pressure.
The usual form is to state the density of 1 m3 of the gas at 0 degrees centigrade & 760 mm Of Hg
(Normal atmospheric pressure), this being known as a normal cubic metres, abbreviated to m3
(n).
Relative density is used to indicate the density of a gas in relation to that of air at the same
temperature & pressure. If the relative density is greater than unity, the gas is heavier than air.
LPG is about 1.5 to 2 times as heavy as air.
1.2.8 COEFFICIENT OF VOLUMETRIC EXPANSION
The coefficient, of volumetric expansion indicates the change in volume per unit volume of
liquid for each degree of temperature change.
Its value varies slightly with temperature, and the table therefore states the coefficient for the
two temperature ranges that may be encountered in practice. The rate of expansion or
contraction also varies depending upon the composition of the product.
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In the case of propane, the expansion rate between 0°C and +40°C is approximately 13.2%,
whereas the expansion rate of butane for the same temperature increase is approximately 8.0%.
In general, it may be said that the lower the density of the liquid the greater the rate of expansion
or contraction.
Note: This feature guides operating & designed temp of LPG in pipe line & vessels, storage
capacity in cylinder/vessel/tank. Incorporating thermal relief valve in blocked segment.
1.2.9 VOLUMETRIC EXPANSION OF LPG
Since the coefficient of volumetric expansion of LPG is about 100 times that of steel it will be
realized that this must be taken into account when a container is being filled with LPG.
In consequence, a LPG container must only be filled to a certain volume in order to leave a
sufficient expansion volume, which varies with the temperature and density of the liquid LPG.
To fill LPG container with specific density, volume to be filled up shall depend on Filing Ratio so
that at 55 degrees centigrade( in case of cylinders, temp at 65 deg C), there will be 5 % space left
in the container. Any container be filled up basis maximum permissible filling ratio as given in
Appendix D.
Note: This feature determine storage capacity of cylinder/vessel/tank/cavern cavity, pipe line
designed pressure.
1.2.10 MELTING OR FREEZING POINT
LPG can exist as a liquid over a wide range of temperature. The lowest temperature is that at
which the liquid assumes the solid state. This is known as the melting point and is such a low
temperature that it is without practical interest.
Note: This parameter is insignificant for LPG handling in pressurised vessel/pipeline. However
it is very important for handling LPG in refrigerated form where mollier diagram is used to find
out thermodynamic state of LPG involving refrigeration process. Certain equipments like
compressor design may need this parameter.
1.2.11 CRITICAL TEMPERATURE
The highest temperature at which a substance can exist as a liquid is known as the critical
temperature. Above this temperature the substance is gaseous, whatever pressure is applied.
Note: This parameter is insignificant for LPG handling in pressurised vessel/pipeline. However
it is very important for handling LPG in refrigerated form where mollier diagram is used to find
out thermodynamic state of LPG involving refrigeration process. Certain equipments like
compressor design may need this parameter.
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1.2.12 CRITICAL PRESSURE
To obtain the substance in liquid form at the critical temperature a certain minimum
pressure is required, this being known as the critical pressure. At temperature below the
critical temperature the substance can exist either as a gas or as a liquid.
When the substance exists as gas and liquid simultaneously we say that there is a state of
equilibrium between gas and liquid. At any given temperature there will, under these conditions,
be a definite pressure.
1.2.13 BOILING POINT
The temperature at which the vapour pressure of a liquid becomes equal to the
external pressure is the boiling point.
This temperature differs for the liquid under different pressures.
The normal boiling point is the temperature at which the vapour pressure
reaches 760 mm of mercury or 1 atmosphere.
Considering liquid in an container exposed to the atmosphere, a pressure equivalent to atmospheric

pressure (one atmosphere) is applied to the surface of the liquid. As the temperature of the
liquid increases, its vapour pressure approaches atmospheric pressure.
At the temperature at which vapour pressure equals atmospheric pressure the opposition to
evaporation exerted by the atmosphere is neutralized and boiling takes place. From a practical
standpoint, it is the liquid temperature at which evaporation is rapid enough, to produce noticeable
formation of vapour bubbles within, the liquid.
Note: A very important parameter which influences selection of materials to avoid brittle fracture
of LPG handling equipments, Design & operating temperature and other parameters of LPG &
equipments. Every aspect of LPG operations, emergency handling and various industrial uses of
LPG depends on boiling point.
1.2.14 VAPOUR PRESSURE
Vapour pressure is the pressure developed over a liquid in a closed container. The vapour pressure
of LPG depends upon the temperature of the liquid and the composition in terms of the primary
hydrocarbons present.
If liquid is heated in an open container the molecules (collectively called vapour) move away from
the liquid and the liquid is said to evaporate.
If, on the other hand, the liquid is in a closed container the motion of the escaping molecules is
confined to the vapour space above. As an increasing number strike and re-enter the liquid, a
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point of equilibrium is eventually reached when the rate of escape of molecules from the liquid
equals the rate of return to the liquid.
The pressure exerted by the escaping vapour at this point of equilibrium is vapour pressure. The
volume of liquid within a LPG container does not effect the vapour pressure if product in liquid
form remains, after equilibrium has been reached. Considering an identical product and identical
temperatures, when equilibrium is reached in a container with 5% liquid and 9.5% vapour, the
vapour pressure will be the same as that found in the same container with 85% liquid and 15%
vapour.
From a practical standpoint, equilibrium will only be reached in a container when vapours are not
being withdrawn and the ambient temperature remains constant. Whenever product is being
withdrawn from the container it is anticipated that the internal pressure will be depressed below
the true vapour pressure which would be observed if equilibrium did exist.
Vapour pressure is usually stated in kg/cm2. This unit can be also be written “at”, being then
known as a technical atmosphere, to distinguish it from the normal atmosphere, atm (1 atm =
1.033 at).
Since the vapour pressure is independent of the pressure of the air or atmosphere it is usually
stated as the “absolute” pressure, e.g. in absolute technical atmosphere = ata. If LPG is to be
obtained in gaseous form from a container the temperature must be such as to give a vapour
pressure at least as great as the pressure of the air. Accordingly, vapour pressure can also be
stated as overpressures in relation to the normal pressure of the air, usually called ‘gauge’
pressures.
Note: one of the most important property of LPG which decides operating pressure of storage
vessels/cylinders/pipe line, safety valve design. Operating pressure of all equipments , design
of pump& compressor , various safety features incorporated in equipments. Vapour pressure is
directly related to mechanical integrity of LPG handling system. Risk analysis & EIA is influenced
by vapour pressure .Various industrial application of LPG make use of this parameter
For information relating to vapour pressure of commercial products and mixtures or blends see
Appendix”L”.
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CHART 1
VAPOUR PRESSURE CHARTS FOR DIFFERENT HYDROCARBONS
a – Propylene
b – Propane
c – Iso butane
d – N- butane
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CHART 2
VAPOR PRESSURE CHART FOR LPG AT DIFFERENT COMPOSITIONS
P – Propane
B - Butane
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1.2.15 LATENT HEAT OF VAPQURIZATION
The quantity of heat absorbed by a unit mass when changing from the liquid to the
gaseous phase while remaining at the same temperature. In addition to the heat required to
change or increase the temperature of a liquid there is an additional heat requirement to
cause actual vaporization. This quantity of heat is referred to as the latent heat of
vaporization. The term is expressed in kilocalories per kilogram of the substance. The
temperature should also be stated since the value decreases somewhat with an increase in
temperature. -
As an example, the latent heat of vaporization of propane at -20° is 96 kcal/kg and
at +20°C the value is 82 kcai/kg.
While LPG vaporization takes place, it takes latent heat from the body of the container during
change of phase from liquid to vapour. In case vaporization rate is higher then the body
temperature of the container is reduced resulting in ice formation on the surface.
Note: One of the important parameter which decides operating conditions (like temperature) of
LPG and equipments used in handling of LPG. Design of vapouriser and combustion process of
LPG depends on this parameter. Material selection and extreme design temp depends on it. This
is a predominent operating parameter for refrigerated storage. Total heat available in combustion
process influenced by this parameter.
1.2.16 SPECIFIC HEAT
Specific heat is defined as the quantity of heat required to raise unit mass of a
material through a unit temperature interval.
Specific heat may also be expressed as the amount of heat required to warm a sub.-stance
in the solid, liquid or gaseous state,
Specific heat is expressed as the number of kilocalories required to warm 1 kg of a substance
through 1°C. Specific heat is dependent to a degree upon the temperature of the substance.
For gases, moreover, it is necessary to indicate whether the pressure or the volume is
constant.
One kilocalorie is the quantity of heat required to raise the temperature of 1 kg of
water through 1°C from 14.5 to 15.5°C As an example, propane has a specific heat of
0.57 kcal
Note: This parameter is important to design vapouriser used in industrial application. Design of
compressor and refrigeration process in refrigerated storage of LPG need to take consideration
of this parameter. Fire fighting facilities design need to consider this parameter. Reliquification
of LPG vapour in liquid form depends on this parameter.
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1.2.17 FLAMMABILITY
Flammability is defined by percentage by volume of the gas in mixture with air that forms a
flammable mixture at atmospheric pressure & ambient temperature. Flammability range is
difference between the minimum & maximum percentage by volume of the gas in mixture with
air .
In case of LPG, the flammability range is 1.8 % to 9.0 % with air.
The above indicates that in the event there is an insufficient supply of LPG vapour mixed with
air, the combination will not burn. Conversely, if an excessive amount of LPG vapour is mixed in
the atmosphere, combustion again can not be accomplished.
Note: This parameter is important to avoid hazardous condition due to the presence of LPG in
working area due to leakage or any other reason. Working of gas monitoring system/explosive
meter is related to this property.
For right combustion of LPG, percentage of LPG in air have to be within this limit.
This parameter has a major role in risk analysis/EIA to asses damage distances/contour due to
the release of LPG and consequent fire.
Vessel entry/hot work, M&R, operations of any kind need non flamm able environment. Due
consideration need to be given for plant layout, site selection based on this property of LPG.
1.2.18 AUTO IGNITION TEMPERATURE
Auto Ignition is the lowest temperature at which a material will ignite without an external source
of ignition. In case of LPG it is 410 to 580 degrees centigrade varying on account of composition.
1.2.19 VOLATILITY
Volatility is the property of the substance to get converted into vapour phase from liquid phase
after absorbing latent heat of evaporation from surrounding at a certain pressure. In the case of
LPG , it is the temperature of residue LPG at balance quantity of 5 ml inside weathering tube of
100 ml capacity at atmospheric pressure. As per IS 4576 , the volatility of LPG can be of maximum
+2 Deg.C.
Note: This parameter is related to the quality/composition of LPG .The less volatile temp tells us
that product has better evaporation quality and will not leave residue components ,which is
desirable for any use of LPG . This parameter is very important for industrial use of LPG & auto
LPG .
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Table 5
Property values for Propane & Butane
Description Propane Butane

Fomula C3H8 C4H10
Liquid Density @ 15 deg. 0.508 0.584
centigrade
Co-efficient of Volumetric
Expansion per degree C
Mean Value Between :
-20 degrees and + 20 degrees C 0.0028 0.0018
0 degrees and + 40 degrees C 0.0033 0.0020
Melting Point (degrees C) -187 -137
Critical Temp. degrees C 97 152
Auto Ignition Temp. degrees C 481 441
Critical Pressure ata. (kg/cm2) 43 39
Boiling Point at 760 mm of Hg,
degrees C -42.1 -0.5
Vapour Pressure ata. (Kg/cm2)
At -40 degrees C 1.11 0.17
At -20 degrees C 2.4 0.45
At 0 degrees C 4.8 1.04
At +20 degrees C 8.3 2.1
At +40 degrees C 14.0 3.9
Latent heat of Vapourization Kcal/kg
At -20 degrees C 96 96
At 0 degrees C 90 92
At +20 degrees C 82 87
Specific Heat at 0 degrees C
(Kcal/kg/degrees C 0.57 0.54
Relative Density w.r.t. AIR
(Air =1) 1.561 2.091
Ratio Gas/liquid 274 230
Flammability limit 2.2 - 9.5% 1.8 - 8.5%
The above values for LPG will depend upon the proportion of Butane & Propane in the mixture.
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1.3 COMBUSTION
Combustion may be defined as the oxidation of the product. In the context of LPG, combustion is the
combination of oxygen usually from air with LPG vapour to form carbon dioxide & water vapour
As an example of the process, 0.4 volume of LPG when combined with 9.5 volume of air, after combustion
will produce 1.6 volume of water vapour, 1.2 volume of carbon dioxide and 7.5 volume of nitrogen.
Flame temperature of LPG depends on the composition of the product. The maximum Flame temperature
of LPG attained is about 2000 degrees centigrade
The combustion reaction of LPG increases the volume of products in addition to the generation of heat.
LPG requires upto 50 times its own volume of air for complete combustion and at the same time yields 3
or 4 times its own volume of carbon-dioxide yielding approx. 10,900 kcal to 16000 kcal heat per kg
depending upon the composition.
Thus it is essential that adequate ventilation is provided when LPG is burnt in enclosed spaces otherwise
asphyxiation due to depletion of oxygen apart from the formation of carbon-dioxide can occur.
Uncontrolled combustion also can lead to accidents and explosion.
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1.4 SOLUBILITY OF WATER IN LPG
Atomic structure of LPG has covalent bond whereas water has Electrovalent bond and water is
not soluble in LPG. However it contains some amount of impurities and hence very little amount
of water is present in LPG
Water present in LPG may cause rust and corrosion and freeze-up of valves, drain valves, excess-
flow check valves, cylinder valves and regulators. Ice-formation may prevent the closure of
drain valves, bleeders in LPG vessels and lines, self closing valves, etc. and result in leakage of
LPG. Ice crystals formed at the regulator orifice may lead to plugging of the orifice and thus
stopping the flow of gas. Ice crystals may also make the linkages in a regulator inoperable.
This property of LPG is used in degassing of pressure vessels and also in handling Emergencies
involving tanker / cross country pipelines to block / displace LPG.
1.5 FLAME PROPOGATION
Flame propagation is defined as the Flame velocity normal to the surface of the inner core of a
flame and is relative to the velocity of the unburned gases.
This property is one of the basis for Risk analysis of LPG facilities which influences site
selection & equipments layout, for efficient combustion of LPG for industrial /auto application
& mitigation measures to be adopted to ensure safety in case of any explosions
1.6 PRESENCE OF SULPHUR

LPG contain some volatile sulphur which generates sulphur oxide during combustion.
Presence of sulphur in LPG should be as minimum as possible. Free sulphur also reacts with
iron particle of vessel causing corrosion. As per IS-4576 sulphur content in LPG should not
exceed 150 PPM.
Presence of the Sulphur in LPG will produce sulphur oxides ( Predominantly sulphur dioxide)
which inturn will produce acid which is highly corrosive in nature and may effect the equipments
in long term. In certain applications during combustion process, Sulphur oxides will be a part of
flue gas and will pollute environment. This may violate statutory limits on emission control set by
Pollution Control Boards and hence the less presence of Sulphur in LPG is desirable.
Presence of Hydrogen sulphide will generate sulphur and hydrogen ions. The sulphur inturn will
generate oxides and acids as explained above and leads to corrosion and environmental pollution.
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1.7 PYROFORIC IRON
Pyrophoric Iron sulphide is a highly inflammable compound formed due to the reaction of sulphur
and its compounds with the loose iron/ iron oxide on a ferrous surface. Thus the pyrophoric Iron
Sulphide can be controlled by totally eliminating highly corrosive hydrogen sulphide, limiting the
total volatile sulphur to 0.02% by mass reducing the loose iron oxide by thoroughly cleaning the
storage vessels internally during the outage.
Pyrophoric Iron Sulphide will not ignite spontaneously in a sphere/ cylinder containing a
concentration of vapour of gas as long as the concentration is above the upper flammable range
limit. When the contents of the vessels come in contact of air (during opening to atmosphere or
air entrapped condition) within or below the range, Pyrophoric iron sulphide will ignite
spontaneously, unless water or steam is used to cut the sulphur iron reaction. The most effective
extinguishing agent is water spray or fog. Similar type of precaution is warranted while opening
of LPG pump strainers and any location where loose iron oxide is expected.
Presence of light will accelarate auto reaction in absence of water and so a water seal is required
at water drain sump at vessels to avoid fire.
1.8 PRESENCE OF CAUSTIC SODA ( NAOH) RESIDUE
Caustic soda treatment employed for the removal of hydrogen sulphide could leave traces of
caustic soda in LPG. This may lead to corrosion on the storage vessel and other LPG handling
equipment with predominant effect on aluminium alloys. Hence stipulating absence of caustic is
essential in addition to IS-4576 specification.
1.9 EXPLOSION PROPERTIES OF LPG: ( PUVCE AND BLEVE’S PHENOMENA )
The hazards associated with the release to atmosphere of a boiling flammable liquid show
themselves disproportionately where large quantities are involved - they can give rise to two
phenomena which are highly hazardous ; (a) Unconfined Vapour Cloud Explosion (UVCE) and (b)
Boiling Liquid Expanding Vapour Explosion (BLEVE).
Vapour cloud can ignite and burn as deflagrations or fire balls causing lot of damage by radiation
starting secondary fires at some distance. Vapour cloud ignites and explodes causing high over
pressures and very heavy damage. The later is termed as ‘percussive unconfined vapour cloud
explosion’ i.e. PUVCE in short. Even though large quantities of LPG emission is necessary, only a
fraction of this contributes to the percussive effect ( more reactive molecules such as ethylene
in much smaller quantities). Rare though PUVCE may be, their damage is large and sometimes
enormous.
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The boiling liquid expanding vapour explosion (BLEVE) is due to holding a pressurised flammable
liquid above its boiling point. This may result from inadequate vapour space for temperature
expansion of the contents or high temperature due to radiation heat from the adjacent vessel
fires or due to any mechanical damage. BLEVE even though not as serious as PUVCE, its potential
for spreading fire over a wide area makes them significant in terms of both life and property
damage.
Ejection of boiling liquid produces reaction rupturing the vessel causing the rocket projectioning
of dish ends. The released liquid flashes and atomizes immediately, often resulting in a large fire
ball. Although the fire ball lasts only a few seconds, its effect can be devastating due to flame
contact and thermal radiation.
1.10 TESTING PROCEDURES AS PER IS:1448
The following tests are carried out on LPG as per IS:1448
· Test for Odour

· Test for Volatility
· Vapour Pressure Test
· Specific Gravity Test
· Copper Strip corrosion Test
· Hydrogen Sulphide Test
· Dryness Test
In addition to the above specified tests as outlined in IS:1448, composition test by using Gas
Chromatograph is also carried out.
The above tests are carried out at the following locations:

· Refinery Locations
· Fractionator Locations
· LPG Import/ Coastal movement Terminals
· LPG Loading Terminals
Brief test procedures outlined as per IS-1448. However for test procedure in detail, above
code shall be referred.
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1.10.1TESTING PROCEDURE FOR ODOUR OF LIQUEFIED PETROLEUM GAS (IS : 1448 )
a SCOPE
This method prescribes the procedure for the evaluation of the odour of LPG
b OUTLINE OF METHOD
The sample is diluted with air to 20% of its lower explosive limit (LEL).Tests for the assessment
of the odour level shall be carried out by three persons in a room free from pronounced odours.
These persons shall spend at least 5 minutes in the open air before attempting an assessment
and shall not take more than 3 breaths to determine the odour level.
c APPARATUS
i. Air purifying & regulating system

ii. LPG regulating system
iii. Gas mixing & assessing system
iv. Explosimeter
d PROCEDURE
Place the apparatus under a well-ventilated hood and connect the compressed air supply with the
needle valve fully open. Adjust the flow until a pressure head of about 15 cm is indicated on the
manometer. Adjust the needle valve to give a pressure head of 10 cm. Purge the apparatus with
air for at least 5 minutes and, in any case, until no smell is detectable.
Connect the LPG sample container through the reducing valve to the apparatus. Close the gas
control needle valve and open the container valve fully.
Connect the explosimeter to the appropriate point and test to ensure that it reads zero when no
LPG is entering the system testing continuously.
With the explosimeter, bring the concentration of LPG in the mixed gas stream up to 20 percent
of LEL by manipulation of the gas control needle valve. Do not make any alteration to the air
supply. When stable conditions have been obtained, allow the apparatus to flush for 2 minutes.
Then let 3 observers enter in turn and inhale the mixture issuing from the filter funnel. Properly
ventilate the hood between successive observations. Let the observers assess the odour levels
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with the help of the scale given below and record the average of the 3 observations :
Level Description
0 No detectable odour
1 Very faint, but positively perceptible odour
2 Easily detectable odour
Alternately, Doctor test can be carried out to determine the adequacy of odour in LPG.
Add 5ml Doctor Solution + 8 ml Iso-Octane + Pinch of Flower Sulphur in 25 ml stoppered cylinder.
Shake and add 2 ml LPG (Aq). Shake slowly by releasing pressure. Odour is adequate if sulphur
turns yellowish brown.
IS 1448 [ P : 75 ], Odour test method is also acceptable as an alternate method.
1.10.2 VOLATILITY OF LIQUEFIED PETROLEUM GASES
a. SCOPE
This method is intended to determine the volatility of the various types of LPG as indicated by
the approximate amount of higher boiling constituents present.
b. OUTLINE OF THE METHOD
The product is refrigerated by means of a cooling coil and 100 ml of the liquid is collected in a
weathering tube. The liquid is allowed to weather under specified conditions, and the temperature
is observed when 95 percent of the initial quantity has evaporated.
c. APPARATUS
i. Weathering tube with support

ii. Water Bath
iii. Thermometer
iv. Sample pre-cooling equipment
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d. PROCEDURE
Obtaining a Test Sample – Fill the cooling vessel with the pre-coolant so as to cover the cooling
coil. Attach the inlet of the cooling coil to the source from which the sample is to be taken with
a short line connection pipe of 6 mm diameter having a sampling valve large enough to prevent
vaporization of the material due to the drop in pressure across the valve seat. Purge the
sampling line and cooling coil by opening both the sampling valve and the 3-mm needle valve on
the down-stream end of the cooling coil. Fill the weathering tube with the sample flowing
through the cooling coil. Empty this first sample, add one or two grains of charcoal, and then
refill the weathering tube to the 100-ml mark with fresh liquid sample passing through the
cooling coil. Carefully insert into the centrifuge tube the pre-cooled armoured thermometer up
to the desired depth (i.e. with its up at a distance of 21+/-1 mm from the inside bottom edge of
the tube). Centre the armoured thermometer in the tube by means of a slotted cork.
Weathering of LPG
Butane and Butane-Propane Mixture types – If the temperature of the sample is below -12oC,
allow it to weather in the atmosphere until the temperature has reached -12oC. At this point,
place the weathering tube with the armoured thermometer still in place in the water-bath in a
vertical position submerging it to the 1.5 ml mark and allow the contents to weather.
CAUTION : Safe means for disposal of products of weathering should be provided.
Propane Type – Allow the sample to weather in the atmosphere taking care to disturb the frost
on the tube as little as possible (see Caution). An acetone or alcohol swab may be used to
remove frost sufficient to permit reading of the temperature.
Reading of Temperature – When the liquid level in the weathering tube, with the armoured
thermometer in place, corresponds with the level previously determined after 5 ml of water was
put in the weathering tube, read and record the temperature of the sample in accordance with
above depending on the type of LPG Sample.
e. CALCULATION AND REPORTING
Correct the thermometer reading at the 95 percent boiling point (5 percent residue) for the
thermometer error.
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Correct further the value obtained in above from the observed atmospheric pressure in millimeters
of mercury to a base barometric pressure of 760 mm as given below :
Weathering Test (for LPG Type) Correction for each 10 mm

of Mercury (for Pressure)
___________________________________
Above 760 mm Below 760 mm
Propane -0.3oC +0.3oC
Butane and butane- -0.4oC +0.4oC

Propane mixture
Report the value obtained in above to the nearest 0.1oC as “95 percent evaporated point at 760 mm of
mercury”.
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1.10.3 VAPOUR PRESSURE OF LIQUEFIED PETROLEUM GASES (IS:1448 (P :71) -1979)
a. SCOPE
This test method covers the determination of gauge pressure of liquefied Petroleum Gas products
at temperatures of 37.8 degrees centigrade upto & including a test temperature of 70 degrees
centigrade
b. APPARATUS
i. Two inter-connected chambers
ii. Pressure Gauge – Bourdan type spring gauge of test gauge quality 114 to 140 mm in
diameter
c. OUTLINE OF THE METHOD

Thirty-three and one-third to forty ( 331/3 to 40) percent by volume of the liquid content of the
apparatus is immediately withdrawn to provide adequate free space for product expansion. The
apparatus is then immersed in a water bath maintained at the standard test temperature of
37.8o C or, optionally, at some higher test temperature upto and including a test temperature of
70o C.
The observed gauge pressure at equilibrium, after correcting for gauge error and correcting to
a standard barometric pressure, is reported as the ‘LPG Vapour pressure’ at the selected test
temperature.
d. PROCEDURE
Invert the apparatus and shake it vigorously. Return the apparatus to its normal upright position
and immerse it in the constant temperature water bath maintained at the test temperature.
The apparatus including the bleeder valve coupling, but excluding the pressure gauge, shall be
immersed. Throughout the determination, the temperature of the water bath shall be checked
periodically by means of the bath thermometer.
At test temperature of 50o C or below, maintain the bath within +/- 0.1oC of the test temperature.
At test temperature above 50oC, up to and including 70oC, maintain the bath within +/- 0.3oC of
the test temperature.
Observe the apparatus assembly throughout the test period to ensure freedom from leaks.
Discontinue the test and discard the results at any time a leak is detected.
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After 5 minutes have elapsed, withdraw the apparatus from the water bath, invert it, shake it
vigorously, and then return it to the bath, perform the shaking operation quickly, to avoid excessive
cooling of the apparatus and its contents. Thereafter, at intervals of not less than 2 minutes,
withdraw the apparatus from the bath, invert, shake it vigorously and then return it to the bath.
Prior to each removal of the apparatus from the water bath, tap the gauge lightly and observe
the pressure reading. These operations will normally require 20 to 30 minutes to ensure
equilibrium. After this time, if consecutive observed gauge readings are constant, record the
pressure reading as the “Uncorrected LPG vapour pressure’ of the sample at the test temperature.
Without removing the pressure gauge from the apparatus or the apparatus from the bath, attach
a test gauge, previously calibrated against a dead-weight tester, to the bleeder valve outlet and
open the bleeder valve. At the end of 5 minutes compare the readings of the two gauges.
Record any correction thus determined as ‘gauge correction.’
e. CALCULATION
Correct the ‘uncorrected LPG Vapour pressure’ for gauge errors.
Convert the corrected vapour pressure as calculated in to a Standard barometric pressure of

101,3 KPa by means of the following formula.
Pv = Po - (101, 3 - Pb) where
Pv is the gauge vapour pressure converted to a standard absolute barometric pressure of 101,3
KPa (Kilopascals)
Po is the corrected gauge vapour pressure in Kilopascals
Pv is the observed absolute barometric pressure in Kilopasals
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1.10.4 SPECIFIC GRAVITY TEST - HYDROMETER TEST
a SCOPE
This test describes the determination of specific gravity of LPG.
b APPARATUS
A hydrometer, enclosed in a cylinder constructed of clear plastic or glass, graduated in
specific gravity with a range from 0.500 to 0.650 having a self contained thermometer.
Apparatus has one inlet, one outlet valve at the bottom and a vent valve at top.
c OUTLINE OF METHOD
The specific gravity is measured using a hydrometer submerged in a properly designed
cylinder constructed of clear plastic or glass.
d PROCEDURE
1. While taking the sample in to the cylinder, control the inlet pressure to be less than the
LPG vapour pressure.
2. Purge the hydrometer with the sample.
3. When hydrometer is sufficiently purged, the outlet valve is closed and inlet valve is kept
open permitting the liquid to enter the pressure cylinder until it is completely full. If
necessary, the vent valve may be opened slightly to permit complete filling of the pressure
cylinder and then closed.
4. Drain the product completely by closing the inlet valve and opening the outlet valve.
5. Close the outlet valve and open the inlet valve filling the cylinder to a level at which the
enclosed hydrometer floats freely.
6. With all the valves closed, examine the apparatus for leaks. If leaks are present, discard
the sample, repair the leaks and repeat the sampling procedure.
7. Keep the cylinder in the water bath set at 37.8 deg C.
8. When the product temperature has reached the set temp observe the density.
9. Using ASTM tables the density at 15 deg C can be obtained.
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1.10.5 COPPER STRIP CORROSION TEST
a. Scope
This method is intended for detection of corrosiveness to copper of Liquified Petroleum
Gas
b. Out line of Method
i. A polished copper strip is immersed in a given quantity of sample & heated at a

temperature and for a time characteristic of the material being tested. At the end of
this period, the copper strip is removed, washed & compared with the ASTM copper strip
corrosion standards.
c. Apparatus
i. Corrosion Test Cylinder – constructed of stainless steel and capable of withstanding a

pressure of 70 bar
ii. Test Cylinder Bath – capable of being maintained at a constant temperature of 38.0 +/-
0.5 degrees centigrade and having suitable supports to hold the test cylinder in an
upright position. It shall be deep enough so that the entire test cylinder & valves are
covered with water during the test.
iii. Thermometer – Having range of -20 degrees centigrade to 102 degrees centigrade
d. Procedure
I. The sample bomb is purged by filling and emptying with a portion of sample before
Filling with the sample to be tested
II. The sample is taken inside the bomb in such a way that the copper strip is submerged
inside liquid LPG, keeping sufficient space for volumetric expansion.
III. Heater and stirrer of the water bath are switched on, after ensuring that the thermostat
is set at 38 +/- 0.5 deg C.
IV. After a uniform temperature of 38 degrees Celsius is stabilized, the sample bomb is
immersed inside the water bath for one hour duration.
V. After one hour, liquid content inside the bomb is vented out and the copper strip is taken
out.
VI. The colour of the copper strip is compared with standard ASTM colour chart and corrosion
level is ascertained.
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1.10.6 HYDROGEN SULPHIDE TEST
a. Scope
This method covers the detection of hydrogen sulphide in liquefied petroleum gases.
b. Outline of method
The vapourised gas is passed over moist lead acetate paper under controlled conditions.
Hydrogen sulphide reacts with lead acetate to form Lead sulphide & thus produces
colouration on the paper which will vary from yellow to black depending upon the amount
of Hydrogen sulphide present.
c. Apparatus
i. Stainless steel sample cylinder
ii. Glass cylinder – 1 ¾ inch dia x 8 inch long
iii. Lead Acetate Test paper
iv. Flow Indicator
d. Procedure
I. Connect the test apparatus to the sample source by use of a minimum length of
clean stainless steel tubing.
II. Moderately flush the line & apparatus for about 1 minute.
III. Fill the water reservoir with warm water (50 -70 degrees centigrade)
IV. By use of needle valve, adjust the rate of Gas flow to 2.3 +/- 0.2 ltrs/min.
V. Immediately place a single strip of water moistened lead acetate paper on the hook
in the test cylinder so that the paper is held midway between the watch glass & the
bottom of the upper stopper. Expose the moist paper exactly for 04 minutes to the
gas flow of 2.3 +/- 0.2 ltrs/min.
VI. Compare the exposed test paper with a moist test paper that has not been exposed.
In the absence of distinct colouration, report hydrogen sulphide negative, if there
is a distinct colouration, wait for 5 minutes before interpreting the test results
either negative or positive. The presence of Methyl mercaptan in Liquified Petroleum
Gas, gives a distinct yellow stain to the test paper which however fades completely
in less than 05 minutes.
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1.10.7 Dryness Test
a. Scope
This test is intended to give an indication of the dryness of Liquified Petroleum Gas
b. Outline of method
Vapours of LPG are brought in intimate contact with Cobaltous bromide colour indicator
under specified condition, dryness is indicated by observing the colour of Cobaltous
bromide.
c. Apparatus
i Indicator – It is essentially a device for intimately contacting a Gas or vapour with

finely devided Cobaltous bromide under such conditions that the colour of Cobaltous
bromide may be observed at all times
ii Pressure Gauge – of suitable range graduated in 0.1 kg/cm2
iii Ice Bath – Having depth sufficient to immerse the cooling coil and all but the tip of
the attached indicator
iv Cooling Coil – Shall consist of at least 0.6 m of 6 mm outside dia copper tubing
coiled so that it may be conveniently immersed in the ice bath
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d. Procedure
I. The valve on the source of LPG to be tested shall be opened & the cap removed from
the outlet of the indicator
II. The needle valve shall be carefully opened until the pressure gauge registers 3.5 +/
- 0.1 kg/cm2 & shall be adjusted to maintain the pressure for the duration of the
test.
III. If the original blue colour persists for 30 minutes of test exposure, the pressure
shall be then reduced to 0.5 +/- 0.1 kg/cm2 for 5 minutes.
IV. If the original blue colour persists throughout this period (35 mins.), the material
shall be reported as being “Dry” and shall be considered to have passed the test. If
the colour changes to lavender or pink at reduced pressure, then the material shall
be reported as being “Wet” and shall be considered not to have passed the test.
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1.10.8 COMPOSITION TEST - GAS CHROMATOGRAPH (ASTM D 2163)
International standard describes the simplified method for the calculation of density and vapour
pressure of Liquified Petroleum Gases based on compositional data and density & vapour pressure
factors for individual LPG components. This test is carried out to determine the chemical
composition of Liquified Petroleum Gas. This is carried out through a specialized equipment –
Gas Chromatograph.
a. Procedure for start up of GC
i. Open nitrogen, hydrogen, air cylinders using cylinder opening key and read cylinder
pressure on the pressure gauge. It should be above 10 kg/cm2, if less replace the
cylinder.
ii. Turn clockwise the black regulator knob to adjust the outlet pressure to the red
mark (4 kg/sq cm).
iii. Open the on/off valve given below, it should read pressure as given below:
· Carrier - 3.0 bar

· TCD Carrier - 3.2 bar.
· Hydrogen FID - 1.2 bar
· Air FID - 0.7 bar
iv. Switch on the GC and select the method 03. All required parameters will be loaded
onto the GC.
v. Ignite FID flame by pressing ‘Extra Function’ key. Use the arrow key to make the
ignition status “YES” and press clear.
vi. Press B and signal key and press enter key so that it will make the signal value
“DET B BASELINE TO 4.0 4.0”. Press clear.
vii. Now the GC displays “GC Ready” message and is ready for sample injection.
b. Procedure for preparation and injection of LPG sample
i. Connect the metal canister to the T joint with a 10/12 spanner.
ii. Another end of the T joint is connected to a teflon tube. Connect this tube to the
LPG sampling bomb with a suitable reducing nut.
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iii. The third end of the T joint is connected to the on/off valve. Open this valve and
connect the flexible tubing and vacuum pump to the outlet of this valve.
iv. Close the valve of LPG sampling bomb tightly.
v. Open the valve of the metal canister.
vi. Open the on-off valve.
vii. Switch on the vacuum pump. This will evacuate the whole canister and tubing. It
may take 2-3 minutes.
viii. Close the on off valve and remove the PVC tubing from the valve.
ix. Switch off the vacuum pump. Open the valve of the ‘T’ joint to check evacuation
and repeat the process of evacuation.
x. Remove the vacuum pump from the T joint.
xi. Hold the LPG sampling bomb upside down and open the valve slowly so that only
liquid LPG fully fills the PVC tubing, gas phase can be vented by slightly opening the
on-off valve of the T joint.
xii. Close the LPG sampling bomb tightly.
xiii. Open the valve of the metal canister so that the LPG present in the PVC tubing is
sucked into the canister.
xiv. Close the valve of the canister and disconnect the metal canister from the T joint.
xv. Connect the pressure gauge to the canister.
xvi.Open the valve on the canister and check the pressure. It should be between 10-20
psi. Close the canister and remove the gauge from the canister. Now the canister is
ready for sample injection.
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c Testing Procedure
i. Ensure the GC displays “GC READY”.
ii. Connect the canister to the sampling inlet point using the PVC tubing. Purge the
sample loop for a while and ensure that the sample comes out through the vent of
loop in the form of bubbles. Press the ‘START’ key of the GC and close the sample
flow.
iii. In the meantime, switch on the computer, open winchrom run program and open
required method file. Edit the sample name.
iv. On pressing the “START” key of GC, chromatograph is generated on the computer
screen. On completion of the test, “REPORT READY” message is displayed. Print of
chromatograph and report is taken. Report gives the composition of the sample
indicating the percentages of various components.
v. Before injection of next LPG sample, flush the sample loop with nitrogen gas provided
at the ‘make up gas’ line of the GC panel. The flow rate has to be controlled using
the on-off valve. This can also be used to start and stop the nitrogen flow.
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d. GC switching off procedure
i. Press method 10 and press enter.

ii. Close hydrogen and air cylinder with cylinder key.
iii. Wait for 45 minutes. The oven temperature reaches around 30 deg.
iv. Switch off the GC.
v. Close the nitrogen cylinder with the cylinder key.
vi. Turn anti clockwise the black knobs to close the outlet valves on each of the three
cylinders.
vii. Close the following on-off valves: Carrier C, TCD Carrier, Hydrogen FID. Air FID.
On analysis of composition of C1, C2, C3, C4, C5 etc in LPG, density & vapour pressure to be
derived mathematically.
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IMPORTANT STATUTES APPLICABLE TO LPG
PLANTS/INSTALLATIONS
INDEX
2.0 General 1
2.1 Indian Explosive Act -1884 1
2.1.1 License to store compressed gas (Bulk LPG) in 2

pressure vessel ( SMPV Rules 1981)
2.1.2 License to fill & store compressed gas (LPG) in 3

cylinders ( Gas Cylinder Rules – 2004)
2.1.3 Important provisions of SMPV Rules - 1981 3
2.1.4 Important provisions of Gas Cylinder Rules - 2004 4
2.2 The LPG (Regulation of supply & distribution)

Order – 2000 5
2.3 Factory Act 5
2.3.1 Salient features/provisions of Factory Act 5
2.3.2 Approval, licenses & registration of factories 6
2.3.3 Provision of Safety Officer 7
2.3.4 Provision of Employee Welfare 7
2.4 Environment (Protection Act ) – 1986 8
2.4.1 Air (Prevention & Control of Pollution) Act – 1981 8
2.4.2 Water (Prevention & Control of Pollution) Act – 1974 8
2.4.3 Hazardous Waste (Management & Handling) Rules – 1989 9
2.4.4 Requirement of effluent treatment plant (ETP) 9
2.5 Legal Metrology Provisions 10
2.5.1 Standards of Weights & Measures Act – 1976 10
2.5.2 Packaged Commodities Rules – 1977 11
2.6 Contract Labour ( Regulation & Abolition ) Act – 1970 11
2.6.1 Applicability of Contract Labour (R&A) Act – 1970 11

2
2.6.2 Important terminology related to Contract Labour (R&A) Act 11
2.6.3 Compliance to be made 12
2.6.4 Important information to be displayed 13
2.7 Employee State Insurance Act – 1948 13
2.8 Employee Provident Fund Act – 1952 13
2.9 Workmen’s Compensation act – 1923 14
2.10 Minimum wages Act – 1948 14
2.11 Indian Electricity Rules – 1956 14
2.11.1 Enforcement of IER – 1956 14
2.11.2 Requirement of Electrical Installations 15
2.12 Central Motor Vehicle Rules 9 – 1993 16
2.13 Public Liability Insurance Act – 1991 16
2.14 OISD Standards 17
2.15 Vasudevan Committee – 1983 17
2.15.1 VC – 1983 ( For LPG Bottling Plant) 17
2.15.2 VC – 1983 ( For Cylinders/Valves/Regulators) 18
2.15.3 VC – 1983 ( For Transportation of LPG) 18
2.15.4 VC – 1983 ( For LPG Distributor) 18
2.16 Sudha Joshi Committee 19
2.17 Right to Information Act – 2005 20

2
2.0 GENERAL.
LPG Bottling Plant / Installations are considered as factories. Operations and administration of
these locations are governed by various applicable statutory guidelines. It is imperative that
compliance to the requirements of the applicable statutory guidelines to be ensured. Compliance
of statutory requirements plays important role towards safety, health and environment issues
concerning not only Corporation but Society as a whole.
Following are some of the important statutory Guidelines applicable to LPG Plants / Installations.
L Indian Explosive Act-1884
u Gas Cylinders Rules- 1981 amended in 2004.

u Static & Mobile Pressure Vessels (Unfired) Rules – 1981.
L The liquefied Petroleum Gas (Regulation of supply & distribution) order 2000.
L Factory Act-1948
L Environment Protection Act 1986
u Air (P&CP) ACT-1981

u Water (P&CP) ACT-1974
u Hazardous Waste (Management & Handling) Rules – 1989.
L Legal Metrology (W&M)
u Standard W&M ACT-1976 & Rules 1987

u Standards W&M , Packaged Commodities Rules 1977
L Contract Labour ( Regulation & Abolition ) Act, 1970
L ESIC Act -1948
L Employees Provident fund Act- 1952
L Workmen’s Compensation Act - 1923
L Minimum Wages Act 1948
L Indian Electricity Rules 1980
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L Central Motor Vehicle Rules 1989 (Amended 1993)
L Public Liability Insurance Policy (PLI) -1991
L OISD Standards 105 &144
L Vasudevan Committee (MOP & C),1983.
L Sudha Joshi Committee – 1987
L Right to Information Act – 2005
Salient features of these Acts applicable to LPG locations to be complied are given below. However
these Acts be referred for any issues pertaining to LPG Plant / Installation Operations.
2.1 INDIAN EXPLOSIVE ACT-1884
Enforcement body : Petroleum & Explosives Safety Organisation ( PESO ) – Headed by The Chief
Controller of Explosives.
Following three Explosive Licenses are required for LPG Bottling Plant :
I. License to store Bulk LPG in Storage Vessel (As per SMPV Rules)
II. License to Fill LPG in Cylinders (As per Gas Cylinder Rules)
III. License to Store Filled LPG Cylinders (As per Gas Cylinder Rules )
In addition to above, permission from Explosive Department is required for specific installation
like cross country pipelines, cylinder testing unit, T/W repair unit, Degassing facilities etc.
2.1.1 License to store compressed gas (Bulk LPG) in pressure Vessel : (SMPV Rules-1981)
Applicable Rules : 49,50,54 & 55 of SMPV Rules,1981
Rule 49 : Gives details of Application for obtaining of License. Application for obtaining new
license for storage of Bulk LPG to be submitted as per Form I or Form IA ( For Auto LPG Station)
and for renewal application is to be made in Form III or Form V ( For Auto LPG Station). Form IV
for renewal of transport of compressed gas in pressure vessel by vehicles.
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Rule 50 : Specifies the period of licence. Licence shall remain in force until the 31st day of March
of the year upto the same is granted or renewed. License under SMPV rules are granted or
renewed subject to a maximum period of 3 years.
Rule 54 : Specifies the procedure for amendment of Licence
Rule 55 : Specifies the procedure for renewal of Licence
Performa of forms with requirements for application of licences/renewal etc are given in the
SMPV rules. Same be referred for making application for new licence/renewal.
2.1.2 Licence to Fill & Store compressed gas (LPG) in cylinders : (Gas Cylinder Rules – 2004)
Applicable Rules 49, 50,51,54 &55 of Gas Cylinder Rules 2004
Rule 49 : Specifies the application for obtaining licence. Application for grant /
amendment /renewal of a licence to fill/store compressed gas in cylinder.
Rule 50 : Specifies the conditions for Grant of licence.
Rule 51 : Specifies licence period which may be granted/renewed. Granted/renewed licence are
issued in Form E for licence to fill compressed gas in cylinders and Form F to store compressed
gas in cylinders. Similarly licence is issued in Form G to dispense compressed natural gas (CNG)
in a CNG station as automotive fuel. These Licences shall remain in force until the 30th day of
September of the year upto the same is granted or renewed. This license are granted or renewed
subject to a maximum period of 10 years.
Rule 54 : Specifies procedure for amendment of Licence
Rule 55 : Specifies procedure for renewal of Licence.
2.1.3 Important provisions of SMPV Rules 1981
Rule 6 : Specifies procedure for repair of pressure vessel.
Rule 10 : Specifies precautions against accident.
Rule 15 : Specifies filling capacity and filling pressure.
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Rule 18 : Specifies fitting & relief devices for pressure vessels.
Rule 19 : Specifies the details on periodic testing of pressure vessels in service
Rule 33 : Gives the certificate of Safety by a competent person
SMPV rules also specifies minimum safety distances to be maintained for various capacities of
vessels used for various types of gases. Refer table 3 for minimum safety distances for Liquified
Flammable Gases.
Rules : 49,50,54 & 55 – Refer 2.1.1 for detail
2.1.4 Important provisions of Gas Cylinder Rules 2004
Rule 6 : Specifies marking of cylinders
Rule 7 : Specifies marking on valves
Rule 8 : Specifies colour of cylinders
Rule 9 : Labelling of Cylinders
Every cylinder shall be labeled with the name of Gas & the name and address of person by whom
the cylinder is filled
u Warnings to be attached with each LPG cylinder:
u Do not change the colour of cylinder
u Cylinder shall not be filled with any Gas other than the one it contains
u No Flammable material should be stored in the close vicinity of the cylinder or in the same
room
u No Oil or similar lubricant shall be used on the valves or the other fittings of the cylinders
u Next Test date to be prominently displayed
Rule 21 : Specifies storage of cylinders
Rule 26 : Specifies cylinder should not be used & transport until retest has been done properly.
Rule 35 : Specifies periodicity & procedure for retesting of cylinders (Refer schedule IV for required
facilities for a cylinder testing station & detail testing procedure)
Rule 43 & 44 : Specifies requirement of licence for filling & possession of gas cylinder.
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Rules 49, 50,51,54 &55 – Refer 2.1.2 for detail

2.2 THE LIQUIFIED PETROLEUM GAS (REGULATION OF SUPPLY & DISTRIBUTION) ORDER 2000
In exercise of powers conferred by section 3 of “Essential Commodities Act 1955” (10 of 1955),
the central Government has made this order with a view to protect consumer interest. This
order is applicable for the whole country and for all Government oil companies, parallel marketers
who are engaged in business of purchase, sale or storage for sale of liquefied petroleum gas in
cylinder to consumers.
The important features of this order are:

L Restriction on unauthorized possession, supply and consumption of LPG.
L Restriction on storage & transport of LPG.
L Restriction on sale or distribution of LPG below or in excess of the standard weight.
L Prohibition on carrying unauthorized business of selling LPG.
L Possession, supply or sale of LPG equipments.
L Display of stocks and price of LPG.
L Procurement, storage & sale of LPG by a distributor.
L Maintenance of register, account book by a distributor.
L Maintenance of records & furnishing of information by parallel marketeers.
L power of entry, search & seizure.
2.3 FACTORY ACT 1948
2.3.1 Salient features/provisions of the act are:
l Formalities before starting a factories (Refer Section 6)

1. Submit plan of factory to Chief Inspector or State Government
2. Obtain permission of the site of factory from State Government or Chief inspector
l Applicability
1. Factory having 10 workmen with aid of power, 20 without aid of power, employed
directly or by agency
2. Premises with less than 10 workers, if notified (Refer Section 85)
l Factory {Refer Section 2(m)} – Any premises including precincts thereof where
l Manufacturing process is carried on with aid of power 10 or more workers are working or
have worked on any day in preceding 12 months.
l Does not include : Mines under Mines Act and mobile unit of armed force
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l Manufacturing process {Refer Section 2(k)} – Means process of :

L making, altering, repairing, ornamenting etc of any article or substance with intent to
use sale, transport, delivery or disposal, or
L Pumping oil, waste etc, or
L Generating or transforming or transmitting power, or
L Composing types of printing, lithograph etc. or
L Constructing, reconstruction etc of ships or vessels
L Preserving or storing any article in cold storage.
l Workers {Refer Section 2(l)} – Means person employed :

L directly or through an agency (including Contractor) with or without knowledge of employer,
whether on remuneration or not in manufacturing process or cleaning any machinery or
premises used in mfg. process, any other work incidental to or connected with or subject
of mfg. process.
L Does not include : Members of Armed force of Union.
l Occupier {Refer Section 2 (n)} – In relation to factory means :

L a person having ultimate control over the affairs of the company.
l Annual leave with wages (Refer Section 79): If worked for 240 days in a year
L for adult : one day for 20 days work
L for child : one day for 15 days work.
l Working hours ( Refer Section 51 & Section 58) : No adult to work more than 48 hours per
week or 9 hours per day and extra wages for overtime. Compensatory holiday to be given if
worked on weekly holiday.
l Notice of accident (Refer Section 88) :

L To inspector and ESIC within 24 hour in form 24
2.3.2 Approval, licencing and registration of Factories ( Refer Section 6)
L Application for approval of plans be made in Form I (Rule 3)and licence is granted by
Chief Inspector of Factories under Form IV.
L Renewal period : Renewal for licence shall be submitted in Form 3 before two months
from the date of expiry of existing licence. In case of delay in submission for renewal of
application, a penalty of maximum 25% of fees to be paid alongwith application (Refer
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Rule 8 & schedule). Licence are renewable maximum for 10 years.

L Renewal fees depends upon Electrical load (HP) & Manpower ( Max. nos. of workers).
L Submit Statement of Annual Return on or before 1st February in duplicate in form-27

under Rule-119 (1) of FA-1948.
L Muster Roll for all employees employed in a factory under Rule-122 in FORM-29 & updated
each month.
L Register of accident & dangerous occurrence to be maintained under Rule 123 in Form
30.
L Maintenance of Inspection Book in FORM-31 under Rule-124
L Notice for change of Manager under Rule-15 in FORM-5 within 7days from the date of
change.
L Hoist & lift shall be examined once in six month (Refer Section 28).
2.3.3 Provision of Safety Officer (Refer Section 40B)
1. In every factory
i. wherein 1000 or more workers are ordinarily employed or
ii. wherein in the opinion of State Government, any manufacturing process or operation
is carried on, which process or operation involves any risk of bodily injury, poisoning
or disease, or any other hazard to health, to the persons employed in the factory,
the occupier shall, if so, required by the state government, by notification in the
official gazette, employ such number of Safety Officers as may be specified in that
notification.
2. The duties, qualifications and conditions of service of Safety Officer shall be such as
may be prescribed by the State Government.
2.3.4 Provision of employee welfare :

L Washing facility : adequate, suitable & separate for male & female workers
L Rest Room : sitting facility during rest hours shall be provided.
L First aid boxes : in every 100 workers 1 first aid box or cupboard equipped with prescribed
contents to be made available.
L Canteen facility : to be provided where number of employees exceeds 250 in a factory.
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2.4 ENVIRONMENT (PROTECTION ACT) -1986
This act specify to take all measures as it deems necessary or expedient for the purpose of
protecting & improving the quality of environment & preventing, controlling & abating
environment pollution.
Every person carrying on an industry, operation or process requiring consent under the Water
(Prevention & control of Pollution) Act-1974, consent under Air (Prevention & control of Pollution)
Act-1981 & authorization under hazardous waste (Management & Handling) Rules- 1989. The
industry/factory shall submit & environmental statement for the financial year ending 31st March
in the Form V to the concerned State Pollution Board on or before 30th September of every year.
2.4.1 Air (Prevention and Control of Pollution) Act 1981.
The objective of this Act is to provide for the prevention, control and abatement of air pollution,
for the establishment, with a view to carrying out the aforesaid purposes, of Boards, for conferring
on and assigning to such Boards powers and functions relating thereto and for matters connected
therewith.
• Air consent is required under Section-22.
• Application for renewal of consent shall be made 30 days before the date of expiry of
consent.
• Maintain LOG book for running of all air pollution control devices
• Height of the stack of DG/Fire Engines need to be specified
• Test reports by competent authorities for Ambient air quality and Stack emission to be
submitted during renewal of license.
• Submit On-site & Off- Site Emergency Plan.
• Comply Public liability Insurance Rule-1991
• Submit Environmental Statement along with renewal of consent.
2.4.2 Water (Prevention & Control of Pollution) Act-1974
The objectives of the Water (Prevention and Control of Pollution) Act are to provide for the
Prevention and Control of Water Pollution and the maintenance or restoration of the wholesomeness
of water for the establishment, with a view to carrying out the purposes aforesaid, of Boards for
the prevention and control of water pollution, for conferring on and assigning to such Boards
powers and functions relating thereto and for matters connected therewith.
• Prior consent is required from concerned SPCB for discharge of effluent under Section -
25.
• Application for renewal of consent shall be made 30 days before the date of expiry of
consent along with required consent fees.
• Test reports by competent authorities for Effluent quality to be submitted during renewal
of license
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State board may from time to time review condition imposed under grant of consent & may
serve notice for making any reasonable variation of conditions imposed during grant of consent.
Plant/installation should ensure compliance of conditions mentioned under the consent & provision
of the act.
2.4.3 Hazardous Waste (Management & Handling) Rules – 1989
These rules apply to hazardous waste specify in the schedule 1, 2 & 3 (Refer schedule for detail).
Rules shall not be applied to waste water and exhaust gases covered under provision of Water
Pollution act 1974 & Air Pollution Act 1981.
Salient features of the rules :

L The Occupier shall be responsible for proper collection, reception, treatment, storage, handling
and disposal of hazardous waste.
L The occupier shall design & set up disposal facility as per guidelines issued by Central/State
Government from time to time.
L The occupier of a factory shall be liable for damages caused to the environment resulting
into improper handling & disposal of hazardous waste listed in schedule 1, 2 & 3.
L Occupier shall also be liable to reinstate or restore damaged or destroyed elements of the
environment.
L Occupier will be liable to pay fine as levied by State Pollution Control Board with the approval
of Central Pollution Control Board for any violation of the provision under the rule.
2.4.4 Requirement of effluent treatment Plant (ETP)
In case effluent sample does not meet the specified norms, ETP has to be installed for treatment
for effluent. The sludge generated has to be disposed as per the following procedure:
a) Sludge from LPG Bullets / Sphere testing and mandatory testing of cylinders
i. The sludge is to be weathered for evaporation of oil and water

ii. Sample of sludge to be tested through a reputed chemical laboratory for ascertaining
lead and cobalt content.
iii. The relative dry sludge without lead or cobalt should be disposed off in a land filling.
iv. Dry sludge containing lead or cobalt should be embedded in concrete blocks preferably of
1 cft size or as per the quantity of sludge and these blocks are to be finally buried in the
ground. The following precautions to be taken for burying the sludge.
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L Selection of location within plant premises, preferably away from water resources.
L Fencing around the territory to prevent people or live stock
L Excavation of land fill to a depth of 2 m depending upon water table
L Covering the land fill with the soil from the excavated area
b) Sludge formed at painting booth
This is a heavy solid and must be collected in a container and should be buried to a depth of
2 m depending upon the water table away from human settlement, water resources or
agricultural fields.
2.5 LEGAL METROLOGY PROVISIONS
2.5.1 Standards of Weights & Measures Act 1976
l Every weights or measure used or intended to be used in any transaction shall be verified or
re-verified as prescribed by Controller of Weights & Measures ( Sect-24).
l Every weights or measures should be present for verification at the office of Inspector on or
before due date (Sect-26).
l For Every weights or measures which cannot be moved from its location, it shall be reported
to Inspector at least 30 days in advance for verification.
l The certificate of verification to be exhibited at a place where weights or measures are
used.
l Maximum permissible ERROR on NET Quantities declared by weights or by volume. Under
“THE SECOND SCHEDULE See Rule-2(i)(ii), TABLE-1, of the standard weight & measure
packaged commodities rule 1977
l 1-10 kg +/- 1.5 %

l 10-15 kg +/-150 gms
l More than 15 kg +/-1.0 %
l Dead weight required for verification of WB is 25% of maximum load
Sample size & permissible error to be as per Schedule 9 i.e.

Sample size should be 32 for batch size less than 4000 &
Sample size should be 80 for batch size more than 4000.
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2.5.2 Packaged Commodities Rules 1977
Declaration to be made on each Package ( Rule 6)
l Name & Address of the manufacturer

l Common generic Name
l Net Quantity
l Month & Year of the Manufacture
l Retail Sale Price of the Package
Declaration to be made for Whole sale packages ( Rule 29)

l Name & Address of the Manufacturer
l Identity of the commodity
l Total number of retail package in whole sale packages
Exemption in respect of certain Packages (Rule 34)
Registration of Manufacturer ,packers & Importers.( Rule 35 )

l Name of the firm
l Name of the applicant
l Complete Address of the Party/Importer.
2.6 Contract Labour ( Regulation & Abolition ) Act, 1970
2.6.1 Applicability
i. To every establishment in which 20 or more workmen are employed or were employed on
any day of the proceeding twelve months as contract labour.
ii. To every contractor who employs or who employed on any day of the proceeding twelve
months twenty or more workmen
Provided that the appropriate government may, after giving not less than two months notice of
its intention so to do, by notification in the Official Gazette, apply the provisions of this Act to
any establishment or contractor employing such number of workmen less than twenty as may be
specified in the notification.
2.6.2 Important Terminology Related to This ACT (Given in Section 2)
l Appropriate Government
l Contract Labour
l Contractor
l Controlled Industry
l Establishment
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l Principle Employer
l Wages
l Workmen
2.6.3 Compliance to be Made
Registration of Establishment for employing contract labour (Refer Section 6, 7,8 & 9)
Registration of Establishment to be made as per Form I and Certificate of Registration to be
issued as per Form II.
Licensing of Contractors (Refer Section 11,12,13 & 14)
The contractor has to apply in Form IV to obtain labour license, and license is issued in Form
VI
Renewal of license under Form VII
Welfare & Health of Contract Labour (Refer Section 16,17,18 & 19)
Responsibility of Payment of Wages (Refer Section 21)
Register of wages to be maintained as per Form XVII
Returns as per Section 82 of Contract Labour (R&A) Central Rules 1971
Half yearly return to be submitted by Principle Employer (Form No. XXIV) by 30th October.
Annual Return to be submitted by Principle Employer (Form No. XXV) by 15th Feb of next
year.
Principle Employer has to give a certificate in Form V to the contractor employing more than
specified number of contract labour.
Notice of commencement & completion of contract work ( As per Form VI B) Notice to be
submitted by principle employer (In our case Plant Manager/Occupier) to the office of LEO.
The principal employer has to maintain Register of Contractors as per Form XII
The principal employer has to ensure that the following registers are to be maintained by the
contractor:
o Employment card in Form XIV

o Muster roll in Form XVI
o Register of Wages & Deductions in Form XVII
o Wage slip as per Form XIX
o Register of Fines in Form XXI
o Register of Advances in Form XXII
o Register of Overtime in Form XXIII
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2.6.4 The following information is to be displayed prominently in Plant in local language
o Name of address of the licensing authority

o Plant working hour and break time details
o Applicable minimum wages under unskilled, semi skilled and skilled categories
o Wage distribution date and wage period
2.7 EMPLOYEE STATE INSURANCE ACT ( 1948) :
This is a piece of social welfare legislation enacted primarily with the objective to provide detail
benefits to employees in case of sickness, maternity , employment injuries and also to make
provisions for certain other matters .
This act applies to the employees, contract labours falling within the wage limit specified in the
act from time to time. Further, this act will be applicable if the factory falls within the area
classification by ESIC (Employees State Insurance Corporation) .
The contribution to be paid ESIC by the employee and the employer as per provisions of the act.
Employees are issued ESIC Card to get treatment for their self and family members in the
nominated ESIC hospitals.
In case of accidents or incidents, the act specifies accidents benefits / disablement benefits ,
treatment expenses etc.
Plants/Locations to ensure that contractors shall obtain registration number under the act &
comply with the provision & passes the benefit define in the act.
Every principal & immediate employer shall submit return to the ESIC giving particulars of
employees to any factory or establishment.
2.8 EMPLOYEES PROVIDENT FUND ACT - 1952.
Any person employed by or through a contractor in or in connection with the work of the
establishment is also an employee unless otherwise covered under the act and will be thus eligible
to get the benefit of the schemes framed under the act. Thus the employees engaged through
the contractor will be liable to be covered under the provisions of Employees Provident Fund Act.
Contractor has to obtain a separate identification code for the employees rendering services on
contract basis. On termination of the services, the amount can be withdrawn or continued with
the new contractor.
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Principal employer has to ensure that contribution made by the contractor are deposited with the
Employee Provident Fund under the code of employer & employee.
2.9 WORKMEN’S COMPENSATION ACT - 1923
The act deals with the liability of demand of compensation as per provision of the act to a
contract labour for personal injury caused by accident arising out of and in course of employment.
The principal employer shall be liable to pay any workman employed in the execution of the work
any compensation which he would have been liable to pay if that workman had been immediately
employed by him.
2.10 MIMIMUM WAGES ACT ( 1948 )
Act provides that the principal employer will ensure that the worker engaged thru the contractor
will be paid wages not less than minimum range as specified in that.
The minimum wage rates are specified for different categories of jobs and skills of labour
required to be employed by the factory / establishments.
Act also specifies minimum wages will be applicable basis appropriate Governments for the
establishment i.e. in case of HPC minimum wages specified for Central Government will apply.
However, higher of the minimum wages notified by the sate / Central Government notifications
shall be payable .
2.11 INDIAN ELECTRICY RULES – 1956 (Amended upto 25th Nov 2000)
The Indian Electricity Rules,1956 (Amended upto Nov 2000) are framed under Section 37 of the
Indian Electricity Act, 1910 to regulate the supply, transmission, generation, and use of electricity.
These are primarily necessary measures required to be adopted in construction, installation and
maintenance of transmission, distribution, generation and use of electricity and precautions to
be observed in carrying out any work in relation to such installations to avoid any sort of electrical
accident.
2.11.1 Enforcement
Under the provisions of the Rules 5, 46, 47A and 63 of the Indian Electricity Rules,1956 , the
Inspecting Staff of Electrical Inspectorate conducts the inspections of electrical installation of
industrial units/generating plants/ high voltage/extra high voltage installations of the consumers
and suppliers
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As per provisions of Rule 45, the conditions were framed for issue of licences to Electrical
Contractors and Certificate of Competency Class-I/Class-II to the electrical workmen.
Under the provisions of rule 63 of the said Rules the inspection of the electrical installation of
high voltage/extra high voltage, installation of consumer/supplier is carried out and necessary
approval is issued after ascertaining the relevant provisions of the said Rules are being complied
with by the owner/occupier of the said installation. Subsequent inspection/ testing shall be
required at intervals not exceeding five years or as specified.
The Electrical Inspectorate also carries out enquiries into the electrical accident under section 33
of the Indian Electricity Act,1910 and Rule 44 A of the Indian Electricity Rules,1956 .
Under section 26 of the Indian Electricity Act, 1910, the Electrical Inspector also takes-up the
dispute cases regarding correctness of the energy meter between the consumer and supplier on
application by either party.
2.11.2 REQUIREMENTS OF ELECTRICAL INSTALLATIONS:
All earthing system in the installation shall require to be tested for resistance during the dry
season not less than once a year or as specified by the authorities. Record of every earth test
shall be maintained by the occupier incharge of the installation and shall be produced as required
before the inspector or authorised officer. (Refer OISD STD 137 for earthing test frequencies).
Suitable fire extinguishers for dealing with electrical fire like CO2, DCP type extinguishers should
be placed in electrical installations.
Note :
i) For appropriate area classification, guidelines contained in IS:5572 (part 1) 1978 should
be followed.
ii) For selection of electrical equipment, guidelines contained in IS:5571-1979 & IS:9570-
1980 as revised from time to time should be followed.
Authorised person is a responsible person of the Electrical Section in the owner organisation,
authorised by Electrical-in-charge to carry out Electrical Isolation/Energisation. He is also
authorised under the provisions of Rule No.3 in the Indian Electricity Rules specifically referred in
I.E. Rules 36(2), 51(1) (a), 64(1)(a). 64(2) (e) & (f), 110(2), 121(1), 121(4), 124 and 124 (8).
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The Rule 141 of the Indian Electricity Rules,1956 prescribes the penalty in case of non compliance
of rules.
2.12 CENTRAL MOTOR VEHICLE RULE 9 ( 1993 )
Any person driving a goods carrying a goods carriage carrying goods of dangerous or hazardous
nature to human life shall in addition to being the holder of a driving license to drive a transport
vehicle, also has the ability to read and write at least one Indian Language out of those (
Specified in the VIII Schedule of the Constitution ) and English and also possess a certificate of
having successfully passed a course consisting of following syllabus and periodicity with the
transport of such goods.
Period of Training = 3 days

Place of Training at any Institute recognized by the State Govt. Syllabus
2.13 PUBLIC LIABILITY INSURANCE ACT ( 1991 )
Public Liability Insurance act ( 1991) Is valid for one year from the date of renewal.
As per the act, Insurance is to be obtained by HPCL for protecting the interest of the affected
people and to give immediate relief in case of accidents involving operations , transportation or
handling of OIL products.
Policy covers all operations of the ensured for all locations within Geographically limit including
refineries / road transportations / pipelines.
Policy Covers accident involving fortuitous, sudden or unintentional occurrence.
Maximum aggregate liability shall not exceeds Rs.5.0 Crs for an accident and Rs 15.0 Crs in
aggregate for more than One Accident.
Any Claim Under this act is to be forwarded through the District Collector
Time Barred for Claim under this act is 5 years
On Occurrence of accidents, same shall be brought immediately to the notice of concerned

District Magistrate by HPCL.
FIR has to be lodged by the victims or affected person for claim.
Claim application is to be made to the DM by the Victim / Relatives as per Form-1 of this Act.
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2.14 OISD STANDARDS
2.14.1 OISD 105 – This standard specifies work permit system for cold & hot work to be
implemented at LPG Plant/Location for safe operations.
2.14.2 OISD 144 – This standard specifies layout, design, operations, maintenance & safety
aspects of LPG Bottling Plant with capacity more than 12 TMTPA and having bulk storage
capacity more than 100 MT.
2.15 Vasudevan Committee ( MOP&C ) ,1983.
Ministry of Petroleum & Chemicals had set up a high level committee in May, 1983 headed by Shri
R. Vasudevan, the then Joint Secretary, Deptt. of Petroleum to review all safety and operational
procedures adopted in LPG filling plants, transportation of LPG by rail/ road, and in the distribution/
delivery of LPG cylinders. Several recommendations for improvements in operations/ systems
were made by the committee for adoption/ implementation by the oil industry. Gist of key points
pertaining to the recommendations are given below :
2.15.1 LPG BOTTLING PLANT
i. Location - Should not be adjoin residential areas
ii. Size - Desirable to restrict to 25 TMTPA on 2 shift basis.
iii. Layout - Provision of 80 M wide green belt beyond perimeter wall, access roads etc.
iv. Cylinder Filling - 100% cross checking of weighments on manual scale.
v. Cylinder Testing - Use of compact valve tester, water bath to check for leaks.
vi. Cylinder Handling - Conveyor system, loading/ unloading at 15 M distance from shed.
vii. Evacuation of leaky cylinders - Use of proper evacuation system and recovery of
LPG, gas freeing prior to repairs/ replacements of valve.
viii.Cylinder Storage - Vertical stacking in small lots with min. separation distance of 1
metre segregated storage for empty and filled cylinders, mastic flooring in the shed.
ix. Other Safety features/ practices - Fail-safe shut-off valves, extraction of gas/ air
mixtures, adequate communication facilities etc. One designated Safety Officer for
each plant.
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x. Manpower & Training - LPG plants to be headed by Sr. Officers. Structured training/
refresher courses for staff and officers on LPG operations, emergency handling etc. No
contract labour on shop floor for LPG operations.
xi. Fire Prevention/ Fire Fighting - Strict security check prevention of smoking, Gas
detection/ alarms, automatic Fire Water deluge/ sprinkler system. Automatic starting
of Fire Water Pumps, fire drills etc.
2.15.2 CYLINDERS/ VALVES/ REGULATORS
Standardisation and strict quality control in manufacture of cylinder and fittings, industry
inspection system for quality assurance etc.
2.15.3 TRANSPORTATION OF LPG
i) Bulk by Rail - LPG movement in bulk rake of 68 wagons, unloading/ loading in lot of 34
(500 MT) wagons. Provision of remote operated water sprinklers at Gantries.
ii) Bulk by Road - Safety training of Driver/ Attendant, special safety precautions during
loading/ unloading LPG.
iii) Cylinders by Road - Vertical stacking, gradual switchover to palletisation.
2.15.4 LPG DISTRIBUTION :
i) Distributor’s godown - Properly designed distributor godowns with mastic covered flooring,
fire fighting equipment etc.
ii) Delivery Equipment - Standardisation approach with cage design, use of 3 wheeler
scooters/ delivery van.
iii) Training of delivery boys/ mechanics - suitable training programme by oil companies
with certification scheme.
iv) Customer Education - Audio Visual aids/ films on TV , booklets on LPG safety emergency
complaint cells etc.
v) Control and Supervision - System of periodic inspection to oversee and control the working
of the distributors by oil companies.
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2.16 SUDHA JOSHI COMMITTEE - 1987 :
Ministry of Petroleum & Natural Gas in 1986 had set up a committee headed by Mrs. Sudha Joshi,
the then M.P. and Marketing Directors of Oil Companies as members with a view to provide
better services to LPG users with due regard to safety.
Brief summary of important recommendations w.r.t. safety aspects are outlined below :
-Streamlining of registration/ release of LPG 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 pre-delivery 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 curriculam to high school.
Oil companies to strengthen the inspection system of LPG bottling plants and working of
the Distributors.
Establishment of more bottling plants near the consuming centre to the extent possible.
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2.17 Right to Information Act – 2005
Salient features of the act
Statutory provisions made for Right to Information
All citizens possesses the Right to Information
Information includes any mode of information in any form of record, document, email,
circular, press release, contract, sample or electronic data etc.
Information can be obtained within 30 days of date of request in a normal case
If information is a matter of life or liberty of a person, it can be obtained within 48

hours from the time of request.
Every pubic authority is under obligation to provide information on written request by

electronic means
Certain information are prohibited.
Restriction made for third party information
Appeal against the decisions of the central information commission or state information
commissions can be made to an official who is senior in rank
Penalty for refusal to receive an application for information or not providing information
is Rs 250/- per day but total amount of penalty should not exceed Rs. 25000/-
Central Information commission and State information commission are to be instituted

by the central government and state governments.
No court can entertain any suit, application or other proceedings in respect of any order
made under the act.
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RECEIPT & DISPATCH OF BULK LPG
INDEX
3.0 Overview 1
3.1 Brief description of mode of transport 1
3.2 Receipts by Road 2
3.2.1 Types of tank truck 2
3.2.2 Design features of Tank Trucks 2
3.2.3 Fittings of Tank Trucks 3
3.2.4 Protection of fittings 5
3.2.5 Design parameters of Tank Truck 5
3.2.6 Approvals & statutory requirements for Tank Truck 6
3.2.7 Operating procedures 7
3.2.8 Procedure to unload sick truck 10
3.2.9 Loading operation 11
3.2.10 Automation in loading operation 15
3.2.11 Safety precautions during loading/unloading operations 17
3.2.12 Accident & rescue operations involving Tank Truck 18
3.2.13 General (Typical drawing, Detail in name plate etc) 22
3.3 Receipt & Dispatch by Rail 29
3.3.1 Overview 29
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3.3.2 Fittings on Railway Wagon 30
3.3.3 Gau©ging 31
3.3.5 Unloading operations of Tank Wagons 33
3.3.6 Loading operations of Tank Wagons 38
3.3.7 Degassing of sick/leaky Tank Wagons 40
3.3.8 Safety precautions for loading/unloading of Tank Wagon 40
3.4 Transfer by pipeline 46
3.4.1 Overview 46
3.4.2 Advantages of pipeline mode of transportation 48
3.4.3 Cross country pipeline 49
3.4.4 Transfer pipe-work 51
3.4.5 Operations of cross country pipelines 51
3.4.6 Inspection & maintenance of cross country pipelines 52
3.4.7 Monitoring of internal corrosion 55
3.4.8 Pipeline maintenance equipment 56
3.4.9 Telecommunication system / equipment 56
3.4.10 Telemetry system / equipment 56
3.4.11 Documentation 57
3.4.12 Inspection & maintenance of jetty pipelines 57
3.4.13 Checks on jetty pipeline 57

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3.4.14 Gauging / quantification of pipeline transfer 59
3.5 Receipts & Dispatches by coastal / import through Sea 61
3.5.1 Bulk handling for movement by sea 61©©
3.5.2 Cargo carrier design & construction 62
3.5.3 Facilities in the tanker 63
3.5.4 Safety devices 65
3.5.5 Transfer pipe-work 65
3.5.6 Terminal facilities 66
3.5.7 Ancillary equipments 66
3.5.8 Unloading operations 66
3.5.9 Communication 67
3.5.10 Pre-cargo transfer discussions 67
3.5.11 Calculating the quantity of liquid on board 67
3.5.12 Operating procedures for unloading ship 68
3.5.13 Operating instructions for unloading arm 73

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3.0 OVERVIEW
LPG is transported through the following modes from Source to Receipt Bottling plants
1. By Road from Refinery / Terminal / Fractionators to LPG Bottling plants

2. By Rail from Refinery / Terminal / Fractionators to LPG Bottling plants and Intermediate
nodal points
3. By pipelines from Refinery / Fractionators / Import Facilities / Terminals to Terminals /
Intermediate nodal points / LPG Bottling plants
4. By Coastal / Import through Tankers to LPG Import Facilities / Terminals
Various Mode of LPG Transportation in terms of its %age share out - at present is being classified
as under :
Pipeline 18
Road 64
Rail 18
It is exclusive of Marine transportation
3.1 BRIEF DESCRIPTION OF MODES OF TRANSPORT
Road: LPG is moved in Tank Trucks of varying capacities of 6 to 18 MT (Mertic Tonnes) from
Refinery / Terminal to LPG Bottling plants. This is the most commonly used mode of transport at
present due to the minimal requirement of infrastructure and better connectivity between source
and destination. It also gives more flexibility in loading / unloading operations and transportation.
The facility for Tank Truck handling is available in all LPG Bottling plants. However volume
restrictions, transportation costs & Hazards involved during transportation are the limitations
for this mode of transport
Rail: LPG is moved in Tank Wagons of varying capacities of 14 to 37 MT in RDSO (Research,

Design & Standards Organisation) and BTPGLN (Bogie Type Pneumatic) type from Refinery /
Terminal to Intermediate nodal points / LPG Bottling plants. Large volume of product can be
transported economically through this mode of transport, however infrastructural constraints
and poor connectivity are the limitations.
Pipeline: LPG is moved through pipeline from Refinery / Fractionators to terminals to LPG
Bottling plants by onshore pipelines and Cross country pipelines of 6” to 24” Dia with a pumping
capacity of 100 MT to 300 MT per hour. This mode of transportation is considered to be very
economical, safe and fastest. Large volume of product can be transported at low cost. However
high cost of initial infrastructure limits putting up more facilities unless the large thruputs are
handled.
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Coastal / Import by Sea: LPG is moved from Coastal Refineries / Import locations to Import
Facilities/Terminals through Marine LPG Tankers of varying capacities from 2500 MT to 40000
MT by 6” to 14” size pipeline with a pumping capacity of 200-400 MT to 1000-2000 Mts per hour
based on pressurized facilities / refrigerated facilities.
3.2 RECEIPTS BY ROAD
Transportation of LPG in bulk is regulated through The Static and Mobile Pressure Vessels (unfired)
Rules, 1981 and The Motor Vehicle Act, 1988. Pressure vessels used for transportation of LPG
shall be designed and fabricated in accordance with The Static and Mobile Pressure Vessels
(Unfired) Rules 1981 and as per Code IS: 2825.
3.2.1 Types of Tank Trucks
There are Tank Trucks of Single axle with capacities of 6 to 12 MT and of Double axle ( Trailer )
type with capacities of 12 to 18 MTS.
3.2.2 Design features of Tank Trucks
Design / fabrication of vessels with material specifications, fittings and mountings, for
transportation of LPG conforming to IS: 4576 having maximum vapour pressure not exceeding
16.87 Kg/Sq. cm. at 65 Deg. C. in bulk by road tank trucks.
a. Design Pressure
Vapour pressure of LPG conforming to IS:4576 at a maximum anticipated service

temperature of 55 deg. C. to be considered. Providing a minimum vapour volume of 5%
as per code requirements, the minimum design pressure shall be 14.5 kg/sq.cm.
b. Design Temperature
The design temperature of the vessel shall be in line with the specification of LPG and as
per statutory requirement.
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 Authorities.
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d Material Specifications
Material used in the manufacture of pressure parts of the vessel shall be in accordance
with that specified in IS: 2825 (latest edition), BS-5500, ASME SEC. VIII or equivalent
code as adopted. A single code shall be adopted for materials, fabrication, inspection
and testing.
e Markings
Vessel Identification Plate
Each vessel shall have a non-corrosive metal plate permanently affixed by brazing or welding
with the following details
1. Vessel Manufacturer
2. Vessel Manufacturer’s Serial No.
3. Design code
4. Radiography
5. PWHT( Post Weld Heat Treatment )
6. Design Pressure
7. Design Temperature
8. Hydrostatic test pressure
9. First test date and subsequent test dates
10. Water capacity in litres
11. Licensed Product capacity in tonne and symbol or chemical name.
12. Name of the Inspection Agency with their stamp.
13. Certificate number of Inspecting Agency.
14. a) Shell thickness
b) Dish End Thickness
15. Next hydro test date of the vessel shall be painted on the body of the vessel.
3.2.3 Fittings of Tank Truck
Fittings to be provided on the vessel shall be as follows:
a 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.
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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. (Refer OISD
Std. 160).
The safety relief valves shall be installed at the top surface around the rear portion of
the vessel. The Set pressure of the Safety Relief valve shall be 15.95 Kg/cm2 ( 225 PSI).
The reset pressure shall be of 10% below the designed pressure.
Safety relief valves shall have following marking punched:
i) Manufacturer’s name and Serial no.

ii) Set Pressure
iii) Rate of discharge in Cu.M per minute of the gas at 15 deg. C. and at atmospheric
pressure.
iv) Date of first test
v) Name of the Inspecting Agency with their stamp.
b Liquid / Vapour Connections

1 no. 50 mm size liquid inlet / outlet (maximum 2 nos. and minimum 1 no.) 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.
c Internal Valve with Excess Flow Check Valve

Internal valves with EFCV of appropriate ratings shall be installed on LPG liquid and
vapour line. ‘Built in’ internal valve shall be remotely operable from drivers cabin/rear
end of vehicle manually or pneumatically with a lever through a cable system extending
to driver’s cabin and fitted with a thermal fuse link. This valve shall have an in-built
internal excess flow check valve
d 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 of min
thickness of 5 mm shall be provided.
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e Pressure Gauge
1 no. dial type (100mm) 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.
f Temperature Gauge
Provision is considered not necessary. However, subject to suitable amendment to SMPV
Rules, 1981, the same can be provided.
g Drain
Suitable drain of maximum 25 mm NPT plug to be provided on the bottom side of vessel
with proper shield.
h 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.
i 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 deg.C. and shall be
capable of withstanding the most severe combined stresses set up by the following:
Maximum vapour pressure of the product in service.

Superimposed pumping pressure.
The shock loading during transport movements.
3.2.4. Protection of fittings
a) 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.
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b) The protective devices or housing must be designed to withstand static loading in any
direction equal to twice the weight of the tank and attachments when filled with the
lading, using a safety factor of not less than 4 based on the ultimate strength of the
material to be used without damage to the fittings protected, and must be made of
metal at least 5 mm thick.
3.2.5 A brief of design parameters of Tank Truck

Parameter Measuring Unit Value
Type of Pr Vessel ------ Class 1 Pr. Vessel
Capacity MT 6-18 MT
Design Pressure Kg/Cm2(g) 14.5+3G Effect
Design Temp Deg. Centigrade (-)6 to (+)55 deg. C
Wear & Tear Allowance mm 0.5
Heat Treatment(PWHT) ------ Stress Relieved

Radio Graphy % OF Welded Joints 100%
Hydrotest Pressure Kg/Cm2(g) 20.51(1.3 times of
Designed pressure)
Shell Material ------ SA 106 GR 70
SRV Rating CFM 13500
SRV Test Pr. Kg/Cm2(g) 15.95 Kg/cm2 or 225 PSI
3.2.6 Approvals and statutory requirements for tank trucks
i. ‘Licence 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.
ii. ‘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.
iii. ‘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.
iv. ‘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.
v. Monthly servicing certificate of DCP Fire Extinguishers.
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vi. Driving licence which should specifically mention that the driver is certified to drive
vehicles carrying hazardous chemicals as per CMV Rule 9, 1993.
vii. ‘Safety Check List for Road Tankers’ pertaining to the truck issued by the unloading
location.
3.2.7 Operating procedures
a Unloading Operation
i. At the Entry Gate, Registration of the Tank Truck shall be done on the basis of Tranship-
ment order advice ( TOA )
ii. Weighment of Tank Truck is done at Electronic Weighbridge with relevant details
iii. Place the Tank Truck in neutral gear at appropriate place & driveout position. Put wooden
wedges under the Tyres.
iv. Switch off the Master Switch.
v. Ensure the crew comes out of cabin
vi. Make earthing connection.
vii. Set the Tank truck’s Roto - gauge at 0% and check for presence of water. If water is
present, then drain it out safely
viii. Make entry to this effect in T/T water draining register.
ix. Connect Tank Truck’s valves with LPG liquid & Vapour pipe lines respectively and check
for leakages, if any. After the Vapour and liquid hoses / unloading arms are con-
nected and before any valves are opened, the valves on the vehicle tank are “cracked”
or slightly opened in order to apply pressure to the hoses / arms as a test for leaks.
if any leaks appear, the valve should be immediately closed and corrective mea-
sures to be applied
x. Decant Liquid LPG fully by operating the Compressor.
xi. Ensure that Tank Truck is completely decanted by observing Rotoguage reading and
cross-checks with the help of sight flow indicator.
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xii. Change the 4-way valve position and decant LPG vapours upto a pressure of 1.5 kg/
sq.cm
xiii. Close all the main valves and depressurize LPG hoses / unloading arms. Before discon-
necting the hoses or pipes the valves within the tank truck should be rechecked and
the valves at the receiving risers or bulkhead should, likewise be rechecked.
xiv. Vent valves are attached to the hoses/unloading arms, they should be opened to
release the pressure and ensure that the shut-off valves are closed tight .
xv. A responsible, trained LPG operator must be present during the entire unloading
operation. Earthing Connection, Engaging and Disengaging of Hoses / Unloading
arms, opening and closing of Valves shall be performed by the LPG Operator. In the
event of an emergency, it is his responsibility to respond immediately and take
action.
xvi. Disconnect LPG hoses / unloading arms and earthing connections. Remove wooden
wedges.
xvii. Send the Tank Truck for weighing.
xviii After completion of Decantation operation , Checklist cum loading advice shall be
issued to tank truck .
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b. Compressor operation
After the necessary hose / unloading arm connections have been made and the proper
valves opened, allow LPG TT pressure and storage tank pressure to equalize. If the pressure
within the truck tank is lower than the pressure in the receiving storage tank, equalize
through the vapour connection.
If the tank truck pressure is higher than the receiving storage tank pressure, equalize with the
liquid stream.
Compressor is started and suction is taken from the receiving storage tank and the vapours
from the compressor are discharged into the tank truck above the liquid.
For proper unloading of tank truck pressure should be maintained 2 kg/cm2 above the storage
tank pressure depending upon the distance between the tank truck and the storage tank, the
design of the piping system and the height of the storage tank compared to tank truck. If
the pressure differential is too low, unloading will be slow. If the differential is too high,
the excess flow check valve in the tank truck liquid pipeline will close and unloading would
stop.
Care must be exercised to see that the pressure created within the tank truck does not
approach or exceed the setting of the safety relief valve within.
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After all the liquid LPG has been decanted from the tank truck, the vapour remaining in the
TT shall be recovered by operating 4 way valve and thereby connecting the suction of the
compressor to the vapour connection of the tank truck and the discharge of the compressor
is connected to the receiving storage tank.
These vapours should be discharged below the liquid level in the receiving tank to hasten
the liquefaction and to prevent the development of excessive pressure.
When the tank truck pressure has been reduced to 1.5 kg/cm2 stop the compressor and close
all valves.
Evacuate liquid and vapour from unloading lines by venting into vent lines
When it is ensured that shut-off valves are closed tight, disconnect unloading arms /
hoses. After disconnection, plug the unloading arm / hoses.
3.2.8 Procedure to unload sick trucks
At loading locations, facilities are provided for loading tank trucks. However, one bay is generally
identified along with facilities for unloading sick tank trucks or overloaded trucks. Unloading
process will be same as enumerated above.
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3.2.9 Loading operation
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i. At the Entry Gate, Registration of the Tank Truck shall be done on the basis of checklist
cum loading advise from unloading location
ii. Place the tare-weighed truck in the gantry and adjust the position of the truck to
facilitate easy connection of loading arms / hoses
iii. The truck should switch off its main battery switch and the hand brake or air brake has
to be applied.
iv. Connect the earthing clamps to the tank truck
v. 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
vi. Keep the DCP fire extinguisher of the truck in ready to use position.
vii. Open the valves on the liquid and vapour lines before the respective loading arms/
hoses.
viii. Crack open the ball valves and check for leakage in the flange connections.
ix. 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.
x. 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.
xi. The crew of the truck should be available near the loading arms throughout the loading
operation.
xii. Tank trucks are usually loaded by means of pumps
xiii. The liquid may be discharged into the liquid space or the vapour space of the truck
tank.
xiv. The quantity loaded in the truck can be determined by liquid level, weighment,
positive displacement meter, mass flow meter.
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xv. The quantity of LPG filled shall be lower of the quantity approved by CCOE or RLW of
the tank truck.
xvi. Liquid level may be determined by rotogauge or fixed liquid level gauge. Percentage
volume to be filled shall not exceed 85 %.
xvii. After the loading is completed close all the valves of the truck and the loading arms.
xviii. 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.
xix. Remove the earthling clamps.
xx. Ask the truck crew to take the truck out of the gantry slowly for gross weighment.
xxi. 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 sick 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.
a. TANK TRUCK FILLING (LOADING) CONSIDERATIONS:
i) 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 deg. C.
To arrive at the filling capacity, the maximum filling densities at 15 deg. C. for LPG of
various related densities shall be calculated and effected by loading bases as per IS:6044
(Part II), 1972 (Latest Edition). 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 Statutory authority (CCOE).
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ii) Gauging
The contents of the road transport may be verified by weight or by gauging. In the
event the weighing method is used, the process is extremely simple since the unit
is weighed prior to the loading operation (tare weight) and then weighed after the
loading operation has been completed (Gross weight) ; the difference representing
the Net weight.
In the event the contents of the load is to be determined by the “liquid level”
method, the tank truck will be fitted with a roto gauge and a fixed liquid level
gauge.
Keep the Roto gauge in 100% position and open bleed valve. Initially some liquid in
the Roto gauge tube may come out and then vapour will come out. In case liquid
continues to come out the tank is apparently overfilled/or Rotogauge is defective.
Overfilling of tanker can be checked from level gauge reading. Proper precaution
should be taken for unloading such tankers. When in normal course the vapour
starts coming out rotate the pointer gradually till liquid starts coming out. The
reading-at the point will show the % of volume of liquid in the tank.
The accuracy of the roto gauge may be roughly verified at that time. The verification
is accomplished by placing the roto gauge In the 100% or maximum fill position
then slowly depressing the gauge indicator until a liquid discharge is noted.
The reading of the rotogauge should correspond to the liquid level which has been
predetermined by the use of the fixed liquid level gauge.
For accuracy, it is recommended that the rotogauge be operated both on the right
and left hand side and an average be struck. In case the readings of gauge on both
the sides are different, corrective actions to be advised in the checklist during
release of the tank truck.
Noting the results of the gauging and the temperature and pressure of the contents
of the tank, the correct volume may be determined.
In case of automation, Mass Flow meters / Positive Displacement meters are used as an
alternative to conventional gauging systems.
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3.2.10 Automation in loading operation
The terminal data management (TDM) system is designed for automated loading of LPG Bulk
tank truck . The salient features of the bulk loading operation are as follows:-
1. The registration of each and every T/T is done at entry gate where the following
verifications are carried out:
• Tanker records viz. validity of RC book & CCOE licence, tanker’s fitness etc.
• Capacity and Tare Weight of the tanker.
• Any other detail related to tanker.
The TDM computer system is connected with system for real time data transfer, for
integrated terminal operation.
2. Once the verification is done, the TDM downloads the details of T/T and and product
type to Tank Truck Entry System (TTES) computer where the the Filling Advice Note
(FAN) is generated. The same is validated and informed to the empty bay in TTES. The
FAN and proximity card(smart card) is handed over to the T/T Driver which gets authorized
to enter into the plant for further weighment at weighbridge.
3. By presenting the card to the AUC (Access Control Unit) card reader at the entry barrier,
the Tank truck is allowed to proceed at the weigh bridge . The truck driver then takes
truck to weigh Bridge where he once again presents the card to AUC card reader and the
empty truck identification is recorded in supervisory computer for reference. If the tare
weight of tanker differs by 250 Kg from the mean of last 10 weighment for the said T/
T , OIC(operator interface console) will show tare failed and it is not tare weighed, T/T
is rejected for further verification and only after confirmation by the officer it will be
accepted in TTES.
4. If the Tank Truck passes after weighment the Tare weight is registered automatically on
computer screen and a print slip is taken and T/T proceeds to the assigned bay for further
loading . When the driver first enters the bay, the batch controller and LOCAL CONTROL
STATION(LCS) ensures the driver identity when he puts the card on the screen. Upon
successful completion of the identification sequence, the supervisory computer displays
the truck registration number on the Batch Controller until the driver presses the push
button to confirm that number has been read and confirmed.
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5. After the tanker is parked in designated bay, following checks shall be conducted:
Tanker has been parked at the correct bay or not.
Tanker has been properly connected or not.
Earthing connection is proper or not.
Connection of loading Arms is proper or not.
6. The batch controller now checks to ensure that the truck earth safety permissive is satisfied.
Each bay is equipped with its own earthing clip.
If the driver has already connected the truck earth clip the truck is electrically grounded
and other safety permissive e.g. loading arm is properly satisfied, the LRC ( Load Rack
Computer – Supervisory Computer ) continues onto the next step in the loading sequence
through Batch Controller. If the LRC/BC detects that the truck is not grounded or any of the
required permissive is not satisfied, then the batch controller displays the same on screen.
This message remains on the batch controller display until the earthing clip is connected
and the safety permissive is satisfied.
7. Once the driver has connected the loading arm, he pushes the “ACK” (ACKNOWLEDGE)
button on the LCS which starts flashing to indicate that Supervisory computer is preparing
the Batch controller for loading.
8. After downloading of the batch preset quantity data from the supervisory computer/LRC
to the batch controller, LCS sets steady, indicating that Batch Controller is ready to start the
loading operation.
9. The driver now pushes the “START” push button on the LCS to command flow to begin.
Upon sensing the start request, the Supervisory Computer issues a remote start command
to the Batch Controller, the necessary product pumps are started, and the digital control
valve and ROV on vapour lines opens. While loading is in progress, all primary loading
control functions are handled by the Batch Controller. It continuously updates preset remaining
and volume loaded during operation.
Loading proceeds under Batch Controller, so long as no alarm or stop conditions are
encountered. When the preset approaches the final delivered quantity, the Batch Controller
automatically initiates a multistage shutdown process. Loading is stopped when the preset
quantity is fully loaded.
Upon completion of the loading batch controller calls for the operator card so that the BAY
is in Idle status for next loading.
After purging of loading arm the earthing clips and loading arm are disconnected safely.
Now the loading bay becomes free for the next truck in queue.
Similarly, after filling, the truck driver once again takes the truck to the same weigh
scale where he once again presents his card to the card sensor and gets his truck weighed.
Supervisory computer downloads the truck no., Bay No., Product name and Code No. and
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Dispatched quantity to TTE/TDM for final invoicing. Final invoice is made only on the
basis of the weigh bridge measurement. After the truck driver collects the invoice the
control system opens the exit gate through PLC after the truck driver presents the
proximity card to card sensor at the exit gate.
Once all filling operations are complete, the driver parks the truck if required or in a queue
near the exit gates and proceeds to planning room to collect the post loading documentation
reports. When any truck completes loading, the supervisory computer prepares the loading
details for the TDM.
After collecting the post loading documentation, the driver proceeds to the security gate,
where the driver surrenders the security card to the security officer and after checking the
documents the driver is allowed to take out his tanker.
3.2.11 Safety precautions during loading / unloading operations
i. Transfer of LPG to / or from a tank truck requires special attention as accidental movement
of vehicle may cause rupture in the transfer equipments.
ii. No source of ignition must be allowed in the area where product transfer operations are
carried out.
iii. Fire extinguishers shall be placed near the tank trucks during transfer operations.
iv. The first operation after positioning the truck should be to provide proper earthing.
Earthing shall be disconnected just before the release of the truck. In automated loading
if earthing in not proper T/T loading can not start thru solenoid operated valve.
v. 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.
vi. Hoses should be handled with care and inspected periodically (Refer OISD Standard 135
on Inspection of Loading / Unloading Hoses for Petroleum Products).
vii. While disconnecting hoses/pipes, connections should be loosened only slightly at first
to allow release of trapped pressure, if any.
viii. 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.
ix. Gas detection system shall be provided in line with OISD-STD-144.
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x. 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.
xi. No repairs shall be made on the truck while it is in the loading area.
xii. New tank trucks vessels or vessels received after repair shall be purged before loading.
xiii. 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.
xiv. 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.
xv. Filling/transfer operations should be stopped immediately in the event of -
• Uncontrolled leakage occurring

• A fire occurring in the vicinity
• Lightning and thunder storm
3.2.12 Accident and rescue operations involving tank trucks
a SCENARIOS
On receipt of information in T/T accident, nearest Plant should arrange for rescue
operation without any delay.
i) Accident resulting in tank truck falling off the road with damage to bullet, fittings
with or without leakage and requiring evacuation of product.
ii) Toppling of tank truck, rupture of liquid line and LPG leak with or without tank truck
engulfed in fire.
iii) Total loss due to vapour cloud explosion, injuries, fatalities and damages to the
surrounding areas.
Rescue team shall carry out survey in situation and assess damage to bullet and will
guide the complete operation.
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b ACCIDENT HANDLING
(i) ACCIDENT RESULTING IN TANK TRUCK FALLING OFF THE ROAD WITH DAMAGE TO
BULLET, FITTING WITH OR WITHOUT LEAKAGE AND REQUIRING EVACUATION OF THE
PRODUCT
a) WITH NO LEAKAGE
The following steps should be taken:
Asses the situation of damage, in case of damage to anchoring of bullet , effort shall be made to
decant in situ, otherwise it shall be lifted with the help of crane and tank truck should be emptied
before putting it back on wheels.
Tank truck can be decanted by using any of the following procedure:

Connect depressurised tank lorry brought from the LPG Bottling Plant. Make temporary
earthing connection with some electric pole or with iron rod driven in the earth upto sufficient
depth. Remaining vapour shall be discharged in a controlled way with proper safety
precautions like cordon off the area, monitoring of Gas levels, Coordinating with District
Authorities.
Alternately can be unloaded upto 1.5 kg/cm2 by using ERV (Emergency Rescue Vehicle) and
then releasing remaining LPG in atmosphere in controlled manner)
WITH LEAKAGE
a) Warn people to stop all open fire, lantern, no smoking within the vicinity of minimum
300 m. Stop traffic on both sides of the road upto the above distances. Divert
traffic from all the roads approaching the site. Check possibility of stopping leak by
wetting the area of leakage with gunny bags and water, plugging of safety relief valve
using leak seal pad, tightening of liquid and vapour valve, sample valve and by using M-
seal.
b) In case leakage is profuse and cannot be stopped, ensure that no person should stay
within the vapour cloud and within the vicinity in the wind direction. On arrival of the
Fire Brigade, the vapour cloud should be dispersed toward unin- habitated area using
wide angle spray till the entire product has been vented out(in a controlled manner).
Concentration of vapour shall be checked using Explosivemeter. Only after all the
vapours have cleared out from the leakage source and dispersed below LEL level, the
movement of traffic shall be allowed.
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ii) TOPPLING OF TANK TRUCK, RUPTURE OF LIQUID LINE AND LPG TRUCK ENGULFED IN FIRE.
If the Rescue team reaches the site of accident after start of fire, the following action should be
taken:
a) To cool the tank trucks, specially the area in contact with vapour and area around dish-
end by the Fire tender. No body is to be allowed to move by the side of either of the dish-
ends of the tank trucks. All people from the area within a radius of 1 km to be evacuated
to safer places.
b) To use narrow angle spray for cooling the bullet and extinguishing fire if the source of
leakage is small, otherwise, burning may be continued under controlled condition as
above.
c) If the fire from overturned LPG tank lorry envelopes the pressure vessel and if it is not
possible to arrange water for sustained cooling, the entire area upto a radius of 1 km
must be evacuated, much before water gets exhausted. Fire fighters should also be
prepared to escape and abandon the vessel in such an event.
d) Local Hospitals/Ambulances should be alerted to be ready to provide medical aid to

affected people, as the scenario may lead to an Unconfined Vapour Cloud Explosion
(UVCE)/BLEVE resulting in loss of public life and property necessitating major rescue
operation.
e) In all the accidents Police shall be informed to control traffic and general public near the
accidental spot.
iii) LOSSES DUE TO UNCONFINED VAPOUR CLOUD EXPLOSION/BLEVE RESULTING IN INJURIES,

FATALITIES AND DAMAGES TO THE SURROUNDING AREAS.
(Consider 18 tons LPG tank truck involved in the accident and entire product has come out)
There could be possibility of a situation when the accident affected tank lorry might have released
a large amount of LPG through the damaged fittings and/or liquid/vapour manifolds. Since
there is a large inventory of LPG in the bullet, LPG would continue to leak through these openings.
In the case of delayed ignition, the released LPG would form vapour cloud and disperse along the
wind direction. The vapour cloud will increase in its size and dilution of the cloud will be occurring
around the outer surface of the plume. Therefore, the vapour cloud may either explode when it
comes in contact with the source of ignition or disperse safely. In case, vapour cloud explodes
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there would be blast wave/shock wave propagate resulting in damage as a function of distance.
Followed by explosion, there will be fire which would travel back to the affected tank lorry.
Depending upon the nature of damage and type of release, the bullet may be subjected to flame
impingement which may subsequently lead to BLEVE (Boiling Liquid Expanding Vapour Explosion)
The computer models used to analyse the dispersion characteristics of the released LPG for
different wind velocities and the damage due to blast/shock wave arising out of an explosion
has been computed accordingly.
It has been found that LPG vapour cloud could travel long distances depending upon the wind
velocity (2-5 m/s) and extent of leakage and still remain within the flammable limits. In case of
failure of 2” liquid loading line, the LPG vapour cloud could travel as much as 360m upto which
vapour will still exist within LEL. In contact with a source of ignition, the unconfined vapour
cloud may explode resulting in fatalities and injuries
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3.2.13 General
Following tools and tackles should always be made available in Tank Truck :
Tools for all fittings.
4 Nos. caution sign board wit luminous paint for stopping traffic in case of any emergency.
Based on the nature of defects either all the deficiencies should be got corrected at the unloading
location itself or the tanker should be allowed to get the repairs done enroute and submit the
details at loading location.
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Notes
1. All dimensions are in MM, unless otherwise specified.
2. All Flange Bolt Holes to Straddle C/C Centres Line, unless otherwise specified.
3. Dish Ends shall be made by Cold Pressing.
4. Circumferential & Longitudial Weld shall be Clear, all Coupling & Reinforcement Pads.
5. All Butt Welds are Full Penetration Weld Accesible from other side, shall be Gouged Back to
Sound Metal & Rewelded.
6. All Sharp Corners will be Rounded Off.
7. All Fittings Approved by CCOE, Nagpur.
8. Electrodes - AWS E - 7018.
9. IS:226 is Weldable Quality.
10. All Pads to be Tested for Tightness Pneumatically to 2 Kg/Sqcm(G)with Soap Solution on
Attachment Welds.
11. Flanges to have Serrated Finish.
12. Plate Thickness should be +ve Tolerance.
13. Weld Cap should be Normalised After Pressing.
NOZZLE SCHEDULE
Sr.No. Service Qty Size Sch/Thk Remarks
M1 Manway 1 18” NB Pad Type With Cover
N4,N5 Safety Relief Valve 2 2” NPT Half CPLG With S.R.V.
N1 Liquid Inlet 1 2” NPT Half CPLG With E.F.V. + B.V.
N10 Lquid Outlet 1 2” NPT Half CPLG With E.F.V. + B.V.
N7 Drain 1 1” NPT Half CPLG With Plug
N2 Vapour Connection 1 1-½” NPT Full CPLG With E.F.V. + B.V.
N8 Roto Guage 1 1” NPT Half CPLG With Rotoguage
N6 Pressure Guage 1 ¾” ¼” NPT Half CPLG With E.F.V. + P.G.
N9 Fix Level Gauge 1 ¼” NPT Half CPLG With Fix Level Guage
DESIGN DATA
Design Code IS:2825-1969,C.L. 1 SMPV, Rules (UF) 1981.
Design Temperature As per Statutory Requirement
Design Pressure 14.5 Kg/cm (g) + 3G. Effect = 15.77 kg/cm2
Radiography 100%
Weld Joint Efficiency 1
P.W.H.T. Stress Relieved
Corrosion Allowance 0.5 MM
Test Pressure 20.5 kg/cm2 (g)
Service L.P.G.
Water Capacity 38290 Litres (Approx)
Painting Two Coates of White Enamal paint
Pay Load 18000 K.G.S.
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No. Discription Qty Size Material Remarks

1 Shell 1 2320 I.D.x7500x12Thk SA-515,Gr.-70
2 DISH END 2 2320 i.d. X 8 Thk SA-515,Gr.-70
3 Bearing Plate 4 2580 x 250 x 12 Thk SA-515,Gr.-70
4 Base Plate 8 380x220x12 Thk IS:226/IS:2062
5 Bearing Plate 1 500x2580x12 Thk SA-515,Gr.-70
6 Base Plate 2 12 Thk x To Suit IS:226/IS:2062
7 Rib Plate 24 8 Thk x To Suit IS:226/IS:2062
8 Pad For Lifting Lug 2 300x150x12 Thk SA-515,Gr.-70
9 Lifting Lug 2 220x140x20 Thk IS:226/IS:2062
10 Name Plate Bracket 1 290x130x5 Thk SA-515,Gr.-70
11 Name Plate 1 210x110x3 Thk S.S.-304
12 Pad Plate For Manhole 1 610 O.D.x 450 I.D.x49 Thk SA-515/516,Gr.-70
13 Manhole Cover 1 610 Dia x 38 Thk SA-515,Gr.-70
14 Gasket For Manhole 1 520 O.D.x 450 I.D.x 3 Thk CAF-40
15 Handle For Manhole 2 20 Dia x 330 LG IS:226
16 Studs For Manhole 16 1” Dia x 4” LG UNC SA-193,Gr.-87
17 Nuts For Manhole 16 1” Dia UNC SA-194,Gr.-2H
18 Plug For N7 1 1” NPT x 6000# A-105
19 Half CPLG N7 1 1” NPT x 6000# A-105
20 Half CPLG N9 1 ¼” NPT x 6000# A-105
21 Half CPLG N6 1 ¾” NPT x 6000# A-105
22 Half CPLG N1,N4,N5,N10 4 2” NPT x 6000# A-105
23 Full CPLG N2 1 1 ½” NPT x 6000# A-105
24 Full CPLG N3 1 ½” BSP x 6000# A-105
25 Pipe End Boss 1 22 Dia x 25 Thk SA-515,Gr.-70
26 Pipe For N3 1 ½” NBxSCH.80 x 312 Long A-106,Gr.-8
27 SPPORT Plate N2 1 100 x 230 x 8 Thk SA-515,Gr.-70
28 Pipe For N2 1 1½”NBxSCH.80x312 Long A-106,Gr.-8
29 Weld Cap For N9 1 6” NB x 12 Thk SA-515,Gr.-70
30 Weld Cap For N4,N5 2 8” NB x 12 Thk SA-515,Gr.-70
31 R.F. Pad N9,N4,N5 1 1100x400x12 Thk SA-515/516,Gr.-70
32 Ladder Support Pad 4 100x75x8 Thk SA-515,Gr.-70
33 Baffle Pad Plate 6 1500x100x8 Thk SA-515/516,Gr.-70
34 Baffle Plate Support 36 150x100x8 Thk IS:226
35 Bafle Plate 3 1744x2234x3 Thk M.S.
36 Earthing Boss 1 35 Dia x 35 Long IS-226/IS-2062
37 Half CPLG For N8 1 1” NPT x 6000# A-105
38 Weld Cap For N8 1 10” NB x 12 Thk SA-515,Gr.-70
39 Pad For N8 1 550 Dia x 12 Thk SA-515,Gr.-70
40 Pad For N2 1 150 x 100 x 8 Thk SA-515,Gr.-70
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3.3 RECEIPT & DESPATCH BY RAIL
3.3.1 Overview:
In India, Railway Administration, acting as a carrier of Petroleum Products, is exempted from

taking a license for transporting it under Petroleum Rules 1976. Railway Administration have
elaborate rules for the carriage of petroleum by rail as provided in Indian Railways Act.
a. Design criteria
All tank wagons used for the transportation of petroleum products and LPG shall be of a
design approved by RDSO / IS 2825 / ASME. Design parameters for tank wagons used
for transportation by rail are issued by the Wagon Directorate, Research, Design, and
Standards Organisation of Indian Railways.
b. Tank wagons for LPG
The maximum quantity of LPG filled in any tank wagon shall be limited to the filling
density of the LPG and shall be such that the tank wagon shall not be liquid full due to
expansion of the contents with rise of the temperature to 55 degree C. or limited to
specified gross weight on the wagon whichever is less.
Tank wagons for LPG (Railway code TG) (4-wheeler/8-wheeler)
• Tank wagons designed by RDSO are provided with safety valve with Discharge
Capacity : 10.3 cum/sec.
• All other fittings such as liquid valves, vapour valves, magnetic gauging device,
thermo well, sample valve and safety valves, pressure gauges are provided on
top of the pressure vessel in a protective housing known as ‘dome’ with a cover.
• After repair or maintenance tank wagons are required to be purged with LPG/
inert gases.
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3.3.2 Fittings on Railway Wagon
TYPICAL ARRANGEMENT OF TANK WAGON DOME WITH ALL FITTINGS
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PART NO. DESCRIPTION PART NO. DESCRIPTION

62 Bonnet Cover Handle 339 Manway Cover Plate
141 Sump (optional - not shown) 340 Vent Cover
255 Safety Valve Assembly 361 Hinge
275 Check Valve 372 Seal Pin
230 Angle Valve 450 Pipe Brackets
296 Thermometer Well 453 Pipe Guide
297 Thermometer Well Fitting 454 (a) Education Pipes
318 Gauging Device Assembly 454 (b) Test Tube
335 Manway Bonnet Cover 463 Pipe Guide Bracket
336 Manway Sonnet
2. Drain point is provided at the bottom of the tank wagon vessels (RDSO type)
3.3.3 Gauging
Before the tank wagons arrive at the bottling plant for unloading, the receiving tank or tanks-
should be gauged i.e., the gauging devices on the tank or tanks should be utilized to positively
establish there is sufficient capacity to receive the entire incoming load.
3.3.4. Operating procedures
a. Inspection before unloading
• All swinging platforms should be in ‘UP’ position with lock before allowing the rake
inside the gantry.
• Any leakage or passing of the vent points or joints to be checked and necessary
corrective measures to be taken.
• The unloading area must be free and clear of any material which might present
a potential fire hazard.
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• The surface of the ground together with stairs, ladders and platforms, if
any, must be in such condition that the operator can perform his duties without
hazard.
• Placement of rake to be supervised by Plant Officers on shift.
• Railway engine should be parked at least 15 m away from the last point of the
gantry. CAUTION sign board at a distance of 15 m from the last point from the
gantry has to be made available and engine should not be allowed beyond that
point.
• Insulation has to be provided in joints of the rail at the entry to plant. Connection
nozzles to be made available at every point
• Double earthing system to be in order in all point
• Hoses / unloading arms to be in plugged positions when not in use
b. The following equipment must be available in the immediate area of

the unloading point.
• Caution signs for placing on track after wagon has been placed/connected. As
an example, the signs may bear the words, “Stop - Tank Wagon Connected”
or “Stop - Men At Work” or - “Stop - No Shunting - Wagon under Unloading”.
The word “Stop” must be in letters four inches high and other words
must be at least two inches high. Letters must be Red on a white background.
• Teflon tape/ Sealant or “Dope” for making up pipe connections. This
material must be suitable for LPG service.
• Low temperature ISI approved gloves .
• Extra sealing washers, flange packings, nut bolts suitable for flanges.
• Extra valve handles/wheels suitable for wagon valves.
• Portable dry powder chemical fire extinguishers placed at easily accessible
location.
• Fire hoses in good condition near fire hydrant points.
• Verify the wagon number and identify product by reference to the shipping
document or other shipping papers.
• Inspect the seal to see it has not been broken or tampered with. Report
immediately to railway authorities any broken seals, leakage, loss or damage to
wagon or contents and make specific notation of the damage or loss when wagon
is delivered and make an appropriate report and also get the joint certificate.
• Set the brakes and block the wheels at both ends of the wagon.
• Place the appropriate signs such as “Stop - Tank Wagon Connected on the open end
or ends of the siding, at least one wagon length away from the wagon which is being
unloaded.
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• These signs must remain in place until the wagon is unloaded and disconnected
from the unloading connection.
• In the event that the unloading siding is electrified, special precautions must
be observed by de-energizing the overhead wire until such time as the unloading
has been completed and the wagon disconnected from the unloading connections.
• Make bonding connections.
c. After the above steps have been completed, ascend to the dome of the wagon. In most
tank wagons the manway or dome opening is closed by a heavy plate(dome cover)
bolted to the flange attached to the tank shell. The valves and fittings are installed
within this plate. Do Not disturb this plate or the bolts attached thereto.
• Break the seal, remove the dome cover pin and carefully lift the dome .-cover.
• Inside the dome will be found the valves, unloading connections, gauging devices,
thermometer well and safety valve and fitting for connecting pressure gauge.
• Do not at any time tamper with the safety relief valve. Never place your hand or
face over the relief valve opening.
• Unscrew the plug in the top of the thermometer well; this should be done slowly.
Listen for the hiss of escaping vapour. If this is heard, stop unscrewing the plug
and wait for the pressure to bleed off then remove the plug. Insert the
thermometer into the well.
• If the thermometer well is broken or leaking, vapours will continue to escape.
If this happens, do not remove the -cover or plug but tighten it again. It may be
possible to .-.complete the unloading without taking a temperature reading. If
not, enquiry can be made with the source to ask for further instruction.
• The well should be filled with an antifreeze liquid such as kerosene/glycerine.
Never put water in the thermometer well.
d. Rake loading / unloading at terminal / plant requires following operations ;
i. In case weigh bridge is available, records to be maintained for gross weight of

each wagon.
ii. Placement of rakes in accordance with the positions of loading / unloading points.
iii. Ensure that railways apply hand brake before removal of engine.
iv. In case hand brake is not applied, loading / unloading operation shall not be
carried out.
v. Placement should be made in such a way that loading arms / hose connectivity
to the tank wagon dome ( liquid and vapour lines) is convenient.
vi. Check the seal condition and leakage of wagons
vii. Check the gauge readings as per the following procedure:
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Tank wagon are provided with magnetic slip tube gauges. This slip tube works
on Magnetism principle.The slip tube is fitted with a permanent magnet at
bottom and travels up & down in the dip well of material stainless steel &fixed
in a closed Aluminium tube with a magnetic float around it . The slip tube
moves up and down with the float floating on the liquid surface and the reading
is shown by graduated markings on the slip tube. Such slip tubes do not require
bleeding of product for gauging. To avoid movement of slip tube during transit,
locking arrangement is provided . To release the lock for taking the reading the
slip tube is pressed inside slightly and released gradually.
Remove and read the thermometer and replace the cover on the thermometer
well. The thermometer should remain in the well for at least fifteen minutes
prior to the reading.
When ready to take the reading, raise the thermometer quickly and read it at
once. Do not remove the thermometer any further than necessary to read it.
Always recheck the reading.
Note the pressure gauge reading after opening of valve. Keep the valve open
during operation to check the pressure inside the wagon.
Where facilities for unloading more wagons at one time are available, pressure
gauge on the liquid line at a prominent place should be installed to keep a watch
on pressure in the system during operation.
NOTE: The thermometer and the pressure gauge must be tested periodically to
ensure its accuracy.
Read the gauge tube and thermometer readings.

viii.CAUTION: The gauge tube cover must be left in place at all times except during
the gauging operation.
ix. Connect the earthing system one to the chasis and one to the vessel
x. Connect the unloading / loading arms / hoses
3.3.5 Unloading operation of tank wagons
Unloading of LPG from tank wagons shall be done with the help of compressor. The compressor is
used to create a differential pressure of min 2 kg/ cm2 between the receiving and discharging
vessels by withdrawing vapors from the receiving vessel and forcing it at high pressure into the
discharging vessel thereby establishing a smooth flow. The content of tank wagons can be
ascertained by weighment on “In motion weigh bridge” before and after emptying or, alternatively,
the quantity can be determined based on wagon gauge readings and differential in storage tank
gauge readings before and after receipt, wherever physical weighment is not possible
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In most cases two swing arms or unloading hoses will be provided on each unloading rack. It
is suggested that both of these liquid unloading connections be utilized in order to speed up
the unloading operation and to lessen the chance of closing the excess flow check valves
which are located within the discharge pipeline inside the tank wagon.
i. Ascertain that the liquid discharge valve and the vapour valve within the tank wagon
cover are in the closed position.
ii. Open the port covers in the side of the domeshell, if exist. Unscrew the plugs in the
outlets of the vapour valve and the liquid valves using a box wrench. This must be done
safely.
iii. If there is any sound of escaping vapour or if there seems to be pressure behind the
plugs, the pressure must be allowed to relieve itself past the threads before the plugs
are entirely disengaged.
iv. If the vapour discharge continues or if there is evidence of a liquid discharge, the valves
should be retightened carefully.
v. With the plugs removed, screw pipe nipples into the outlets of the valves after first
having applied a modest quantity of sealant to the male threads, keeping the sealant
away from the end of the thread. Tighten nipples with a pipe wrench.
vi. Connect the two liquid transfer unloading swing arms or hoses to the nipples attached to
the liquid discharge valves. Connect the vapour or equalizing swing arm or hose to the
nipple attached to the vapour valve.
vii. After the vapour and liquid hoses have been connected and before any valve is opened,
the valves on the tank wagon are crack opened in order to apply pressure to the hoses /
unloading arm as a test for leaks.
viii. If any leak appears, the valve should be immediately closed and corrective measures
applied.
ix. Recheck the lines and connections to make sure that they are connected correctly.
x. After the liquid and vapour lines have been secured and tested, both liquid valves should
be opened slowly and completely. Then, open all other valves in the liquid line working
from the tank wagon to the storage tank.
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xi. Open the storage tank filling / unloading valve slowly, be careful not to open this valve
too far if the tank wagon pressure is in excess of the storage tank pressure or the tank
wagon excess flow check valves may get closed.
If normal attempts to open an excess flow check valve fail, the following procedure
is suggested.
• Close all valves on the tank wagon and the unloading riser.
• Reduce pressure within hoses / arms to atmosphere.
• Wait for some time & check the pressure in wagon as compared to liquid line
pressure. In case pressure comes down in the wagon, open the liquid valve
slowly & see the outflow of LPG from wagon.
• Check the pressure inside the wagon as compared to line pressure. Once
differential pressure is less than 02 kg/cm2, then open the valve in the vapour
line.
Rapidly rising pressure indicates the line is still blocked.
xii. If the pressure reaches near the safety relief valve setting on the compressor, stop
the compressor, close the valve on the tank wagon and on the unloading riser. Bleed
down the hose It may be necessary to repeat the procedure several times before the
closed valve will open
xiii. If the tank wagon pressure is higher than that in the storage tank, do not open the
valves in vapour line or operate the compressor. When the rate of liquid flow drops to an
unsatisfactory level with the storage tank filling valve wide open, open the vapour valves
between the tank wagon and the storage tank. Differential pressure has to be monitored
and supervised closely to ensure that excess flow valves are not getting closed and
wagon is getting pressurized.
xiv. At this point, make sure that the control valves at the compressor are in a position
which allow the compressor to draw vapour from the storage tank and force it into the
tank wagon, then start the compressor.
xv. When the tank wagon is held at a pressure of 2.0 to 2.5 Kg/sq.cm. above the storage
tank pressure, the tank wagon should be emptied into the storage vessel.
xvi. A flow of gas instead of liquid through the sight-flow glass in the unloading line indicates
that the wagon is empty of liquid.
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xvii. When the tank wagon is emptied of all liquid, stop the compressor and close the liquid
valves beginning at the storage tank and progressing to the tank wagon.
xviii. If the facilities are so arranged that vapours may be removed from the tank wagon, the
pipeline at the compressor should be arranged so that the compressor will draw vapour
from the tank wagon and force it into the storage tank.
xix. In this operation, the vapour should be discharged below the surface of the liquid in the
storage tank to hasten the liquefaction and, in turn, help prevent excessive pressure in
the storage tank.
xx. Restart the compressor and when the tank wagon pressure is reduced to about 1.5 Kg/
sq.cm., stop the compressor and close all the valves in the vapour line.
xxi. Monitor the vapour recovery from each wagon through close supervision. This is
must because in case wagon is not emptied of liquid, there will be sweating from
the wagon while recovering vapour and hissing sound will come from the wagon,
line pressure will not get reduced till emptied out of liquid. In case liquid is found
during vapor recovery, then vapour recovery to be stopped, 4 way valves to be
changed again and liquid to be recovered from such wagons immediately. On recovery
of liquid, the operations to be repeated.
In case of any doubt about the presence of liquid LPG inside T/W it is better to open
another liquid line partially and find out whether liquid is coming out.
xxii. After bleeding off the pressure in the hoses/ hard arms, disconnect both the liquid and
vapour lines. Replace all the plugs in the tank wagon valves and the unloading fittings.
xxiii. Recheck sample valve, gauging device and thermometer well to determine that they
have been returned to their original condition and are closed tight. Lower the dome
cover carefully and lock it in place with the locking pin or secure by appropriate means.
xxiv. Remove bonding connections.
xxv. Reverse or remove and replace the “Flammable” placard with “Dangerous - Empty”
placard, if applicable.
xxvi. Remove the “Stop - Tank Wagon Connected” sign and wheel blocks.
xxvii. Any defect observed in the tank wagon should be noted on the appropriate forms and
routed in accordance with acceptable procedure.
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xxviii. Notify the railways in writing about release of wagon and ensure that it is removed from
the siding promptly.
xxix. Gauge the storage tanks, within the plant, which have received the LPG to determine
that the liquid level is appropriate.
xxx. In the event of LPG received on weight basis, the tank wagon may require weighing
following the completion of the unloading operation.
3.3.6 LOADING OPERATION
i. In case In-motion weighbridge available, take Tare weight of each wagon & record the
same.
ii. Take the mass flow meter reading connected with each wagon . In case mass flow
meter is not available, calculate the slip tube/dip Rod setting of wagon basis tare
weight of wagon.
iii. Ask loco to move away and exhibit caution sign at suitable distance away from the
wagons on both ends.
iv. Switch off loco engine, if parked nearby.
v. Note down wagon numbers and placement time.
vi. Take loading advice.
vii. Note the time of receipt of advice.
viii. Connect earthing lugs to the wagons.
ix. Lower the flapper bridge (Swing platform) slowly on the wagon.
x. Open the lid of the wagon.
xi. Connect the filling hose / arms and vapour return line hose / arms to the wagon. Ensure
that the flare connection valves are closed.
xii. Check that the wagon being loaded has a minimum of 1.5 kg/cm2 pressure; otherwise
wagon may be repurged and checked for leaks.
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xiii. Ensure that the header is charged with LPG and the bulk loading pump is running.
xiv. Open the tanker filling line valve and vapour return line valve.
xv. Check the system for leaks.
xvi. Open the valve on the vapour return line. Now slowly open the valve on the filling line.
Increase the valve opening and gradually open the valve fully.
xvii. If everything is satisfactory, gradually throttle valve on return line.
xviii. Keep a check on the slip tube reading & Mass flow reading to ensure filling permissible
quantity in the Tank Wagon. Net weight loaded should not be more than the permissible
quantity.
xix. Once tank wagon is filled, close the wagon filling and vapour return lines valves and also
valves on filling and vapour return lines at the loading point.
xx. Open the valve on vent line connection to both feed line and vapour return line. Thus,
the hoses / arms are depressurised. Then, close the vent line connection valves.
xxi. Disconnect the filling and vapour return line hose / arms connections from the wagon.
Replace and tighten the plugs on filling and vapour return lines.
xxii. Close the top cover of the wagon and seal it properly. Remove earthing connections.
xxiii. Release the hand brake of the wagon
xxiv. Release all the Rake.

Once loading / unloading are over, following operations to be carried out.
Take out the swinging platform
Prepare a checklist as per OISD 144 & G 65 (as per railway rule)
Issue release memo & checklist to railways
Send the release memo and check list to railways for removal of rake from the
siding
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3.3.7 Degassing of sick/leaky tank wagons

Sick T/W to be degassed in the following way:
- Unload liquid by vapour pressurising.
- De pressurise upto 2 kg/cm2 using compressor.
- Displace vapour by water filling leaving about a meter space on top of water surface.
- Vent residue vapour to atmosphere.
- Completely fill T/W with water.
- Displace water by compressed air.
- If steam is available use steam for degassing further. Otherwise pressurise T/W by air and
vent it out to dilute vapour if any.
- Take explosimeter reading.
3.3.8 Safety precautions for loading / unloading of tank wagon
Unloading to be limited to half rake ( 600 MT) at one go unless otherwise specific approval for
location is given by CCOE.
i. Do not allow the locomotive to come on the weigh bridge due to its capacity limitation.
Sufficient number of dummy wagons may be used to avoid loco coming closer to the
gantry.
ii. In the event of leak:

Stop the loading pump / unloading compressors.
Stop the movement of loco on the adjoining rails.
Switch off all internal combustion engines that may be running in the nearby area.
Stop hot works, if any, in the nearby area.
Stop all the vehicular traffic in the vicinity.
Start water monitors to form a blanket covering the leak and the wagon/piping from
which LPG is coming out.
Call fire engine with crew to standby till the emergency exists.
Stop all the maintenance jobs in the area.
Depressurize the system before attending to the leak.
Take immediate steps to decant the wagon, if the leak is from wagon.
Clear the area of all the people except those who are required to meet the emergency
situation.
Cut off power supply in the area where leak is detected.
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iii. The first operation after positioning the wagon shall be to provide for proper earthing.
Earthing shall be disconnected just before the release of the wagon.
iv. For connecting and disconnecting hoses, it is advisable to use non-sparking type of
tools.
v. After the wagons are placed on weigh bridge and before the loco is detached, the hand
brakes on each and every wagon should be applied.
vi. Like-wise, before the wagons are moved from the weigh bridge, release brakes on all
the wagons.
vii. Do not use footwear with protruding nails.
viii. Ensure that the lower portion of flapper bridge (swing platform) at wagon side is fitted
with rubber or wooden padding.
ix. Ensure that coir matting/rubber sheet is spread on the platform
x. Ensure that electrical continuity of the system is intact.
xi. Ensure that all fittings on the wagons are checked physically.
xii. Hoses should be hydraulically tested at least twice a year (six monthly) (Refer OISD-
STD- 135 on “Inspection of Loading/Unloading Hoses for Petroleum Products”).
xiii. Excess flow check valve will stop the flow of LPG in case the flow is in excess due to
accidental rupture of hoses etc. Close the isolation valve at grade level.
xiv. During the loading/unloading operation, the operator must present near the wagons.
xv. During unloading operation, after the liquid transfer is over, the wagon pressure shall
not be reduced below 1.5 Kg/sq.cm.(g).
xvi. Within the loading area there is to be No Smoking or open flames.
xvii. Vehicles must be kept at a safe distance from loading racks while tank wagons are being
loaded.
xviii. Any leak discovered during the loading operation is cause for discontinuance of the
operation. Leaks must be repaired immediately or, if impractical, must be reported
to the supervisor immediately.
xix. Tank wagon found to be in any way defective shall not be loaded until repairs have
been made and a report should be made to the supervisor.
xx. Jumping from loading racks to tank wagon or from wagon to wagon is extremely hazardous
and is prohibited.
xxi. Any undue rough handling of tank wagons, whether loaded or not, on company property
should be immediately reported.
xxii. Employees should keep a safe distance away from tank wagons when a railway crew is
coupling or uncoupling the wagons.
xxiii. Tank wagons should be spotted as close as possible to the specific -point for most
convenient loading whether it be an elevated loading rack or ground level connection.
xxiv. The use of open lights is prohibited. If flashlights or electric lanterns are required,
they must be of a vapour-proof type.
xxv. Tank wagons should be spotted on the insulated part of track only. In no case should a
tank wagon be permitted to rest partly on insulated and partly on un-insulated track.
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xxvi. The maximum permitted filling -density or filling level must not be exceeded under
any circumstance.
xxvii. After completing the loading operations, hoses or other pipes should be secured in
appropriate locations.
xxviii. Tank wagons should be inspected thoroughly for leaks before being approved for
shipment.
xxix. Raise and secure walkways after completing final inspection.
xxx. Loaded tank wagons fee labelled with placards or signs designated by the railway
authorities.
A Safety checklist is to be made as per Annexure-4
The matter regarding tank wagon not complying with any of above checks shall be taken up with
loading location.
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3.4 TRANSFER BY PIPELINE
The pipeline transfer operations are basically of two types as follows
o JETTY / PLT pipelines from Jetty / Refinery to Terminal / LPG Filling plant
o Cross Country pipeline covering various tap of points
3.4.1 Overview
Receiving product in a bottling plant by means of pipeline is the most desirable method and
presents fewer hazards than may be associated with any other method.
The techniques and procedures which may be necessary for the transfer of LPG may vary
widely since in one case, the transfer line may be extremely short merely passing through a
fence from a refinery to a bulk storage plant located immediately adjacent, whereas on the other
hand, the line may traverse many kilometres from a refinery to a bottling plant conveniently
located for distributing purposes. In the event that relatively short distances are involved
in a pipeline transfer, it may be practical to utilize relatively simple methods of determining
the volume transferred.
The quality and specifications of the product may be determined by sampling the tank from
which the product is to be withdrawn.
In cases where relatively long distances are concerned, it may be essential to measure or meter
the incoming product’. Samples may be withdrawn from the pipeline at the beginning and
end of the operation or in certain cases, a monitoring process may be required during the
entire transfer.
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3.4.2 Advantages of P/L mode of transportation
• Economic
• safe
• Low noise
• Least contact with populace
• Flexible
• Minimum dependency on existing Infrastructure
No Change in land use

• Minimum transit loss and pilferage
• Reduced rail and road traffic
• Enhanced efficiency
• Environment Friendly
• Least escalation on traffic
• High capacity utilization
• Low depreciation
• Well defined standards
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3.4.3 Cross Country Pipeline
Cross-country pipeline has been in use for transportation of water, petroleum liquids and gases
for the last 70-80 years in the developed countries. In India, cross-country pipelines have been
installed and operated for the past 25-30 years. A cross-country pipeline (CCP) can be underground,
submarine or aboveground.
In case of cross-country pipeline transportation of liquid petroleum products, physical and chemical
characteristic of the chemical to be carried are required to be considered for design of pipeline
system. OISD- STD- 141, ANSI-B 31.4, B 31.8, AWWA C-203 and other ANSI, ASME, ASTM, API and
BIS Codes are followed during design, construction, commissioning & operation of pipeline system.
In addition to above, fire fighting and safety systems in any cross-country pipeline is designed
and operated according to NFPA and OISD standards. Thus, pipeline system is safe for operation
within designed parameters and monitoring system is also is in place.
a. Cross Country Pipeline (CCP)
A CCP is primarily a transmission line for transporting bulk quantity of fluids over large
distances. A CCP may cover distances of a few thousand kilometres. For example, in
India, the CCP for LPG transportation from Jamnagar in Gujarat to Loni in UP covers a
distance of about 1,400 km, whereas the HBJ gas pipeline covers a distance of almost
2,300 km.
The conventional mode of transportation of fluids before the advent of CCP was by sea,
rail or road transport. These modes are still in use. However, wherever bulk transportation
on a continuous basis between two fixed locations is required, a CCP is the most
economical mode.
The reason is that the transportation by CCP is continuous and so it reduces the quantity
to be transported, to a manageable level. The risk involved in transportation by rail,
truck or ship is very high. Also, CCPs are generally provided with safety devices, which
are built into the system at the design stage, e.g. safety relief valves etc.
b. Applicable codes
The Codes that are generally followed for the design of a CCP are:
* ASME B 31.4: Pipeline Transportation Systems for Liquid Hydrocarbon & Other Liquids
* ASME B 31.8 - For gas transportation
* API 5L - Material of pipes
It must be noted that the Code is not absolute in everything and that is where expertise and
experience are needed. Nonetheless, there are two features that the code calls out, which are
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worth mentioning:
1. The code spells out even the qualifications of an inspector
2. Protection against corrosion
c. Line sizing and thickness
Sizing of the line is an important study and calls for a techno-economic

analysis. The various parameters that affect line size are:
* Pressure: High pressure will reduce the pipe size, but will increase the
pipe thickness
* Size of the pipe: The bigger the pipe, the higher the cost
* Thickness: Various factors affect the pipe thickness. E.g. Soil cover
with the line having internal pressure/line in empty condition but
having external soil pressure etc
* Pipe material
* Booster stations: How many booster stations will be there along the
route? If the fluid pressure is low, the thickness decreases, but we
need more booster stations and the reverse is the case if the fluid
pressure is high
* Pipe fabrication: Manufactured pipe versus roll-and-weld pipe
* Buoyancy effect: Under-soil or underwater pipeline gets lifted up
d. Routing of the lines
Routing needs the following considerations:
The number of pipes that will be placed in a single trench: This requires attention,
especially for pipe spacing at the line turning points.
The terrain is also an important factor. The terrain can be agricultural land, under roads,
past and existing crude oil tank farm, a marine causeway, river crossing etc. You may
intend to route a CCP underground, but rock may be encountered at a shallow depth.
e. Other points:
* Safety of pipeline and public

* Shortest pipeline length
* Infrastructure and access
* Existing and future developments
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f. Statutory requirements
A CCP route will also need the following statutory clearances:

* Local municipality
* Gram panchayat
* Ministry of forests
* Fire brigade etc
3.4.4 Transfer pipework
The following facilities on transfer piping between Shipper and receiver should be provided:
a) ROVs / MOV’s at both the ends of transfer line.(Additional ROV / MOV at critical locations
in the pipe line route.)
b) Relief valves on liquid line to surge vessel with an audible alarm system connected to
high safe venting system
c) Both side must be interlinked with security system to trip all the system to stop the flow
of liquid in case of High Level in Vessel while receiving the product; High pressure built
up inside pipeline due to closure of valves; in case of emergency alarm raised .
d) Both side Mass Flow meters should be provided with Pressure and Flow control Valves to
maintain the pressure and avoid any surge / back pressure effect.
e) Physical protection against impact to vent/drain pipes
f) Protection of pipeline against corrosion, particularly when the pipeline passes Under
public road way, which is likely to be water-logged.
g) Pipe work passing public road way be designed to acceptable public highway Authority
standard in terms of roadway axle weights
3.4.5 Operations of Cross Country Pipelines

i. Plan for the Pipeline transfer in coordination with Receipt /Despatch location
ii. Ensure sufficient ullage availability in a standalone vessel
iii. Gauging of Mass Flow meters / Level Gauges at both the locations should be done
and certified jointly (if necessary)
iv. Line up the Vessel for dispatch / receipt and confirm the readiness to the other
location for startup of transfer operation
v. Start the operation by pumps from dispatch location and ensure optimum flow ,
pressure to ensure the better accuracy of the metering system
vi. Log all the events and gauging shall be cross checked on hourly basis. At SCADA
locations, the data may be recorded on realtime and historical basis.
vii. Monitor all the operational and safety parameters on continous basis. Any deviation
in the parameters may be brought to the notice of the dispatch / receipt location
for necessary corrective action
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viii. Plan well in advance for switchover to the other storage vessels as per requirement
and intimate the other location accordingly. During the switchover both locations
should be careful in monitoring all the parameters
ix. At the end of pipeline transfer , intimate the other location and stop the transfer.
x. Close all the Valves in the line as per operating manual / procedure.
xi. Final reading and gauging of mass flowmeters / Level gauges shall be noted and the
quantities dispatched / received shall be quantified and joint certified. Any variation
beyond permissible limit shall be brought into notice of dispatch location to take the
corrective measures
3.4.6 Inspection and maintenance of cross country pipelines
a. Pipeline patrolling
Each operating company shall maintain a periodic pipelines patrol programme to observe
surface conditions on and adjacent to the Pipeline right to way, indications of lack,
construction activity other than performed by the company and other factors affecting
the safety and operation of the pipeline.
Patrolling (Aerial/Ground) of On-shore Cross Country Pipelines shall be carried out once
in a week for LPG Pipelines
b. Right of way inspection
The right of way shall be inspected and maintained once in a year to ensure clear
visibility of ROW/ ROU, access to maintenance crew along the ROW/ROU, valve locations
and other pipeline facilities. All pipeline markers/kilometer posts and other signs/specific
indication marks shall be maintained once in a year. API 1109, ANSI B 31.4 & ANSI B 31.8
shall be referred for guidance.
c. Inspection of pipeline crossing
i) Rail/Road Bridge and Suspended Crossing
Rail Bridge, Road Bridge, Suspended crossings shall be inspected once in a quarter to
check wear and tear of supports/structures and condition of coatings at the points
where pipe exits and enters the ground. Ultrasonic thickness measurements shall be
taken on exposed sections of the pipeline once in four years for LPG pipelines. This
thickness measurement shall be taken at 4 locations (i.e. 12, 3, 6 and 9 O’clock
positions) at the exists, bends and at every ten metre interval of exposed piping.
Where pipes are cased it shall be ensured that casings are free of water and muck.
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ii) Road and Highway Crossing

Road and Highway crossings shall be inspected once in a quarter. The carrier/casing
pipe annulus shall be kept free of water.
iii) Submerged Crossing and Intertidal Zone
Submerged crossing locations shall be inspected for erosion/washouts twice in a

year i.e., prior to and after monsoon and topographic changes if any shall be recorded
for corrective actions.
Affected length of pipeline falling in intertidal Zones shall be inspected once in a
quarter for checking the condition of coating and wrapping.
d. Pigging
i) Descaling
The frequency of descaling of LPG pipelines shall be once in a year
Record of quantity and quality of deposits (pig residue) collected after descaling
shall be examined to monitor condition of the Pipeline and to determine subsequent
frequency of pigging
ii) Intelligent Pigging
The pipeline should be inspected once in 5 years for corrosion / dents / pits etc. by means of
electronic / intelligent pigging. The results of subsequent inspections shall be compared with
original commissioning data in order to assess the health of the pipeline and subsequent periodicity
of intelligent pigging.
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e. Static leak test

Static Leak Test of the pipeline shall be performed once in five years using the liquid
transported through the pipeline. The capacity test is used only to quantify the pressure
and liquid containment capability of an existing Pipeline System. API 1110 (Section 3.0)
shall be referred for guidance.
f. Monitoring of external corrosion
1. Pipe to Soil Potential (PSP) Reading
i) PSP readings at feeding points shall be monitored fortnightly.
ii) The PSP reading at the test lead points for entire pipeline shall be taken once in a
quarter. The PSP survey results shall be plotted graphically to identify and locate
cathodic holidays. The minimum pipe to soil potential shall be more negative than
- 0.85 volts with respect to copper/copper sulphate half cell. In areas where anaerobic
bacteria are active minimum PSP shall be more negative than - 0.95 volts instead
of - 0.85 volts. Over protection of coated pipelines shall be avoided by ensuring
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that polarisation potential is below - 1.2 volts with respect to copper/copper sulphate
half cells. Polarisation potential can be measured at a given location on a coated
pipeline by measuring pipe to earth potential immediately (within the first second
or two) after simultaneously interrupting the current output from all cathodic
protection sources affecting that portion of the pipeline.
2 Pearson Survey
Pearson / CAT / DCVG Survey shall be carried out once in three years.
3. Continuous Potential Survey

Continuous Potential Logging (CPL) survey should be carried out once in five years.
4. Insulating Joint/Coupling Inspection

Insulating joints and couplings shall be inspected once in a year.
g. External Corrosion Control for above ground sections of Piping

Above ground piping and accessories shall be inspected visually once in a year for external
corrosion. ANSI B.31.4 shall be referred for guidance.
h. Soil Testing
If any industrial effluent is flowing over the ROW/ROU or any environmental change is
noticed on the ROW, the soil samples shall be tested for determining the efficacy of the
existing coating and wrapping of the pipeline.
3.4.7 Monitoring of internal corrosion

Internal corrosion is a function of what the pipeline contains and conveys.
Presence of corrosive constituents and other contaminating impurities in the transported

fluid may lead to internal metal loss in the pipeline resulting in general corrosion or
pitting type of corrosion. Such constituents could be due to salinity of sea water, presence
of carbon-dioxide together with moisture etc.
Presence of sulphur dioxide can lead to serious sulphide stress cracking of steels which
is essentially not a metal loss, but causes stepwise cracking in steel. For this type of
corrosion, its mitigation can be done by injecting chemical inhibitors along with the
product flow. The sulphide stress cracking can be mitigated by treating steel with certain
alloying elements and controlling its hardness. Corrosion mitigation by using inhibitors
may also help but only in case of certain specific types of fluid constituents. Another
method of safe guarding against internal corrosion could be by providing lining on the
inner wall of pipeline with an inert protective material compatible with the fluid
transported.
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The following schedules/activities shall be followed to monitor internal corrosion
i) Effectiveness of corrosion mitigation measures checked once in a year by analysing

the corrosion coupon.
ii) Electrical resistance probes may be installed for monitoring the effectiveness on
corrosion mitigation measures and reading should be checked once in a quarter.
iii) whenever the sections of the pipeline are running overground, ultrasonic thickness
measurements of the pipeline shall be taken once in two years .
iv) Whenever repairs to the pipeline are carried out, internal visual inspection shall be
done to supplement ultrasonic thickness readings taken externally.
a. CHECKING OF LEAK DETECTION SYSTEM

Leak detection system shall be checked and calibrated for accuracy and effectiveness of
operation once in three months.
b. WELD REPAIRS AND INSPECTION

All weld repairs and inspection shall be carried out in accordance with API 1104, ANSI
B.31.4 and ANSI B.31.8. API 2200, API 2201 and API 1107 shall be referred for guidance.
All repaired welds shall be 100% radiographed.
c. HYDROSTATIC TESTING OF PIPELINES AFTER REPAIR

Pre-tested pipe shall be used for all replacements in line with the requirements of OISD
141, ANSI B.31.4 and ANSI B.31.8 and API 1100.
3.4.8 Pipeline maintenance equipment

The specialised pipeline maintenance equipment required for maintenance of pipeline
shall be inspected once in a month.
3.4.9 Telecommunication system/equipment
i) System functional tests shall be carried out daily.
ii) Telecommunication equipment shall be inspected as per manufacturer’s

recommendation.
3.4.10 Telemetry system/equipment
i) System functional tests shall be carried out daily.
ii) Telemetry equipment shall be inspected as per manufacturer’s recommendation.
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3.4.11 Documentation
Formats for recording inspection findings shall be designed specifically for the equipment/
instrument/system used in the Pipelines/System.
The following datas also shall be available on record in all the Pipeline installations:
a) The basic datas and parameters of the Pipelines/System such as Layout, Length,
Diameter, Location of the different stations etc.
b) A complete route strip map showing all the details of the passage of the Pipelines
with respect to other public facilities such as roads, rivers, urban centres, rural
areas etc. and all isolating valve locations.
c) List of various codes to which the Pipelines/system have been designed
3.4.12 Inspection and maintenance of jetty pipelines
a. Internal corrosion
Jetty Pipelines, which occasionally carry water, are subjected to considerable internal
corrosion. In such pipelines salt water frequently remains in the pipeline after a
barge or ship completes loading/unloading operations. In such cases, where possible
it is desirable to flush the pipeline with fresh water to stall corrosion. Inhibiting
chemicals shall be used if the pipeline is left with Salt Water.
b. External corrosion
External corrosion of above ground lines shall be prevented by regular maintenance/
Painting.
External corrosion of underground pipelines shall be prevented by suitable coating/

wrapping and cathodic protection system.
3.4.13 Checks on jetty pipelines
i) Jetty Pipelines above ground shall be ultrasonically gauged for thickness once every
three years at vulnerable points. Visual inspection shall be carried out by walking
along the pipelines once in a month.
ii) The PSP reading at feeding locations shall be monitored fortnightly.
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iii) The PSP readings at test lead points for entire pipelines shall be taken quarterly.
The PSP survey shall be plotted graphically to identify and locate cathodic holidays.
The minimum pipe to soil potential PSP shall be more negative than -0.85 volts with
respect copper/copper sulphate half cell. The areas where anaerobic bacterial are
active minimum PSP shall be more negative than -0.95 volts instead of -0.85 volts.
Over protection of coated pipelines shall be avoided by ensuring that polarisation
potential is below -1.2 volts with respect to copper/copper sulphate half cell.
Polarisation potential can be measured at a given location on a coated pipeline by
measuring pipe to earth potential immediately (within the first second or two) after
simultaneously interrupting the current output from all cathodic protection sources
affecting that portion of the pipeline.
iv) Pearson Survey for underground section of Jetty Pipelines shall be carried out once
in three years.
v) Jetty Pipelines should be pressure tested at 1.5 times the maximum operating pressure
once in a year.
vi) Repaired section Jetty Pipelines shall be tested as per ANSI B.31.4
a. Block valve
A Block valve is installed in Jetty Pipeline where the land section ends and pipeline
comes out to go into the dock approach. This valve shall be kept closed at all times
when the pipeline is not in actual operation. The reason for this is to minimise spillage
of products. The block valve of Jetty pipelines shall be tested and serviced once in a
year.
b. Marine header
The marine header shall be inspected and tested once in a year along the testing of the
line. The header pit shall be maintained dry and shall be inspected daily.
c. Jetty embankment/ RCC support/staging
i) Grade levels shall be checked once in a year to ensure embankment/supporting

structures etc., are rigid and have not undergone gradual settlement/erosion.
ii) Conditions of concrete/steel tressels /supports shall be visually checked once in a

quarter for erosion/cracks/corrosion.
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iii) Structural steel supports likely to touch sea water shall be inspected for condition of
the protective coating once in six months.
iv) PSP readings of structures cathodically protected shall be monitored once in a fortnight.
d. Earthing
Earthing connections between Ship/Barge and shore pipeline shall be visually inspected
before EVERY loading and unloading operation.
Earthing connection between ship and shore line is not permitted and insulating gasket
is provided to keep electrical discontinuty at loading /unloading arm. Earthing of ship is
taken care of by saline water. Shore line need to be earthed at bottom of unloading arm.
e. Communication system
Functional test of communication system between Jetty to Terminal shall be done before
commencement of loading/unloading operation.
f. Documentation
Formats for recording inspection findings shall be designed specifically for the equipment/
system used in the Pipeline/System.
The following datas also shall be available on record in all the Jetty Pipeline Installations.
i) The basic datas and parameters of the pipeline System such as Layout, Length,
Diameter etc.,
ii) A complete route strip map showing all the details of passage of the pipelines.
iii) List of various codes to which the Pipeline/System have been designed.
3.4.14 Gauging / quantification of pipeline transfer
The Quantification of pipeline transfer is done through Mass Flow Meters installed at
Despatch and Receipt Locations. The Mass Flow Meters function on Coriolis Principle
which gives accuracy of 0.15% at normal flow and 0.20% at full range of the meter. It
directly gives Mass, Density, Temperature and Flow. The meter has to be calibrated once
in six months by FCRI, Palghat.
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Principles of Operation
Introduction to Coriolis
Whether for liquid, gases or slurries, Micro Motion’s

Coriolis technology offers many advantages over tradi-
tional volumetric technologies.
• Multi-variable measurement:
Mass flow rate
Volumetric flow rate
Density
Temperature
• High accuracy (+/-0.1%) and repeatability which
means improved product quality and reduced
waste.
• Easy installation because there are no special
mounting, no flow conditioning, and no straight CMF300 Sensor
pipe run requirements. Micro Motion sensors areavailable in a
Low maintenance because there are no moving parts, variety of sensor types, materials and
and it’s non-intrusive sizes.
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3.5 RECEIPTS & DESPATCHES BY COASTAL / IMPORTS THROUGH SEA
3.5.1 Bulk handling for movement by sea

Transportation of LPG in bulk by tankers may be carried out under fully-pressurised,
semi-pressurised (semi-refrigerated) or fully refrigerated at atmospheric pressure
conditions.
a. Pressurised Ships
The cargo is carried in a number of cylindrical (or spherical) pressure vessels (or
cargo tanks) capable of withstanding the maximum pressure likely to be met in
service (usually 17 bars).
b. Semi-Refrigerated Ships
The pressure of the cargo is very much reduced by lowering its temperature to about
0 deg.C by the process of refrigeration and tanks containing the cargo need not be
so strong as those of pressurised ships. The tanks are thermally insulated.
c. Fully Refrigerated Ships

The cargo is carried at atmospheric pressure and the cargo tanks are “box-shaped”
as opposed to cylindrical/ spherical in case of pressurised/semi-refrigerated tankers
for better utilisation of ship’s space.
Pressurised ships usually range from very small capacity upto 2000 cum. capacity.
The capacity of semi-refrigerated ships usually ranges from 1000 to 15000 cu.m.
Fully-refrigerated tankers could be made very much larger and for any given size,
much lighter.
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3.5.2 Cargo carrier design & construction
International Maritime Organisation (IMO) code for the construction and equipment of ships
carrying liquefied gases in bulk, covers ships contracted on or after October 31, 1976. The IMO
code for existing ships carrying liquefied gases in bulk covers ships built before the application
date of the new ship code. Putting together these codes are known as the IMO gas codes. The
international code for the construction and equipment of ships carrying liquefied gases in bulk,
with the short title of the International Gas Carrier (IGC) code, applies to ships contracted on or
after July 1, 1986. With its revised and clarified wording, this IGC code includes all the updated
requirements of the previous gas codes for new ships. The ISG code has been incorporated into
the 1974 Safety of Life at Sea (SOLAS) Convention and in 1986 became mandatory for all Flags
whose governments are signatories to the SOLAS Convention.
Some of the factors to be taken into consideration, which effect the design and construction of
ships carrying gas, are :
• Types of cargo to be carried
• Condition of the carriage (i.e. fully pressurised, semi-refrigerated or fully refrigerated)
• Type of trade, which in turn, determines the degree of cargo handling flexibility required
by the tanker.
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• Terminal facilities available when loading or discharging the vessel.
• Cargo containment systems (IMO code identifies five different types).
• Materials of construction (Fully refrigerated LPG cargoes must have tanks capable of with-
standing temperatures down to (-)55 degree C. Alloy steels such as fully killed fine grain
carbon manganese steel, sometimes alloyed with 0.5% Nickel are used.)
• Tank insulation (for refrigerated cargo)
• Tanker layout and safety features
• Survival capability and tank location
As specified by IMO codes, gas carriers are required to undergo five different types of survey
and have the certificates of fitness issued or endorsed. The certificate of fitness signifies that
a minimum standard of constructional safety has been achieved. In order for a tanker to comply
with code throughout its life time, it must be subjected to re-inspection to maintain its validity.
3.5.3 Facilities in the tanker
The cargo handling equipments in a tanker usually comprise of :
o Cargo pumps (submersible and booster)
o Compressors
o Condensers
o Heat Exchangers
o Vapourisers
o Cargo heaters
The deep well pump supplies liquid to the booster pump to send the product ashore. In pressurised
ship, liquid is withdrawn by pressurising the tank through vapour compression from other tanks.
All semi and fully-refrigerated tankers are provided with cargo heaters to enable the vessels to
discharge into pressure storage ashore and a booster pump if the discharge pressure is signifi-
cantly above 9 bars. Each cargo tank is provided with the following equipments:
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a) Two cargo pumps, one each on either side of the longitudinal bulk head.
b) Liquid discharge line from the tank dome, connected to the main liquid line.
c) All emergency pump trunk way.
d) A liquid loading line connected to the main liquid line.
e) Two liquid level indicating devices one on each side. These usually consist of a float attached
to a self winding tape which moves up and down, either on guide wires or inside a guide
tube. The liquid level is read off the tape through a gas-tight window at the top of and
outside the tank.
f) Two sets of purge lines at the top and bottom of the tank. These are used to distribute inert
gas or vapour for gas-freeing or gassing-up of the cargo tanks.
g) A vapour line for withdrawal of vapour to the compressor.
h) Sample tubes.
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3.5.4 Safety Devices
(a) Atleast two safety valves in each cargo tank
(b) High and Low level alarms
(c) Overfill alarm. When actuated, this will shuttle main loading valve and sound an alarm.
However, the design of the tankers with regard to provision of facilities, equipments,
accessories and safety features must be in accordance with the IMO requirements.
The electrical equipments of all gas tankers are subject to the requirements of the Flag
Administration, the Classification Society and of IMO. The certified safe electrical equipment
found on gas tankers are :
• Intrinsically safe
• Flameproof
• Pressurised or purged
• Increased safety
3.5.5 Transfer pipework
The following facilities on transfer piping between Terminal and Shore tanks should be provided:
(a) ROVs at both the ends of transfer line.(Additional ROV at critical locations in the pipe line
route.)
(b) Relief valves on liquid line to surge vessel with an audible alarm system connected to high
safe venting system
(c) Physical protection against impact to vent/drain pipes
(d) Protection of pipeline against corrosion, particularly when the pipeline passes under public
road way, which is likely to be water-logged
(e) Pipe work passing public road way be designed to acceptable public highway authority standard
in terms of roadway axle weights
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3.5.6 Terminal facilities
Transfer of LPG from ship to terminal and vice versa is accomplished using hoses or
loading arms. If terminal authorities supply the cargo transfer hoses, it is recommended
that NFPA section 59 regulation 4.5 be followed and complied with. However, if the hoses
are ship hoses, these should conform to section 5 of IMO (IGC).
Provision of vapour return facility depends on economics, transfer rates, distance of

jetty from storage tanks, product pressures and temperatures etc.
In case of pressurised gas transfer, it is observed that the pumping rate falls off gradually
due to back pressure of the shore tank. A suitable vapour recovery system or reliqifaction
of the gas from the receiving tank is well considered.
3.5.7 Ancillary equipments
(a) These include pipe work, valves, relief valves, rotating equipment (pumps,
compressors), exchangers, instrumentation, gas detection systems etc.
(b) Transfer line inerting facilities such as inert gas generation combined with water
base foam generator and pipeline pig system or water storage with corrosion inhibitor
chemical dosing transfer and supply facilities.
(c) Nitrogen cylinders with attendant facilities for hose purging/ leak testing and alternate
supply to ROVs and other instruments.
(d) The following agents may be incorporated in terminal fire control system :
(i) Water
(ii) Foam
(iii) Dry chemical powder
e) Mercaptan dosing unit consisting of dosing pumps,mercaptan dosing pot,pipelines.
3.5.8 Unloading operations
It is essential that the ship and terminal operators are familiar with the basic
characteristics of each other’s facilities, are aware of the precise division of
responsibilities and are able to communicate effectively during the time they are together
involved in the joint operation of cargo handling.
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3.5.9 Communication
Reliable and effective communications, irrespective of whether they are directly between
the tanker and the terminal or indirectly via third party, are pre- requisites of safe and
efficient cargo operations before the tanker comes alongside and during the period of
cargo operations and until the tanker departs. Terminal communication should be
compatible with tanker’s system.
3.5.10 Pre-cargo transfer discussions

Before any cargo transfer operation is commenced, it is imperative that the intended
procedures are thoroughly discussed and a meeting held between the responsible personnel
from the tanker and the terminal. The purpose of the meeting is primarily to make both
sides fully conversant with the characteristics of the tanker and shore cargo handling
systems, the envisaged operational and safety procedures and requirements and the
parameters to be adhered to during the transfer.
The content of the meeting will depend on a wide variety of circumstances but the
following broad outlines form the basis of such meetings :
(a) The names and roles of terminal and ship personnel who will be responsible for cargo
transfer operations may be noted.
(b) The terminal representatives shall check that pre-arrival instructions to the ship on
cargo, cargo disposition and cargo conditioning have been carried out. They also
shall check that all necessary tanker equipments inspection and tests have been
performed.
(c) Similarly, the tanker’s officers shall satisfy themselves that the relevant terminal
equipment and inspection checks have been carried out satisfactorily.
(d) Terminal representatives and customs and/or independent surveyors, where necessary,
will be informed of the cargo tank data e.g. temperature, pressure, whether free of
cargo, liquid heel or arrival dip, composition of tank vapour and quantity of cargo on
board.
3.5.11 Calculating the quantity of liquid on board
Before commencement of tanker discharge operation, tank readings for temperature,

pressure liquid level etc. are jointly agreed by the shore and tank representatives. The
corrections applied to assess the quantity of cargo on board are :
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(i) Trim correction - to make allowance for the liquid level indicating devices not centrally
located.
(ii) Shrinkage factor - for correction of volume at 15 deg.C.
(iii) Low sounding trim corrections to allow for the wedge shaped volume.
Volume at Corrected
15 Deg.C = Volume X VRF
Quantity at Volume at
15 Deg. C = 15 Deg. C X Density
at 15 Deg. C
(VRF is ascertained by ASTM-IP Table - 54).
3.5.12 Operating procedures for unloading ship
i. Vessel program including date of arrival, quantity to be discharged, desired date of

berthing would be advised by HQO-LPG distribution.
ii. Upon receiving all documents from HQO-LPG distribution, Terminal shall take clearance
from Customs / Excise and pay the necessary duties, wharfages to port
iii. Terminal to coordinate with port coordinator and conform date of berthing as per
availability of berth and inform the Traffic Manager, Harbour Master and DC of the
port regarding the date of berthing and confirm up the berthing program.
iv. Terminal shall inform the safety surveyor, quantity surveyor and C&F agents about
the date and time of berthing.
v. Safety surveyor shall board the pilot for pre-entry survey at the outer anchorage /
on board at the notified date and time.
vi. Terminal ensures thorough re-checking of the fire fighting facilities & the
communication system at Jetty prior to berthing of the vessel.
vii. Port authorities shall ensure safe berthing of the vessel in presence of the Safety
surveyor.
viii. For import cargo, the Customs officials shall first board the vessel and clear cargo
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for discharge. The boarding officer ( B/O ) shall ensure completion of all the
formalities with the assistance of C&F agents.
ix. Notice of Readiness (NOR) is then handed over to the B/O by the captain of the
ship. B/O also collects the load port quantity survey reports and other load port
documents from Chief Officer of ship.
x. Samples of bulk LPG cargo are then drawn for quality checks and will be dispatched
immediately to the Terminal QC Laboratory / Third party Quality surveyor.
xi. The quantity on board is calculated by the Quantity surveyor and Chief Officer.
This will be witnessed by the Boarding officer. LPG Ullage Report is made by the
B/O. In case of any variation in onboard quantity from the load port after-loading
quantity, B/O shall issue protest letter to the Master.
xii. B/O shall then ensure with the help of handling crew, connecting the unloading
arm, purging it with nitrogen followed by leak tests of the connections made in
the presence of Safety surveyor at a pressure of 1 ½ times of operating pressure.
xiii. B/O keeps in touch with the terminal Control Room for ascertaining results of the
quality tests and seeking clearance for commencement of discharge. B/O discusses
with Control Room regarding its receipt plan.
xiv. B/O issues Voyage Instructions to the ship detailing desired operating parameters
during unloading operations.
xv. Product pipeline Motor operated valves (MOV) / other valves at jetty end are then
made through up to terminal battery limit.
xvi. Meanwhile, at the terminal QC Laboratory / Third party Surveyor, sample bombs
containing LPG cargo samples are put to test processes immediately upon receipt.
Tests are conducted on critical parameters like vapour pressure, volatility & copper
strip corrosion. Other tests like hydrogen sulphide, total volatile sulphur &
composition analysis are also carried out in line with standard IS:4576:1999.
xvii. If the sample passes the required Quality norms, Control Room communicates to
the B/O the same & gives 15 / 30 minutes advance notice to the ship for
commencing discharge.
xviii. The Terminal meanwhile identifies a sphere with available ullage in an area where
other operations are not concurrently going on. Necessary communication is made
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with the help of operators for lining up of the storage vessel for receipt. Initial
gauges of the identified sphere are noted by control room in presence of Quantity
surveyor for initial quantification.
xix. For lining up of the storage vessel, all valves are lined up and confirm to control
room
xx. Control Room should further cross-check the status of the line up from indications
available in the Control Room, and then advise B/O its readiness to accept
discharge.
xxi. B/O communicates with the ship & advises to start discharge. Ship confirms the
start of discharge along with the time of commencement.
xxii. Control Room monitors increase of pressure in the jetty receipt pipeline and also
the inflow into the lined-up storage vessel / suction of booster pumps. The
Terminal shall start the booster pumps ( wherever available ) upon reaching the
minimum pressure in coordination with Ship and stabilize the system slowly by
starting each pump , maintaining all the parameters one by one.
xxiii. After pumping the pipeline filled quantity ( theoretical volume of the pipeline )
pumping should be stopped ( direct to storage vessel) / online gauges ( Through
booster pumps ) at both the locations shall be taken for calculating P/L relaxation
qty. Pumping should resume ( Direct to storage vessel ) / shall continue ( Through
booster pumps ) once both quantities are compared and the relaxation qty is
ascertained.
xxiv. B/O shall ensure uninterrupted power supply and continuous lighting at the jetty
during discharge operation.
xxv. During the entire duration of ship unloading Control room maintains constant
contact with the B/O & Receipt Terminal / Bottling plant over radio transreceivers
/ Telephone / Hotlines , to ensure optimum & safe operating parameters.
xxvi. B/O shall ensure that the temperature and pressure of the cargo are maintained
as per the voyage instructions.
xxvii. Control room shall constantly monitor the flow rate, temperature & pressure of
the receiving sphere as well as jetty receipt pipeline. Hourly figures of the discharge
& receipt quantities should be calculated at ship & terminal ends. At the ship end,
hourly gauges will be taken by ship officials and witnessed by B/O and quantity
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surveyor and discharge quantity ascertained. At the Terminal end, hourly gauges
will be taken by Terminal and witnessed by quantity surveyor and receipt quantity
calculated. These parameters along with any other developments are logged on
‘Time Sheet’ by Control Room & B/O at both ends.
xxviii. The above hourly figures are exchanged between B/O and the Control Room. In
case of abnormal variation, reasons to be ascertained & suitable action to be
taken by the Control Room in consultation with Installation In-charge.
xxix. For any exigency / unsafe development e.g. abnormal increase in jetty line
pressure, accidental closure of ROV/ MOV, any fire / emergency at the Terminal
or, Jetty etc., Control Room shall immediately advise B/O to stop the ship
discharge.
xxx. Thirty minutes before completion of receipt into a storage vessel, an alternate
Storage vessel is lined up for next receipt. All the valves are opened in the
receipt line of the next storage vessel, leaving only the Main Header Valve closed
as the controlling valve.
xxxi. The likely time of switchover is communicated to B/O by the Control room well
in advance – 15/ 30 minutes. At the time of switchover, the above mentioned
valve is opened, allowing the product to flow into the new Storage vessel. Increase
in level gauge reading & the inflow rate of new Storage vessel confirms receipt,
which is conveyed to the B/O.
xxxii. After some time, the earlier storage vessel is isolated. Closing gauges of the
storage vessels are taken, basis which quantity surveyors calculate the net
receipt into the earlier storage vessel.
xxxiii. The B/O should maintain a statement of facts and shall record all the happenings
during discharge with the exact time of occurrence. These are noted in a format
called ‘Tanker Discharge Record’ . In case, any special instructions are obtained
from the port /shore, the same shall be recorded with the name of the person
who passed on the instruction.
xxxiv. On completion of discharge, the assessment of the quantity on board is carried

out by the B/O, the Quantity surveyor and the ship’s Chief officer.
xxxv. Similarly, Quantity Surveyor at shore completes the final gauging & calculates
the total receipt quantity from the vessel and submits a report called ‘Tanker
Outturn’. This is again cross-checked by the Control Room.
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xxxvi. In case of major variation of ship discharge quantity from the receipt quantity
at shore, B/O shall issue Letter of Protest to the ship.
xxxvii. At the end of operations, B/O shall ensure to collect all the reports, viz. initial &
final quantity reports, Statement of Facts and Protest Letters received or, issued
during discharge. All reports/documents should be duly acknowledged by the
Ship’s Chief officer / Master.
xxxviii. In case of HPC chartered vessels, B/O shall coordinate for supply of bunkers,
fresh water etc. as required by the vessel with HPCL POL terminal, IOC & other
agencies concerned.
xxxix.On cessation of the discharge operations loading arm to be disconnected after

ensuring draining of LPG left between the loading arm ball valve and the ships
manifold.
xl. The boarding officer informs the port control regarding the time at which the ship
will be ready to sail.
xli. Terminal shall send the reports covering the quantities, timings to the shipping
department at the HQO.
xlii. In case of any emergency during the course of discharge in any part of the jetty
the following actions are to be taken.
o Advise the Control room / coastal terminal to close the ROV’s/ MOV’s.
o Control room shall alert all stations, advise boarding officer / ship to stop the
pumping.
o Close the battery limit valve on the receipt line.
o Activate the jumbo curtain to form water curtain between the shore and ship
in coordination with Fire Fighting crew.
o Activate the monitors towards the spot of emergency.
o Boarding officer shall alert the ship to go for an emergency cast off.
o Control room shall inform the port control of the emergency and request for
emergency casting off.
o Disengage the loading arms as per the emergency procedure.
o Disembark the ship, allow the ship to cast of along with quantity surveyor who
will complete the ullaging at the outer anchorage.
o Assistance can be given to the ship including the supply of fire water.
A detailed checklist for Liquefied Gas Cargo Transfer is to be made as per
Annexure-4
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3.5.13 Operating instructions for unloading arm
a. Inspection before the arrival of tanker:
WARNING: Unloading arms should be maneuvered only in empty condition. In

case of Emergency disconnection it should be locked in position.
Visual inspection for Satisfactory Operating conditions, Hydraulic system for leaks,
Cables & fittings for security.
b. Checking the arm for maneuvers(checks to be made once a week)
• Raise the Outboard arm – Movements should be smooth without jerks.

• Check to ensure that balancing beam is parallel to the outboard arm.
• Check to ensure that the Outboard arm is in fixed position once the maneuver is
stopped. Arm should remain in position as long as it is not operated & is selected.
c. Positioning of the tanker
• Tanker to be positioned in such a way that the axis of the bank of the arm (spot line)
is with respect to the axis of the manifold as per the drawing.
• To moor properly so that the tanker does not pull the arms away from the working
envelope.
• Add extra spool piece, when the tanker flange is located outside the limits or when
the tanker flange is likely to go out of its operating limits. Spool must be supported
so that it does not lead to stresses on tanker flange. Spool should be installed on the
tanker flange and not on the Loading arm.
• Never connect the arm to a flange with an axis parallel to the axis of the tanker.
Elbows to be used in such cases.
• Never cross two arms.
• Movement of arm/tanker is permitted within operating envelope only.
d. Connecting the arm
WARNING: IN CASE OF HIGH LATERAL WIND ON THE BERTH, THE CONNECTED ARM CAN
GET OUT OF CONTROL WHEN SLOW MOTION IS NOT SELECTED AND TURN DUE TO WIND
LOADING
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WARNING: THE ARM SHOULD BE EMPTY BEFORE CONNECTION. CHECK THAT THERE HAS
BEEN NO PRESSURE BUILD UP INSIDE THE ARM AFTER LAST OPERATION.
IN CASE OF HIGH VELOCITY OF WIND CARGO TRANSFER TO BE STOPPED AT A MUTUALLY
AGREED WIND VELOCITY (SAY 35 NAUTICAL MILES) DEPENDING UPON SHIP/UNLOADING
ARM PARAMETER.
NOTE: IT IS ADVISABLE TO OPERATE THE ARM USING REMOTE CONTROL SYSTEM
e. Connecting the arm from local control panel
• Power on and Start the pump. Pump 1 ON / Pump 2 ON lights up.

• Operate the selected arm to bring the arm to the close proximity of the tanker
discharge flange after getting directions from the man aboard the tanker.
• Check that the manifold group is empty.
• The man aboard the ship should remove the blanking plate.
• Check that the O-ring seal is in working condition.
• As directed by the man aboard the tanker, move slowly the arm to engage the flange
clips by using slow speed on the Selector switch “Fast / Slow”
Turn the arm to keep on Free wheeling mode and will move with the tanker.
WARNING: DO NOT TURN THE POWER OFF
f. Connecting the arm from the remote control panel
• Switch “Local / Remote” is in “Remote” position – Start the pump from the Remote
Control panel after taking it out from the Storage box. Pump 1 ON / Pump 2 ON
lights up.
• Take the portable remote control panel from its storage box and go aboard the
tanker in order to operate the same from the deck.
• Carryout all the above mentioned operations as mentioned in section
• After completing the connection the remote control panel should be kept back in its
storage box. Keep the system in freewheel mode before start up of discharge
operations
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THE TANKER TRANSFER CAN BE STARTED.
g. Disconnection of the arm
WARNING: AS SOON AS THE PUMPING IS OVER, VENT THE LPG IN THE ARM BY USING
NITROGEN PURGING LINE. THE ENTIRE ARM MUST BE VENTED BEFORE DISCONNECTING
THE FLANGE FROM THE TANKER.
WAIT FOR DISCONNECTION TILL SUCH TIME THE RESIDUAL QUANTITY OF THE ARM IS
MELTED.
h. Retracting the arm to rest position
• With Power ON, Selector switch correctly positioned ARM from the hip flange, Provide
altitude to the arm by combination of movements taking care of any possible
interference of Tanker structures.
• If necessary slew the arm before and after clearing clearing from the side of the
ship.
• If during the maneuver, inboard arm comes behind the riser, it may be necessary to
raise the outboard arm to avoid any interference between the front arm & riser.
• As soon as the arm is in rest position, lock it.
• When the arm is in secured position, stop the hydraulic power unit.
• Replace the remote control panel in its storage box.
• Cut-off the power of the Electrical Control Panel.
• Mercaptan Dosing to be done as below:
“Generally imported LPG/butane need to be dosed with 20 ppm ethyl mercaptans

before receiving in shore terminal tank. LPG terminals are provided with mercaptan
dosing pumps of reciprocating type with adjustable stroke length. Depending upon
the flow rate of LPG discharge from ship stroke length is adjusted to mix 20 ppm
mercaptan in LPG.”
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A SAMPLE LINE DIAGRAM OF SHIP DISCHARGE LINEUP AT RECEIVING TERMINAL
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STORAGE OF BULK LPG
INDEX
4.0 Overview 1
4.1 Types of storage 1
4.1.1 Pressurized storage vessel 1
4.1.2 Refrigerated storage vessel 2
4.1.3 Cavern storage 2
4.1.4 Comparison of different types of LPG storage 3
4.2 LPG Bullet & Sphere 4
4.2.1 Design Criteria 4
4.2.2 Design Parameters 4
4.2.3 Layout requirements 4
4.2.4 Fittings & vessel accessories 5
4.2.6 Maintenance & Inspection 10
4.3 Mounded LPG Storage 14
4.3.1 Design code 14
4.3.2 Design Criteria 15
4.3.3 Fittings & instruments on a mounded vessel 16
4.3.4 Operations, Maintenance & Inspection 18

4
STORAGE OF BULK LPG
4.4 Refrigerated storage 23
4.4.2 Design criteria 23
4.4.3 Operation procedure 26
4.5 Cavern 26
4.5.1 Hydraulic containment principle 28
4.5.3 Design criteria 29
4.5.4 Operation procedure 29
4.6 Fitting & accessories of storage vessel 33
4.6.1 Safety Relief Valves 33
4.6.2 Liquid Connection Valves 36
4.6.3 Vapour Connection Valves 40
4.6.4 Guages 41
4.6.5 Pressure guage 48
4.6.6 Temperature guage 48

4
STORAGE OF BULK LPG
4.0 OVERVIEW
Liquified Petroleum Gas known as LPG is obtained from refining of crude oil in Petroleum Refineries
and fractionating Natural Gas from Oil & Gas Fields. The product conforms to the requirement of
IS 4576:1999.
Because of its flammability and explosive nature LPG is a hazardous substance. The conventional
method of storage in India is in a pressurized vessel, installed above ground. Alternative storage
methods viz. Refrigerated ,Mounded and Cavern storage have evolved over a period of time.
These methods of storage have been able to overcome most of the safety and operations
limitations compared to conventional storage.
4.1 TYPES OF STORAGE
Considering the various operational requirements and applications, LPG is stored in following
type of storages :
a) Pressurised Storage Vessel

b) Refrigerated Storage Vessel
c) Cavern
Above kinds of storages have their own advantages and limitations. Choice of storage depends
upon the suitability and relative advantages.
4.1.1 Pressurised Storage Vessel

LPG at ambient Temperature and pressure is in vapourised state. Due to high liquid-
vapour expansion ratio of LPG,it is not feasible to store LPG in Vapour form. Hence
storage of LPG in liquid form at ambient temperature in pressurised vessel is the most
commonly used option. Different types of Pressurised Vessels are used for LPG storage
LPG Bullet
The most common type of Pressurised LPG Storage is conventional horizontal Bullet in
the capacity range of one-quarter to 150 MT.
Shop fabricated tanks can be handled with relative ease; likewise, the units facilitate
easy arrangement of piping, access ladders, walkways and other fittings.
Horton LPG Sphere

The economical form of storage in the capacity range of 600 to 2800 MT is spherical type
storage vessel. Though this kind of storage is more economical compared to Bullet and
can handle large volumes, inherent limitations are long process piping and high fire
water pressure requirement in case of emergency.
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STORAGE OF BULK LPG
Mounded Storage
A storage vessel sited above ground and completely covered by a mound of earth or similar inert
material except for nozzles, manhole covers, inspection covers fitted on vessel. Horizontally
placed cylindrical vessel of capacity ranging from 200 to 4500 MT, shall be used for mounded
storage. the external surface of the vessel which is covered by mound should be suitably treated
to protect it from corrosion. The Mounded Storage of LPG has proved to be safer compared to
above ground storage vessel since it provides intrinsically passive and safe environment and
eliminates the possibility of BLEVE.
4.1.2 Refrigerated Storage Vessels :
The Refrigerated LPG Vessel is used for large capacity storage. It is safe and economical
for more than 5000 MT of LPG .In Refrigerated storage tank, LPG is stored in double
walled insulated above grounded tanks at NTP. BLEVE is completely eliminated for this
type of storage.
4.1.3 Cavern storage
Cavern storage is economical only for high storage of LPG i.e. 50,000MT and above.
Cavern storage technology is based on the natural storage method whereby hydrocarbons
are contained in naturally occurring reservoirs and reserves.
At a depth of 130 Meter the pressure surrounding the caverns created by the head or
weight of water table in the water saturated rock is greater than the pressure inside the
caverns caused by the temperature and weight of LPG. As a result of this difference in
pressure LPG will not flow from the cavern or escape into the surrounding water saturated
rock. The seepage of water is periodically removed from cavern by pumps.
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STORAGE OF BULK LPG
4.1.4 COMPARISON OF DIFFERENT TYPES OF LPG STORAGE
TABLE 1
RELATIVE ADVANTAGE & LIMITATIONS :
Type of Storage Advantage Limitations

1.Suitable for small storage 1. High risk of Exposure and
2.Ease of Operations , BLEVE
Bullet Maintenance & inspection. 2.Visual Impact is High
3.Can be factory fabricated and 3. Low Storage
can be relocated
1.Economical for High storage 1.High risk of Exposure and
Horton Sphere 2.Ease of Operations and Maintenance BLEVE
2.Visual Impact is very high
3. Long Process Piping
1.Eliminates the possibility of BLEVE. 1.Maintenance requirement is
2.Nil risk of exposure from fire in more stringent
close proximity 2. No ease of inspection
Mounded Storage 3.Reduction in inter distances
4. Area of Land required is very low
5. Any no. of vessels can be put in
one group
6. Cost of fire fighting equipment is low.
Refrigerated 1.Eliminates the possibility of 1.High Operating cost because
Storage BLEVE. of stringent cooling requirement
2 Economic for high storage 2. Complexity of operation due
3. High rate of product transfer to requirement of re-heating
during product transfer.
3. Requirement of 100% spill
containment
Cavern Storage 1.Costs for fire fighting equipment 1.Geological Constraints,
are relatively low. suitable only for typical strata.
2.Land requirement is relatively low 2.Very high initial investment
3.Visual impact is low & Reduce 3. No ease of inspection
exposure to damage
4.Reduced BLEVE or explosion risk
5.Safety hazard on account of sabotage,
storms, earthquakes and explosion
are minimized
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4.2 LPG BULLET & SPHERE:
4.2.1 Design criteria

LPG Storage vessel shall be designed, constructed and tested in accordance with BIS
code IS 2825 or any other international standard code like BS 5500 or ASME section VIII
and approved by CCOE. LPG storage bullets / spheres and facility are designed in
accordance with “The Static & Mobile Pressure Vessels ( Unfired ) Rules 1981”.
4.2.2 Design Parameters

Design Pressure: Design pressure of vessel of bulk LPG shall not be less than vapour
pressure of LPG at 55 deg C.
Design Temperature: The design temperature of the vessel shall be in line with the
specifications of LPG and statutory requirements.
Maximum Quantity of LPG: It shall be governed by the filling density of LPG and shall be
such that the vessel shall not be more than 95 % liquid full due to expansion of contents
with rise in temperature to 55 deg. C
A typical LPG bullet /sphere is designed as per the following parameters :
DESIGN CODE : IS 2825

Design Pressure 14.5 kg/cm2 at 55 deg C
Design Temperature -27 deg C to +55 deg C
Corrosion allowance Min 1.5 mm
Radiography Full
Stress relieving 100 %
Wind pressures As per IS 875
Earthquake pressure As per IS 1893
Hydrotest pressure As per design code
4.2.3 Layout requirements:

A minimum safety distance between storage vessel, between vessel and property line /
facilities shall be maintained as per OISD 118 & OISD 144.
Bullets shall be oriented so that the longitudinal axis do not point towards other vessels,
vital equipments, facilities.
The aggregate capacity of a storage group shall be limited to 15000 cum.
The top surface of the vessels installed in a group shall be in the same plane.
Spheres and bullets shall not be grouped together.
A kerb wall shall be provided on three sides of the vessel with a pit on the fourth side of
height not more than 60 cm.
Foundation and supports: Supporting structures shall be fire proofed in accordance with
OISD 144.
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4.2.4 Fittings and Vessel accessories:

All fittings and accessories of the storage vessels shall be in accordance with
SMPV rules, 1981.
Each storage vessel shall be provided with the following:
Inspection manhole at top 1 No.
Pressure relief valves 2 Nos.
Bottom nozzle for liquid inlet and outlet 1 No.
Pressure gauge 1 No.
Liquid level indicator 2 Nos. (01 should be floating type)
Temperature measuring device 1 No.
Vapour inlet and outlet nozzle 1 No each.
High level alarm switch 1 No.
Spheres and bullets shall have a single nozzle at the bottom for inlet as well as for
outlet. The nozzle shall be full welded pipe, stress relieved along with the vessel and
shall extend minimum three (3) metres from the shadow of the sphere / bullet. A fire
safe remote operated (shutdown) valve (ROV) shall be provided on this bottom nozzle at
a distance of at least three (3) metres from the shadow of sphere/bullet. The nozzle
pipe shall have a slope of 1.5 degrees.
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Bullet Storage
Sphere Storage
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There shall not be any other flanges, manhole, instrument tapping on this nozzle upto
the ROV or on sphere/bullet bottom. The top vapour zone of the vessel shall be provided
with nozzles for vapour outlet and re-circulation which shall also be provided with fire-
safe ROVs as per OISD Standard 144. A valve is considered fire-safe if, when exposed
to fire conditions, it will continue to provide minimum leakage through the seat and
stem, and provide effective shut off during or following fire or exposure to excessive
temperatures. Standards relating to fire safety are set out in BS 6755 and API RP 6FA.
ROV / MOV ( Plug / Ball Valves): These valves are used as the main shutdown valve in all
plants for isolating storage vessel from other facilities like pipelines etc. ROV’s operate
on Electro-Pneumatic principle and MOV operate on Electrical supply of 3 phase 415 V.
Both the valves can be operated remotely.
(a) Remote Operated Valve (ROV)
The basic operation of the valve is pneumatic with spring loaded actuator. Normally
the valve opens on air supply and closes on release of air. This action of air supply
and release is achieved by providing a flameproof solenoid valve. The time taken
for operating this valve is very less. The bottom may be plug / ball valve and the top
actuator unit is attached with the the valve operating lever.
(b) Motor Operated Valve (MOV)
The basic operation of the valve is Electrical operated motor actuator along with
gear box and suitable adaptor fitted on the valve operating lever. However this kind
of valve operates slowly when compared to ROV. This requires 3 Phase 415 V supply
and the actuator fitted is of Flameproof suitable for usage in Gr. II A & II B. The
actuator will have a provision to operate the valve manually with a handle in case of
power failure / repair of actuator.
(c) Bottom water draw off/drain valve
Two valves, with suitable distance piece between them, shall be provided between
ROV and the first isolation valve. The first drain valve from the vessel should be of
quick shut-off type valve while the second valve should be throttle type (Globe Valve).
Low Temperature Valves are used normally in the drain lines. The material of
construction of these valves shall be of low temperature carbon steel. This valves
avoids the stem / seat choking when LPG comes in contact while draining at low
temperature. These valves handle fluids at Sub-zero temperatures. These are with
extended-bonnet gate and globe valves with low temperature services of upto –46
Deg.C .
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(d) Sampling Valve
Two valves with suitable distance piece between them shall be provided between
ROV and the first isolation valve for avoiding icing problem in the upstream valve.
(e) Liquid level gauging device
The storage vessel shall have minimum two different types of level indicators and
one independent high level switch. High level alarm shall be set at the level not more
than 85% of the volumetric capacity of the vessel.
(f) Pressure Gauge
Minimum of one pressure gauge, duly calibrated, shall be provided in the vapour
space at the top.
(g) Pressure relief valve
Minimum of two pressure relieving valves shall be provided in the vapour space at
the vessel top in accordance with the design code of the vessel.
Relief Valves shall be spring loaded. Weight loaded relief valves shall not be permitted.
Each safety relief valve (having 100% relieving capacity) shall be set to start-to-
discharge at a pressure not in excess of 110 percent of the design pressure of the
vessel and shall have a total relieving capacity sufficient to prevent the maximum
pressure in the vessel of more than 120 percent of the design pressure.
Each safety relief valve shall be provided with isolation valve between it and the
vessel. Each valve shall be of adequate capacity to allow full required capacity flow
through it. Suitable provision to avoid accidental closing of the isolation valve is
recommended.
Relief valves shall be fitted with extended vent pipes having outlets at least 3 meters
above the top of the vessel and atleast 3.5 meters above the ground level when not
connected to flare system. A weephole with a nipple at low point shall be provided on
the vent pipe in order to drain the rainwater which may get accumulated otherwise.
Weephole nipples shall be so oriented that in case of safety valve lifting and consequent
fire, the flame resulting from LPG coming out from weephole does not impinge on
the vessel or structure. A loose fitting rain cap with a chain (non-sparking) fitted to
vent pipe shall be provided on top of SRV.
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Relief valves shall be tested for correct operation not less than once in a year or as
per the statutory requirements and a record of such tests shall be maintained.
4.2.5 Operating Procedure
a) Draining
Bullet draining operations is to be carried out before commencement of shift
operations under the supervision of Shift Officer and records to be maintained. The
same is also to be carried out whenever there is a change in vessel for filling
operations. Detailed procedure outlined in Chapter on filling operations.
b) Gauging
Gauging operation has to be carried out at the beginning and end of each shift and
records to be maintained in gauge book. Along with the gauge, temperature, pressure
and density as per IS 4576 and as outlined in LPG quality manual shall also be recorded.
c) Valves operation
At the end of operations, it has to be ensured that all isolation valves including ROVs
are in closed position. Preferably separate vessels to be used for cylinder filling and
tanker decanting operations.
d) Stock Calculation
Refer Chapter no. 6 for detailed stock calculation procedure to be followed.
4.2.6 MAINTENANCE AND INSPECTION
a) ROLE OF INSPECTION
i) To inspect, measure and record the deterioration of materials and to evaluate
present physical condition of the pressure vessel for its soundness to continue
in service.
ii) To corelate the deterioration rate with design life for further run.
iii) To determine causes of deterioration and to advise remedial measures.
iv) To recommend/forecast short-term and long-term repairs and replacements to
v) ensure further run length on the basis of economics and safety.
b) INSPECTION TOOLS
Tools required for Pressure Vessels inspection are as follows
i) Ultrasonic Thickness Gauge.

ii) Ultrasonic Flaw Detector.
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iii) Radiography Equipment.

iv) Magnetic Particle Testing Kit. (Wet Fluorescent Type)
v) Dye Penetrant Kit.
vi) Paint Thickness Gauge.
vii) Holiday Detector.
c) LIKELY LOCATIONS OF METAL WASTAGE
BULLETS AND SPHERE
The corrosion and scaling is generally confined to the bottom between 5 to 7 O’

clock positions probably due to the presence of corrodents like H2S and water. LPG
storage vessels are also prone to stress corrosion cracking. The circumferential
weld joints below the equitorial plates in the LPG Horton spheres are more prone on
such cracking.
d) FREQUENCY OF INSPECTION
i) All new vessels, regardless of service shall be inspected within first 2 years of
operation. Thereafter, the periods of future inspection shall be scheduled on
the basis of established corrosion rates, the type of service, remaining corrosion
allowance and the life expectancy.
e) INSPECTION PROCEDURES
i) FOUNDATION AND SUPPORTS
Foundations
Foundations for pressure vessels are mostly constructed of steel reinforced
concrete or of fireproofed structural steel. These shall be checked for spalling
cracking and settlement. Settlement shall be checked till it gets stabilised. If
due to cracks, big gaps have been formed, steel should be checked for external
corrosion by removing the concrete at cracked locations.
Support of Horizontal Vessels
Horizontal vessels resting on concrete saddle supports where water can accumulate
and cause external corrosion shall also be inspected. Horizontal vessels operating
at high temperatures shall be checked to ensure free thermal expansion.
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ii) FOUNDATION/ANCHOR BOLTS
Foundation bolts shall be inspected for corrosion and damage. The nuts on
anchor bolts may be inspected to see that these are properly tightened.
iii) LADDERS, STAIRWAYS, PLATFORMS AND STRUCTURALS
These shall be inspected visually for corrosion, cracks, paint failure etc. Visual
inspection shall be supplemented by hammer testing. Corrosion is most likely
to occur at points where moisture can accumulate. Crevice corrosion may exist
around the heads and nuts of bolts. Ladders shall be examined for free movement
to take up expansion of the vessels.
iv) INSULATION AND PROTECTIVE COATINGS
Visual examination of insulation will reveal its condition. Insulation shielding

shall also be checked for quality and thickness. At few locations samples may be
removed to determine condition of the insulation and of the metal underneath.
Paint or protective coating shall be examined for peeling or rusting . Insulation
shielding should be intact. If at any time insulation shielding/cladding is blown
off or damaged the same shall be put back immediately after repairs to avoid
corrosion. The insulation retaining rings shall be checked to see that moisture
is not trapped between the rings and weldment.
v) EARTHING
Grounding connections shall be visually examined to see that good electrical

contact is maintained. The earthing strip shall be examined for continuity. Its
resistance shall be checked at intervals as outlined in OISD standard-137
(Inspection of Electrical Equipment).
vi) NOZZLES AND SMALL CONNECTIONS
The nozzles on a pressure vessel shall be visually inspected and thickness

surveyed. Small diameter nozzles (less than 50mm) are difficult to be thickness
surveyed ultrasonically. The thickness may be determined by taking radiographs
wherever possible.
Special attention should be given to nipples used for pressure and temperature
gauges etc.
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vii) EXTERNAL INSPECTION OF METAL SURFACE
a) Visual Inspection
The external surface of the pressure vessel shall be inspected visually. The external
surface may show signs of deterioration due to atmospheric corrosion and mechanical
damage.
External corrosion takes place in humid areas and in areas where corrosive chemical
vapours are present. External corrosion can be determined by visual inspection.
b) Weld Joints
The weld joints shall be checked visually for cracks. In case of doubt it should be
checked by dye penetrant test.
c) Ultrasonic Inspection
Thickness measurement of the shell and domes may be taken from outside. Exact
location of thickness measurement may be decided after internal inspection only.
d) Fire Proofing
LPG Bullets and spheres having fire proofing on the outside surface shall be examined
for cracks, spalling, bulging and deterioration of fire proofing. Appearance of rust
stains on the surface of fire proofing is an indication of presence of corrosion of
metal underneath. If above indications are apparent the fire proofing in suspected
areas shall be removed and the external surface shall be inspected for any corrosion.
viii) Internal Inspection
Pressure vessels entry shall be made only with an applicable work permit.
The pressure vessel shall be examined from the outside to detect any unusual
condition during operation, the condition of the bolts and flanges, the apparent
condition of insulation and any other visible defects. Preliminary inspection will
also reveal the areas having deposits, scales etc. requiring thorough cleaning
to detect metal wastage underneath the deposits during detailed inspection.
All weld joints shall be checked internally by wet fluorescent magnetic particle examination
to detect cracks due to stress corrosion cracking, once in ten years, besides the normal
inspection.
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SAFETY RELIEF DEVICES
The safety relief valves on the pressure vessels should be tested once in a year by a
competent authority approved by CCOE and records maintained.
Hydrostatic Test
Hydrotesting of vessels shall be carried out once in 5 years. After satisfactory inspection
and radiography, the vessel is hydrostatically tested at a pressure calculated by applicable
code. The pressure should be held for a minimum of 30 minutes. During hydraulic
testing the pressure gauge should be installed at the highest point. It is recommended
that two pressure gauges be used. The range of the pressure gauge should be 30% more
than test pressure and calibrated pressure gauges shall be used.
DOCUMENTATION
Observations of each inspection shall be properly recorded and history cards maintained.
4.3 MOUNDED LPG STORAGE
4.3.1 Design code
ASME SEC. VIII or BS - 5500 or equivalent duly approved by CCOE.
A typical LPG Mounded storage is designed as per the following parameters
DESIGN CODE : ASME SEC. VIII or BS – 5500

Design Pressure 14.5 kg/cm2 at 55 deg C
Design Temperature -27 deg C to +55 deg C
Corrosion allowance Min 1.5 mm
Radiography Full
Stress relieving 100 %
Earthquake pressure As per IS 1893
Hydrotest pressure As per design code
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4.3.2 Design Criteria
The external surface of the vessels that are mounded should be suitably treated to
protect them from corrosion. Methods of protection shall include surface coatings (suitable
for design conditions as specified above) and cathodic protection (Impressed current
system).
The cathodically protected vessel shall be isolated from the unprotected structures /
surfaces by installing monolithic joints i.e. one each on liquid and vapour lines. A suitable
isolation shall also be provided on utility pipe lines etc(such as air line to ROV)
Reference points on inner surface of the vessel shall be marked for NDT, for subsequent
inspections.
Mounded vessel(s) should be placed on a firm foundation and installed so as to prevent

movement or floatation . The foundation should be constructed such that in the
longitudinal direction of a vessel slope of at least 1:200 is maintained to facilitate
draining of the vessel. Reference may be made to attached Drawing 1,2 & 3.
The sub-soil water, rainwater or any other surface water should not be allowed to percolate
in to the mound.
The foundation should have sufficient load bearing capacity.
The following factors affecting the foundation should be considered while designing;
a) The load of the vessel during normal operations and also during hydro test when the
specific gravity of liquid is 1 (one) instead of that of LPG.
b) The earth/sand cover

c) The settlement behavior of the foundation which include
i) Overall settlement
ii) Differential settlement which causes bending of the vessel
iii) Differential settlement which causes sloping of vessel
The mound should protect the vessel from the effects of thermal radiation and should be
sufficiently robust to remain in place in the event of jet flame impingement.
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Mounding material shall be earth, sand or other non-combustible, non-corrosive materials

such as Vermiculate or Perlite and shall provide at least 700 mili-meters minimum thickness
of cover for the container.
The earth cover shall be protected against erosion by rain or wind by providing a suitable
protective cover such as covering with pre-fabricated stone elements, open concrete
tiles.
Moisture ingress into the mound shall be minimised by a suitable method to check the
corrosion by providing impervious layer with a suitable material. Proper drainage and
slope on top of the mound shall also be provided to achieve this objective. However a
continuous impermeable cover shall not be installed, to prevent the possibility of gas
accumulation inside the mound.
Where the vessels are installed parallel with ends in line, any number of vessels shall be
permitted to be in one group.
Where more than one row is installed the adjacent ends of the vessel in each row shall
be separated by not less than 3 meters.
The valves and appurtenances of mounded vessel(s) shall be accessible for operation or
repair, without disturbing the mounding material.
Provision shall be made to monitor the settlements of the mound by providing permanent
reference point. A minimum of three reference points shall be installed to be able to also
identify possible vessel bending (One each near the vessel ends and one in the middle.)
Maximum permissible differential settlements shall be determined at the project

designing stage and procedures established to regularly monitor the settlement throughout
the lifetime of the vessel.
Proper provision shall be provided for inserting portable CuSO4 reference electrode on
top of the mound for measurement of PSP at 12 o-clock position of the vessel. This shall
be suitable sealed to prevent moisture ingress in the mound.
4.3.3 Fittings and instruments on a mounded vessel:
The following requirements are applicable up-to Fire-safe ROV (i.e. the valve connected
to the first flange of the vessel)
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The fire safe Remote Operated Shutdown Valve (ROV) on liquid drain line from the vessel
shall be either from bottom of the vessel or from the top of the vessel as per the design
considerations. However in case of provision of liquid outlet from the top of the vessel,
the same shall be through dip pipe.
In case of liquid drain line from the bottom of the vessel, the minimum distance of 3
meters from the vessel to ROV shall be maintained. The nozzle pipe shall have a slope of
1.5 Deg.
The top vapour zone of the vessel shall be provided with nozzles for vapour outlet and
re-circulation, which shall also be provided with fire-safe ROVs.
There shall not be any other flanges, or any other tapping up-to the ROV except in case
of liquid drain line from top of the vessel(s).
Minimum two nos. of manhole shall be provided on top of the vessel.
Each vessel shall have at-least two pressure relief valves. The full flow capacity of Pressure
Relief Valves (PRV) on mounded vessel(s) may be reduced to not less than 30% of the
capacity required for an equivalent size of above ground vessel.
In case of non-availability of flare system, the discharge from safety valve shall be
vented vertically upwards to atmosphere at an elevation of 3-meter (minimum) from
the top of the mound or exposed nozzle whichever is higher for effective dispersion of
hydrocarbons. In this case, isolation valves on down stream of PRVs are not required. A
weephole with a nipple at low point shall be provided on the vent pipe in order to drain
the rainwater which may get accumulated otherwise. Weephole nipples shall be so oriented
that in case of safety valve lifting and consequent fire, the flame resulting from LPG
coming out from weephole does not impinge on the vessel or structure. A loose fitting
rain cap with a chain (non-sparking) fitted to vent pipe shall be provided on top of PRV.
Each storage vessel shall have minimum two different types of level indicators and one
independent high level switch. High level alarms shall be set at not more than 85% level
of the volumetric capacity of the vessel.
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4.3.4 Operation, Maintenance and Inspection
The following provisions specific to mounded storage facility shall be followed and
respective records to be maintained:
The Safety Relief valves shall be tested and calibrated every year by a competent person
and records maintained.
Cathodic protection system, shall be maintained, tested and records maintained as follows
a) Pipe to Soil Potential (PSP) Reading
i) PSP readings at feeding points shall be monitored fortnightly.
ii) The PSP reading at the test lead points for entire vessel shall be taken once in a
quarter. The PSP survey results shall be plotted graphically to identify and locate
cathodic holidays. The minimum pipe to soil potential shall be more negative
than - 0.85 volts with respect to copper/copper sulphate half-cell. In areas where
anaerobic bacteria are active minimum PSP shall be more negative than - 0.95
volts instead of - 0.85 volts. Over protection of coated vessel shall be avoided
by ensuring that polarisation potential is below - 1.2 volts with respect to copper/
copper sulphate half cells. Polarisation potential can be measured at a given
location on a coated vessel by measuring pipe to earth potential immediately
(within the first second or two) after simultaneously interrupting the current
output from all cathodic protection sources affecting that portion of the vessel.
iii) The PSP readings shall also be recorded on weekly basis with respect to permanent
Zinc reference cell.
iv) The polarisation cell shall be checked for replenishing the liquid levels(KOH)
v) The protective current shall be monitored every quarter
b) Insulating Joint/Coupling Inspection
Insulating joints and couplings shall be inspected once in a year.
The settlement of the vessel shall be monitored on half yearly basis.
A vessel shall be subjected to hydro test once every 10 years or at every welding
to the vessel (repairs or new connections) whichever is earlier, by a competent
person and records maintained.
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Mounded vessel shall be tested once in every 5 years internally using visual and other
techniques for the following:
a) All the weld joints of the vessel shall be examined through Non-Destructive Testing
(NDT) techniques e.g., radiography, Wet Magnetic Particle method (WPT), Dye
Penetration Test (DPT), hardness, ultrasonic flaw detection to ensure the integrity
of the joints.
b) The wall thickness of the vessel shall be measured ultrasonically.
For (a) and (b) above other established NDT techniques may be used for example
acoustic emission testing.
Note: - In case of any indication of defect or doubts about any defect , the mound
cover of the vessel shall be removed to expose the outer surface for
necessary examination from outside.
If internal access to mounded vessel is not possible, the external surface of the
vessel will need to be exposed to enable examination
Any repairs or modifications undertaken should be after statutory approval from

applicable authority.
Draining
Bullet draining operations is to be carried out before commencement of daily
operations under the supervision of Shift Officer and records to be maintained.
The same is also to be carried out whenever there is a change in vessel for filling
operations. Detailed procedure outlined in Chapter on filling operations.
Gauging
Gauging operation has to be carried out at the beginning and end of each day and
records to be maintained in gauge book. Along with the gauge, temperature, pressure
and density as per IS 4576 and as outlined in LPG quality manual shall also be
recorded.
Valves operation
At the end of operations, it has to be ensured that all isolation valves including
ROVs are in closed position. Preferably separate vessels to be used for cylinder
filling and tanker decanting operations.
Stock Calculation:
Refer chapter no. 6 on stock calculation procedures to be followed.
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4.4 REFRIGERATED STORAGE
4.4.1 Design Code
Refrigerated LPG storage is designed as per International Codes API 620, 650 and 2000,
ASME Section II, V & VIII and interdistances as per NFPA – 58 and other distances as per
OISD 144.
4.4.2 Design Criteria:
Tank shall be double walled metallic type secondary containment concept i.e; outer tank
shall be able to contain liquid stored in inner tank.
Outer tank shall be designed to contain liquid and to contain the vapour phaseof the
tank at the design pressure. It shall be made of carbon steel and shall consist of
o flat bottom
o cylindrical wall
o outer dome roof
Inner tank and suspended roof shall be designed to contain stored liquid and shall consist
of
o Flat bottom
o Cylindrical wall
o A flat deck made of aluminum or carbon steel, suspended from outer dome roof by
suitable rods loosely fit to tank wall to allow vertical and horizontal movement and
designed to support the roof insulation.
a) Tank foundation
Tank foundation shall be designed based upon reports of soil investigation. Tanks shall
be supported by suitable reinforced concrete slabs supported by piles.
b) Anchor bolts
Anchor bolts to prevent uplift shall be provided which shall allow tank radial contraction
and expansion without obstruction during operation.
c) Insulation
Tank insulation shall consist of
o A Bottom insulation installed on outer tank bottom and supporting the load of the
tank and the stored product
o A shell insulation
o A roof insulation laid on the supported deck.
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d) Nozzles and accessories

All connections to and from the inner tank shall be installed through outer tank roof and
suspended roof or thorugh the tank bottom. There shall be no nozzles on inner tank
shell.
Outer tank shall be provided with all necessary platforms, stairways, walkways and
handrails for access to all accessories etc and shall be designed as per API 650.
e) Control and safety equipments

Control and safety equipments shall be designed for remote operations as required by
relevant codes .
Each tank shall be provided with

- a chain of thermocouples for measurement of inner tank bottom, shell and roof
temperatures ( a minimum of 12 sensors)
- a chain of resistance temperature detectors set along a vertical support for
measurement of liquid temperature ( a minimum of 12 sensors)
- a density temperature measurement system by means of a detector automatically
moving a vertical support in set increments.
Each tank shall be provided with

- a floating level instrument for normal operation
- a second level instrument of DP cell type
- a high level detector of magnetic type or equivalent
Tanks shall be provided with

- A high and low pressure system control loop allowing venting of tank to atmosphere
at high pressure level and supplying tank with makeup gas at low pressure level
- A set of pressure safety valves pilot monitored
- A set of vacuum safety valves
f) Heating / foundation system :

If the type of foundation does not allow natural venting of the slab, each tank shall be
provided with an electric heating slab system. The design shall be so that temperature
in the slab shall be maintained at a value of +5 deg C maximum.
Heating shall be made by means of resistance monitored by temperature sensors installed

in sheaths laid across concrete slabs and allowing the maintenance of the equipment.
The equipment shall conform to electrical area classification. It shall be protected from
atmospheric moisture.
Hydrostatic and pneumatic tests as per API 620 R shall be carried out and the tests to be
done before application of shell and roof insulation.
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REFRIGERATED LPG STORAGE TANK
REFRIGERATED LPG STORAGE TANK – CROSS SECTION
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4.4.3 Operating Procedure
1 SHIP LOADING : Before unloading refrigerated liquefied petroleum gas product from
a storage tank to an export ship, the loading line should be cooled from ambient to
loaded product temperature. This action minimizes the LPG evaporation during ship
loading. Pre cooling the LPG transfer / loading lines is a common practice.
The cooling operation is accomplished by running a small stream of refrigerated product

through the loading line. The partially or totally vaporized fluid is recycled to the storage
tank through a cool down return line.
2. TT LOADING : In case of loading from the refrigerated storage tank to road TTs
the loading line should be pre heated using water / steam to a temperature of 12 0 C to
facilitate further handling of product for subsequent operations.
4.5 CAVERN
The underground storage of liquid and gaseous hydrocarbons is based on a principle of natural hydraulic
containment.
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In an oversimplified way this is expressed by the principle that for the cavern to be leak-tight (meaning
to ensure the containment of the stored product) the pressure in the cavern has to be lower at any point
of the cavern wall than the pressure of water in the rock mass at the corresponding point. However, the
real hydraulic containment principle is based on a potential criterion rather than on a pressure criterion.
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SCHEMATIC SECTION OF LPG CAVERN STORAGE
4.5.1 The hydraulic containment principle
The rockmass in which the cavern is excavated is a fully water saturated rockmass. This
means that it is situated below a permanent water table (it is termed an aquifer, in
particular when its water yield possibilities are high.).
If one opens a hole in such a rock mass and fills it with hydrocarbons:
- the liquid hydrocarbons being non miscible with and lighter than water will not penetrate
the saturated rock unless they are pressurized above the water pressure,
- the gaseous phase is contained by two complementary mechanisms:
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- for the smaller pores and fissures, the gas is prevented from entering the rockmass
by capillary pressure (the fact that the water sticks to the pores and cracks, when
they are sufficiently narrow, and cannot be easily moved) as long as a given maximum
gas pressure (the threshold displacement pressure) is not exceeded,
- for the larger voids and fissures, where capillary pressure is negligible or
non-existent, by the water flow.
4.5.2 Design code
Construction of underground cavern shall be governed by various geotechnical /

Seismological / mining codes applicable.
Product stored in cavern shall conform to the Liquefied Petroleum Gas specification and
to Indian Standard IS 4576-1999.
4.5.3 Design criteria
Mined caverns used for the storage of hydrocarbons are usually excavated in hard rock.
The rockmass hosting the cavern cannot be considered as impervious to liquid or gas
(except in few cases of clay or clay-rich rock and rock salt) because of the many defects
-or potential defects- affecting it naturally (pores and fissures) or created by the
construction process (cracks from blasting for instance).
In practice, the tightness cannot be ensured by rock improvement techniques such as

grouting or by lining, because of the unreliability of the techniques and/or their high
cost (steel lining of the underground cavern, for instance).
The storage capacity of the underground LPG storage can be in the range of 60,000 to
400 000 m3, plus 3 % allowance for minimum vapour space.
4.5.4 Operations
LPG is received either from large fully refrigerated ocean tankers up to 50 000 metric
tons capacity with separate propane and butane tanks, or from small pressurized ships
of typically 6000 tons capacity.
Onshore new receiving facilities shall include boosting pumps, a propane/butane mixing
unit, a seawater heater, an ejector at cavern inlet and a vertical fill-line down to storage
galleries.
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Sea tankers tank gauging will be used to measure LPG quantities received and exported
from/to ship, while quantities exported to refinery will be measured by mass meters. In
addition, mass meters will be used for ship export but only for comparison with ship
tanks gauging.
Seepage water accumulating in the storage galleries is regularly pumped out by submerged
pumps. LPG dissolved in seepage water is removed through an air-stripping column
before disposal to the sewage system.
The following Cavern parameters are to be continuously monitored :

- LPG and water levels
- Cavern pressure
- Seepage water flowrate evolution
a) LPG level
The LPG level is continuously measured by a plunger system inside a dedicated

casing installed in the access shaft.
The reading will be displayed on cavern control Distributed Control System (DCS)
view.
At regular intervals, typically every hour, the plunger system located in the operating
shaft and normally assigned to water level measurement, will be raised to check LPG
level. In case of discrepancy between both values, an alarm will be generated on the
DCS.
The LPG level is also monitored by means of capacitive probes on the level alarms
string inside the operation shaft. In normal operation, the level must always remain
below a very high level corresponding to a gaseous phase occupying 3 % of the total
cavern volume, in order to avoid cavern overfilling.
This is achieved by automatically stopping ship unloading when very high LPG level
is reached on either of the two plunger systems. The level alarms string (capacitive
probes) will only generate an alarm when very high level is reached.
An alarm will be generated at LPG high level, i.e. 0.3 m below very high level to
warn the operator that the maximum allowable capacity is about to be reached. This
will imply to follow a specific operating instruction including flowrate reduction and
checks of LPG level versus received quantities at regular time intervals.
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LPG level must also remain above a minimum level to provide a sufficient pressure
at LPG submerged pumps suction. This is achieved by automatically shutting down
the LPG pumps at very low LPG level (initiated by either plunger system). An alarm
is generated at LPG low level, 0.2 m above very low level to warn the operator that
the minimum allowable levels is about to be reached.
b) Water level
Water level control by seepage water pumps shall be carried out.
c) Cavern pressure
Cavern pressure is constantly monitored in control room.

The operator also has access to cavern pressure history curves to monitor pressure
variations and check correlations with import/export movements.
In order to protect cavern against overpressure, LPG receiving is automatically shut

down on very high pressure, at M.O.P. (Maximum Operating pressure). A pre-alarm
is initiated at high pressure, 20 kPa below M.O.P.
An ultimate overpressure protection is provided by cavern Pressure Safety Valves

(PSVs) set at cavern M.A.W.P. (Maximum Allowable Working Pressure) equipped
with a flow switch at their discharge that also automatically triggers LPG receiving
shutdown.
During LPG receiving, injected liquid flows through ejector whose function is to
draw vapour from cavern to prevent pressure build-up due to gas compression.
A controller on the vapour line will automatically adjust gas flowrate to maintain a
constant cavern pressure equal to set point fixed by the operator.
d) Seepage flowrate evolution
The seepage water flowrate is monitored daily. It is determined by dividing the

volume of water evacuated during a pumping operation by the time elapsed since
the end of the last pumping operation.
In case of abnormal values, not correlated with cavern pressure variations, level
systems will first be checked. If levels reliability is confirmed, piezometer and water
table levels variations during the same period will need to be analysed.
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e) Stock accounting & Inventory
Cavern inventory must be performed on a regular basis. It is generally carried out

daily after all movements are stopped.
A dedicated software will calculate the LPG mass stored in liquid and vapour phase
in the cavern from the following measured parameters:
- LPG level in cavern

- Water level in cavern
- Temperature of liquid and vapour propane.
- Cavern pressure
- Density of stored product deduced from measured composition of outgoing
product.
The accounted stock is calculated by adding to the initial stock value, received
quantities obtained by differential ship tanks gauging and subtracting quantities
exported to refinery (obtained from Mass Flow Meters )/ or to ship (by ship tanks
gauging).
Discrepancy between accounted stock and cavern inventory is monitored every day
to detect possible anomalies coming either from the metered quantities or the level
systems.
f) Products quality control
Received LPG will be checked to conform to received products specifications e.g. on

vapour pressure or composition, by taking samples from ship tanks and analysing
them with site laboratory to ensure that the product quality conforms to the
requirements of IS 4576 - 1999, prior to starting ship unloading, with special attention
to corrosion copper strip test (ASTM D 1838), sulphur test (D 2784) and hydrogen
sulphide test (D 2420) to avoid a storage pollution
Before ship loading, remaining product in ship tanks will also be analysed to check
its conformity to loaded product specification.
Product exported to ship and/or refinery will continuously be analysed using an on-line
chromatograph at submerged pumps discharge. Product’s conformity to loaded product
specification will be checked.
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g) Pressure relief
Thermal expansion and fire case

Thermal expansion pressure safety valves (PSV) are installed on all LPG line sections
possibly blocked between valves. They shall discharge into a common header connected
to cavern vapour phase via the vent casing to avoid regular and possibly significant
LPG release to atmosphere. Set pressures shall be just above the Maximum Operating
Pressure at their location. Pilot-operated valves are selected to compensate for the
varying cavern backpressure.
Protection against fire shall be ensured as follows:
- Pressure vessels:
PSVs are calculated for the fire case and discharging into the vent stack network.
This applies to dryers, heat exchangers and gas separators on metering units.
- Lines:
PSVs protecting line against thermal expansion shall be sized to handle the fire
case.
With this philosophy, the pressure in the lines is maintained below approximately
50 % of the design pressure (2500 kPa g for approximately 5000 kPa g) even in the
fire case, and the release of large quantities of LPG to atmosphere via the cold vent
which constitutes a hazard in itself is avoided.
4.6 FITTINGS AND ACCESSORIES OF STORAGE VESSELS
4.6.1 Safety Relief Valves

Spring-loaded safety relief valves designed for LPG service are provided with five
basic parts; body, seat disc retainer, resilient seal, spring and spring-adjusting means.
A resilient sealing device is required within a safety relief valve in order to prevent
leakage of LPG when the unit is in a closed position.
The relative position of the safety relief valve spring determines the design configura-
tion of the valve and predetermines the type of installation which is used.
An “Internal spring valve” is provided with a spring positioned on the upstream side of
the valve seat. When installed, the spring is located within the tank or manifold.
One modification of this design permits the removal and replacement of the resil-
ient sealing disc without removing the tank contents.
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In the “External spring valve” the spring is located downstream from the valve
seat. Therefore, the valve body and all other functional parts are installed exter-
nally with respect to the tank.
SCHEMATIC DIAGRAM OF OPERATION OF SAFETY RELIEF VALVE
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Installation
All tank safety relief devices shall be located on the tank and have direct communication with the vapour
space of the container.
Shutoff valves shall not be installed between the safety relief device and the tank, or the equipment
or piping to which the safety relief device is connected, except that a shutoff valve may be used
where the arrangement of this valve is such that full required capacity flow through the safety
relief device is always afforded.
Safety relief valves shall be arranged so the possibility of tampering will be minimized. If pressure
setting or adjustment is external, the relief valve adjusting means should be permanently sealed in
place.
The discharge from the safety relief valve shall be vented away from the container vertically upward
to a point at least three meters above the container and unobstructed to the open air in such a
manner as to prevent any impingement of escaping gas upon the container.
If a drain is used, a means shall be provided to protect the container, adjacent containers, piping
and equipment against impingement of flame resulting from ignition of product escaping from the
drain.
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Vent stacks or vent piping attached to the outlet of safety relief valves should be properly supported
in order to prevent damage to the safety relief device.
Setting
Each safety relief valve (having 100% relieving capacity) shall be set to start-to-discharge at a pressure
not in excess of 110 percent of the design pressure of the vessel and shall have a total relieving capacity
sufficient to prevent the maximum pressure in the vessel of more than 120 percent of the design pressure.
Each safety relief valve shall be provided with isolation valve between it and the vessel. Each valve shall
be of adequate capacity to allow full required capacity flow through it. Suitable provision to avoid accidental
closing of the isolation valve is recommended.
4.6.2 Liquid Connection Valves
a. Excess Flow Check Valves
Excess flow check valves, when installed in liquid connections, will permit the
free flow of liquid into the tank and will close or stop the flow of liquid out of
the tank when a predetermined rate of flow has been reached. After closure has
been effected, a bleed stream will still persist through the valve because this
stream is necessary to equalize pressure on the upstream and downstream sides of
the valve should it close due to surging within a closed piping system.
A sudden surge or increase of flow through an excess flow check valve may be
sufficient to cause closure under normal operating conditions. If this occurs, it
is necessary that the system be closed downstream of the excess flow check valve,
allowing sufficient time for pressure to equalize across the valve.
Because of this operating characteristic, it is customary to size an excess flow

valve with a closing capacity equivalent to 150% to 200% of the maximum flow
rate anticipated under normal operating conditions.
While excess flow check valves may have limited utility in other operating areas, it
is not a recommended device for a liquid outlet of a stationery bulk storage
tank.
b. Non Return Valves
These are of swing-type and bolted-cover construction. They conform to BS 1868

and also meet the general requirements of API 600, including shell wall thickness.
This features a seal-welded seat ring that gives a leakproof design as it eliminates
the leakage path between the seat ring and body.
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c. Shutoff Valve
Gate Valve, Plug Valve and Globe valves, quick-acting ball valve & disc valves
may be used as shutoff valves adjacent to liquid connections in containers. This
type of valve is used to provide means for isolating the tank from the remainder
of the piping system.
Gate and Globe valves are dependable devices capable of forming a gas-tight
seal even after being used for long periods of time. However, because of their
design, relatively high flow resistance is developed in these units, therefore, a
valve with a lower resistance factor is preferable.
Ball valves and quick-acting disc valves offer a minimum of restriction since,
when they are in the open position, a number of models offer porting which is
approximately the same inside diameter as the attached piping. Straight through
flow naturally results in a minimum of restriction.
Plug valves offer reasonably low flow resistance and may be utilized to particular
advantage in larger size.
ROV / MOV ( Plug / Ball Valves):These valves are used as the main shutdown valve in
all plants for isolating storage vessel from other facilities like pipelines etc. ROV’s
operate on Electro-Pneumatic principle and MOV operate on Electrical supply of 3
phase 415 V. Both the valves can be operated remotely.
ROV: The basic operation of the valve is pneumatic with spring loaded actuator.
Normally the valve opens on air supply and closes on release of air. This action of air
supply and release is achieved by providing a flameproof solenoid valve. The time
taken for operating this valve is very less. The bottom may be plug / Ball valve and
the top actuator unit is attached with the the valve operating lever.
MOV: The basic operation of the valve is Electrical operated motor actuator along
with gear box and suitable adaptor fitted on the valve operating lever. However this
kind of valve operates slowly when compared to ROV. This requires 3 Phase 415 V
supply and the actuator fitted is of Flameproof suitable for usage in Gr. II A & II B.
The actuator will have a provision to operate the valve manually with a handle in
case of power failure / repair of actuator.
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GATE VALVE – SECTIONAL VIEW
GLOBE VALVE –SECTIONAL VIEW
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EXCESS FLOW CHECK VALVE – SCHEMATIC DIAGRAM
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4.6.3 Vapour Connection Valve
a. Excess Flow Check Valve:
An excess flow check valve in a tank vapour connection will permit the
unrestricted flow of vapour into the tank and will automatically close when the
flow of vapour from the tank exceeds a predetermined rate.
In order to ensure that the excess flow check valve does not close as a result -
of normal operations or rapid opening of a shutoff valve, a device must be
selected which has a predetermined closing flow rate considerably in excess of
the maximum anticipated operating flow rate.
In view of the operating difficulties which may be experienced and the

questionable safety which may be developed through their use, it is recommended
that excess flow check valves be utilized in connections smaller than 1-1/4
inch (31.75mm) pipe size.
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b. Shutoff Valve
In addition to the excess flow check valve installed within the vapour connection
of the tank, a positive shutoff valve should be installed adjacent to the connection.
A sufficient length of pipe with a union or a spool piece should be provided so
the shutoff valve can be disconnected from the tank vapour connection and
the ends of the line plugged, capped or fitted with a blind flange.
A ball valve, a quick-acting disc valve or a plug valve can be utilized at this
point. If globe or gate valves are readily available, they may be utilized in
vapour lines since the restriction which they cause will not be particularly
objectionable provided there is adequate line size.
4.6.4 Gauges
a. Roto Gauge
A roto gauge is in effect a sensing device in the form of a tube formed so it may be
rotated through the tank from top to bottom. As the outer end of the tube passes
through vapour space, a vapour discharge will be noted at the outer extremity of the
gauge through a small bleed valve. As the end of the tube enters the liquid , liquid
discharge will be noted. By observing the position of the gauge pointer on the
percentage dial, the liquid level can be determined.
The accuracy of this type of device is dependant upon the alignment of the gauge
when installed & the ability of the gauge tube to retain its original form. A rotogauge
is considered to be a satisfactory optional device for the determination of the liquid
contents of a tank.
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b. Slip Tube Gauge
A slip tube gauge is another tubular device which may be withdrawn vertically
from the top of the tank for the purpose of determining whether the tank content
is in liquid or vapour form at the inner end of the gauge tube. As the tube is
withdrawn and the liquid level is determined, measurement of the tube from
predetermined reference marks will readily indicate the liquid outage or vapour
space within the tank.
Because of the construction of the gauge, a tank greater than 2 meters in diameter
will usually be fitted with two slip tube gauges; one device capable of measuring
the contents of the lower half of the tank, while the second gauge sensing in the
upper half of the tank.
A slip tube gauge, because of its simplicity and design form, is inherently accurate
and can be used for extended periods of time without tests, or recalibration. It
is, however, a rather awkward device to use and may, under certain
circumstances, be dangerous if the user exposes his person to the gauge should
it be accidentally expelled from the tank when initially released.
The device is a satisfactory gauging means and if utilized-properly can function

for years with a minimum of attention. It is considered a satisfactory optional gauging
device.
c. Visible Float Gauge (Rochester Gauge)
A visible float gauge is an automatic gauging device with a counter-balanced

float supported by the liquid level within the tank. The movement of the float and
counter-balance shaft is transmitted to a magnet located immediately to the
rear of a solid metal section supporting the gauge dial on the exterior of the
tank. The indicator on the gauge dial is a magnet or is attached directly to a
magnet which is free to rotate on a pin in the middle of the dial. As the float
moves, the attached magnet duplicates the motion; the magnet, in the form of
an Indicator, follows the movement and by observing the indicator on the dial,
the liquid level within the tank can be determined.
The use of this type of device is widespread and generally accepted. While, in
some instances, the accuracy of the device may be questioned, it does provide
convenient means of determining the approximate liquid contents of a tank.
When used in connection with a fixed liquid level gauge, it provides an efficient
method for the filling of a tank.
The accuracy of this type of device can be determined by comparison of gauge

readings with fixed liquid level gauges.
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A visible float gauge is considered to be a satisfactory device and its inclusion

in a bulk storage tank is recommended.
d . Differential Pressure Type Gauge
The principle applied is differential pressure. The pressure at the top of storage
tank is vapour pressure while at the bottom of tank is vapour pressure plus
pressure exerted by liquid column. Two tappings are taken - one from top of
tank and one from bottom of tank and connected to a sensing device. The net
pressure at the sensing device is equal to the height of liquid column. The sensing
device gives the indication in form of % of height of ‘liquid as compared to total
height of storage tank which in turn can be converted into the actual height of
liquid column
DPT gauges are being calibrated assuming fixed density. However, density of
LPG which varies with composition, temperature etc. This limitation can be
eliminated by taking density using online density meter while calibration.
e . Servo level Gauges
Servo gauges is an improvement of conventional type of float gauges. In these

gauges, liquid level is detected by digitally controlled electro servo balancer type, in
combination with small size displacer, measuring wire and wire drum. A displacer is
attached to one end of measuring wire that is wound onto measuring drum which is
connected to driving shaft, stepping motor and worm gear through spring. Displacer
always follows liquid surface with stable draft line. Rotating angle of measuring
drum which corresponds to length of unwound measuring wire, represents height of
liquid in the tank.
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SERVO GAUGE
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SCHEMATIC DIAGRAM SHOWING WORKING OF SERVO GAUGE
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f. Radar level Gauges
This is the most modern gauging system with the highest accuracy because no
mechanical parts are involved. Radar (Radio detection and Ranging) detects
and measures the distance between the level gauge (located on the top of the
liquid storage tank) and the liquid surface. A pulse is emitted from the Radar
antenna, is received and is reflected back to the same antenna by the liquid
surface. The resulting time-of-flight is a parameter defining the distance
between the top of the tank and the liquid surface (Ullage / outage ) or the
liquid level.
Based on the above principle, there are two types of Radar level gauges in use.
- Synthesised Pulse Radar (SPR)
- Frequency Modulated Continuous Wave (FMCW)
a. Synthesised Pulse Radar (SPR)
Pulse radar system was the first commercially available radar system. During
a short time span (a pulse), a constant radar frequency is sent towards the
object . This signal is reflected by the obstacle and arrives at the radar an-
tenna again. The time required to travel towards the object and back again is
called the time of flight and is a parameter to measure the distance.
Mainly due to high radar propagation speed ( which is the speed of light in
vacuum), pulse radar systems started to find their way in the area of long
distance measurements. For an empty tank of 15 m, the time of flight will be
about 0.000 000 048 seconds. When the tank is filled this time of flight is
again getting deceased further. So for measuring tank gauges with high accu-
racy of 1 mm has become difficult task for this type of gauges. This led to the
development of other radar systems using the frequency difference as param-
eter.
b. Frequency Modulated Continuous Wave (FMCW)
Radar gauge transmits a signal towards the surface of the liquid with a continu-
ously varying frequency(9.7-10.3 GHz). Reflected signal is mixed with the signal
that is being transmitted at that moment results in a signal with low frequency.
Difference between transmitted and received frequency is proportional to the dis-
tance to the surface.
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WORKING PRINCIPLE OF FMCW SYSTEM
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4.6.5 Pressure Gauge
Every vessel shall be fitted at the vapour space with at least one pressure gauge capable
of indicating the maximum pressure that may ever be anticipated within the unit.
4.6.6 Temperature Gauge
A temperature gauge with a range of 0 to 100°C should be available for insertion

within a thermometer well. A device of this type is recommended since it can easily
be calibrated and can be removed from the thermometer well and placed in a
protected location when not in use.
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LPG PLANT / TERMINAL OPERATIONS
Process
Identified P/L & N/L cylinders are diverted by operator to the machine.
Defective cylinder to be placed by the operator on the machine & clamping device to
be actuated to clamp the cylinder
On clamping the cylinder, operator to place the Machine head on the cylinder valve
for removal of the valve
Operator to actuate the head for clamping the valve & open it from the cylinder
On opening of the valve, torque head comes out with the defective valve & actuates
the limit switch to close the LPG chamber
Operator to take out the defective valve & place a sound valve on the torque head
The torque head is brought down through the control panel
During this process, through the limit switch Gas chamber opens up & allows the
placement of new valve for tightening
Torque is preset in the Machine at the specified limit
The Gas trapped in the chamber during opening & closing process is vented auto-
matically
The head is disengaged only after venting process is over
The process takes around 1.5 to 2.0 minutes & capacity of machine is defined as 35
cylinders per hour
5.3.14 SQC of filled cylinder :
Finally filled cylinders are further subjected to random checking during the course of
shift operation from time to time. The random checking as per existing guidelines
should be done for 2 % of filling per shift subject to minimum of 50 cylinders.
Necessary records to this effect should be maintained by the shift officer & counter-
signed by the plant manager on daily basis.
Any official visiting the plant from R.O./Zone/HQO should also carry-out random quality
check of filled cylinders.
The following parameters are checked during SQC of filled
cylinders
a) Weight of LPG in the cylinders
b) Next test due cycle for the cylinders
c) Leakage from cylinder valves
d) Leakage from valve o’rings
e) Quality of capping & sealing
f) Overall appearance of cylinders
Refer Annexure 6 for details of SQC format
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BULK STOCK MONITORING & INVENTORY MANAGEMENT
INDEX

6.0 General 1
6.1 Types of stock loss 1
6.2 Physical stock calculation 1
6.3 Bulk LPG receipt 2
6.3.1 Road fed location 2
6.3.2 Rail fed location 3
6.3.3 Pipeline receipts 4
6.4 Volumetric calculation for LPG stock in storage vessel 4
6.4.1 Measurement of LPG liquid by volume 4
6.4.2 Liquid equivalent of LPG vapour at observed temperature 6
6.4.3 Total volumetric quantity at 15 0C 7
6.4.4 Weight of the volumetric quantity in the sphere 7
6.4.5 Vapour / liquid volume ratios 9
6.4.6 Sample stock calculation table 10
6.4.7 Detail of break-up losses 11
6.5 Calibration of storage vessel 12
6.5.1 Responsibility 12
6.5.2 Calibration tables 12
6.6 Accurate gauging of vessel 13

6
6.6.1 Temperature measurement 13
6.6.2 Pressure measurement 14
6.6.3 Metering – Liquid LPG 14
6.7 Effect of density in volumetric calculation & stock 15

variation in LPG
6.8 Inventory Management 16
6.8.1 Inventory Management of Cylinders 16
6.8.2 Inventory Management of Regulators 16
6.8.3 Inventory Management of Valves 17
6.8.4 Inventory Management of Bulk LPG 17
6.8.5 Inventory Management of HSD & Lubricants 18
6.8.6 Inventory Management of Store Items 18
6.9 Bulk stock monitoring & Inventory Management in JDE system 18
6.9.1 Bulk stock accounting 18
6.9.2 Bulk receipt 20
6.9.3 Filling / Decanting 21
6.9.4 Inventory Management in JDE system 31
6.10 Cycle Count – LPG 34

6
6.0 GENERAL
Stock accounting plays a very important role in Plant operations and it is part of daily routine
activity. In the case of LPG bottling Plants/Installations, stock (product) inside the plant can be
in storage vessels, pipelines or filled LPG Cylinders. At the opening (beginning) & closing (end)
of the Plant operations, physical guage reading of all pressure vessels must be taken. Similarly,
physical inventory of filled & defective cylinders also be taken.
Stock accounting means computation of physical stock available in Plant, compare the same &
process necessary entry to bring book stock in line with physical stock. Stock accounting shall be
carried out after the closing of shift operation or prior to start of shift operation and accordingly
“Book stock” & “Physical stock” shall be tallied and variation (Loss/Gain) shall be calculated.
Stock variation is difference between physical & book stock. If physical stock at any particular
time is more than the stock available as per book stock, it is a case of Stock Gain and vice
versa. Necessary entries to be processed as per accounting system to tally book stock with
physical stock.
Stock calculation shall be done basis physical density , temperature & pressure observed by the
Plant at the time of gauging of storage vessel. If stock accounting is not properly done, it can
result in altogether wrong picture of stock position in the Plant. This can severely affect the
Product Planning & movement which is monitored by the controlling offices in line with Industry
Logistics Planning. Further huge losses on account of poor stock monitoring means irrecoverable
financial loss to the corporation.
Hence, book stock has to be in line with physical stock at the end of the day by processing
stock gain / loss entry in line with accounting procedure.
6.1 TYPES OF STOCK LOSS

Stock loss at LPG locations may be of two kinds i.e. Operational loss & Transit loss
A) Loss in operation - Operational loss occurs due to inherent losses during operational
activities, venting, behaviour & accuracy of weighing equipments etc. Maintenance of
equipment, operation of the Plant within specified parameters and safe operating practices
plays an important in controlling operational loss at LPG Plants/Installations.
B) Transit loss – Transit losses occurs in receipt of LPG at Plant/Installation thru various means
i.e. by ships/ocean tanker, by pipeline, by rail & by road.
6.2 PHYSICAL STOCK CALCULATION

By physical gauging of storage tanks, stock volumes to be calculated for LPG liquid as well as
vapour quantities. For physical gauging, readings are always to betaken on minimum two devices
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provided on storage vessels. However calculation is based on reading of one device & second
device reading acts as back up for cross verification
Gauge reading is to be taken twice as mentioned earlier (at the start of shift & at the close of
shift). However one reading be used for calculation on daily basis.
STEPS FOR CALCULATION OF STOCK ACCOUNTING
• Physical density to be taken at a particular time in the day with temperature (as per density
meter)
• Opening stock of bulk LPG to be taken
• Opening stock of filled good & defective cylinders to be taken
• Filling entries (good / defective) are to be processed
• Bulk receipt / dispatch entries are to be processed & accounted
• Evacuation of defective filled cylinders is to be accounted for
• Pipeline quantity (generally fixed) to be taken into account
• PRCN to be accounted on day to day basis
• Any product consumed for own use (TT70) i.e. for canteen, purging etc to be accounted for
• Any claimable transit loss (TT82) i.e. loss more than set limit received from T/T ( as per
transport contract agreement ) to be accounted for
• Any non-claimable loss (TT81) i.e. loss below than the set limit received from T/T are accounted
for
• Stock calculation is done in terms of weight only.
• Total loss is equal to operational loss plus non claimable transit loss
Note : Transit losses are the losses encountered while receiving the bulk LPG. It is difference
between shipped & received quantities
6.3 BULK LPG RECEIPT
6.3.1 Road fed locations
In case of Receipt through Roads, actual quantity arrived basis gross & tare weighment
of tankers at the locations. At present, permissible variation in weighment is 100 kg as
per agreement. In case, any variation more than 100 kg, the total quantity of short
receipt to be debited to the transporter and same to be treated as transit loss. In case,
any variation less than 100 kg, the loss to be borne by the receiving location as a part of
operational loss. Plant/installation shall analyse transit loss thru particular transport/
truck and take corrective action to eliminate such loss in transit. In case, it is established
that short receipt is uniform in all T/T and irrespective of transporter/truck, the receiving
location shall verify the weigh bridge thru standard weight/take up with shipping location
as a case may be for corrective action.
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6.3.2 Rail fed locations

In case of Receipt through Rakes, actual quantity received to be arrived as
below
I. Through In-motion Weighbridge, if the same is available at location
II. Through Mass Flow meters, if the same is available at location
III. Otherwise through Gauge reading of the storage vessel
Quantity received through above process shall be compared with dispatch quantity. In
case, variations observed, then unloading locations should take up with the loading
location for corrective action.
In case, no positive response is found or improvement is found in subsequent rakes,

unloading location shall send their representative to witness the loading at loading location
and find out any discrepancies found in the process / variation observed in receipt. This
will help the locations to resolve the stock loss on receipt of LPG through rakes.
At many times, No. of wagons are found to be missed from the rake dispatched from
loading location, missing wagons to be handled as below:
a. On receipt of the rake, Wagon numbers to be tallied with the dispatch documents.
Immediate information memo to be sent to the local railway station regarding non
receipt of particular wagons .Acknowledgement of the station master to be obtained
on this. Copies of RR, intimation memo to the railways along with claim letter to be
send to our Zonal claim section to enable them to lodge claim with the railways.
b. Quantity received in such rakes to be punched on actual basis, except the quantity
of wagon not received. This will enable the system to generate unmatched entry
ensuring system control over the receipt.
c. In case wagon is received at a later date, then the quantity to be accounted for and
claim section to be advised on receipt of such wagon to reverse the claim.
d. In case OMC receives such wagons, then joint certification is to be obtained from
recipient company. PDR to be generated and acknowledgement to be obtained from
the receiving company. PDR in original and JC to be sent to the Oil Exchange section
for regularizing this exchange.
e. Railways claims for any missing wagons is time barred by six months. Hence claim
should be lodged to the railways without fail within the time period.
f. On receipt of claim from railway, the same shall be accounted during the month.
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6.3.3 Pipeline receipts
In case of pipeline receipt, product is received thorough custody mass flow meter.
Transporter company (presently GAIL) provides mass flow meter in the receipt line known
as a custody mass flow meter. Further there should be mass flow meter from operating
company as a check meter for cross verification. The check meter has to be same
make, range, and accuracy to ensure that both the meters are in same line of operations.
Quantity received through custody meter shall be taken as receipt quantity
In case variation custody meter and check meter is beyond specified limit as per the
agreement between the companies, the same should be taken with the companies for
appropriate action.
In case of variation is beyond the specified limit and transporter is informed appropriately
in time, the transporter should analyse the same and advise the TOP / take corrective
action to rectify the meters. Otherwise, quantity beyond the specified limit should be
claimed from the transporter.
However, storage tank gauging has also to be taken to arrive at the quantity received
through pipeline transfer and also to arrive at stock loss calculation. Variations in receipt
through meters vs gauge reading also can be arrived through this process. However,
use of this data to be limited to monitoring and corrective action.
6.4 VOLUMETRIC CALCULATIONS FOR LPG STOCK IN STORAGE VESSELS
6.4.1 Measurement of LPG liquid by volume

The accurate measurement of LPG liquid by volume can be accomplished by correcting
the volume of gas as measured at an observed temperature to the volume which would
exist at the standard base temperature of 15 oC. In order to make this volume corrections
it is necessary to know the density of LPG liquid at 15 oC. The density depends upon the
composition of the LPG, in other words it is dependent upon the proportions of propane
and butane within the product.
The density may be determined by any one of the following methods:
• By laboratory measurement with a density apparatus.
• By the standard method of test for density of light hydrocarbons by pressure

hydrometer
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• By referring to the documents covering the shipment or specification laboratory test

report provided with the shipment.
As source of product may be multiple, temperature & pressure may be different ,

it is preferable that each location should take physical density and record the same
in the gauge book.
Briefly determining the density by laboratory methods consists of weighing a specific

density apparatus containing LPG at a temperature of exactly 15 oC, and again weighing
the same apparatus when filled with water at exactly 15 oC. The weight of the empty
apparatus is then subtracted from each of the above total weights to give the weights of
the liquids. The ratio of weights of the LPG to the weight of water defined as density
and stated as density at 15 oC.
LPG of different densities will expand or contract in varying amounts as the temperature
is raised or lowered. This change in volume, as the temperature changes, is measured
by the co-efficient of thermal expansion. In general, it can be said that the lower the
density the greater the expansion or contraction or the greater will be the value of the
coefficient of thermal expansion. The multiplying factors in ASTM-IP table 54 (Annexure
VII) are based on this relationship between density and temperature. Referring to ASTM-
IP table 54 it can be seen by comparing the volume correction factors that the expansion
is considerably larger for propane than for butane over the range of atmospheric
temperature. It is therefore necessary to correlate the multiplier with the density of the
liquid at the base temperature of 15 oC. The observed volume (actual volume measured)
multiplied by the factor directly opposite the observed temperature at the time of
measurement equals the corresponding or correct volume at the base temperature of 15
o
C.
For example, consider a LPG storage container with butane-propane mixture, the density
of which is known to be 0.560 at 15 oC. The temperature of the liquid is measured and
found to be 26 oC. At the same time the tank gauge indicates a volume of 1000 litres
liquid within the vessel. The factor selected from ASTM Table 54 should then be 0.975
and the net volume at 15 oC is 1000 x 0.975 or 975 litres.
When the temperature of liquid changes, the volume of the LPG changes as discussed
above. Likewise, the density will change. Table 53 of ASTM-IP (Annexure VII ) is used to
convert the observed (measured) density at the liquid temperature to the corrected
density at 15 oC. Consider as an example a LPG storage container with butane-propane
mixture the density of which is unknown. However, the density may be determined with
a hydrometer and found to be 0.550 at 26 oC. Table 53 may then be used to convert this
reading to the corresponding density at 15 oC. Find the column for 0.550 in the “observed
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density” heading on Table 53. Remaining in this column read downward until directly
opposite the observed temperature of 26 oC and find the value 0.564. This is the density
at 15 oC. Once this is determined the volume can be corrected to 15 oC by using Table 54
as previously discussed.
Note :
Alternatively Liquid stock can be arrived by multiplying measured volume at the

observed temperature with the Observed density at the same temperature.
However liquid equivalent of vapour has to be calculated in all instances as per the
procedure given below
6.4.2 Liquid equivalent of LPG vapour at observed temperature
On gauging a 1000 M3 sphere was found to contain 450 M3 of liquid LPG. The vapour
content was at a temperature of 30 oC and pressure of 6.0 kg/cm2 at the time of gauging
the liquid volume of the above stated vapour content of the sphere is worked out as
follows.
Vapour Volume at 30 oC = Water Cap. of the sphere minus the volume of liquid LPG
= 1000 – 450 = 550 M3
Convert the vapour pressure at 30 oC and 6 kg/cm2 pressure to NPT (– Normal Temperature
and Pressure) where normal temperature = 15 oC and normal pressure
= 0 using following formulae.
P1 V1 P2 V2
T1 = T2
Where P1 = Observed gauge pressure + Atmospheric pressure i.e. 1.0335 kgs/cm2
V1 = Volume of pressure at observed temperature i.e. 30 oK

T1 = Observed temperature + 273 oK
P2 = Zero pressure in the vessel + Atmospheric pressure i.e. 1.0335 kg/cm2
T2 = 15 oC, Standard Temperature + 273 oK = 288 oK
Therefore V2 = P1 x V1 x T2
T1 x P2
= (6.0 + 1.0335) x (1000 – 450) x (15 + 273 )oK

(30 + 273)oK x (0 + 1.0335)
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= 1114106.4
313.1505
= 3558 M3
Using liquid / vapour ratio of 247.7, 3558 M3 of vapour volume at zero pressure and 15 oC would
work out to liquid equivalent of :
3558/ 247.7 = 14.36 M3 at 15 oC
6.4.3 Total Volumetric Quantity at 15 OC
Add the liquid equivalent of vapour at 15 oC to the liquid volume at 15 oC to arrive at the
total volumetric quantity in the sphere.
6.4.4 Weight of the Volumetric Quantity in the Sphere
Having determined the volume at 15 oC by use of ASTM – IP table no 54 as explained

earlier :
Multiply volume at 15 oC by weight reduction factor (WRF i.e. density at 15 oC minus

0.011) by using ASTM-IP table no. 53 – metric edition (Annexure III). The result would
give total weight of LPG in the sphere. As an example, the 1000 M3 sphere was found to
contain 450 M3 of liquid LPG at the time of gauging. The total weight of LPG in the
sphere if the density of liquid LPG is 0.5600 kg/litre at 15oC would be =
Convert liquid volume at 30 oC to the equivalent at 15 oC as explained above.
Liquid Volume = Volume at 30 oC (in litres) x VRF at 15 oC

(in liters )
= 450 x 1000 x 0.9600
= 432000 liters
Convert liquid equivalent of vapour contents in the sphere as explained above
Liquid equivalent of 550 M3 of vapour = 14.36 M3 at NPT
= 14360 liters at NPT
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Total quantity of LPG in the sphere would be :
Liquid volume + Liquid equivalent of vapour
= 432000 + 14360
= 446360 Litres
The WRF (Weigh Reduction Factor) for LPG with density of 0.560 at 15 oC indicates a figure of
0.5589 – Refer ASTM – IP table no. 56. Therefore to arrive at a total weight of LPG in the sphere
Multiply total volume at 15 oC x WRF
= 446360 x 0.5589
= 249470.6 Liters
= 249.471 MT
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6.4.5 Vapour / Liquid volume ratios
PRODUCT RATIOS AT 15 OC
Ethane 293.3
Propane 266.7
Iso-Butane 221.9
Normal-Butane 229.5
Iso-Pentane 193.7
Normal-Pentane 194.8
The values given above are the ratio of the volume of vapour – at one atmosphere and
15 oC – to the volume of liquid at 15 oC and saturated pressure.
The vapour / liquid volume ratio for the grade of LPG presently marketed may be assumed
0
as 247.7. at 15 C
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6.4.6 Sample stock calculation table

MONTH CUMM.
OPENING BULK 663.380 647.382
PACKED 38.244 24.005
RECEIPT BULK 4579.858 14367.923
PACKED 0.000 0.000
DEF. RET. 0.764 2.863
SUB TOTAL (A) 5282.246 15042.173
DESPATCHES BULK 0.000 0.000
PACKED 4599.440 14387.855
OWN USE 0.304 0.912
LOSS (CL.) 1.470 2.575
CLOSING BULK 661.198 661.198
PACKED 19.633 19.633
SUB TOTAL (B) 5282.045 15072.173
LOSS / (GAIN) (A-B) 0.20 ( 30.00)
Note: For month, the opening figures are the closing values of previous month. For cumulative
(Apr.-March), the opening figures are the closing as of previous financial year ending 31st March.
The packed figures are converted into bulk (MT) by multiplying the no. of cylinders with appropriate
cylinder capacity.
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6.4.7 Details of break-up of loses
BREAKUP OF LOSSES MONTH CUMMULATIVE
T/T 81 T/T 82 T/T 70 T/T 81 T/T 82 T/T 70
TRANSIT T/T 13.34 1.47 XXXX 33.14 2.58 XXXX
TRANSIT T/W 0.00 0.00 XXXX 0.00 0.00 XXXX
PURGING OF BULK XXXX XXXX 0.00 XXXX XXXX 0.00

VESSELS
PRODUCTOWN USE XXXX XXXX 0.30 XXXX XXXX 0.91
DEBITED TO IOC XXXX 0.00 XXXX XXXX 0.00 XXXX
DEBITED TO BPC XXXX 0.00 XXXX XXXX 0.00 XXXX
OPERATIONAL LOSS (13.14) XXXX XXXX (63.14) XXXX XXXX
TOTAL 0.20 1.47 0.30 (30.00) 2.58 0.91
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6.5 CALIBRATION OF STORAGE VESSELS
6.5.1 Responsibility
It is essential that the storage and transport vessel are accurately calibrated for effective
control of LPG stock inventory and stock loss.
The procedure and methods for calibration of pressure vessels are covered In the
following ISI publications :
IS – 2827 - Method of Calibration of Pressurized Storage Tanks
IS – 2808 - Method of Computation of Capacity Tables for Pressurized Storage

Tanks.
The above publication should be available at all locations handling LPG and it should be
ensured by the manager of each location that all statutory requirements are met.
The plant manager must ensure that appropriate personnel carry out calibration of all
vessels and that certified calibration tables for each vessel are available.
6.5.2 Calibration Tables
The plant manager should certify each calibration table which must be countersigned by
the official who carried out the calibration. Where LPG is stored under bond, the tables
must be certified by Competent party and stamped by Statutory Authorities also.
A minimum of two copies of calibration table should be maintained at the plant, in a

transparent plastic cover to prevent soiling or deterioration due to handling and should
be handled as important documents.
Calibration tables are either based on measurement of liquid depth or on ullage

measurements (i.e. distance from top of vessel to liquid level). These measurement
should indicate at least the degree of accuracy of the main gauge of the vessel.
The calibration tables should preferably show the equivalent liquid and vapour volume
for any liquid depth. The liquid and vapour volume should be in separate column and the
table should carry a notation that vapour volume must not be used directly in stock
calculation but must be converted to liquid equivalent.
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Unless authorized by appropriate authority no changes should be made in the calibration tables.
6.6 ACCURATE GAUGING OF VESSELS
Gauging is of little use if the vessel is not accurately calibrated.
When product turbulence occurs as during movement of product at different temperatures,

gauging cannot be accurate, and certain types of ‘float’ operated gauges can be damaged.
Accurate gauging can be possible only if the gauging installed in accordance with manufacture’s
instructions.
All main storage vessels must be installed with two liquid level gauges both of which have to be
robust and reliable. The accuracy of auxiliary or stand by gauge need not necessarily equal that
of the main gauge.
Operators must be properly guided regarding correct use of gauges and in avoidance of errors
such as parallax etc.
Recording of observed reading must always be accurate.

Routine gauging ( Daily opening & closing ) must be carried out using the accurate main gauge.
Gauging by ‘venting’ must be carried out safely, away from the source of ignition and vent valve
closed immediately after use.
Gauging after product receipt must be done after at least one hour settling time to allow for
turbulence (boil-off) caused by differences in product temperatures to subside. Water draining
is to be carried out after settlement before taking final gauge readings.
Damage to gauges due to seized or broken wires / tapes etc. or unaccountable readings on the
gauges must be immediately reported.
6.6.1 Temperature Measurement

Accuracy in temperature measurement is essential because an error by say 3 oC in the
determination of the average temperature of a parcel which has a co-efficient of
approximately 0.003 per degree centigrade., would cause an error of 1% in the volume
calculations.
The necessity for determining both vapour and liquid temperature for bulk quantity
determination is illustrated by the following.
The ‘liquid equivalent’ of vapour in a vessel half full of liquid at 30 oC is approximately

3% of the liquid content; for the same vessel one quarter full (at 30 oC) the ‘liquid
equivalent’ of the vapour rises to approximately 10% of the liquid contents. All LPG
storage should, therefore, be provided with at least one thermometer in each of the
liquid and vapour phases.
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6.6.2 Pressure Measurements
Determination of the pressure in the vapour space of LPG storage vessels is necessary
for following reasons :
As a check on product quality as the vapour pressure is directly linked to the temperature
and product characteristics.
To enable liquid equivalent of vapour quantities to be calculated.
As a safety check against over-pressurization.
Pressure gauges are also useful for operational control purposes as they provide details
of pump differential pressure and thus performance and give warning for correcting
opening or closure of valves or pipeline / equipment failure.
Operators should be trained in the use and correct reading of gauges.
6.6.3 Metering – Liquid LPG
LPG meters are sufficiently accurate for stock control purposes but their accuracy is
inadequate where safety controls are concerned. For instance a meter may show that a
quantity of 10m3 has been filled into a vessel but will not show when the vehicle has
been filled to its maximum safe level, which is the function of the ullage gauge. However,
vessels are provided with level alarms. In case of level in the vessel reaches the specified
level set in the system, it gets actuated and closes the ROV, stopping further entry of
LPG into the vessel. Similarly, pressure switches are also provided as interlock for
safety system, and in case of high pressure, the ROV gets closed through activation of
pressure switch.
Meters can be relied upon to measure quantities with required degree of accuracy only
when incorporated in a properly designed and maintained system which include the
following.
The meter
A fine – mesh strainer of 80mm micron size to catch small particles
A vapour eliminator because vapour registers like a liquid giving false reading
A back pressure / differential valve to prevent vapourization of product
The above units are normally included as a part of meter package. To work satisfactorily,
meter system should meet the following design requirements.
Must be suitable for pressure associated with the LPG being metered – vapour pressure
plus pump differential.
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Must have capacity to match their associated prime mover.
Must be always flooded with liquid. The product will deposit any contaminants it contains
if allowed to evaporate in the meter and further, evaporation could result in false meter
reading.
A new meter is normally calibrated by manufacturer just before dispatch and supplied
with the certificate showing percentage error over its rated flow range.
Periodical recalibration is necessary to determine the change in accuracy brought about

by wear and tear. Regular servicing / maintenance should include cleaning, lubrication,
etc., in accordance with the manufacturer’s recommendations. Calibration can be
carried out on-line i,e in-situ or meter can be sent to FCRI, Palghat for calibration &
proving.
Strainers must be cleaned regularly.
Leaks, signs of wear (noise) or mal-functioning should be attended to promptly. Records

should be maintained of original calibration, subsequent recalibration and of servicing
and maintenance.
Meters used as delivery equipment must be certified by Weights and Measure Authority.
6.7 EFFECT OF DENSITY IN VOLUMETRIC CALCULATION AND STOCK VARIATION IN LPG
Density of LPG to be taken on daily at the time of taking opening & closing gauge reading for the
day based on which stock variation at plant being arrived. Inaccurate density is a major contributory
factor in stock variation at locations. Thus density to be measured through approved type
density meter available at plant . In case of any discrepancy observed in measuring density with
approved type density meter then density can be measured through laboratory method to arrive
at correct density of the product.
In case density of the product is more in compared to density taken for calculation basis data
from shipping location or density obtained in density meter then actual stock in vessels will be
more in compared to calculated one. Similarly , in case actual density is less then the density
taken for calculation , then actual product quantity in vessels will be less than the calculated one.
In view of above density of product play an important role in arriving at bulk stock with location
and monitoring stock variation performance on day to day basis.
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Further variation arrived from physical density taken also will depend on accuracy in observation
and temp of the product in density meter vis-à-vis temperature of product in the vessel. In case
of variation in density in third decimal point for a plant like Bahadurgarh , MLIF , Chakan,
Visakh, Khapri, Cherlapally etc, where huge storage is there , will give major variation due to
error in taking Physical density.
Accuracy of density meters be proved through approved laboratories from time to time as per
manufacturers recommendations and quality management system .
6.8 INVENTORY MANAGEMENT
In the context of LPG Plants, inventory signifies all the material inside Plant which is having
financial value. However for the sake of Inventory Management in Plants, the following critical
aspects are considered:
• Inventory of CVR
• inventory of bulk LPG
• inventory of consumables
• inventory of lubricants / HSD for own use.
• inventory of spares & other Store-house material
Inventory Management of CVR to be handled as below:
6.8.1 Inventory Management of Cylinders
Accounting of receipt / dispatch of cylinders as per the specified norms of Accounting

manual with further cross-checking by way of records / registers provided with
security
Accounting of Different types of cylinders to be done separately
Taking physical inventory of cylinders as per laid down policy guideline & tallying the
same with book stock.
To assist in proper inventory taking, cylinder stacking has to be ensured in separate
identifiable & countable lots. To further assist on same, different categories of
cylinders should be demarcated in different lots with suitable identification boards.
To have system of surprise checks on movement of cylinders in trucks
6.8.2 Inventory Management of Regulators
Accounting of receipt / dispatch of regulators as per the specified norms of Accounting

manual with further cross-checking by way of records / registers provided with
security
Accounting of different types of regulators to be done separately
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Taking physical inventory of regulators as per laid down policy guidelines & tallying
the same with book stock
Positive segregation of Good, Salvaged, defective, scrappable regulators to be ensured
For scrappable regulators, the storing has to be in demarcated & sealed containers/
drums.
Surprise checking of movement of new regulator boxes/cases by randomly opening
of same
6.8.3 Inventory Management of Valves
Separate system for movement of valves within (for valve changing operation & for
in-house testing) & outside (to repairers) the Plant as per laid down procedures &
further cross-checking by way of records / registers maintained with security. The
movement of valves within Plant has to be strictly against Material Issue Vouchers
(MIV)
System of maintaining BIN cards for different types of valves to be implemented
Taking physical inventory of valves as per laid down policy guidelines & tallying the
same with book stock
Positive segregation of Good, Salvaged, defective, scrappable valves to be ensured
For Defective & scrappable valves, the storing has to be in demarcated & sealed
containers/ drums.
Surprise checking of movement of new valve boxes / cases by randomly opening of
same
For CVR Inventory management, process of cycle count has to be done at the end of
month. SPPI for CVR has to be made at the month end & reported to controlling
offices.
In case of variations in physical & book stock, the same has to be thoroughly
investigated & brought to the attention of appropriate authority. As per the laid
down guidelines, Irregularity report has to be made for any loss in inventory. In case
the cause of loss can not be established internally & there is sufficient evidence of
pilferage etc., necessary FIR has to be lodged.
6.8.4 Inventory Management of Bulk LPG
Inventory Management of Bulk LPG is as per the Stock Accounting procedure explained
in the previous section. The exact bulk quantity at the end of month has to be reported
in SPPI.
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6.8.5 Inventory Management of HSD & Lubricants
The receipt of HSD & Lubricants to be as per the procedure laid down in Accounting
manual.
At the end of month, necessary inventory entries (consumption) for own use of HSD
& Lubricants are to be processed
The storage of lubricants & HSD (in drums) has to be in properly sealed way in
demarcated & covered area
Physical inventory of HSD & Lubricants has to be taken as per laid down guidelines
Opening & Final dip of HSD tank (wherever applicable) has to be taken after each
receipt & issue in addition to above
At the end of month, physically inventory of HSD & Lubricants has to be reported in
SPPI
6.8.6 Inventory Management of Store Items
Inventory Management of consumables & other Store-house material to be handled as

below:
Receipt of Material through RGP

Store registers are to be maintained showing opening balance, receipt , issue &
closing balances
Issue of material through Material Issue Vouchers
Storage of material in demarcated area preferably in bins (for maintenance spares)
Inventory of consumables & other store house material has to be taken as per laid
down guidelines & cross checked with records / registers maintained by security
6.9 BULK STOCK MONITORING & INVENTORY MANAGEMENT IN JDE SYSTEM
6.9.1 Bulk stock accounting
a) Book or System ( Dummy Tanks)

b) Physical Stock ( Physical Tanks)
PHYSICAL TANKS : Physical tanks are the actual Tanks wherein the Strapping Tables (
Calibration Charts) are attached so that the Physical Stock can be ascertained by entering
the Dips. Physical tanks are only for the purpose of Stock calculation from Dip gauges.
DUMMY / LOGICAL TANKS : These are Fictitious tanks created in the system.The entire
Book Stock is Stored in the system in Dummy Tanks. This is because in LPG the Physical
tanks are not Operationally reconciled.
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Dummy tanks help in Operational reconciliation. Only Dummy Tank inventory has to be
reconcilied instead of Physically reconciling every individual Tank.
In Dummy tanks there are no Strapping Charts attached.
Product Accounting ( Book Stock)of Bulk in JDE is done in Dummy Tanks. Normal convention
for Bottling plants are XXXXXDOM ( for Domestic Bulk ) & XXXXXNDM ( for Non Domestic
Bulk).Where XXXXX refers to the branch plant.
Receipts & filling entries are done from the Dummy tanks. Gain/Loss entries are also
booked from Dummy tanks.
Physical tanks are only for the purpose of Stock calculation from Dip gauges. The Stock
herewith calculated is to be compared with Book stock at the Day end and the gain/Loss
for the day are booked.
6.9.2 Bulk Receipts
a) Road
b) Rail
c) Pipeline
d) Ship
Can be entered any time as & when the TT/TW gets decanted.
The bulk inventory in the system will increase.( IN THE DUMMY TANKS)
Note Item Availability before starting Bulk LPG Receipts

Double-click DELIVERY CONFIRM
Enter the Load Number of Loading Base and Click FIND (Here the load Status is 50)
Highlight the row and Click CONFIRM DELIVERY
Click OK
Click OK
Here the Load status moves to 80
Note Receipt Document Number (OV) from Item Ledger
Print Receipt Report for Bulk LPG
Check Item availability after completion of Receipts & Check by adding receipt with
earlier noted Item availability.
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6.9.3 Filling / Decanting
a) Filling
Regular
Defective
Overtime
b) Decanting Entries
Repacking
Dip Reading
Gain /Loss booking
Bulk rebranding
FILLING ENTRIES
TO BE DONE FROM THE RESPECTIVE APPLICATIONS.

Since the Reports will fetch data from the respective Tables. If the proper application is
not chosen then the reports will give incorrect information. It is based on the Reason
Code which defaults from the corresponding application.
The Filling Entries to be done at Day end after closing of Filling Operation and after all
Sales orders / reversals are completed.
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REGULAR FILLING
Document Type – ML. Reason Code – REG.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations
Regular Filling.( P415101- HPLPG001).Click ADD.The Following screen appears.
Data Entry : After doing Data Entry Click OK.
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DEFECTIVE FILLING
Document Type – ML. Reason Code – DEF.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations Defective
Filling.( P415101- HPLPG002).Click ADD.The Following screen appears.
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OVERTIME FILLING :
Document Type -ML. Reason Code – OVT.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations Overtime
Filling.( P415101- HPLPG003).Click ADD.The Following screen appears.
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DECANTING ENTRIES ( Defective Cylinder Evacuation)
Document Type – MC.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations Decanting (
P415101- HPLPG020).
Click ADD.The Following screen appears.
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REPACKING
(For Decantation/ evacuation of Part Filled Defective Cylinders) Document type – IG.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations REPACKING
Def. pkd to Bulk LPG ( P415101- HPBSRB02).
After doing filling entries, the inventory of Bulk & empty cylinders will deplete from system.
Whereas filled cylinders inventory will increase.
We will get the closing inventory of cylinders.
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Thus we will be able to see the availability of each item in the system in “Item Summary
Availability”
☞ Getting There : Operations Officer Menu LPG Reconciliation ( P41202) Detailed

Availability
The Following screen appears.
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DIP READINGS
To be entered after doing the filling entries.

After doing the Filling entries the Bulk LPG in the Tanks will get depleted and the closing stock will be
obtained.
☞ Getting There : Operations Officer Menu LPG Reconciliation Dip Reading ( P415106)
Data Entry
Enter the dip readings & Press calculate key & note down the bulk qty in the Bullets. Click OK
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Stock Position Report (R551417)
☞ Getting There : Planning Officer Menu LPG Reports (H3390) LPG Daily Reports (H33DLYREPO)
Daily Reports-Tested & OK(H33DLYOK) Bulk Stock Position Report ( R551417 – HPINV002).
Data Entry
Double click on “Bulk Stock Position Report ”.
Data Selection screen will appear. Click on Data selection Submit.
Enter Business Unit as Your Branch Plant. Click OK.
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View PDF/CSV.
View the Report & Then Do Gain/Loss Booking.

Gain /Loss booking: To be done from LPG Reconciliation menu.
( Document type G 4 )
Book the gain / loss in the following manner.
If there is a gain then make the entry as “T” in Bullet/sphere
If there is a loss then make the entry as “F” in Bullet/Sphere.
☞ Getting There : Operations Officer Menu LPG Reconciliation LPG reconciliation Thru Adjustment
( G4) ( P415101 – HPCLBADJ07)
Data Entry
Click ADD.The Following screen appears.Do the entry & Click OK.
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6.9.4 Inventory Management in JDE system
a) DPT Generation
b) Valve Repairs
c) In-house testing
d) Valve/Regulator salvaging
e) Inventory Reclassification
Inventory Transfers ( Document Type I4)

Inventory transfers are done for discrete inventory items wherein the item
number remains the same. The item moves from one Location to other
within the same Branch Plant. eg. After Valve changing the cylinders are
moved from Repairable location to Good Empty Location.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations
Dicrete Transfers
Click ADD. The Following screen appears.
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Discrete Issues ( Document Type I3)

This is done for the issue of discrete items wherein the inventory is depleted from the Locations. eg.
Consumption of consumables like seals , caps etc.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations Dicrete Issues
Data Entry : After doing Data Entry Click OK
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Reclassification ( Document Type – IF)

This is to be used when the item is rebranded.
eg. Rebranding of Bulk from Non Domestic to Domestic.
☞ Getting There : Operations Officer Menu LPG Plant Operations LPG Operations Dicrete Reclass
Data Entry : After doing Data Entry Click OK
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6.10 CYCLE COUNT – LPG
Cycle Count is used for reconciliation of Discrete Inventory Items.

While doing Cycle Count ,all transactions affecting the inventory have to stopped so that the
inventory is frozen at that time.
During Cycle Count the inventory of various items in all locations are printed on the Cycle Count
Sheets. The Physical Inventory has to be compared with these Cycle Count sheets & the system
stock has to be reconciled & brought in line with the Physical stock.
This can be done by doing Inventory Transfers, Decanting, Repacking etc.
Following are the steps :
1. SELECT ITEMS FOR CYCLE COUNT
Data Selection to be used

- Business Unit=”XXXXX”
- Quantity on Hand-Primary Unit “ not equal to “ Zero.
View the PDF file of the print and note down the cycle count number. The system at this moment picks up
the inventory of the plant at that particular moment.
The cycle count status is at 10.
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2.PRINT CYLCE COUNT SHEETS
- Data Selection to be used

- Business Unit =”XXXXX”.
The print will give the items location wise wherever the inventory is traceable, but the inventory will not
be printed in the sheets. The sheets are to be given to the storekeeper who will fill up the sheets .
The cycle count status moves to 20.
3.ENTER CYLE COUNT
In Cycle Count Entry menu,Give the cycle count no and find. In the row exit click enter cycle count(THIRD
FROM TOP)
Enter the inventory as per the inventory in the sheets. The quantity once entered can also be changed
at this stage by adding or subtracting suitable quantities.
After entering the quantity,click OK.

The Cycle count status is now at 30.
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4.CYCLE COUNT VARIANCE PRINT

- Business Unit = “XXXXX”.
The report will give whatever the variations between the system inventory and the actual inventory..
5.REVIEW CYCLE COUNT
In Cycle Count Review menu, Find the cycle count giving the cycle count no and review it .
6.APPROVE CYCLE COUNT

In the review cycle count menu , cycle count can be approved using the approve button in the row exit.
The cycle count status moves to 40.
7.UPDATE CYCLE COUNT

- Business Unit = “ XXXXX”
At this stage the cycle count inventory will update the system inventory.
The cycle count status moves to 50-COMPLETED.
Sorage Point Physical Inventory Report (R552210)
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The SPPI report gives the Closing Stock AS OF a particular month end.
☞ Getting There : LPG reports LPG Monthly reports SPPI ( R552210- HPCSPPI)
Data Entry
Double click on “SPPI”.
Data Selection screen will appear. Enter Business Unit as Your Branch Plant. Click
OK.
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Processing Option screen will appear.
Enter your in “Period”
Enter Month in Fiscal Period (April =1 & March = 12) and Fiscal Year as 2005 ( April 05 to March
06).
View PDF/CSV.
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Own use ( Document Type – ME )
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DESIGN, MANUFACTURING & MAINTENANCE
FEATURES OF CVR
INDEX

7.1 Cylinders 1
7.1.1 Cylinder design 2
7.1.2 Safe filling capacity of cylinders 2
7.1.3 Standardized markings on cylinder 3
7.1.4 Colour code for age profile 5
7.1.5 Protection ring of cylinder 5
7.1.6 Stencilling details 6
7.1.7 Marking / Identing for ownership 7
7.1.8 Colour coding for next test cycle details 8
7.1.9 Identification of non-conforming & cylinders owned by Pvt Bottlers 9
7.2 Cylinder Valve 9
7.2.1 Materials of construction 9
7.2.2 Working pressure 9
7.2.3 Filling time 9
7.2.4 Markings on the valve 10
7.2.5 Types of cylinder valve 10
7.2.6 Design 10
7.2.7 Leakage 11
7.2.8 Valve protection 12

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FEATURES OF CVR
7.2.9 Salvaging of defective valve 12
7.3 Pressure Regulator 13
7.3.1 General 13
7.3.2 Markings on Pressure Regulator 13
7.3.3 Identification of OMC Regulator 14
7.3.4 Mounting of the Regulator – SC type 16
7.3.5 Regulator freezing – Causes 16
7.3.6 Testing of regulator at Plant 17
7.4 Mandatory testing of cylinder 18
7.4.1 Equipment / Facilities 19
7.4.2 Mandatory testing & painting procedure 20
7.5 Re-conditioning of used LPG cylinders (Hot Repair) 25

7
FEATURES OF CVR
7.1 CYLINDERS
In this section LPG vessels designated as “Cylinders” will be described with reference being
made to their potential utilization. Reference to accepted specifications for design,
fabrication, inspection, testing and maintenance of cylinders is part of this section.
Valves and other accessories, which are integral parts of the cylinders are treated, so
appropriate selections can be made for the completion of cylinder assemblies.
As a general term practically all vessels used for the containment of LPG are cylindrical in
form regardless of their size. Specifically a LPG “Cylinder” is a vessel having a volume
exceeding 500 ml. but not exceeding 1000 litres and intended to be charged at a central
filling or manufacturing plant, subsequently to be transported in a charged condition through
various means to the ultimate customer. The cylinder is not designed to be fitted to a
special transport or undercarriage.
The types of cylinders presently in use are as follows :

Domestic cylinder of 11.7 litre water capacity for handling 5 kg. of low pressure
LPG
Domestic cylinder of 33.3 litre water capacity for handling 14.2 kg. LPG
Commercial Cylinder of 44.5 litre water capacity for handling 19.0 Kg LPG.
Industrial cylinder of 82.2 litre water capacity for handling 35 kg of low pressure LPG.
Industrial cylinder of 111.0 litre water capacity for handling 47.5 kg. of low
pressure LPG
The cylinders mentioned above are exchangeable and may have a long service life provided
proper maintenance and reconditioning is observed.
An LPG cylinder may be distinguished from other types of vessels in that the openings on
within the surface of the vessel must be located in the longitudinal axis of vessel head of
the unit. Likewise opening from the vessel such as valve must be attached to the units
on the heads . Weldments to or penetration of the cylindrical portion or pressurized shell
of a cylinder is not permitted. All portable cylinders with projecting type of cylinder valves
are provided with permanently attached valve protection rings mounted on stay plates so
that assurance is gained that the protection will be available at all times regardless of
whether the cylinder is in use, in transportation, or otherwise disposed.
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FEATURES OF CVR
7.1.1 Cylinder design
Design & Fabrication of LPG cylinders exceeding 5 litre water capacity is governed
by BIS Specification IS 3196 (Part-I) where as cylinders of water capacity upto 5
litres are covered as per IS:7142 ( i.e. Specification for welded low carbon steel gas
cylinders for low pressure liquefiable gases ). They are inspected and certified by
BIS Inspector strictly in conformity to the applicable standards after which they are
approved by the Petroleum Explosives and safety organization ( PESO ) .
As part of the inspection before certification the cylinders are hydrostatically tested
to the pressure limits of 25.00 Kg / Cm2 ( 2.45 Mpa). After the fitment of the
valve the cylinders are pneumatically tested to the pressure of 12 kgf/cm2.
Domestic LPG cylinders are standardized on Industry-basis for a design of

maximum working pressure of 16.9 kgf/cm2 (1.66 Mpa) which is the
maximum permissible vapour pressure for propane-butane blends as per IS
Specification IS-4576 -1999 at the assessed temperature of 65°C (149°F).
The basic design specifications are given below :

Design Code IS-3196
Working Pressure 1.66 MPa (16.9 kgf/cm2)
Test Pressure 2.45 MPa (25.00 kgf/cmZ )
Working Temperature Water Ambient
Water Capacity 33.3 Litres (for 14.2 kg cylinder)
(Variation Limit +3%, -0%)
However, the tolerance for water capacity shall be + 5 % - 0 % for cylinders upto and
including 13 litres
7.1.2 Safe filling capacity for Cylinders
The safe weight of LPG with which a cylinder may be filled is related to its maximum
temperatures of usage. Filling density or “filling ratio” is a relationship between
the safe weight of product and the weight of water required to fill the cylinder at
15°C.
The “filling ratios” for LPG cylinder should be as specified in Indian Standard
Code IS-3710.
The safe filling capacity of cylinders is arrived at after allowing 5% ullage remaining
when the liquid contents is at the assessed temperature of 65°C.
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FEATURES OF CVR
7.1.3 Standardized markings on Cylinders
Markings on cylinders are standardized on Industry basis as follows:
(a) Markings on Bungs
Details of serial number, manufacturer’s identification, tare

weight and year of manufacture are punched on the top of cylinder
bung.
(b) Markings on Vertical Stays
There are 3 vertical stays on the valve protection ring and are marked as
follows:
1ST stay plate :

Manufacturer’s Identification abbreviated name ( e.g. HWL repre-
sents Hindustan Wires Limited)
Serial Number of the Cylinder ( Source of steel to be punched after serial No.)
Tare weight of the cylinder
Max.Gross weight of the cylinder
2nd Stay :
BIS Monogram and IS Specification No
Water capacity in litres
Maximum Working pressure in Mpa ( 1.66 Mpa)
Test Pressure in Mpa ( 2.45 Mpa)
3rd Stay :
Batch No
Test dates ( Month / year of manufacture)
( c ) Markings on Foot Rings
Foot rings are stamped or embossed with oil company’s name ( e.g. HPC) on one
side and product name ( e.g. HP GAS) on the other side.
Refer attached drawings for details of markings on foot ring.
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FEATURES OF CVR
(d) Markings for Age Profile
To facilitate segregation of cylinders at the plant for carrying out of statu

tory testing, a uniform procedure is evolved by the Oil Industry.
According to the procedure being followed now, colour coding / marking is done
on inside face of the vertical stay ( 3rd stay of wider width ) of the valve protection
ring. This procedure is introduced during November 1983. In the entire system the
last digit of the year of manufacturer is punched on bung and one of the stay
plate. Further, the due date of the 1st retesting cycle is painted in bold
letters on the inside of the wider stay plate of each cylinder for identifi-
cation of the age profile.
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FEATURES OF CVR
7.1.4 Colour code for age profile
Although the date of initial test ( month & year of manufacture ) is punched on the bung
and stay of the cylinder, segregation of the cylinder for statutory testing based on the
punched markings is not only cumbersome but a very time consuming process. A system
for colour coding of the cylinders to indicate the age profile has, therefore, been developed
on an Industry basis.
As per Gas Cylinder Rules 2004, the following two conditions are mandatory:
Quarter and year of initial testing must be stamped on every cylinder.

Quarter and year of next testing should also be indicated on every cylinder.
7.1.5 Protection ring of Cylinder
Immediately after re-testing of these cylinders, the quarter and year shall be punched
on the outside of one of the stays on ( stay plate of wider width of 91 mm ) . Effective
2001, one stay plate has been made wider to 91 mm width for HPCL cylinders.
Each quarter will be distinguished as under:
January to March by letter ‘A’
April to June by letter ‘B’
July to September by letter ‘ C’
October to December by letter ‘D’
The year of test would be identified by the two digits of the year. For example, figure 05
would represent the year 2005.
Accordingly, if a cylinder has been tested in the month of July’05 the punched marking
should be ‘ C-05’ based on the above guidelines. In order to indicate the next quarter
of testing, inside of one of the stays ( of wider width ) should be painted with appropriate
colour as detailed in item 7.1.8
And the next quarter and year of testing due be stenciled with appropriate colour on the
painted background. For example, if a cylinder has been manufactured in C-05, the
marking on the inside of the stay will be C-12 for 1st retesting due ( after 7 years for new
cylinders) and if the cylinder is tested in C-12 , the markings for next due date of
testing shall be marked on inside of the stay as C-17 ( after every 5 years ).
Every time a cylinder is retested outside of the one of the stay of the cylinder shall be
used for stamping the next period of testing, retaining the earlier mark. In other words,
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FEATURES OF CVR
when the cylinder completes three period of a statutory test, it would indicate three test
dates on the stay meaning that the cylinder has completed 15 years of use.
As per the present practice of the manufacturers utilizing outer space of all the 3
vertical stays for indicating the statutory information such as water capacity, testing
pressure, manufacturer’s identification, manufacturing period etc., the manufacturers
should also mention the month / year of testing on the outside of one of the stay
leaving rest of the space of this stay blank for future stamping of testing dates.
7.1.6 Stenciling details
In addition to above stated markings on the cylinders, the following information is stenciled
(by way of screen printing) :
Tare weight on the Shroud portion of cylinder at three equidistant locations
Tare weight on the inside of stay plates
On the inside of wider stay plate, Tare weight is stenciled in addition to identification
of retesting cycle
Safety messages (bilingually) on the cylinder body are to be screen printed as per
the drawing details. At present these messages are to be screen printed in Font size
7 mm & Font type Ariel
On Domestic cylinders, message FOR DOMESTIC USE ONLY is to be screen printed
bilingually in Font size of 13 mm & font type Ariel
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FEATURES OF CVR
7.1.7 Markinq / Identinq for Ownership
A typical checklist for identification of 14.2 kg domestic cylinder on industry bais

has given under
PARAMETER HPCL IOCL BPCL

Colour Identification Cylinder Body Cylinder Body in Cylinder Body in
in Red colour with Red Colour Only Red colour with Shroud
Shroud portion french Blue Golden Yellow
Stay Plate Design 02 stay Plates of size All three stay Plates All three stay Plates
52 mm & third stay are of 65 mm size of 65 mm size
plate of 91 mm size
Foot Ring Markings HPC & HP GAS IOC & INDANE BPC & BHARATGAS
embossed on embossed on embossed on Footring
Footring Footring
For IBP, all the three stay plates are of similar size. All identifications on stay
plates are similar to other company cylinders. The area inside the shroud is painted
with black colour. Foot ring of IBP cylinders has got 6 holes with markings of IBP
and IBP GAS .
Since all cylinders in use by the industry are standardized to some specifications,
the industry has adopted the following convention to facilitate identification of
ownership.
HPC cylinders are painted red but circular portion around the bung (shroud) and
upto vertical stays are painted with French blue. The foot rings have 6 nos. vertically
elliptical holes of (11 x 20 mm) size. The foot rings have been embossed with HPC
& HPGAS on diagonally opposite side. HPC cylinders are also stenciled with HPGAS
logo on one of the stay plate ( 91 mm width stay ) apart from two stenciling of
HPGAS logo on the body of the cylinder on diagonally opposite to each other.
IOC cylinders are painted fully red. Foot rings have oval holes. Footring is marked
with INDANE markings .
BPC cylinders are painted red but circular portion around the bung and upto the
vertical stays are painted with golden yellow. The foot rings have round holes. BPC
& BHARAT GAS are embossed in the footring for BPC cylinders.
The safety messages screen printed on different Oil Company cylinders also vary
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FEATURES OF CVR
7.1.8 Colour coding for next test cycle details

The following seven colours have been selected for colour coding of cylinders for first
retesting. However, the subsequent retesting will be after a period of 5 years and the
same colours shall be repeated in the same order. Colour coding of inside portion of one
of vertical stay plate for first retesting is as follows:-
Background BIS Spec Lettering Year of Year of

Colour for Shade Colour Manufacture Retesting
Air Craft Blue IS-108 White 2005 2012
Salmon Pink IS-443 Black 2006 2013
Black IS-521 White 2007 2014
Yellow IS-355 Black 2008 2015
White IS-127 Black 2009 2016
Sea Green IS-217 Black 2010 2017
Dove Grey IS-694 Black 2011 2018
The above colour scheme shall be followed by manufacturers of new cylinders, hot repairers
and statutory testing plants. The above colour coding scheme shall be followed by Industry
in respect of cylinders in circulation, due for testing.
It is essential that periodic visual inspection of markings, paintings and stampings on

cylinders are undertaken at the bottling plants to ensure that they are legible at all
times.
Since the stamping will be done for each year of testing, the due date of hydrostatic
stretch test ( after 15 years of first test ) can easily be established.
The system of colour coding described above is introduced for convenience of segregation
of cylinders due for retesting. Before actually undertaking the retest, it must however,
be established by checking the stamped mark of the last test date on the cylinder that
it is really due for retesting.
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FEATURES OF CVR
7.1.9 Identification of non conforming & cylinders owned by private bottlers
The following identification criteria distinguishes Non conforming cylinders (Cylinders

of Pvt. Bottlers included) from those owned by OMCs :
Size of Cylinder in terms of Height & Diameter is different
Type & Design of Valve is Different
No. of Stay Plates is more than three
Size of Stay Plates is different
Design of Footring is different
Spurious Cylinders
Cylinders not owned & marketed by OMCs ( HPC, IOC, BPC & IBP) are branded as Spurious
Cylinders
For SQC check details of new cylinders, refer Annexure 6
7.2 CYLINDER VALVES
7.2.1 Material of Construction
The Self Closing Valves being used on LPG Cylinders are as per IS 8737.The valve
block is fabricated from forged or extruded section of brass which is an alloy of
Copper & Zinc with composition criteria of 60 % copper and 40 % Zinc.
The material selected for construction of the components of the valves should not
be affected by chemical, thermal and cyclic stress influences that would be
encountered in normal use.
Function of the valve is to provide gas-tight seal in closed position to prevent the
contents from leaking and in open position to allow operation such as filling, discharge,
evacuation, venting etc., in a controlled manner.
7.2.2 Working Pressure
The valves should withstand the working pressure of the cylinder to which they are
fitted. They should be designed for a maximum working pressure of 17.0 Kgf/Cm2.
7.2.3 Filling Time

The internal mechanism of the valve is so designed that when a fully assembled
valve is fitted on to any empty cylinder it should be possible to fill 15 kg. of LPG, at
the vapour pressure stipulated, within a maximum of 60 seconds at a
differential pressure of 2 kg/cm 2 across the valve and the filling head, in case of
self-closing compact valves.
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FEATURES OF CVR
7.2.4 Marking on the Valves

The SC (Self Closing) Valve currently in use are having six hexagonal faces. Following
markings must be stamped on the valves fitted to LPG cylinders :
Flat 1: Licence Number of the Manufacturer ( CM/L No.)
Flat 2: Quarter & Year of Manufacturing and Batch No
Flat 3: Specification of the valve (i.e. ISI mark as per BIS stds – is 8737
Flat 4: Max. Working Pressure (WP) in Mpa ( 1.66 Mpa)
Flat5: Purchaser Company ( i.e. HPC / BPC / IOC )
Flat 6: Manufacturer’s Identification Symbol
7.2.5 Types of cylinder valve
Earlier ‘F’ Type Valve and ‘MB’ Type valves were being used on LPG Cylinders.
However, these types of valves has now been phased out and been replaced by New
‘SC Type Valve (which is self-closing type of modified design of Kosan Technova ) .
This current type of Kosan Technova design SC valves are similar in design to MB
valve except for the seal between the regulator and the SC valve is inside the valve
whereas in MB valve it is outside of the valve. As in the case of MB valve the SC
valve also closes automatically by removal of the Pressure Regulator or Filling Gun
whether accidental or otherwise. This SC type self closing valve has been standardized
on industry basis and all new cylinders are now provided with this type of
valve.
7.2.6 Design
Inlet ends of SC valves are provided with ¾ “ N.G.T. tapered male threads to
match the female threads in the cylinder bung conforming to IS-8737. Approved
sealant (as per IS-8737) is used to provide gas-tight joint between the
cylinder and the valve.
The outlet end has provision to lock the SC type sierra ( 5 point locking ) pressure
regulator and also a sealing arrangement to prevent leakage of LPG from the coupling
joint between the valve and inlet of pressure regulator . The MB valve which was
earlier prevalent in use has this seal on the outside of valve whereas the SC type
has it inside the valve.
This SC Valves outlet has a spring loaded valve spindle which opens the valve when
depressed by the valve operating lever on SC Pressure regulators or filling gun. The
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FEATURES OF CVR
valve spindles in SC Valves spring back to positive shut-off position when the
regulator or filling gun is removed. Vapour pressure within the cylinder further assists
in keeping SC Valve closed.
The security cap on SC valve is made of Dupont Derlin Material and is locked
into position with the help of locking spring. A nylon cord is provided to pull the
spring, thereby unlocking the cap. The function of security cap ensures
effective protection against blows as well as dampness and dirt. The protection cap
covers the valve when it is not in use. The packing inside the protection cap is guaranteed
to seal the cylinder valve tightly upto a cylinder pressure of 17kgf/cm2. It must be
noted that only SC regulators can be fitted on SC valve and vice-versa.
7.2.7 Leakage
The leakage in this type of valve (SC Valve) could occur as under with valve in
closed position and valve outlet open :
- Leakage could occur through the valve outlet indicating that the valve seat
is defective.
- Leakage past valve seat could occur in case dirt/rust particles are preventing
the proper seal. Slight opening and re-closing the valve may stop the leak.
- In case the valve seat is damaged/defective, the valve would need replacement.
Escape of vapour to the atmosphere in case of leakage through valve seat can
be prevented to some extent-by closing the valve outlet with a security cap.
This should, however, be adopted as purely a temporary measure till such time
the contents are safely evacuated.
With valve in open position and outlet closed :
As described earlier the valve seat in this type of valve remains closed unless external
pressure is applied. Therefore to keep the valve seat open there would be a need
for special type of adaptor (a dummy pressure regulator). In this case the leakage
could occur through the connection between the valve outlet and the special adaptor
(dummy pressure regulator) indicating that the sealing ‘O’ ring is absent or defective.
This would necessitate replacement of ‘O’ ring.
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FEATURES OF CVR
7.2.8 Valve Protection
The valve connection to the cylinder should be protected while in transit, in storage,
and while being moved to or from the point of final utilization.
The provision of valve protection rings ( light , medium or heavy type depending on
the category/size of the cylinder ) ably supported by vertical stay plates has been
made on Industry basis to provide valve protection arrangement as an integral part
of the cylinder.
This valve protection design consists of a metal ring around the valve connected to
the cylinder with the help of 3 nos. vertical metal stays as shown in the attached
drawing.
This arrangement provides adequate protection to the cylinder under most “handling”
conditions the cylinder is exposed to.
For SQC checks on new SC Valves at Plants, refer Annexure 6
7.2.9 Salvaging of defective Valves
Defective Valves segregated in the Filing process shall be handled as per the following:
Valve with broken pin to be segregated & declared as scrap
Valves manufactured before 1985 to be declared as scrap
New Defective Valves within warranty period (02 years) to be segregated for replacement
Balance valves to be taken up for salvaging
(a) Salvaging Process
Equipments Required
Ultrasonic Valve Cleaning Machine
Test Bench (Approved Type)
High Pressure Air Compressor capable to generate more than 17 kg/cm2 pressure
Regulating Devices to reduce the pressure upto 0.5 kg/cm2
Process
Defective Valves taken up for salvaging shall be placed in batches in the Ultrasonic
Valve cleaning Machine filled with carbon tetra chloride / kerosene. The machine
to be operated for 30 mins for cleaning of valves.
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FEATURES OF CVR
The valves are then taken out & dried. The valves are then placed in the Test Bench
and subjected to test of leakage applying high pressure of 17 kg/cm2 & thereafter
with low pressure of 0.5 kg/cm2.
Valves passing the above test to be rebranded as useable & suitably identified.
O’ring for these valves (found sound) to be replaced.
Rejected valves to be identified & rebranded as scrap.
7.3 PRESSURE REGULATORS
7.3.1 General
The pressure within an LPG cylinder would vary depending on the composition of
LPG and its temperature. Usually the pressure in cylinder is considerably higher
than that required by the consuming appliances. A pressure regulator is therefore
required to reduce it to the operating pressure of the appliances.
The Pressure Regulator is a highly sensitive and important component used with the
cylinder and its main functions are as follows :
- To regulate the maximum LPG Inlet Vapour pressure of 16.9 Kg /Cm2 in the
cylinder to a nominal outlet pressure of 30 gf/cm2(g) (300 mm of water column)
for domestic installation of LPG Cylinders.
- To maintain a constant outlet pressure as above under varying gas flow within
its rated capacity of 500 litres/hour ( 0.5 m3/hr ) at outlet of the cylinder
valve.
The pressure regulators currently manufactured for use in domestic installations

are manufactured to meet Indian Standards specification code IS-9798.
Outlet connections for SC type of Pressure Regulators are for fixing the rubber
tubing / Suraksha LPG hose. Basic internal design and working of the regulators are
as per Sierra Design technology.
7.3.2 Markings on Pressure Regulators
Following Markings must be stamped on Pressure Regulator :
Manufacturer’s name or identification mark;
Month and year of manufacture ( i.e. Batch No );
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FEATURES OF CVR
Serial Number of the regulator
Maximum rated capacity in- m3 /h of LPG;
Number of IS Standard (i.e. IS-9798) with BIS monogram
Nominal outlet pressure ( i.e. 300 mm of WC)
Product for which the regulator being used ( LPG )
Owner’s name (i.e. Hindustan Petroleum Corporation Ltd.) in bilingual text with HPGAS
Logo.
Pressure Regulators for ‘SC’ type Valve (refer drawing attached).
7.3.3 Identification of OMC Regulators
Since all Regulators used for domestic purposes by the industry are standardized to
same specifications and are having the same shape & size, the industry has adopted
the following convention to facilitate identification of ownership.
HPC Regulators are powder coated with French Blue colour and HPGAS logo are marked
on the marking plate on cover of the regulator. Apart from the above, a marking
stating it as a property of HPCL in bilingual form also appears on the cover of the
DPRs.
IOC Regulators are powder coated with post office red colour and markings as
applicable for IOC on the marking plate.
BPC Regulators are powder coated with Golden Yellow and markings as applicable for
BPC on the marking plate.
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PARTS OF A HIGH PRESSURE CHAMBER IN A PRESSURE REGULATOR
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7.3.4 Mounting of the Regulator - SC Type

SC Type Pressure Regulators for self-closing cylinder valve —This regulator is similar
to earlier used MB type regulator except that the “mounting mechanism” is different
and has a two position knob as described below :
It has a vertical inlet without any threads. It is mounted on the self-closing cylinder
valve with the help of lever mechanism operated by a 2-position knob. The connection
is easily done by turning the knob on PR to off position, lifting the rubber bush ,
pressing it down gently on the valve outlet and locking the PR by releasing the bush
which ensures a 5 point sealing with the collar of the SC valve and gets checked by
smooth operation of turning the knob to ‘off or ‘on’ position as required.
In “off” position, the PR is locked, but the cylinder valve remains closed. In “on”
position the PR is locked and the cylinder valve-pin is pressed down, leaving the
valve seat open. The design of the PR is such that the valve seat will not open
unless the regulator is properly locked in position on the vale outlet.
The gas tightness on the connection, joining the valve and the PR, is achieved with
the help of sealing ring ( O-ring ) in the valve made of synthetic rubber. It must be
ensured at the time of mounting the regulator on the cylinder valve that this
synthetic seal ring is present in its place in the valve.
For disconnection the knob is turned to ‘disengage’ position and a slight vertical
“pull” is applied to disengage the PR by lifting the rubber bush upwards.
The regulator consists of a gas tight casing, with inlet and outlet passages divided
into two chambers by a flexible rubber diaphragm. The diaphragm is connected to a
valve in the vapour inlet connection, by a lever mechanism which closes the valve
when the diaphragm is raised. An adjustable compression spring is mounted above
the- diaphragm and applies a downward pressure which tends to open the valve. A
vent hole in the upper casing connects the chamber above the diaphragm to the
atmosphere.
The vapour from the cylinder flows into the lower chamber of the PR, and it tends
to lift the diaphragm against spring pressure and thus closes the valve. When the
vapour in the lower chamber is used the pressure under the diaphragm tends
to fall, thereby opening the valve.
In practice, state of balance exists and delivery pressure is held within narrow
limits as described in above coverage.
7.3.5 Regulator Freezing - Causes
Pressure regulators may become frozen if water is present in LPG. Water may enter
the system due to hydrostatic testing of vessels, cylinders, pipelines etc., or due to
breathing-in of empty cylinders if valves are left open.
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LPG both in liquid and vapour phase, absorbs moisture readily until saturation point
is reached. Any water present in the LPG cylinder would freeze due to fall in the
temperature on account of expansion of vapour through the regulator valve.
For SQC checks on new DPRs at Plants, refer Annexure 6
7.3.6 Testing of Regulators at Plant

Plant receives Old used regulators from Distributors due to the following reasons:
• Termination of customer
• Defective Replacement of Regulators by Distributors. Invariably it has been found
that good regulators also replaced due to its aging or appearance even though
functionally these are O.K
Thus Plant should test these regulators for soundness in the Test Bench provided at the
Plant. Basis the test results, condition of the regulators i.e. useable or scrap is decided.
Two type of tests are carried out to check the quality of Old regulators received at Plant.
(a) Soundness test – Regulator to be fitted on the Test bench connecting the test regulator.
By closing the bleeder valve, if bubbles are found in the test tube, then there is a
leakage from regulator body to the atmosphere. Thus regulator is not sound & same
to be rejected. In case regulator is found to be sound, then performance test to be
carried out as a confirmatory test to ensure that functioning of regulator is proper
(b) Performance Test – Connect the outlet of the regulator to a manometer . Switch on
the regulator and see the rise in water column of manometer. In case difference in
level in manometer is 300 mm of water column or below, then regulator is sound &
can be reused. In case the difference in level exceeds 300 mm of water column, the
the regulator is termed as high pressure i.e. there is no regulation of pressure &
regulator cannot be used for Domestic purpose.
Regulators found to be used in the above two tests to be taken in good inventory &
certified by the Plant as Tested O.K. & same can be issued to distributors.
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7.4 MANDATORY TESTING OF CYLINDERS
As described earlier the LPG cylinders are manufactured as per IS-3196. The new cylinders
are inspected and tested by BIS Inspector and a certificate of fitness is issued by them.
Based on the certificate, approval of filling permission is given by the Chief Controller of Explosive
( CCOE ) or his authorised representative (Inspector) for use of the cylinder for LPG. As part of
the test by BIS Inspector, hydrostatic tests and pneumatic tests are conducted on each cylinder
and the data of testing punched on the cylinder body.
Under the Gas Cylinder Rules , after the new cylinder is initially tested at the manufacturer’s
Plant, it is required to be retested periodically to ascertain fitness for further service. The
period of retest currently specified under the rules is every 5 years after the 1 st retesting
done after 7 years on new cylinders. Based on this, the testing for re-conditioning of
cylinders is known as ‘Mandatory testing’ or ‘5 years testing.
The tests for re-conditioning primarily include the following :
Visual inspection of cylinder body; both internally and externally; for dents, cuts, corrosion,
etc.
Hydrostatic test as per IS-3196.
Pneumatic test, after refitting the SC Valve, with the pressure of 12 Kg/Cm2.
For the sake of convenience, other related operations such as re-painting of the cylinder,
attending to cold repairs etc., are also carried out at the mandatory Testing Plant.
The cylinders found unfit for service during the visual inspection or hydrostatic test are
rejected for scrapping. Scrapped cylinders are required to be de-shaped by pressing before
disposal. In view of this, hydraulic press for de-shaping of the cylinders is also provided at
the testing Plant.
As segregation of cylinders for mandatory Testing is done at the filling Plants, the testing
Plants also should be planned in close proximity to minimize expenses on transportation
and also to have fast turn-round of the cylinders. Wherever in-house retesting facility for
pressure testing due cylinders are not available at plants, above selection of parties nearer
to plants assumes significance .
Though the Statutory Testing Plant does not require Chief Controller of Explosive’s licence,
the approval from Chief Controller of Explosive is necessary for running of the Plant. Further,
operations at the Plant have to be supervised by a competent person whose bio-data such
as name, qualification and experience should be sent to Chief Controller of Explosive for
approval.
The Statutory Testing operations at the Plant must be done in accordance

with the Gas Cylinder Rules, and all requirements mentioned therein must
be complied with. .
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As LPG cylinders which are stored and handled at the testing Plant contain LPG vapour, all
rules pertaining to and all precautions applicable to licenced premises must be observed.
One set of Gas Cylinder Rules, BIS Code in the form of Manual of Testing of LPG cylinders in
circulation, and all IS Standards referred to in these two publications MUST be available at
the testing Plant.
7.4.1 Equipments / facilities
Facilities/equipments at the Plant should confirm to Chief

Controller of Explosive requirements as listed in the Gas Cylinder Rules.
All electrical installations in the Plant should be flame-proof.
The basic facilities provided at the Statutory Testing Plant are given below :
• Degassing of cylinders taken out from circulation.

• Covered shed, well ventilated at ground level, for storage of cylinders
to be tested and carrying out the testing operations.
• Sufficient open area to store cylinders already tested, cylinder
discarded for scrapping and cylinders already de-shaped for disposal.
• Fire fighting facilities covering the covered shed and the open area.
• Water storage facility for hydrostatic test.
The basic equipments required at the Statutory Testing Plant are given below :
• Conveyor for transport of cylinders .within the testing Plant through various
stages of operations.
• Washing machine for external cleaning of the cylinders.
• Drying booths.
• Water jets for internal cleaning of the cylinders.
• Valve on-off-screwer.
• Extra low voltage FLP lamps to permit internal viewing of cylinders and
other FLP lamps for close examination of external surfaces.
• A pressure testing machine for hydrostatic test. The machine should conform
to requirements of the tests as detailed in IS-13258.
• Drying equipment for internal surface of the cylinder which would comprise
of jets of hot air.
• Air compressor for pneumatic test at the pressure of 12 kgf/cm2 .
• Weighing scale for verifying tare weight of the cylinder together with standard
test weights stamped by Weights and Measures Department.
• Hand trolleys for manual handling of cylinders.
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• Dead weight pressure gauge tester of appropriate pressure range or a calibrated

pressure gauge of minimum 15 cm diameter covering the appropriate pressure
range
• Miscellaneous equipment such as straight edges, templates, tools, gauges,
equipment for marking/stamping and stenciling.
7.4.2 Mandatory testing & painting procedure

Sequence of operations for the mandatory pressure testing of used LPG Cylinders shall
be as follows:
(i) Segregation of cylinders due for pressure testing.

(ii) Depressurising
(iii) Recording of cylinder details
(iv) Valve removal
(v) Degassing
(vi) External surface cleaning
(vii) External and internal inspection, internal cleaning
(viii) Bung thread inspection by l-1 & l-9 thread plug gauges
(ix) Tare weight checking
(x) Hydrostatic testing
(xi) Internal drying & inspection
(xii) Primer coating
(xiii) Signal red painting & general requirements of painting
(xiv) Punching of new test date and repair bottling plant’s Identification mark.
(xv) Tare weighing
(xvi) Incorporating french blue band on cylinder shroud, screen printing new tare
weight, net weight & next test date.
(xvii) Bung thread cleaning by tapping
(xviii) Valve fixing
(xix) Pneumatic test & air release
(xx) Stencilling of safety messages
(xxi) Record keeping.
(i) Segregation
All the markings of each cylinder shall be scrutinized to establish that it complies
with the requirements of IS:3196-Latest and with any other statutory requirement
applying to its use. The cylinders having lost its identity with respect to its original
manufacturer, serial number, date of manufacture and the relevant code of
manufacture shall be branded and declared unserviceable.
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The cylinders which are due for mandatory testing are segregated based on the due
for testing details (quarter and year) screen printed on the inside portion of one of
the three vertical stay plates. The year is divided into four quarters. January -
March is indicated by ‘A’, April-June is indicated by ‘B’, July - September is indicated
by ‘C’, October - December is indicated by ‘D’. The year is identified by the last two
digits. For example a cylinder which is due for testing in April 2007 is indicated by B-07.
(ii) Depressurising
All the cylinders shall be depressurised to atmospheric pressure in a safe manner by
using suitable adapters. Facilities for de-pressurising of the cylinders must be as
per CCOE guidelines and approved by CCOE.
(iii) Recording of Cylinder Details

Record the details of LPG Cylinders eg. Sr. No., Name of Manufacturer, Previous Test
Date, Present Tare Weight.
(iv) Removal of Valve

All the cylinders shall be depressurised to atmospheric pressure. The contents shall
be released in a safe manner.
At a time not more than 5 cylinders shall be depressurised. The gas shall be cold
flared by using a suitable adopter connected to a header. The gas so collected in the
headers shall be finally vented through a piping above the roof level.
The adopter used for the purpose should not press the valve spindle beyond 2.5 mm.
The valve shall be removed carefully after ensuring complete depressurization. While
removing the valve a suitable adopter and proper fixture shall be used to ensure
that valve cylinder is not damaged. Preferably the Cylinders should be vertical at
the time of valve removal.
(v) Degassing of Cylinders
Work on LPG cylinders shall not be carried out in enclosed space prior to degassing.
Degassing to be carried out in CCOE approved site. Cylinders shall be degassed by
purging the same by inert gas, steam or by filling water till it overflows. The water
shall be retained for not less than one hour to ensure that entire vapor or gas
remaining in the cylinder comes out. After emptying out the water, cylinders shall
be kept in inverted position and be tapped gently by non-metallic hammer to remove
dust, rust or any loose remnants in the cylinder.
After degassing the inside of LPG Cylinder shall be checked by explosimeter to ensure
that the Cylinder is gas freed and shall again be taken up for degassing till it is
completely gas freed.
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(vi) External surface Cleaning

Each cylinder shall have the external surface thoroughly cleaned by caustic soda
solution, non ferrous wire brushing and water jet. Care shall be taken to ensure
that the body of cylinder is not damaged.
While cleaning the surface of cylinder by caustic soda solution or water jet the bung
of cylinder should be closed by suitable plastic/rubber cap to prevent entry of solution
into the cylinder.
(vii) External and Internal Inspection , internal cleaning

All the cylinders shall be visually examined for dents, cuts, gouges, bulges, cracks,
laminations, corrosion at external and internal surfaces of cylinder as per IS:13258.
Cylinders beyond the acceptable limits as specified in IS:13258 shall be branded and
declared unserviceable.
For checking the internal surface of cylinders, a low voltage lamp of suitable intensity
shall be used.
Before carrying out the internal inspection of cylinders, the inside portion of cylinders
shall be properly cleaned by using vacuum pump, compressed/hot air and magnetic
bar to remove any foreign particles and traces of water inside the cylinder.
Cylinders having damaged non pressure parts such as valve protection (VP) ring,
foot ring etc., may be segregated for hot repair.
(viii) Valve pad (Bung) thread inspection

The thread of valve pad (bung) of each cylinder shall be checked by L-1 & L-9 plug
gauge. The valve pad thread shall be properly cleaned by soft wire brush and ¾”x14
NGT thread cleaning tap before checking.
The cylinders of which the valve pad thread is worn out, not meeting their respective
thread gauge, broken at any point, rough surface on threads shall be branded and
declared unserviceable.
(ix) Tare Weight Checking

After degassing and through external and internal cleaning, the cylinders shall be
checked for tare weight.
Any cylinder having lost its weight by more than 5% of original tare weight shall be
branded and declared as unserviceable
(x) Hydrostatic Test

More than one cylinder may be tested at a time provided that they all have the same
test pressure and that each individual test point is capable of being isolated.
The test pressure shall not be less than 2.45Mpa as marked on the cylinder.
The hydrostatic test pressure once attained shall be held for not less than 30 seconds
and during the test period the pressure gauge used for registering the pressure shall
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not indicate any drop in pressure. While carrying out the inspection of cylinder(s)
the external surface shall be totally dried for visual examination of leakage.
During the test period the cylinder(s) shall not show any sign of leakage, visible
deformation or defect.
Any cylinder that fails in the Hydrostatic testing shall be declared and branded as
unserviceable, provided that the drop in pressure due to leakage has not taken
place due to leakage in the fixture or the joints.
All the pressure gauges shall be calibrated once in a month and pressure gauge used
for verification shall be tested once in every 3 months. The records for calibration
shall be maintained.
The testing shed shall have adequate illumination.
(xi) Internal Drying & inspection

Subsequent to hydrostatic test the remaining water inside the cylinder shall be
completely removed. The internal surface shall be dried by compressed air, the
same shall be checked by low voltage lamp.
(xii) Primer Coating

Cylinder(s) found acceptable in all the tests described above shall be taken for primer
coating. Before applying the primer coat, it should be ensured that the external
surface of cylinder is properly cleaned of dirt, dust and loose remnants of previous
paint so that a uniform coating is obtained. The bung threads should be closed by a
plastic / rubber cap to prevent the entry of primer and paint into the cylinder.
The Zinc chromate primer used shall conform to IS:2074 and shall be of brushing
consistency and suitable for spraying. The colour of primer should be of red oxide.
(xiii) Signal Red Painting
After the cylinder(s) have been coated with primer, the cylinder(s) shall be left in air
for drying.
The signal red paint shall be based on super synthetic enamel conforming to IS:2932,
which is also shade No. 537 of IS:5.
The paint shall be of brushing consistency and suitable for application by spraying.
General Requirements for Painting

Both the primer coating and signal red finish paint shall be applied on the external
surface of cylinder by using a suitable pneumatic spraying gun in a fabricated painting
booth having provision for water curtain, draft and rotating arrangement for
cylinders).
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While applying the primer coating and final painting, care should be taken to ensure
that the shadow zones such as surfaces under foot ring, VP ring etc. are properly
coated.
A uniform coating of primer and finish paint shall be applied, the minimum coat
thickness for both layers of primer and paint shall not be less than 30 microns.
Sufficient drying time should be provided after finish painting. The area around the
bung with the VP ring shall be painted with French Blue band.
(xiv) New test date punching /repairer bottling plant’s identification

After satisfactory completion of periodic inspection and testing, each cylinder found
acceptable shall be punched with new test date on the designated stay plate, retaining
the previous test dates.( for example to indicate that the testing has been done in
May 2005 it is to be punched as 5-05 and this punching has to be just below the
previous punched test date ). The retesting bottling plant’s identification mark shall
also be incorporated in this stay plate.
(xv) Tare Weighing

The tare weighing shall be carried out including the weight of valve and safety cap.
The weighing scale used shall have a least count of not more than 50 gms and the
value of tare weight may be rounded off to the nearest 100 gms as per IS:2.
(xvi) French Blue Band incorporation and Screen Printing

The cylinders shall be taken for screen printing of tare weight, net weight and next
due date for testing. French Blue Band (Colour Shade confirming to Shade No. 166
of IS:5) to be incorporated on the shroud.
(xvii) Bung Thread Cleaning by Tapping

Use ¾” NGT Hand Taps for cleaning of Bung Thread
(xviii) Valve Fixing
Each valve shall be fitted with a suitable torque wrench at a torque of 145±15
lb-ft using teflon tape / suitable jointing compound to ensure a seal between the
valve and the bung joint. A suitable adopter shall be used to prevent any damage to
valve during valve fixing operation.
Before valve fixing operation the valve pad (bung) threads shall be cleaned by using
¾” NGT cleaning tap and wire brush.
Before valve fixing, the internal of cylinder shall be dried out by compressed air,
foreign particles etc. shall be removed by bar magnet and checked by low voltage
lamp.
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(xix) Pneumatic Test

Each cylinder after it has been fitted with valve shall be tested for leakage by
subjecting to air pressure of not less than 12 kgf/cm2 for a period of one minute
while immersed in water and shall show no leakage from the body of the cylinder
and the joint between valve and bung. This test shall be carried out after fixing
the safety cap on the valve.
(XX) All safety messages and other information are to be screen printed . Necessary
care to be taken to ensure letter size and font as specified in the approved
drawings.
(xx) Record Keeping & Certification

Record shall be maintained for all tests and inspections at the cylinder testing
station as per prescribed format as given in the annexure i.e. Route card & test
certificate.
Handling of Rejected Cylinder

All rejected cylinders shall be marked prominently with paint showing the reason
of rejection. Following code shall be used
HST-R - HST Testing

PT-R - Pneumatic Testing
LTW-R Tare Weight Loss
BT-R - Bung Thread Rej.
VI-R - Visual Insp. Rej.
MU-R - Marking Unidentified
HR - Hot Repair.
7.5 RE-CONDITIONING OF USED LPG CYLINDERS ( HOT REPAIR)
Cylinders with damaged foot ring and VP ring are permitted for repair with replacement of new
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one through hot work provided the cylinders are found serviceable after detailed external
examination as per IS: 13258.
Hot Repairing/Reconditioning of LPG cylinders shall be carried out in accordance with IS: 13258
(latest ) at the cylinder manufacturer / hot repairer premises.
Detailed scope of the reconditioning of used LPG Cylinders are as under:
A) VISUAL INSPECTION AND SEGREGATION AT LPG PLANT :
The repairer shall depute his technical representative along with necessary labour to the
LPG Plant for inspection and segregation of cylinders as per IS 13258 (latest) along with
LPG Plant officials before despatching them to repairers location for hot repair.
PRELIMINARY INSPECTION
a) The cylinders should be inspected for corrosion, dents, cuts and any other damages
as per the norms contained in latest edition of IS: 13258 (Code of Practice for Visual
Inspection of Low Pressure LP Gas Cylinders) or any other relevant IS Code/
Specification as published by BIS.
During inspection, the cylinders shall be segregated in the following categories: -
i) Repairable.
ii) Non - Repairable.
b) Make separate list of both the categories giving the following details :-
i) Manufacturer’s name.
ii) Serial number.
iii) Month/Year of manufacture.
c) In case of any of the above markings as stated in (b) above are found missing,
cylinders should not be taken for repair and should be segregated separately.
d) The entire repair of the cylinders to be carried out under BIS supervision.
B) PRELIMINARY INSPECTION AT REPAIRER’S PREMISES
Criteria as specified in Clause 6, 10 and Clause 11 of IS: 13258 (Code of Practice for
Inspection made as per Re-conditioning of Used LPG Cylinders) shall be used for
segregation of cylinders into repairable and unserviceable categories. The bung
threads shall be inspected with L - 1, and L - 9 gauges as per IS: 9121 (Latest
Revision)
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Separate list of both the categories are to be made. List of cylinders unserviceable
shall be made as per clause 11.1 Annexure “A” of IS: 13258 and that of cylinders
accepted shall be made as per Clause 19, Annexure “B” of IS: 13258.
Causes for unserviceable rejection and coding are as follows:
1) Bulge E-1
2) Burn E-2
3) Dent E-3
4) Dig E-4
5) Cut E-5
6) Pit E-6
7) line corrosion E-7
8) general corroision E-8
9) bung thread damage E-9
10) loss in tare weight E-10
11) identity lost E-11
12) cylinder identifed as once repaired E-12
13) The bottom of internal defect I-1
cannot be seen and extent cannot be measured
14) Wall thickness has been reduced by l-2
more than specified value
The entire repairs of the cylinders too be carried out under BIS supervision.
C) DEPRESSURIZING, VALVE REMOVAL & DEGASSING
All the valves should be removed and kept aside. Proper account to be kept thereof. Old
valves should be returned to LPG Plant.
D) TARE WEIGHT & MINIMUM THICKNESS VERIFICATION
The cylinder segregated as repairable is to be thoroughly degassed & cleaned internally

and externally and checked for correct determination of the tare weight.
Each cylinder shall be cleaned externally by wire brushing, water jet, abrasive cleaning,
approval chemical cleaning or any other suitable approved method.
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Where interior of the cylinder is affected by rust or other foreign materials, it shall be
cleaned by one of the following methods:-
Approved blasting/rotary: Air jet is applied inside the cylinder to force out the dust
particles and other foreign materials. Magnet is also used to remove shots and any other
magnetic material trapped inside the cylinder.
Burn out treatment: It is carried out in furnace at a temperature not exceeding 300°C
for a period not exceeding one hour after which all rust and any other foreign material
shall be removed stream cleaning or washing with approval solvent. Any cylinder having
lost its tare weight by over 5% of its original tare weight shall be rejected and set aside.
Only those cylinders which pass the tare weight test shall be processed further for repair
as necessary.
Affected portions of the body of the cylinders segregated during inspection under Section
1 of IS: 13258 shall be ground to achieve a defect free surface. Cylinder wall thickness so
achieved shall not be less than 90% of the designed wall thickness
The details of the cylinders rejected subsequent to tare weight & minimum thickness
verifications shall be incorporated in the pro-forma for rejected cylinders.
E) REMOVAL OF OLD DAMAGED FOOTRING & VP RING / STAY PLATES
The old foot ring, VP ring and stay plate , if damaged/defective, is to be removed by
cold method only without damaging the body of the cylinder. The welded spots shall be
ground and cleaned thoroughly for checking the surface for line corrosion, pits, etc. and
wall thickness. No cut or chisel marks shall be permitted on the cylinder body.
F) DE-DENTING OF LPG CYLINDER
De-denting of cylinders, if required, is to be done by cold process and in a manner that

does not impair in any manner the quality of the cylinders as per provision of IS: 3196.
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G) MARKING
Following original markings to be reproduced (wherever foot ring/VP ring has been
charged) as per details given in the standard drawing on the vertical stays of VP ring/
foot ring as the case may be.
i) Cylinder number.
ii) Original manufacturer’s name and repairer’s identification.
iii) Month and year of manufacture, retest and reconditioning.
iv) New tare weight and maximum gross weight of the cylinder in “kg”.
v) The maximum working pressure and test pressure in “kgf/cm2”.
vi) Water capacity in “Litres”.
vii) Any loss in original tare weight observed as per clause 10.4 of IS : 13258 shall be
punched at the foot ring. Example: if the loss in tare weight is 200 gms., it shall be
punched as LTW 200.
In addition, any other markings as supplied a stipulated in the Code of Practice for Hot
Repairing/Reconditioning of LPG Cylinders (IS: 13258) or any other revisions/
modifications of the markings are to be punched/ stamped.
The letter “R” shall be conspicuously stamped on the vertical stay of the valve protection
ring as close to certification mark as practicable for identification that the cylinder is
reconditioned. The letter shall be stamped on the footring also.
H) FIXING OF NEW FOOTRING AND NEW VP RING / STAY PLATES
The New VP RING / Stay Plate & Footring shall be as per standard drawing given by the
Oil Company. New FR & VP ring / shroud shall be welded in accordance to IS-3196 and all
weld shall be inspected for weld defects.
I) HEAT TREATMENT
After hot repairs and de-denting, stress reliving or normalising according to the process
adopted at the time of manufacture shall be carried out. After the heat treatment the
loose rust/foreign material inside the cylinder should be completely removed before
further processing.
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J) HYDROSTATIC TEST
1) Every cylinder shall be subjected to hydrostatic test as required by BIS code.

The hydrostatic test of cylinders should be carried out at the pressure of 2.45 MPa
(25.00 kg/cm2) and shall be retained for a period not less than 30 seconds after
drying the cylinder. Any reduction in pressure noticed during the test, any leakage,
visible bulge or deformation shall be treated as case of failure and all such cylinders
shall be rejected, segregated and details of same to be maintained in the format as
per Annexure - VI.
2) For cylinders passing this test the internal surface should be dried by blowing hot
air after emptying out the cylinders.
3) The details of the cylinders rejected subsequent to Hydrostatic Test shall be

incorporated in the pro-forma for rejected cylinders.
K) SHOT BLASTING / METALLIZING
Entire surface of cylinder, including valve protection collar should be shot blasted and
given the following treatment in sequence indicate below:-
Spraying with zinc metal to give a zinc layer of minimum 40 microns thickness. Zinc wire
used shall conform to IS: 12447 ( Specification for Zinc Wire for Sprayed Zinc Coatings.)
L) PAINTING
Entire surface of the cylinder shall be coated as per the anti-corrosive specifications
given below:-
(a) One coat of Red Oxide Zinc Chromate primer with a minimum coat thickness of 15
microns shall be applied on cylinder surface and allowed to dry.
(b) One coat of synthetic enamel paint as per IS: 2932 shall be applied. Colour shall be
of Signal red (shade 537 of IS: 5 ). Coat thickness of paint shall be minimum of 15
microns.
(c) After painting, all 14.2 kg & 19.0 kg cylinders shall be screen printed with HPGAS
logo as per the given drawing at two places opposite to each other.
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FEATURES OF CVR
M) STENCILLING
(a) Every cylinder to be stenciled for due date of re-test as per standard drawing.
(b) Tare weight/Maximum gross weight of the cylinder to be stenciled on body of the
cylinder as per standard drawing.
(c) Tare weight of the cylinder is also to be stenciled on inner side of stay plates as per
the drawing.
(d) Safety and other messages as specified in the drawing are also to be stenciled.
N) FIXING OF VALVE
Clean the bung internal taper thread to remove any foreign material. This should be
done by using an appropriate tap to ensure the threads are of full form, clean and free
from other imperfections (any foreign materials to be removed from inside). The cylinder
valve is to be fitted by uniformly applying Teflon tape of IS: 3465 having a width of ¾”
and a minimum thickness of 40 microns for a minimum of two and a half rounds. Valves
shall be fitted with a tightened torque of 145 +/-15 lb.-ft. As a thumb rule, it has to be
ensured that 5 to 6 threads are visible above the bung .
O) PNEUMATIC TEST
After fixing the valve, cylinder shall be subjected to internal pneumatic pressure of not
less than 12 kg/cm2 for a period of one minute while immersed in water and the cylinder
shall be checked for leakage from the body of the cylinder & at the joint between valve
& bung. This test shall be carried out after fixing the safety cap on the valve. The test
results must be included in the inspection certificate. Suitable test bath facilitating the
rotation of the cylinder in immersed condition shall be available with proper illumination.
After testing air shall be evacuated till pressure inside the cylinder drops to atmospheric
pressure.
The cylinders rejected while carrying out “Hot Repairs” at the contractors works are to
be returned to LPG Plant in that condition, accompanied by a forwarding note, giving
serial number, name of manufacturer etc. and the cause of rejection.
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FIRE PREVENTION & SAFETY
INDEX
8.0 General 1
8.1 Fire protection system 1
8.2 Design criteria for fire fighting system 1
8.3 Fire water system 2
8.3.1 Components of the fire fighting system 2
8.3.2 Flow rate design 2
8.3.3 Fire water system design 4
8.3.4 Fire water storage 4
8.3.5 Fire water pump 4
8.3.6 Fire hydrant network 5
8.3.7 Material specifications 7
8.3.8 Medium velocity spray sprinkler system 7
8.4 Fire fighting equipment 9
8.4.1 Portable fire-extinguisher 9
8.4.2 Wheeled / mobile fire fighting equipment 10
8.5 Hoses, Nozzles & Accessories 10
8.6 Fire / Alarm / Communication system 12
8.6.1 Fire alarm system 12

8
8.6.2 Communication system 12
8.7 Special fire protection 13
8.8 Inspection & Testing 14
8.9 Changes in fire fighting facilities requirement considering Plants 15

constructed as per OISD 169 with respect to OISD 144
8.9.1 Flow rate design 15
8.9.2 Fire water storage 15
8.9.3 Fire water pump 16
8.10 Automatic fire fighting system 16
8.11 Gas Monitoring system 17
8.11.1 General 17
8.11.2 Application 17
8.12 Safe operating practices 19

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8.0 GENERAL.
LPG Bottling Plants are generally located away from populated areas in view of hazardous nature
of product. With the passage of time these plants get surrounded by settlements/ residential
localities in the absence of any statutory regulations prohibiting their construction.
Due to large quantities of highly inflammable product stored in the Bottling Plants these pose
safety risk to the plant as well as to the surrounding environment. Therefore, it is very much
essential that elaborate in-built Fire Protection Facilities are installed at the LPG Bottling Plants.
8.1 FIRE PROTECTION SYSTEM
a. Portable Fire Extinguishers / Equipments to fight small / approaching fire

b. Fire Fighting system with Automatic Operation to fight Emergency involving major fire
Specific norms of various types of fire extinguishers and equipment to be kept at plant has been
stipulated in the OISD 144.
In case of fire fighting system detailed design and operating parameters have been defined.
Provisions for fire fighting facilities for plants construction as per OISD 144 is different from
plant constructed as per OISD 169. Majority of plants are as per OISD 144. Details of Fire fighting
facilities as per OISD 144 are as below.
8.2 DESIGN CRITERIA FOR FIRE FIGHTING SYSTEM
i) Facilities shall be preferably designed on the basis of plant area, LPG handled, Inhabitation
around the plant and availability of Auxiliary source of water and other facilities near the
plant.
ii) The single largest fire risk shall be considered.
iii) All LPG storage Vessels, Cylinder Storage/ Filling/ Repair Sheds, LPG Pump Houses, Bulk
Lorry and Tank Wagon Gantries shall be fully covered by medium velocity water spray system.
iv) Fire Protection Facilities shall have fire fighting access, means of escape in case of fire and
also segregation of facilities so that the adjacent facilities are not endangered during the
fire. The layout shall permit access from at least two directions.
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v) Detection of fire for automatic actuation of medium velocity water sprinkler system shall be
provided at all critical places like LPG Bulk Storage, Tank Truck/ Tank Wagon Gantry, near
Carousal, LPG pump/ Compressor House, Evacuation, Valve Change Shed etc.
8.3 FIRE WATER SYSTEM
Water is used for fire extinguishment, fire control, cooling of vessels/ equipment and exposure
protection of equipment and personnel from heat radiation.
8.3.1 Components of fire water system
The main components of the system are :
- Fire Water Storage
- Fire Water Pumps
- Fire Hydrant/ Monitor distribution piping network.
- Water Sprinkler/ Deluge system.
8.3.2 Flow rate design
The Fire Water pumping requirement shall be calculated based on minimum spray density
as under :
Storage Vessels - 10.2 LPM/Sqm

LPG Shed - 10.2 LPM/Sqm
LPG Pump/compressor House - 20.4 LPM/Sqm
LPG Loading racks - 10.2 LPM/Sqm
a) Storage Vessels
In case of Bulk Storage of LPG, automatic detection of heat for automatic actuation
of medium velocity (MV) sprinkler system having remote/ local operated deluge valve
with spray density of 10.2 LPM/Sqm of surface area shall be provided. For water
flow calculations adjoining vessels within distance of R+30 Mts. (Where R is the
Radius of the LPG vessel and 30 Mts. shall be measured from the periphery of the
LPG vessel), water density for cooling shall be considered at the rate of 10.2 LPM/
Sqm surface area.
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b) Sheds
MV sprinkler system having remote operated deluge valve and at critical places like
near carousal, evacuation, valve change shed, automatic detection of heat for
automatic operation of sprinkler system with spray density 10.2 LPM/Sq.M. shall be
provided. The shed has to be divided into suitable number of zones, each served by
independent deluge system. The adjacent zones are required to be operative around
the zone under fire and the same shall be considered as a single risk.
In case sheds are separated with 15m safety distance but zoning is not provided in
the same shed, then the full shed shall be considered as one Zone.
c) LPG Pump House
MV sprinkler system with automatic heat detection having remote/ local operated
Deluge valve with spray density of Max. 20.4 LPM/Sqm shall be provided.
d) Tank Lorry Gantry
In case of Tank Lorry Gantry, automatic detection of heat for automatic actuation of
MV sprinkler system having remote/ local operated deluge valve with spray density
10.2 LPM/Sqm of surface area shall be provided. A maximum of 8 bays shall be
considered as single risk area.
e) Tank Wagon Gantry
MV sprinkler system with automatic heat detection having remote/ local operated
deluge valve with effective spray density of 10.2 LPM/Sqm shall be provided. A
minimum of one gantry (600 MTs) shall be considered as single risk, if both the
halves of the gantry is separated with 50m safety distance, otherwise full gantry
shall be considered as single risk area. The spray system shall cover tank wagons
surface on either side of tank wagon gantry as well as the associated LPG pipelines
in the gantry.
The fire water system in the plant shall be designed to meet the highest fire water
flow requirement of a single largest risk of any of the above cases at a time plus 288
Cum/Hr. for operating 2 Nos. Fire water Monitors/ Supplementary Hose requirements.
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8.3.3 Fire water system design
i) The Fire Water pressure system shall be designed for a minimum residual pressure
of 7.0 kgs/ Sqcm at the remotest place of application in the plant.
ii) A fire water ring main shall be provided all around perimeter of the LPG Plant
facilities & it should cover bulk/packed truck parking area with hydrants/ monitors
spaced at 30 M centre to centre. Fire hydrants and monitors shall not be installed
within 15 Meters from the facilities/ equipment to be protected.
iii) Fire hydrant network shall be in closed loops to ensure multidirectional flow in the
system. Isolation valves shall be provided to enable isolation of any section of the
network without affecting the flow in the rest. The isolation valves shall be located
normally near the loop junction. Additional isolation valves shall be provided in the
segments where, the length of the segment exceeds 300 Mts.
8.3.4 Fire water storage
i) Water for the hydrant service shall be stored in any easily accessible surface of
underground concrete reservoir or above ground tank of steel or concrete. However,
above ground tanks shall be preferred in view of the availability of flooded suction
condition for easy start of fire water engines. The effective storage capacity shall
be not less than 4 Hrs. aggregate working capacity of Fire Water pumps. Sample
calculation is given in the annexure 9
ii) Storage tank/ reservoir shall be in two inter connected compartments to facilitate
cleaning and repairs. In case of steel tanks there shall be a minimum of two tanks.
8.3.5 Fire water pumps
i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head. These pumps preferably should have a flooded suction.
ii) There shall be jockey pump of capacity so designed to achieve a pressure of 7 kg/
cm2 at the farthest end of the hydrant system . The system pressure has to be
maintained at 7 kg/cm2 with the help of Jockey Pump operating automatically. Leakage
from the fire hydrant network system should not be there to ensure required water
pressure in the line & minimum operations of jockey pump.
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The Jockey Pump shall be quick auto start-stop type with the help of pressure switches.
A standby jockey pump shall be provided if the number of hydrant points are more
than 100.
iii) The fire water pump(s) including the stand by pump(s) shall be of diesel engine
driven type. The pumps shall be capable of discharging 150% of its rated discharge
at a minimum of 65% of the rated head. Each engine shall have an independent fuel
tank of suitable size for 6 Hrs. continuous running.
iv) No. of stand by pumps shall be provided as per following criteria :
a) Minimum 1 no.
b) 50% upto 4 Nos. of Main pumps.
c) For 4 and above, minimum 2 Nos.
v) Fire water pump house/ Fire water tanks or reservoir shall be located atleast 60 M
(minimum) away from LPG facilities.
vi) Fire water pumps shall be exclusively used for Fire Fighting purpose only.
8.3.6 Fire hydrant network

i) Fire hydrant ring main should be normally laid above ground. Following precautions
should be taken if fire water ring main laid above ground:
a) Pipe line shall be laid at a height of 300 mm to 400mm above finished ground
level. Clearance shall be maintained to avoid corrosion.
b) The mains shall be supported at regular intervals not exceeding 6 meters.
c) The system for above ground portion shall be analysed for flexibility against
thermal expansion and necessary expansion loops where called for shall be
provided.
ii) However the ring main shall be laid underground at the following places :
a) Road crossings.
b) Places where above ground piping is likely to cause obstruction to operation and
vehicle movement.
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c) Places where above ground piping is likely to get damaged mechanically,

particularly in the LPG storage area where water supply lines are laid for feeding
sprinkler deluge system.
d) Where Frost conditions warrant and ambient temperature is likely to fall below
zero deg. centigrade underground piping at least 1 meter below the ground level
should be provided.
iii) If Fire water ring main laid underground the following precautions shall be taken:
a) The Ring main shall have at least one meter earth cushion in open ground and 1.2
meters cushion under the road crossings.
b) The Ring main shall be provided with protection against soil corrosion by suitable
coatings/ wrappings.
c) In case of poor soil conditions it may be necessary to provide concrete/ masonry

supports under the pipe line.
iv) Fire water ring main shall be sized for 120% of the design water rate. Design flow
rates shall be distributed at nodal points to give the most realistic way of water
requirements in an emergency.
v) The fire water network shall be kept pressurised to a pressure of about 7 kg/sqcm
with the help of one or more Jockey pumps.
vi) Hydrants/ monitors shall be located bearing in mind the fire hazards at different
sections of the premises to be protected and to give most effective service.
vii) Hydrant/ monitors shall be provided for every 30 meters in case of hazardous areas
and may be spaced 45 meters in other areas.
viii)Connections for fire water monitors shall be provided with independent isolation
valves.
ix) Hose boxes with 2 nos. hoses and a nozzle shall be provided between the hydrant
points.
x) Considering radiation levels in the event of a fire hydrants/ Monitors/ Control valves
shall be located at a safe distance (minimum distance of 15 mts.) and from hazardous
equipment/ buildings.
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xi) The deluge valves shall be located out side the kerb wall at a safe distance in case of
LPG spheres/ bullets and 15 meters away from the limits of LPG cylinder sheds. A
fire wall shall be provided for the protection of deluge valve and for operating
personnel.
8.3.7 Material specifications
All the materials used in fire water system using fresh water shall be of approved type as
indicated below.
In case of sea water service, the fire water main pipes shall be concrete mortar lined
internally.
i) Pipes CS as per IS:3589/IS:1239

ii)Isolation Valves CS
iii)
Deluge valves CS
iv)Hydrant Standpost CS
Outlet valves Gunmetal/ Aluminium
v) Monitors CS
vi) In case of underground mains the isolation valves shall be located in RCC/ brick
masonary chamber.
vii) The above ground fire water main and the fire hydrant standpost shall be painted
with corrosion resistant “Fire Red” paint.
viii) Water monitor and hose box shall be painted “Luminous Yellow’.
8.3.8 Medium velocity spray sprinkler system
i) Medium velocity sprinkler system based on heat and other detection shall be employed.
ii) Quartzoid Bulb protection can be provided in open areas or in the sheds. The Quartzoid
Bulbs are designed to blow at 79 deg. centigrade (max.) and Quartzoid Bulb network
shall be maintained with plant air at a pressure of about 3.5 kgs/sqcm through a
restriction orifice and is such that the discharge of air through one Quartzoid Bulb
will depressurise the down stream side of the restriction orifice.
iii) The Electro pneumatic (E.P) heat detectors can be provided in the sheds and they
work on the following principle :
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a) Rate of rise of temp 10 deg. C/Minute.
b) At 79 deg. C(max.)
The EP detectors are divided into groups and alternate detectors are connected in
one circuit. Two detectors from two different groups shall function/ operate for
actuation of sprinkler system.
iv) The actuation of detectors shall initiate the following :
a) Opening of deluge valve.
b) Audio-visual alarm at the fire pump house/ control panel.
c) Fire siren.
d) The diesel pump will start based on their set pressure to supplement/ to maintain
the fire water pressure in the ring main.
ROV’s of Fire-safe type shall be provided.
The following areas shall be covered with the medium velocity spray system in the LPG
Bottling Plants :
a) LPG Bulk Storage Area :
Automatic detection of heat for automatic actuation of MV sprinkler system having

remote/ local operated deluge valve shall be provided.
b) Tank Wagon Loading/ Unloading Area :
MV sprinkler system having remote/ local operated deluge valves shall be provided.
Tank wagon loading/ unloading area shall be divided into six zones and one deluge
valve shall cover 12 LPG tank wagons at a time (60 Meters long on each spur).
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c) Tank Lorry Loading/ Unloading Area
Detection of heat for automatic actuation of MV sprinkler system having remote/

local operated deluge valve shall be provided. One deluge valve shall be provided
for a maximum of 4 bays.
d) LPG Sheds
MV sprinkler system having remote/ local operated deluge valve and at critical places
like carousal, evacuation, valve change shed, automatic detection of heat for
automatic operation of sprinkler system shall be provided.
e) LPG Pump/Compressor House
Based on heat detection automatic MV sprinkler system having remote/ local operated
deluge valves shall be provided.
8.4 FIRE FIGHTING EQUIPMENT
8.4.1 Portable fire extinguisher
i) Portable fire extinguishers shall be located at convenient locations and shall at all
times be readily accessible and clearly visible.
ii) The maximum running distance to locate an extinguisher in working areas shall not
exceed 15 meters.
iii) The top surface of the extinguisher shall not be more than 1.5 meter high.
iv) The fire extinguishers shall be provided at various locations as under :
Area Portable Fire Extinguisher

LPG Storage Vessels (Each) 2 Nos. 10 kg DCP extinguisher
LPG cylinder Sheds 2 Nos. 10 kg DCP extinguisher per 200 Sqm area
LPG Pump House 2 Nos. 10 kg. DCP extinguisher per 50 Sqm area.
Tank Truck loading/unloading 1 No. 10 kg. DCP extinguisher in each bay.

gantries
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Tank Wagon loading/ 1 No. 10 kg DCP extinguisher for every

unloading gantries 15/20 meters of gantry.
Other Pump Houses 2 Nos. 10 kg DCP extinguisher
Office/Canteen/Stores At least 2 Nos. 10 kg DCP extinguishers in each building
MCC/DG Room/HT At least 2 nos. 4.5 Kg CO2 extinguishers in

each room or for floor area of about 100 Sq.m.
& 4 sand buckets & a stand shall be provided in MCC/DG room.
v) 100% spare CO2 cartridges and 50% (Min) spare DCP bags (as per Fire Extinguisher
Capacities) shall be stored in the LPG plant.
8.4.2 Wheeled/ mobile fire fighting equipment
i) One No. Mobile 75 Kg DCP fire extinguisher shall be provided in filling shed, LPG
storage vessels/ LPG Pump House area, Tank truck loading/ unloading gantry area
& tank wagon loading/ unloading gantry area.
ii) The Dry chemical powder used in the extinguishers shall be Potassium/ Urea based
or Sodium Bicarbonate as per IS:4308. Nitrogen/ Carbon Dioxide shall be used as
expellent gas.
iii) Considering the large area, and no. of operations involved in Mega LPG Plants,
special fire fighting facilities like DCP fire tenders should preferably be provided.
iv) A trolley with suitable first aid fire protective accessories shall be readily available
in the LPG plant.
8.5 HOSES, NOZZLES AND ACCESSOREIS
i) Reinforced rubber lined hoses (63mm) conforming to IS:636 (type A or B) shall be

provided.
ii) The hoses shall be of 15 Meters standard length and shall be provided with Gun
metal/ Aluminium alloy male & female couplings of instantaneous pattern.
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iii) 50% spare Hoses shall be stored in the LPG plant.
iv) In addition to the nozzles provided in the hose boxes there shall be at least 2 Nos.
spare nozzles in each category viz. Jet Nozzles with branch pipes, Fog Nozzles,
universal Nozzles, water curtain Nozzles, Spray Nozzles and Tripple purpose nozzles
in the plant.
v) The following accessories/ first aid items shall be provided in the plant :
1. Fire hoses 100% of no. of hydrant points.
2. Safety helmets As required ( Min. 10 Nos.) 1 no. for each person
3. Hose Boxes Alternate hydrant point.
4. Stretcher with blankets Min. 2 Nos.
5. First aid Box Min. 2 nos.
6. Rubber hand gloves Min. 2 pairs

for electrical purpose (BIS approved)
7. Low temperature 4 pairs

rubber hand gloves
for LPG emergency.
8. Low tem. protective Min. 2 sets

clothing for LPG
emergency.
9. Explosimeter Min. 2 Nos.
10. Fire proximity suit Min. 1 No.
11. Resuscitator Min. 2 Nos.
12. Red/Green Flags As required
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13. Self contained Min. 1 No.

breathing apparatus
with one spare cyl.
(Cap. 30 minutes)
14. Water jet blankets Min. 2 nos.
The above are guidelines and minimum requirements of each item and can be increased depending
upon the scale of operations, statutory/ mandatory requirement of local bodies/ State
Governments or any other expert body.
8.6 FIRE/ ALARM/ COMMUNICATION SYSTEM
8.6.1 Fire alarm system
i) Sufficient No. of Manual call points shall be provided in the plant.
ii) Electricity operated Fire Siren shall be audible to the farthest distance in the plant (1
K.M. from the periphery of the plant).
iii) Manually operated fire sirens shall be provided at strategic places.
iv) For fire condition the siren shall be wailing sound for minimum 2 minutes and for all
clear signal it shall be straight run siren for 2 minutes.
v) For Disaster condition the wailing sound given shall be repeated thrice with a minimum
10 seconds gap.
8.6.2 Communication system
i) Communication system like telephone/ PA or paging or walkie-talkie shall be provided.
ii) In the hazardous areas flame-proof telephones shall be provided.
iii) Wherever possible Hot line connection between City Fire Brigade/ near by major
Industries shall be provided.
iv) Plant shall have a ‘ Mutual Aid’ arrangement with near by industries.
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8.7 SPECIAL FIRE PROTECTION
The most hazardous situation in LPG vessel is the possibility of BLEVE. This usually takes place
when the vessel is subjected to external fire.
The un-wetted (vapour space) portion of the shell gets overheated and fails even at the operating
pressure. As such, it is important that metal temperature in the vapour space is protected from
overheating by some measures. A passive measure like fire proofing/ insulation or fire retardant
coating will provide protection in the initial period of fire which is very crucial. This will give
some breathing time for activating other fire fighting measures like starting of pumps, organising
people, opening of valves etc. This will also take care of automation failure wherever it is
provided.
The fireproofing of LPG storage vessel should be decided based on the risk analysis keeping in
view local considerations, availability of water and societal risk.
Since the risk of BLEVE gets reduced to insignificant level with the provision of mounded storage,
all new facilities for storage of LPG/ Propane should preferably be of mounded type.
Fire proofing provided on the vessel and supporting legs shall be adequate to protect the shell
material from overheating and consequent failure. The material provided for fire proofing purpose
shall be good enough to provide this protection for the initial 30-60 minutes. Based on this it is
recommended to provide the minimum rating for fire proofing as follows :
LPG storage vessel & connected 1 hour

lines upto the fire safe ROVs
Supporting legs of all above 2 hour
Before fire-proofing application, protected metal surfaces shall be prepared through such means
as sand-blasting and corrosion-protective primers. Particular attention shall be given to the top
junction of the fire-proofing with the protected metal to prevent water ingress.
Fire water line to each sphere should be so routed that it is not exposed to direct fire. This is to
protect it from failure in the initial period when water flow has not commenced. It is recommended
that riser should be located away from bottom ROV. The horizontal run of the Fire Water line
may be buried if fire engulfment cannot be avoided otherwise. Fire proofing shall include
connected LPG lines and pipe supports within 15 M of a storage vessel or in the drainage paths.
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8.8 INSPECTION AND TESTING
The fire protection equipment shall be kept in good operating condition all the time.
The fire fighting system shall be periodically tested for proper functioning and logged for record
and corrective actions. In addition to routine daily checks/ maintenance the following periodic
inspection/ testing shall be ensured.
(a) Fire water pumps
i) Every Pump shall be in test run for atleast 10 min. twice in a week at the rated conditions.
ii) Once in a month each pump shall be checked and tested and the shut-off pressure
observed and logged. Also the pump performance shall be ascertained.
iii) The Jockey pump operation shall be checked periodically. Frequent start/ stop condition
of Jockey pump indicates that there are water leaks in the system.
(b) Fire water ring main
i) The ring main shall be kept pressurised at 7 kg/sq.cm.g with the help of one or more
jockey pumps.
ii) The ring main shall be inspected for any visual leaks, detects, damage and corrosion.
iii) All valves on the ring main/ hydrant/ monitor valves shall be checked for leaks/ operation
and lubricated once in a month.
(c ) Fire water sprinkler system
i) All deluge valves and sprinkler system shall be operated and checked once in a quarter
for correct remote operation performance of each nozzle and effectiveness of system in
total.
ii) The sprinkler system in the sheds shall be tested by closing the outlet of the deluge valve
for correct remote operation once in a quarter.
iii) The strainers provided in the Fire water sprinkler system shall be cleaned once in a
quarter and records maintained.
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(d) Fire water reservoir
In case of a Reservoir the same shall be cleaned once in 6 months or earlier as and when
needed so that there shall not be any foreign particles/ fungus/ vegetation in the reservoir.
Fungus / vegetation can be avoided with treatment of water in reservoir by bleaching
powder or any suitable chemical.
(e) Make up water
Facilities to make up water during fire fighting shall be provided.
8.9 CHANGES IN FIRE FIGHTING FACILITIES REQUIREMENTS CONSIDERING PLANTS CONSTRUCTED

AS PER OISD 169 WITH RESPECT TO OISD 144
8.9.1 Flow rate design

(i) The fire water pumping requirement shall be calculated based on spray density as given
below :
LPG Storage Vessels 10 LPM/Sq M.
LPG Shed 10 LPM/Sq. M.
LPG Unloading Gantry 10 LPM/Sq. M.
(ii) (a) LPG STORAGE VESSELS
Fixed water system with manually operated isolation valve located at a safe distance
of 15 meters shall be provided. For water flow calculations adjoining vessels within
distance of R + 15 Mts. (Where R is the radius of the LPG Vessels) shall be considered.
(b) WATER REQUIREMENT
The fire water system in the plant shall be designed to meet the highest fire water
flow requirement of a single largest risk of any of the above cases at a time plus 72
Cu. M per hour for operating 2 hydrant points.
8.9.2 Fire water storage
(i) Water for the hydrant service shall be stored preferably in above ground tanks for
availing the advantage of flooded suction to enable easy start of fire water pump.
The effective storage capacity shall be for two hours aggregate working capacity of
fire water pumps
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8.9.3 Fire water pump
(i) Centrifugal type fire water pumps shall be installed to meet the designed fire water
flow rate and head.
(ii) Atleast one fire water pump shall be of diesel engine driven type.
(iii) Pumps shall be capable of discharging 150% of its rated discharge at a minimum of
65% of the rated head.
(iv) Fire water pumps shall be exclusively used for fire fighting purposes only.
No. of fire water pumps of appropriate capacity shall be provided as per the following criteria:
(a) Normal operation - 1 No.
(b) Stand –By - 1 No.
8.10 AUTOMATIC FIRE FIGHTING SYSTEM
The fire water hydrant system is to be maintained in pressurized condition with water pressure
of 7 Kg/cm2 at Farthest end. Fire Fighting system is provided with Jockey pump to keep the
system in pressurized condition in Auto mode through pressure switch.
Jockey pump is generally set to operate at minimum of 7 kg/cm2 and cut off pressure at 8 kg/
cm2 or more based on the pipeline network. A standby jockey pump is also to be maintained.
Principle of Operation of Fire Fighting System in Auto Mode: In case jockey pump fails to maintain
pressure due to opening of outlets from the hydrant network, Fire Engines are set logically with
set pressure as below .
First Engine will start immediately on dropping the pressure below 7 Kg/cm2. In case the Engine
is able to maintain the pressure at 7 Kg/cm2 , next pump will not start. In case the pump is not
able to maintain the pressure, then subsequent pumps will start one by one till it maintains the
hydrant pressure of 7 Kg/cm2. Standby pumps shall not be kept in Auto mode as long as the main
pumps are in working order.
The operation of soundness of auto system shall be checked regularly by opening bypass line /
or by opening any of the major risk area.
Fire water network operates in Auto mode basis signal it receives from area under emergency
either through communication as below
1. Breaking of Quartzoid Bulb
2. Manual opening of Air pressure switch
3. Pressing the manual call point
4. Opening of any outlets of pressurized hydrant network
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In any of above case, logic shall be such that solenoid valve at the DV station gets deactivated
opening the sprinkler line. Logic may be provided by way of Relay system or by PLC
(Programmable logic controller) system.
After the Emergency is over, the effected Deluge valve shall be isolated by opening the water
balancing line which balances the inlet pressure and pressure of the deluge valve thereby
closing the deluge valve. Then reset the Fire Fighting panel alarm system and reset the deluge
valve at field.
8.11 GAS MONITORING SYSTEM
8.11.1 General
The best method of prevention of explosion is to avoid basic build up of gas concentration
immediately on occurrence of leakage. This would require basically a reliable and
continuous detection system with warning annunciation to alert the plant personnel to
take corrective action. The Gas Monitoring system is to provide early warning on build
up of dispersed gas concentration below the LFL limits. The system shall be designed
considering small leaks ( leaks which have secondary closures ) such as mechanical seals
failure, sampling point lef open, gasket leaks, hose pinholes, valves gland leakage,
drain point left partially open, TSV’s relief discharge in manifold area, filling / evacuation
hoses leakage.
8.11.2 Application
The detectors for the gas monitoring system shall be strategically located in LPG Bottling
plant at all facilities close to the potential source of leakage
The detection control equipment should be provided in the control room for continous
monitoring even during power failure.
(A) DETECTORS
Amongst the various methods of detection available, the following proven systems
for LPG can be considered.
i) Catalytic detectors
ii) Infra-red detectors
March - 2006 17 of 21
8
(B) CONTROL SYSTEMS
a. This is a critical equipment for plant’s safety. Hence , the system should have
independent control equipment. Power supply, UPS to ensure that the system
remains in operation even if the plant DCS or other common process controls
are not functioning. In case of bottling plant in Refineries, dropping of the
signals on the DCS is acceptable wherever hot standby DCS control system is
available
b. In case of failure or during maintenance when the system is not in operation,
the plant safety officer should keep the plant personnel on alert to be more
vigilant during operations and night security patrolling
c. The control equipment should have data logging facilities to provide print outs
of the history of the events with date and time of leakages
d. The control equipment should be able to generate at least two alarms at different
levels of LEL concentration of gas.
e. The control equipment is not required to have automatic corrective action
capabilities on sensing leakages as this is basically a warning device. However
, in case of any specific recommendations made in the risk analysis / HAZOP
studies, the same should be implemented
(C) ANNUNCIATION SYSTEMS
Appropriate annunciation system shall be available to ensure that all the alarms
generated, both, audio and visual are reported to the plant personnel, who are
authorized to take corrective action. Depending on the manning practice of the
plant, the alarms both, audio and visual can be repeated at additional location to
ensure corrective action is taken.
(D) LOCATION OF DETECTORS

i) The behaviour of the gas leakage governs the positioning of the gas detector.
As LPG is heavier than air, the height of the detector should not be more than
0.3 M from the mounting level
ii) The pre-dominant wind direction should be considered with respect to the
potential source of leakage to ensure positioning of the detector on the down
stream of the wind direction
iii) The detectors especially the catalytic type should be positioned very close to the
potential source of leakage to avoid poisioning of the detectors ( temporary
malfunctioning ). The detectors should be located at least 0.3 mtrs away from
the potential source of leakage.
March - 2006 18 of 21
8
iv) In case of infra-red detectors, the same shall be installed on the down wind side
ensuring the path is free from obstructions. In case any additional expansion/
construction if undertaken, the detectors will have to pre-positioned.
v) The minium detectors facilities-wise are given below:

Storage vessels ( above ground ) – 1 No. top and 1 No. near bottom ROV
LPG Pump house 1 No. in pump hose and1 No. in manifold
Filled cylinder shed – 1 No
Valve change shed – 1 No
8.12 SAFE OPERATING PRACTICES TO BE FOLLOWED AT LPG PLANTS / INSTALLATIONS
Hot Work & Cold Work to be carried out with proper Work Permit system as per OISD -105
Plant Should ensure closure of the permit on completion of job and maintain records for
future reference
Identity card should be issued to all the contractor employees by the contractor authorizing
their entry to the Work area
Safety shoes, hand gloves, helmets etc. and other related protective equipments shall be
used while carrying out the specified job.
Specific care shall be taken while working at heights and entry to a vessel .
Explosimeter to be used to ensure that the working araea is free from LPG before commencing
any hot work.
Authorised and Qualified Electricians to be allowed to work in electrical Installations.
Earthing of all electrical equipment to be checked for its continuity and earth resistance on
regular intervals.
Welding Job shall not be carried out in explosive area unless or otherwise it is unavoidable.
However, In case it is to be carried out , specific permission must be taken from the
location incharge .
Protective equipment shall be used while carrying out weldings.
Floor area in all the operating sheds shall be maintained clean and free from foreign materials
like soap solution, oil spillage, cotton waste etc.
March - 2006 19 of 21
8
Cylinder handling shall be carried out on the conveyor . No rolling of cylinder should be
allowed. In case it is not possible to handle the cylinders ( due to its shape & Size ) in
conveyors then mechanized trolleys / puller or pusher to be used to handle such cylinders.
Maintain the speed of carrousel at its optimum i.e. 66 to 72 seconds per revolution.
Use proper Non sparking tools and tackles for M&R jobs involving LPG equipment.
Use proper earthing while loading / Unloading tank truck / tank wagons .
Use recommended tools for connection and disconnection of loading / Unloading Hoses/
arms.
Ensure the evacuation of valves in defective cylinders at the Day end.
No defective cylinders shall be left uncapped whether it is filled or empty.
Stacking of cylinders shall be made as per VSCR recommendations with identified lots.
De-pressurize the defective cylinders before opening the valves for replacement.
Use Torque wrench for fixing valve in the cylinders with allowable torque.
Maintain standard weights at Check scale and at weigh bridge.
Ensure the operation of vapour extraction system during operating period.
Vapour extraction system should be inter-locked with the operation of the carrousel.
Ensure proper setting of relays for all motors connected with conveyors, compressors , pumps
etc.
Ensure use of recommended Oil, Greases for use in mechanical equipments and chain conveyor.
Trained operator should carry out connection and disconnection of tank trucks hoses / arms
and supervise the loading / unloading operation.
Ensure working condition of ELD, OLD on daily basis thru test cylinders.
Ensure use of rubber mats while loading / unloading of cylinders at the platform from the
trucks and in front of electrical panels.
March - 2006 20 of 21
8
Water draining operation shall be supervised by an Officer.
Highest level of House keeping of the Filling shed to be ensured.
There should be no LPG Leakages from Filling guns, LPG valves etc.
Double earthing of carousel & other equipments should be properly maintained for
effectiveness
Hand Gloves should be used during manual handling works
To ensure regular routine check up equipments etc.
Any near miss must be considered as warning.
Fire fighting equipment to be ready all the time for fighting any untoward incident.
Medical facilities to be kept ready.
March - 2006 21 of 21
ANNEXURES
INDEX
CHAPTER DESCRIPTION PAGES.
Annexure I Glossary of Terms 15
Annexure II Relevant BIS Codes 6
Annexure III Work Permit System 9
Annexure IV Safety Check Lists 6
Annexure V Quality Control of LPG 9
Annexure VI SQC Formats 6
Annexure VII ASTM Tables 12
Annexure VIII Filling Ratio 7
Annexure IX Fire Water Calculation 1

I
GLOSSARY OF TERMS
GLOSSARY OF TERMS
API
American Petroleum Institute, USA
Area Classification
It is method of classifying an area zone wise/ group wise based on the presence of explosive gas/
vapour - air mixture vis-a-vis the requirement of precautions for construction and use of electrical
apparatus.
ASME
The American Society of Mechanical Engineers, USA
ASTM
The American Society of Testing and Materials, USA
AUC
Access Control Unit is a card reader at the entry barrier which permits the opening of the barrier to
allow the vehicle into the premises.
Authorised Person
A person trained and assigned to carry out a specific job by the owner or LPG marketing company.
Auto LPG
A mixture of certain light hydrocarbons derived from petroleum, which are gaseous at normal ambient
temperature and atmospheric pressure but may be condensed to liquid state at normal ambient
temperature by the application of moderate pressure, and which conforms to IS :14861.
AWWA
American Water Works Association
Batch Controller
In case of automation it acts like an interface with LRC ( Load Rack Computer) where the registration
of Bulk T/T is being done for loading and mass flow meter for loading of bulk T/T. In case of non
automatic system it acts like an interface with human and mass flowmeter for loading of bulk T/T.
March - 2006 1 of 15
I
GLOSSARY OF TERMS
BIS
Bureau of Indian Standards
BLEVE
Boiling Liquid Expanding Vapour Explosion
Boiling Point
The Boiling point of a liquid is defined as the temperature at which the vapour pressure equals with the
atmospheric pressure.
Bottling Plant
The marketing installation where LPG is received, stored, bottled and despatched to the distributors.
BTPGLN
Bogie Type Petroleum Gas Liquefied (Extension - Pneumetics)
Bulk Vessels
A pressure vessel used for more than 1000 litres water capacity for storage or transportation.
Bulk Storage
Bulk storage shall mean provision of storage facilities where more than 1000 litres of LPG is stored in a
pressure vessel, e.g. Bullets and Horton Spheres (Refer SMPV Rules).
Bullet
A horizontal pressure vessel used for storage or transportation by rail/ road.
Butane
One of the hydrocarbon gases which is a member of LPG Group having its chemical formula as
C4H10.
March - 2006 2 of 15
I
GLOSSARY OF TERMS
BS
British Standards
Cavern Storage
Cavern storage technology is based on the natural storage method whereby hydrocarbons are contained
in naturally occurring reservoirs and reserves
Compressed Gas
Any permanent gas, liquefiable gas or gas dissolved in liquid under pressure or gas mixture which in a
closed container exercises a pressure either exceeding 2.5 kg/sq.cm. abs @ 15 Deg C or a pressure
exceeding 3.0 kg/Sq.cm. abs @ 50 Deg C or both.
Compressed Natural Gas (CNG)
CNG is a mixture of hydrocarbon gases and vapours consisting of principally methane in gaseous form
which are compressed to a pressure of 200 to 250 Kg/ Sq.cm.g. for use as a vehicular fuel.
Competent Person
Competent person means a person recognised by the applicable Statutory Authority for the job in respect
of which the competency is required.
Corrosion Allowance
The additional thickness of metal which is required to be added to the calculated thickness of a pressure
vessel wall while designing, in order to take care of damage due to corrosion.
Container
A vessel for storing liquefied natural gas. Such a vessel may be above, partially below, or totally below
ground and may consist of an inner and outer tank.
March - 2006 3 of 15
I
GLOSSARY OF TERMS
Covalent bonds
Covalent bonds are formed as a result of the sharing of one or more pairs of bonding electrons. Each
atom donates half of the electrons to be shared.
A single co-valent bond would be the sharing of two electrons between the two bonded atoms. Examples
are:
• H-H
• H-Cl
• F-F
A double co-valent bond is two pairs of electrons being shared. Examples are:
• O=O
• C=O
• C=C
A triple co-valent bond is the sharing of three pairs of electrons. Examples are:
• triple bond between two Nitrogen atoms
• Triple bond between two carbon atoms
• Triple bond between a Carbon and a Nitrogen
Cross Country Pipeline (CCP)
A CCP is primarily a transmission line for transporting bulk quantity of fluids over large distances
Cylinders
A portable container upto 1000 litres water capacity used for both domestic and industrial purposes.
CVT
Compact Valve Tester, used to check Valve Pin & O’ring leakage in manual checking system
DCP
Dry Chemical Powder ( Sodium Bicarbonate ) used in fire extinguishers.
DPT
Due for Pressure Testing – Terminology used to identify Cylinders due for mandatory testing.
Differential Pressure Transmitter – Instrument used to measure the product level in bulk storage vessels.
March - 2006 4 of 15
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GLOSSARY OF TERMS
Design Pressure
The pressure used in the design of equipment, a container, or a vessel for the purpose of determining the
minimum permissible thickness or physical characteristics of its different parts. Where applicable, static
head shall be included in the design pressure to determine the thickness of any specific part.
Dyke
A structure used to establish an impounding area.
EFCV
Exccess Flow check valves provided to control the excessive flow of liquid from the TTs/TWs/PL liquid
& vapour line.
Explosimeter
Portable instrument used to detect the concentration of LPG in the atmosphere.
Explosive mixture
It is a mixture of combustion agent (oxidising product-gas, vapour, liquid or solid) and a fuel (oxidisable
product - gas, liquid or solid) in such proportions that it could give rise to a very rapid and lively oxidisation
reaction liberating more energy than is dissipated through conduction and convection.
Earthing & Bonding
Earthing is the provision of a safe path of electrical current to ground, in order to protect structures,
plant and equipment from the effects of stray electrical current, and electrostatics discharge.
Bonding is the process of connecting the equipment/ system to be earthed to the ground by the bond wire
to prevent sparking between two conducting bodies.
ELD
Electronic Leak Detector. Also known as Gas Detector, used to detect leakage from Cylinder valve Pin &
Valve Joint (Neck Leak)
March - 2006 5 of 15
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GLOSSARY OF TERMS
Electrovalent Bond
Electrovalent bond is a chemical bond in which one atom loses an electron to form a positive ion & other
atom gain an electron to form a negative ion.
Emergency shut off Valve
A shut off valve which, in an emergency, operates automatically or can be operated remotely.
FCS
Filling Control System provided in Automatic Electronic carousels to control filling process
Filling Density
Filling density means the ratio of weight of liquefiable gas allowed in a pressure vessel to the weight of
water that the vessel will hold at 15 degree C.
Keeping in view the industry practice of leaving 5% free space in the vessel, the above definition gets
modified to:
It is the ratio of the weight of liquefied petroleum gas introduced in the vessel, so as to leave a free
space of 5% by volume at the reference temperature, to the weight of water the vessel will hold at 15
degree C. Thus, the filling density is numerically equal to 0.95 times the density of LPG at the reference
temperature.
Filling Ratio
It is the ratio of weight of LPG in a container to the weight of water the same container can hold at 15
deg. C.
Fire safe
As applied to valves, it is the concept of controlling the leakage to an acceptable level after damage
encountered during and after the fire achieved by dual seating.
FLP
Flammeproof
March - 2006 6 of 15
I
GLOSSARY OF TERMS
Flammability Range/Limits
It is the rang of percentage of volume of any flammable vapour which in admixture with air, forms an
explosive mixture.
Fire proofed
It is a passive concept of explosure protection of structures, vessel surface or cables that could be
exposed to direct flame impingement, free burning plus pressure torching conditions, and/ or prolonged
periods of high intensity radiant heat fluxes by the application of coating with a specified rating.
Flammability
It is the percentage of volume of any flammable vapour in air-vapour mixtures capable to form an
explosive mixture.
Flammable ( or Inflammable)
Any substance which when tested in a specified manner will ignite when mixed with air on contact with a
flame and will support combustion.
Fixed-Length Dip Tube
A pipe that has a fixed open end fitted inside a container at a designated elevation that is intended to
show a liquid level
Four Way Valve
It is a valve with four ports which make four ways (four passages) in two different positions of its
spindle. This is used for specific application of Evacuation of LPG from vessels in liquid as well as in
vapour form.
Fractionators
Fractionators are locations where LPG is produced from Natural Gas & other hydro-carbons through the
process of Fractionation
Gas Chromatograph
The instrument used to measure the composition of LPG
March - 2006 7 of 15
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GLOSSARY OF TERMS
Gas-Free
It means the concentration of flammable or toxic gases or both in a pressure vessel or pipeline is within
the safe limits specified for persons to enter and carryout hot work in such vessels/ pipelines.
3 G Effect
This terms is applied for subjected force while LPG Tank truck is in motion. The subject force is equiva-
lent to three times the laden weight of Tank Truck when T/T is in motion with 40 km/hr. speed & brake
is suddenly applied. This is considered for design calculation for various fittings of a tank truck
Hazard Area Classification
It is the classification of hazardous area zone wise/group wise, based on the nature of the flammable
substance and the extent of presence of the explosive vapour- air mixture likely to be present under
operating conditions for the purpose of selection of the type of electrical equipment in the respective
zone/area.
HAZCHEM
Short form for Hazardous Chemicals
HMI
Human Machine Interface – Terminology used in Automatic Electronic Carousel systems
Horton Sphere
A spherical pressure vessel, supported vertically.
Hot Work
It is an activity which may produce enough heat to ignite a flammable air-hydrocarbon mixture or a
flammable substance.
Ignition Source
Any item or substance capable of an energy release of type and magnitude sufficient to ignite any
flammable mixture of gases or vapours that could occur at the site.
March - 2006 8 of 15
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GLOSSARY OF TERMS
ILP
Industry Logistics Planning
In-Motion Weigh Bridge
It is a weigh bridge where weighment is taken while object is in motion
Liquefied Natural Gas
A fluid in the liquid state composed predominantly of methane (CH4) and which may contain minor
quantities of ethane, propane, nitrogen, or other components normally found in natural gas.
LNG
An abbreviation for “liquefied natural gas”
Maximum Allowable Working Pressure
The maximum gauge pressure permissible at the top of an equipment, a container or a pressure vessel
while operating at design temperature.
Kerb Wall
A wall of appropriate height and size constructed of suitable material and designed to contain the LPG
spillage and to direct it to a safe location around the storage vessel.
Liquefied Petroleum Gas (LPG)
The term applies to a mixture of certain light hydrocarbon C2 to C5, derived from petroleum which are
gaseous at ambient temperature and pressure test may be condensed to a liquid state at normal ambient
temperature by the application of moderate pressure.
LRC
Load Rack computer – It is part of Automation System, provided at the entry gate to make registration of
T/T coming for loading
March - 2006 9 of 15
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GLOSSARY OF TERMS
Master Switch
Switch provided inside the vehicle cabin to isolate the power supply from the battery.
Motor Octane Number

A number used to indicate gasoline’s antiknock performance in motor vehicle engines.
Mounded Vessel (s)
A storage vessel(s) sited above ground and completely covered by a mound of earth or similar inert
material except for nozzles, manhole covers, inspection covers fitted on vessel(s).
MOV
Motor Operated Valve
NFPA
National Fire Protection Association
OISD
Oil Industry Safety Directorate
NPT
National Pipe Thread
NGT
National Gas Thread
NRV
Non Return Valve
PLC
Programmable Logic Controller
March - 2006 10 of 15
I
GLOSSARY OF TERMS
POH
Periodic Overhauling
PTFE
Poly Tetra Fluro Ethylene
ROH
Routine Overhauling
Pressure Vessel
Pressure vessel (both static and mobile) means any closed metal container or tank of any shape,
intended for storage of LPG which is subjected to internal pressure and having water capacity of more
than one thousand litres.
PLT
Pipeline Transfer
Pigging
Process to periodically de-scale & check the health of the pipeline
PSP
Pipe to Soil Potential (used in Cathodic Protection)
Purging
It is the act of replacing the atmosphere within a container by an inert substance in such a manner as to
prevent the formation of explosive mixture.
(A) Purging into Service : is the replacement of air in a closed system by an inert substance and
replacement of the later by combustible gas, vapour, or liquid.
(B) Purging out of service : is the replacement of normal combustible content of a closed system by an
inert substance, and replacement of the later by air.
March - 2006 11 of 15
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GLOSSARY OF TERMS
PWHT
Post Weld Heat Treatment
Reference Temperature
This is the temperature at which the density of liquid LPG is to be evaluated for calculating the filling
density. In India, the reference temperature considered for LPG pressure vessels is 55 degree C.
REFINERY
‘Petroleum Refinery” is a plant where crude oil is received and processed to produce various intermedi-
ates and finished products.
Reid Vapour Pressure
Reid Vapour Pressure is the vapour pressure in pounds per square inch (psi) at 100 Deg F as determined
by Reid apparatus.
Repeatability
Repeatability is the variation in measurements taken by a single person or instrument on the same item
and under the same conditions. A measurement is said to be repeatable when this variation is small.
Reproducibility
Reapition of an experiment, based on the original experimental description to find out if results are
similar to those reported by the original experiment .
The result values are said to be commensurate if they are obtained (in distinct experimental trials)
according to the same reproducible experimental description and procedure.
ROW
Right of Way
ROU
Right of Use
ROV
Remote Operated Valve
RLW
Registered Laden Weight
March - 2006 12 of 15
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GLOSSARY OF TERMS
RDSO
Research Design & Standard Organization
Roto Gauge
Level Indicator provided in Tank Trucks
Sick Tank Truck/Wagon
Tank Truck or Tank Wagon which cannot be decanted by using normal process of decantation .
Spheres
A spherical pressure vessel used for storage.
Statutory Authority
It is an authority appointed under specific Act or regulation for administering specific function under the
Act/regulation.
“Chief Controller of Explosives”, hereafter referred as CCOE, is the Statutory Authority for administer-
ing the SMPV (U) Rules 1981.
“Chief Inspector of Factories” in a State/UT is .the Statutory Authority for enforcement of the Factories
Act, 1948 and the Factories Rules made thereunder.“
Sources of Ignition
Devices or equipment which, because of their mode, use or operation, are capable of providing required
thermal energy to ignite flammable LPG-Air mixtures” when introduced to such a mixture or when such
a mixture comes into contact with them.
SMPV (Unfired) Rules
The Static and Mobile Pressure Vessels (Unfired) Rules, 1981, (with latest amendments) abbreviated as
“SMPV (U) Rules”. These are Rules governing the storage, transportation; handling etc. of compressed
gas in vessels exceeding 1000 liters in volume. These rules are framed under the Indian Explosives Act,
1884 and administered by Chief Controller of Explosives.
March - 2006 13 of 15
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GLOSSARY OF TERMS
Safety Relief Valve
A pressure relief device fitted on a pressure vessel to protect the vessel against maximum allowable
pressure.
Tank Truck
A truck mounted with a properly designed vessel/tank for transportation

Tare Weight
It is the weight of the cylinder together with any fitting permanently attached to them and includes the
weight of valve.
TOP
Tap off Point – Provided on Cross Country Pipeline to receive the product at intermediate point
TREM Card
Transport Emergency Card provided to Road T/T crew members
Ullage
Available volume inside the storage vessel to fill the same upto safe limit.
UVCE
Unconfined Vapour Cloud Explosion
Vapour Pressure
The vapour pressure is the pressure exerted by the vapour in equilibrium with the liquid in a closed
container at a particular temperature. The vapour pressure of LPG depends upon the temperature of the
liquid and the composition of LPG.
Vaporisation
Means an addition of thermal energy for changing a liquid or semi-solid to vapour or gaseous state.
March - 2006 14 of 15
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GLOSSARY OF TERMS
Vaporiser
Means a heat transfer facility designed to introduce thermal energy in a controlled manner for changing
a liquid or semisolid to vapour or gaseous state.
Working Pressure
It is saturated vapour pressure at 65 Deg. C.
Wharfage
A charge assessed against either cargo or vessel on that cargo passing or conveyed over, onto, or under
wharves.
Water Capacity
The volume of water in litres that the container can hold at 15 Deg. C.
March - 2006 15 of 15
II
RELEVANT BIS CODES
BIS CODES PERTAINING TO LPG OPERATIONS
CODE NO. NAME
IS:2-1960 - RULES FOR ROUNDING OFF NUMERICAL VALUES
IS:5-1978 - COLOURS FOR READY MIXED PAINTS & ENAMELS
IS:1196-1978 - CODE OF PRACTICE FOR LAYING BITUMEN MASTIC

FLOORING
IS:1432-1959 - GENERAL REQUIREMENTS FOR WEIGHING

INSTRUMENTS
IS:1435-1991 - PLATFORM WEIGHING MACHINE
IS:1436-1991 - WEIGHBRIDGES
IS:1437-1967 - AUTOMATIC WEIGHING MACHINES
IS:1448(P:70-1968) - RESIDUE IN LPG
IS:1448(P:71-1979) - VAPOUR PRESSURE OF LPG
IS:1448(P:72-1968) - VOLATILITY OF LPG
IS:1448(P:73-1968) - HYDROGEN SULPHIDE IN LPG
IS:1448(P:74-1968) - DRYNESS OF LPG

IS:1448(P:75-1968) - ODOUR OF LPG
IS:1448(P:76-1968) - DENSITY OF LPG
IS:1448(P:111-1983) - ANALYSIS OF LPG AND PROPYLENE

CONCENTRATES BY GAS CHROMATOGRAPHY
IS:2148-1981 - FLAMEPROOF ENCLOSURES FOR ELECTRICAL

APPRATUS
March - 2006 1 of 6
II
RELEVANT BIS CODES
IS:2206 - FLAME PROOF ELECTRIC LIGHT FITTINGS
IS:2206(PART 1)-1984 - WELL GLASS AND BULKHEAD TYPES
IS:2206(PART 2)-1976 - FITTINGS USING GLASS TUBES
IS:2808-1964 - METHOD FOR COMPUTATION OF CAPACITY TABLES

FOR PRESSURIZED STORAGE TANKS
IS:2825-1969 - CODE FOR UNFIRED PRESSURE VESSELS
IS:2827-1976 - METHODS FOR CALIBRATION OF PRESSURIZED

STORAGE TANKS
IS:3196(PART 1)-1992 - WELDED LOW CARBON STEEL GAS CYLINDER

EXCEEDING 5 LITRE WATER CAPACITY FOR LOW
PRESSURE LIQUEFIABLE GASES CYLINDERS FOR LPG
IS:3465-1966 - JOINTING COMPOUND FOR USE IN LPG APPLIANCES

AND INSTALLATIONS
IS:3710-1978 - FILLING RATIOS FOR LOW PRESSURE LIQUEFIABLE GAS
IS:4093-1981 - NON-REFILLABLE LPG CONTAINERS
IS:4246-1984 - SPECIFICATION FOR DOMESTIC GAS STOVES FOR

USE WITH LIQUEFIED PETROLEUM GASES
IS:4379-1981 - IDENTIFICATION OF CONTENTS OF INDUSTRIAL GAS

CYLINDERS
IS:4576-1978 - SPECIFICATION FOR LIQUEFIED PETROLEUM GASES
IS:4784-1968 - LOW PRESSURE REGULATORS FOR USE WITH

BUTANE GASES
IS:4785-1968 - LOW PRESSURE REGULATORS FOR USE WITH

PROPANE GAS
IS:4786-1968 - VARIABLE HIGH PRESSURE REGULATORS FOR USE

WITH LPG
March - 2006 2 of 6
II
RELEVANT BIS CODES
IS:4991-1968 - CRITERIA FOR BLAST RESISTANT DESIGN OF

STRUCTURES FOR EXPLOSIONS ABOVE GROUND
IS:5116-1985 - GENERAL REQUIREMENT FOR DOMESTIC AND

COMMERCIAL EQUIPMENT FOR USE WITH LPG
IS:5571-1979 - GUIDE FOR SELECTION OF ELECTRICAL EQUIPMENT

FOR HAZARDOUS AREAS
IS:5572 - CLASSIFICATION OF HAZARDOUS AREAS (OTHER

THAN MINES) FOR ELECTRICAL INSTALLATIONS
IS:5572(PART 1)-1978 - AREAS HAVING FLAMMABLE GASES AND VAPOURS
IS:5844-1970 - RECOMMENDATIONS FOR HYDROSTATIC STRETCH

TESTING OF COMPRESSED GAS CYLINDERS
IS:5845-1984 - CODE OF PRACTICE FOR VISUAL INSPECTION OF

LOW PRESSURE WELDED STEEL GAS CYLINDERS IN USE
IS:5903-1970 - RECOMMENDATIONS FOR SAFETY DEVICES FOR

GAS CYLINDERS
IS:6044 - CODE OF PRACTICE FOR LPG TORAGE INSTALLATIONS
IS:6044(PART 1)-1971 - COMMERCIAL AND INDUSTRIAL CYLINDER INSTALLATIONS
IS:6044(PART 2)-1972 - INDUSTRIAL, COMMERCIAL AND DOMESTIC BULK

STORAGE INSTALLATIONS
IS:6539-1972 - INSTRINSICALLY SAFE MAGNETO TELEPHONES FOR

USE IN HAZARDOUS ATMOSPHERES
IS:6665-1972 - CODE OF PRACTICE FOR INDUSTRIAL LIGHTING
IS:7142-1974 - WELDED LOW CARBON STEEL GAS CYLINDER FOR

LOW PRESSURE LIQUEFIABLE GASES, NOT
EXCEEDING 5 LT WATER CAPACITY
IS:7145-1973 - TECHNICAL SUPPLY CONDITION FOR TORQUE WRENCHES
March - 2006 3 of 6
II
RELEVANT BIS CODES
IS:7241-1981 - GLOSSARY OF TERMS USED IN GAS CYLINDER

TECHNOLOGY
IS:8198(PART 5)-1984 - CODE OF PRACTICE FOR STEEL CYLINDERS FOR

COMPRESSED GASES ; LIQUEFIED PETROLEUM GAS (LPG)
IS:8374-1977 - SPECIFICATION FOR BITUMEN MASTIC, ANTI STATIC

ELECTRICALLY CONDUCTING GRADE
IS:8451-1984 - CODE OF PRACTICE FOR VISUAL INSPECTION OF

HIGH PRESSURE GAS CYLINDERS
IS:8737 - VALUE FITTINGS FOR USE WITH LPG CYLINDERS OF

MORE THAN 5 LIT. WATER CAPACITY
IS:8737(PART 1)-1979 - VALVE FITTINGS FOR REPLACEMENT PURPOSES
IS:8737(PART 2)-1978 - VALVE FITTINGS FOR NEWLY MANUFACTURED LPG

CYLINDERS
IS:8776-1988 - VALVE FITTINGS FOR USE WITH LIQUEFIED

PETROLEUM GAS (LPG) CYL. UPTO AND INCLUDING
5 LIT WATER CAPACITY
IS:8790 - GENERAL REQUIREMENTS OF POWERED

INDUSTRIAL TRUCKS WORKING IN HAZARDOUS AREAS
IS:8790(PART 1)-1978 - INTERNAL COMBUSTION ENGINES POWERED TRUCKS
IS:8790(PART 2)-1979 - ELECTRIC BATTERY POWERED INDL. TRUCKS

IS:8867-1987 - SATURATED VAPOUR PRESSURE AND TEST
PRESSURE FOR LOW PRESSURE LIQUEFIABLE GASES
CONTAINED IN GAS CYLINDERS
IS:8868-1988 - PERIODICAL INSPECTION INTERVAL OF GAS CYLINDERS IN

USE
IS:9121-1979 - INSPECTION GAUGES FOR CHECKING TYPE 1 (SIZE 2)

TAPER THREADS OF GAS CYLINDER VALVES, TAPER 1 IN 16
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RELEVANT BIS CODES
IS:9122-1979 - INSPECTION GAUGES FOR CHECKING TYPE 2 TAPER

THREADS OF GAS CYLINDER VALVES, TAPER 3 IN 25
IS:9199-1979 - INSPECTION GAUGES FOR CHECKING TAPER THREADS OF

GAS CYL. VALVES, TAPER 60 DEGREE INCLUDED ANGEL
IS:9200-1979 - METHOD OF DISPOSALS OF UNSERVICEABLE COMPRESSED

GAS CYLINDERS
IS:9281 - ELECTRONIC WEIGHING SYSTEMS
IS:9281(PART 1)-1979 - TERMS AND DEFINITIONS
IS:9281(PART 2)-1979 - METHODS OF MEASUREMENTS
IS:9281(PART 3)-1981 - REQUIREMENTS
IS:9281(PART 4)-1983 - CODE OF PRACTICE FOR USE & INSTALLATION
IS:9583-1981 - EMERGENCY LIGHTING UNITS
IS:9639-1980 - CODE OF PRACTICE FOR VISUAL INSPECTION OF LOW

PRESSURE WELDED STEEL GAS CYLINDERS IN USE
IS:9777-1981 - DATA SHEET FOR SELECTION OF WEIGHBRIDGES FOR BULK

HANDLING EQUIPMENT
IS:9798-1981 - LOW PRESSURE REGULATORS FOR USE WITH LPG
IS:9902-1982 - RECOMMENDED PRACTICE FOR LEAK TESTING

IS:9975 - ‘O’ RINGS
IS:9975(PART 1)-1981 - DIMENSIONS
IS:9975(PART 2)-1984 - MATERIAL SELECTION & QUALITY ACCEPTANCE CRITERIA
IS:9975(PART 3)-1984 - SEAL HOUSING DIMENSIONS AND TOLERENCES
IS:9975(PART 4)-1984 - TERMINOLOGY AND DEFINITIONS OF TERMS
March - 2006 5 of 6
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RELEVANT BIS CODES
IS:10733-1983 - ELECTRICALLY BONDED ROAD AND RAIL TANKER HOSE OF

RUBBER, RESISTANT TO PETROLEUM PRODUCTS
IS:10908-1991 - FLEXIBLE RUBBER TUBING FOR LPG
IS:11498-1985 - LEVER TYPE DIA GAUGES
IS:12936-1990 - CODE FOR BASIC REQUIREMENTS FOR DELIVERY PERSONS

ENGAGED IN THE DELIVERY OF LPG CYLINDERS
IS:13258-1991 - WELDED LOW CARBON STEEL CYLINDERS EXCEEDING 5 LT

WATER CAPACITY FOR LOW PRESSURE LIQUEFIED
PETROLEUM GAS CODE OF PRACTICE FOR INSPECTION AND
RECONDITIONING OF USED LPG CYLINDERS
IS:13432(PART 1)-1992 - GAS LEAK DETECTOR FOR USE WITH LOW PRESSURE
LIQUEFIED PETROLEUM GAS BURNING APPLIANCES
SPECIFICATION PART I – MECHANICAL TYPE
March - 2006 6 of 6
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WORK PERMIT SYSTEM
(NAME OF COMPANY)
(LOCATION)
COLD WORK PERMIT
Sl.No.______________
AM / PM DATE AM / PM DATE
VALID FROM_________________________ TO_____________________________________
PERMISSION IS GRANTED TO SECTION/CONTRATOR________________________________________
NAME_________________________________________________________________________________________
NATURE OF WORK____________________________________________________________________
LOCATION OF WORK__________________________________________________________________
THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT

(Please put tick [ ] mark in the appropriate box)
——————————————————————————————————————————
S.No. Item Done Not Required
—————————————————————————————————————————----
1. Equipment / Work Area inspected [] [ ]
2. Surrounding area checked,cleaned [] [ ]

and covered
3. Equipment electrically isolated [] [ ]

and tagged
4. Running water hose / Portable [] [ ]

extinguisher provided
5. Equipment blinded/disconnected / [] [ ]
closed / isolated / wedge opened
March - 2006 1 of 9
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WORK PERMIT SYSTEM
6. Equipment properly drained / [] [ ]

depressurised
7. Equipment water flushed [] [ ]
8. Equipment properly steamed / [] [ ]

purged
9. Iron Sulphide removed / kept wet [] [ ]
10. Proper ventilation and [] [ ]

lighting provided
11. Gas test done , found [] [ ]

gas free
12. Area cordoned off [] [ ]

(minimum 15m in case of
radiography)
13. Standby personnel provided [] [ ]

from Process / Maint. /
Contractor/Fire Deptt.
14.
Radio-isotopes kept under [] [ ]
safe containers
———————————————————————————————————————— ——————
SPECIAL INSTRUCTIONS
1. Following personal protective equipment are required (check all items required) :
Safety Helmet / Gloves / Goggles / Safety Shoes / Boiler Suit/ Welding Suit / Dust Respirator / Face Shield
/ Fresh Air Mask/Apron / Lifeline / Safety Belt / Airline /Film Badges / Dosimeter.
2. In case of fire alarm, all work must be stopped. All personnel must leave work site and proceed to
designated areas.
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WORK PERMIT SYSTEM
3. Remarks on toxic/hazardous chemicals, if any:____________________________________________
________________________________________________________________________________________
________________________________________________________________________________________
4. Alternate means of escape available/provided/not required.
5. This permit must be available at work site at all times.
6. Additional items, if any:_____________________________________________________________
________________________________________________________________________________________
Name and_____________________ Name and_______________________
Signature of Receiver__________ Signature of Issuer____________
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WORK PERMIT SYSTEM
Permit Extended upto Signatures

Additional precautions
————————————— required, if any
——————————
Date Time Issuer Receiver
—————————————————————————————————————————————---
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
AM / PM DATE
WORK COMPLETED/STOPPED/AREA CLEARED AT ____________________________________
By___________________ By__________________________
Signature Signature
_____________________ __________________________
(Name of Issuer) (Name of Receiver)
(PLEASE RETURN PERMIT TO ISSUER)
ORIGINAL
(Pink in colour)
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WORK PERMIT SYSTEM
(NAME OF COMPANY)
(LOCATION)
HOT WORK/ VESSEL ENTRY/ VESSEL BOX-UP/ EXCAVATION PERMIT
AM / PM DATE AM / PM DATE
VALID FROM_____________________________ TO___________________________________
PERMISSION IS GRANTED TO SECTION/CONTRACTOR_________________________________________
NAME_________________________________________________________________________________________
NATURE OF WORK______________________________________________________________________
LOCATION OF WORK____________________________________________________________________
THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT

(Please put tick [ ] mark in the appropriate box)
——————————————————————————————————————————————
S.No. Item Done Not required
——————————————————————————————————————————————
1. Equipment / Work Area inspected [] []
2. Surrounding area checked/cleaned [] []

up: oil/ rags/grass etc. removed
3. Sewers , manholes , CBD etc. and [] []

hot surfaces nearby covered
4. Considered hazard from other [ ] []

routine / non-routine operations
and concerned persons alerted
5. Equipment electrically isolated [] []

and tagged
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WORK PERMIT SYSTEM
6. Fire water hose / Portable [] []

extinguisher provided
7. Fire water system checked for [] []

readiness
8. Equipment blinded/disconnected/ [] []
closed / isolated / wedge opened
9. Equipment properly drained / [] []

depressurised
10. Equipment properly steamed/purged [] []
11. Equipment waterflushed [] []
12. Gas / Oxygen deficiency test [ ] []

done and found OK
13. Shield against sparks provided [] []
14. Proper ventilation and lighting [] []

provided
15. Proper means of exit provided [] []
16. Precautionary tags / boards [] []

provided
17. Portable equipment / nozzles [] []

properly grounded
18. Standby personnel provided for [] []

vessel entry
19. Standby personnel provided for [] []

fire watch from Process/Maint./
Contractor / Fire Deptt.
20. Iron Sulphide removed/ kept wet [] []
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WORK PERMIT SYSTEM
21. Area cordoned off [] []
22. Precautions against public [] []

traffic taken
23. Clearance obtained for excavation [] []

from Technical/concerned deptts.
24.* Clearance obtained for road [] []

cutting from Technical / Fire /
concerned deptts.
25.* Clearance obtained for dyke [] []

cutting
26. Checked Flame / Spark arrestor [] []

on mobile equipment
27. Checked for oil / gas trapped [ ] []

behind lining in equipment
28. Welding machine checked for [ ] []

safe location
29. Check for earthing / return [] []

connection to the equipment
being welded
30. Oxygen and Acetylene cylinders [] []

kept outside the vessel/tank
——————————————————————————————————————————————
Note: For Items marked (*), clearance to be obtained from higher designated authority.
SPECIAL INSTRUCTIONS
1. Following personal protective equipment are required

(Check all items required) :
Safety Helmet / Gloves / Goggles / Safety Shoes / Boiler Suit /Welding Suit, Dust Respirator/Face Shield/
Face Shield/ Fresh Air Mask/Apron/Life line/Safety Belt.
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WORK PERMIT SYSTEM
2. In case of fire alarm, all work must be stopped and running fire water must be closed. All personnel must
leave work site and proceed to designated areas.
3. In case of liquid / gas release, stop work and immediately advise concerned Operation Personnel.
4. Only certified vehicles/engines and permitted type of electrical equipment and tools are allowed in
operating areas.
5. Ensure proper grounding/earthing/insulation of cables.
6. For hot tapping, ensure continuous/sufficient flow in the line.
7. This permit must be available at the work site at all times.
8. No hot work shall be permitted unless the Explosimeter reading is zero.
9. Vessel entry, where no hot work is to be carried out, may be permitted if combustible gases are up-to 5%
of lower explosive limit (LEL). Entry with an air supplied mask may be permitted with LEL of upto 50%. The
oxygen level should be at least 19.5 % vol. and the concentration of toxic gases below the threshold limits.
10. Additional remarks, if any:___________________________________________________________
_____________________________________________________________________________________
Name and__________________________ Name and __________________________
Signature of Receiver________________ Signature of Issuer____________________
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WORK PERMIT SYSTEM
________________________________________________________________________________________________
GAS TEST(HYDROCARBON/ PERMIT ADDITIONAL
TOXIC GAS/OXYGEN EXTENDED PRECAUTIONS SIGNATURES
DEFICIENCY)DONE UPTO REQD.,IF ANY
——————————————————————————————————————————————
DATE/ TAKEN TEST DATE/ INITIAL ISSUER RECEIVER
TIME BY VALUE TIME GAS TEST
—————————————————————————————————————————————----
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
——————————————————————————————————————————————
________________________________________________________________________________________________
NOTE: HOT WORK INCLUDES WELDING, BURNING, GRINDING, SOLDERING, SAND BLASTING, CHIPPING,
RIVETING, DRILLING, CAMERA FLASHING, POWER TOOLS, IC ENGINE OPERATIONS/ENTRY, OPEN
FLAME, VEHICLE ENTRY.
AM / PM DATE
WORK COMPLETED / STOPPED / AREA CLEARED AT __________________________________
By____________________________ By____________________________
Signature Signature
____________________________ ____________________________
(Name of Issuer) (Name of Receiver)
(PLEASE RETURN PERMIT TO ISSUER)
March - 2006 9 of 9
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SAFETY CHECK LISTS
CHECKLIST CUM LOADING ADVISE FOR UNLOADING AND LOADING OF BULK LPG TANK TRUCKS
Has suitable spark arrestor of make and design approved by CCOE, Nagpur, properly fixed to
exhaust.
Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and removable position with Truck
No. date of checking and charging painted on it.
Quick closing manifold valve with lever indicating close and open status.
No visible dent on the bullet.
Whether tyres fitted is in roadworthy condition.
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.
Leakage from any fittings or joints.
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.
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SAFETY CHECK LISTS
CHECKS REQUIRED TO BE CARRIED OUT ON RANDOM BASIS
- MINIMUM ONE DAY, ONCE IN A MONTH :
Internals of fire extinguishers in good condition.
Carries TREM CARD, instructions booklet detailing instructions on handling emergencies enroute.
Carries route map.
Carries TERM card.
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.
Excess flow check valves are functioning.
Liquid/vapour lines are adequaltely anchored and are well protected by means of stout steel
guard.
Liquid/vapour pipe lines are in single piece from excess flow check valve to discharge valves
Safety fitting viz. safety valve, roto-gauge, pressure gauge and temperature gauge are adequatlely
protected.
Operative fittings like roto gauge, pressure gauge and temperature gauge are operational.
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SAFETY CHECK LISTS
LIQUEFIED GAS-CARGO TRANSFER CHECK LIST

(Items to be checked before cargo transfer begins)
SHIP:_________________________________________DATE:______________
PORT &BERTH:_________________________________TIME:______________
S.NO CHECK POINT FOR SHIP FOR SHORE
1. Has information on cargo and ship-

shore connection been supplied ?
2. Is the agreed ship-shore communic -

ation system operative ?
3. Are fire and other emergency

procedures agreed ?
4. Are local regulations being

observed ?
5. Has safe access been provided and

warning notices posted ?
6. Are moorings secure and agreement

reached on the use of tension
winches ?
7. Are emergency towing-off wires

correctly positioned ?
8. Is the ship ready to move under its

own power ?
9. Are smoking restrictions in force

and notices posted ?
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SAFETY CHECK LISTS
10. Are naked light restrictions being

observed ?
11. Are portable electrical equipment

cables disconnected ?
12. Are all hand torches and portable

R/T sets of approved type ?
13. Are ship’s main transmitting

aerials and radar switched off
and earthed ?
14. Some doors and ports have to be

closed : are they actually shut ?
15. Are all air conditioning intakes

correctly trimmed and window type
units closed ?
16. Is the water main ready for

immediate use ?
17. Is the water spray system ready

for immediate use ?
18. Are dry powder and all other fire

fighting appliances correctly
positioned and ready for immediate
use ?
19. Is necessary protective clothing

available or being worn ?
20. Are void spaces properly inerted ?
21. Is the required ventilation

equipment in operation ?
22. Is the cargo system set for the

operation ?
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SAFETY CHECK LISTS
23. Are all remote control valves in

working order ?
24. Are cargo tank relief valves

correctly set and in good order ?
25. Are the required cargo pumps and

compressors in good order ?
26. Is reliquefaction or boil-off

control equipment in good order ?
27. Is gas detection equipment set for

the cargo, calibrated and in good
order ?
28. Are cargo system gauges and alarms

correctly set and in good order ?
29. Are scuppers plugged and suitable

drip trays in position ?
30. Are cargo and bunker hoses in good

condition and properly rigged, have
certificates being checked ?
31. Are unused bunker connections

blanked and bunker tank lids
closed ?
32. Are unused cargo connections

(including inert gas line)securely
blanked ?
33. Are automatic shutdown systems

working properly ?
34. Does shore know the closing rate

of ship’s automatic valve at
operating temperature ; does ship
have a similar details of shore
system ?
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SAFETY CHECK LISTS
35. Are all personnel (including

supernumeraries and new arrivals)
aware that cargo transfer is to
begin ?
36. Have all personnel been allocated

emergency stations ?
37. Are non-essential personnel clear

of the cargo area ?
38. Are those directly involved aware

of the agreed cargo transfer
sequence ?
====================================================================================
REMARKS :
We have checked with each other the items on the above check list and have satisfied ourselves that the
entries we have made are correct to the best of our knowledge.
CHECKED BY______________________ _______________________

(For Ship) (For Terminal)
CHECKLIST AT UNLOADING / LOADING LOCATION FOR BULK LPG TANKWAGONS
VISUAL EXAMINATION OF WAGON FOR
- POH/ ROH OVERDUE : FOR BARREL Y/N
- FOR UNDERFRAME Y/N

Damage to Tank Barrel Y/N
- Damage/ missing tank fittings Y/N
- Leakage from dome fittings Y/N
- Seal intact Y/N
- All valves, fittings are in working order Y/N
- The surface is free from rust. Y/N
The paint on the barrel is in good
condition and has not lost its
reflecting characteristics.
March - 2006 6 of 6
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QUALITY CONTROL FORMATS
QUALITY ASSURANCE AT REFINERY & FRACTIONTOR LOCATION
1.1 QUALITY REQUIREMENT
1. Quality of LPG produced at Refinery & fractionator locations shall be tested / certified batch
wise in line with BIS specification IS 4576 1999. A copy of Quality Certificate shall be issued
to Marketing Division / Pipeline Division which shall also indicate the density of the product
at 15 0C.
2. In case, quality of LPG fail in any of the characteristics, the same shall not be released for
dispatch. The quality of the product must be corrected by reprocessing before releasing the
product.
3. Before dispatch, the product shall be doped or ensure the presence of 20 ppm of mercaptan
to have distinct odour and the same shall be recorded in the Quality Certificate. Subject to
agreement between the purchaser and the supplier, odour requirements of lPG may be changed
for certain applications, where unodourized LPG is required.
4. The product shall de drained daily from the storage vessel to ensure the same free of water
and the observation shall be recorded.
1.1 TANK TRUCK AND TANK WAGON LOADING
Whenever bulk loading is involved i.e. transfer of product of tank truck or tank wagon, the
following checks are necessary
1. That the product to be loaded /transferred as per the product grade indicated in the relevant
indent / challan after ensuring that tank wagon / tank truck is fit for loading.
2. The Tank Truck & Tank Wagon in which the product is to be loaded shall be checked for
compatibility for the same e.g. the vessel in which propane is to loaded should be of propane
rating only.
3. After loading, vapour pressure and temperature of the transport vessel shall be checked for
acceptable limits for the product.
March - 2006 1 of 9
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QUALITY CONTROL AT LPG IMPORT / COASTAL MOVEMENT TERMINALS
2.1 IMPORT RECEIPTS:
QUALITY CONTROL CHECKS BEFORE DISCHARGE OF THE TANKER
1. Before discharging the Import cargo, the load port Quality Certificate shall be verified with
contractual specifications.
2.a) For C & F cargoes:

If the load port quality certificate show that the product is not meeting the contractual
specification, the cargo shall be rejected and report to the controlling office / Shipping
Dept. for further necessary action.
b) For FOB Cargoes:
If the load port quality certificate shows that the product is not meeting the contractual
specifications, the cargo shal be tested for Vapour Pressure, Copper strip corrosion,
Volaitility & other IS specifications and if the same meets the requirements of IS 4576,
1999, the cargo shall be accepted.
3. If the load port Quality Certificate meets the contractual specification, the sample from
individual tank(s) shall be drawn and tested as per the following characterstics in line with
the contractual specification.
a) Vapour pressure
b) Copper strip corrosion
c) Volatility * ( See note no. 1 & 2 )
Note 1: The Load port Quality Certificate may indicate only Volatility or only Gas Composition or
both Volatility and Gas Composition
In all cases, the volatility test shall be carried out in line with BIS specifications, IS 4576 -1999
and test method. If the product meets the limit of this specification, the product shall be
discharged.
Note 2: In case the product fails in volatility and the supplier has certified the product, in respect
of gas composition also, the location shall carry out the gas composition test as per either of the
following test methods.
March - 2006 2 of 9
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ASTM D 2163 / IP : 264 : Analysis of Liquefied Petroleum (LP) Gases and Propane Concentrates by
gas Chromotography
OR
ISO 7941:1998 / IP 405-94: Commercial propane and butane analysis by as Chromotography
Basis the result of above gas composition test, if
a) The product meets specification in respect of the gas composition in line with the contractual
specification, the product shall be discharged.
b) The product does not meet specification in respect of the gas composition is within the limit
as per specified in IS 4576 -1999, the product shall be discharged.
c) If the product is failing both in volatility as well as gas composition test, as per IS 4576 –
1999, the product shall not be discharged.
If the product is not cleared for discharge, the detailed test results along with pertinent information
shall be communicated to the controlling office and shipping dept. immediately for necessary
advice.
a) In the meanwhile, without loss of time, 3 sets of fresh samples shall be drawn jointly by the
representatives from receiving Oil Company and mutually agreed surveyor representing seller
/ buyer. One set should be immediately tested as per contractual specification in presence of
the above representatives.
b) The balance 2 sets of samples shall be retained till further advice from Shipping Dept.
2.2 QUALITY CONTROL BEFORE DESPATCH
1. After tanker discharge the product shall be tested for all parameters in line with BIS
specifications including density at 15 Deg. C. In case product does not meet BIS specifications,
necessary corrective action shall be taken in consultation with QC deptt. / Controlling Office
to ensure the release of product to market as per BIS specification.
2. In case blending / dosing is done on-line during dispatch of the product, a sample has to be
taken after blending / dosing and certified for vapour pressure and odour. The testing of the
product is to be done shift-wise and the record shall be maintained.
3. Mercaptan content of minimum 20 ppm must be ensured to maintain odour level 2 before
dispatch of product to bottling plants.
March - 2006 3 of 9
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2.3 TANKER LOADING ( COASTAL MOVEMENT )
1. Procedure to be followed in line with 1.1 as mentioned above
2. Prior to loading, the Quality Certificate shall be scrutinized to ensure that all the characterstics
as per BIS specifications have been tested and certified by the loading refinery and batch
number is indicated on the certificate
3. The surveyor shall ensure the fitness of tanker before loading and necessary fitness certificate
shall be issued.
4. After loading the product, the sample shall be drawn from individual tank of the tanker for
retention and tests if required in case of any quality despute.
5. Two sets of each sample shall be drawn as follows:
a) From loading arm jointly with representative of loading coastal location. One set of the
sample shall be retained by the location and other set shall be with Marketing Company.
b) From the individual tanks of the tanker jointly with master of the tanker. One set shall
be retained with Marketing Company and second set shall be handed over to the master
of the vessel for handing over to the receiving company at disport.
6. All the sample(s) shall be retained till the quality of the product is established at disport or
max. 30 days whichever is earlier. In case of product quality failure either in pre-discharge
test or batch formation tests, the sample shall be retained till further advice from controlling
office.
2.4 TANK TRUCK AND TANK WAGON LOADING
Quality control procedure as outlined in clause 1.2 as mentioned above.
QUALITY CONTROL AT BOTTLING PLANT
Quality control operations at Bottling plants shall be restricted to the following
a) Reading Vapour pressure

b) Reading temperature
c) Checking odour
d) Determining the presence of water and other contaminants such as rust etc
March - 2006 4 of 9
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VAPOUR PRESSURE / TEMPERATURE
For routine plant operations, the vapour pressure determination does not require any special
requirement or procedure,it is necessary only to read pressure gauge and temperature sensing
instrument on the vessel
ODOUR
1. Pure LPG is odourless but the commercial product marketed to consumers is odourised as
per statutory requirement. Unless odourless gas is needed, it is normal practice to stench
LPG sufficiently to make it detectable in concentration with air of 1/5th the lower explosive
limit.
2. The distinctive odour of commercial LPG should be used as quality control check to distinguish
from other gases and all personnel should be familiar with the odur of the stanching agent
used.
3. If draining operations involving venting to atmosphere fail to produce a distinguished odour,
the product shall not be released. A Sample shall be taken for further testing, causes
investigated and corrective action taken.
4. Un-stenched product shall not be allowed to leave the plant unless an odourless grade has
been specified.
WATER AND OTHER CONTAMINANTS
1. Contaminants such as water, other petroleum products, rust etc., can be detected during
routine draining operation and should be removed at once. Solid contaminants also accumulate
in filters. The filters should therefore, be periodically checked and cleaned.
2. Water may be present in LPG in its free state i.e, as droplets or in solution. Water in solution
at a particular temperature will precipitate as free water ( due to fall in temperature )-
hence the desirability of routine draining during early morning.
DRAINING
The purpose of draining is to remove water, heavier petroleum fractions and other contaminats
whose presence would effect the product quality. The procedure of draining operation is given in
Appendix VI.
1. Water or other contaminants found in storage vessels during route drainage checks should
be removed as completely as possible. Care is essential, as otherwise LPG will escape with
water or other contaminants
2. Water and other contaminants should be removed through drain valves ( a double valve
system is required) and piped away from the immediate vicinity of the vessel.
3. Responsible person MUST be in attendance throughout the draining operation
March - 2006 5 of 9
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4. When practicable, the stocks should be arranged so that cargo can be received into one
vessel or group of vessels while normal operations continue from another. This provides
settling time for the new stock, facilitating drainage of water etc.
5. Frequency of draining should be minimized to reduce the hazard arising from the escape of
LPG with water but daily drainage is recommended following any product receipt until no
contaminants are found on two successive days.
6. In order to prevent the escape of spillage in to themain drainage system, surface water from
the storage area shall be directed to the main drainage through a water seal to avoid the
spread of Hydrocarbon
BULK RECEIPTS
1. Certificate of quality, delivery challans, pipeline transfer advises must tally with the
requirements and indicate that the incoming parcel is compatible with the product in the
receiving facility. ]
2. In case of pipeline transfers, verification should be made through the dispatching location to
ensure that the line contents and the plant LPG parcel are identical or compatible.
3. The vapour pressure and temperature of each incoming bulk vessel shipments ( road, rail,
pipeline) should be checked individually to ensure that it is in accordance with the requirements
and with the dispatch advise and that it is compatible with the contents of receiving facilities.
If quality variation or contamination is suspected, the transfer and receiving tanks should
be isolated and product transfer delayed / suspended. The sampling and testing of suspected
product parcels , should be done to investigate causes and initiate corrective measures.
4. During receipt of any shipment, check designated receiving vessels regularly for level, pressure
and temperature readings, to ensure that correct product is received in the nominated
vessel.
5. After receipt of the shipment and minimum 1 hour settling time following checks / tests
should be carried out:
a) Take pressure and temperature to check their correctness

b) Drain receiving vessel and check for water and other contaminants
CYLINDER FILLING
1. Ensure that new cylinders received from statutory test plants / repairers or other cylinders
containing air are purged before filling operation
2. A batch of new cylinders received at plants should be checked at random for presence of
water. If water is observed in the cylinders, all the cylinders in the batch should be checked
and corrective action taken by referring the matter to the supplier through RO / HO. In case
cylinder where presence of water is detected should be taken up for filling unless the water
is completely drained out.
March - 2006 6 of 9
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3. If the adequacy of any cylinder to accept the product involved is in doubt, the cylinder should
be removed from the filling system for subsequent investigation.
4. Bulk Loading: At times bulk supplies can be made through bullets on stock transfer to other
bottling plants and also directly to consumers. Transfer to other bottling plants and also
directly to consumers. In case of stock transfer , following checks shall be carried out.
After loading the TTs , temperature , pressure and density of the product shall be recorded
on the challan
The copy of quality certificate issued by supply source / import terminal shall be attached
along with the challan for the receiving location.
SAMPLING
1. Sampling is very important aid to quality control

2. Samples are drawn for the purpose of ascertaining the conformity of the stock to the relevant
specifications
SAMPLING STANDARD
1. BIS standard IS 1447 ( part 2 ) descirbes method of sampling representative of Liquified

Petroleum Gases such as propane, butane or mixtures therof, in containers other than those
used in laboratory testing apparatus. These procedures are considered adequate for obtaining
representative samples for all routine tests as per IS 4576 1999 specification
2. A liquid sample is transferred from the source into a sample container by purging the container
and filling it with liquid LPG to 80% of the capacity
3. Different sampling bombs are to be used for drawing samples for different tests like vapour
pressure, density , volatility and copper corrosion
TYPES OF SAMPLES
1. Samples for pre-discharge tests. The sample is to be drawn from the manifold of the vessel
grade-wise representing the groupwise product.
2. Sample for discharge test : The sample is to be drawn from the sampling arrangement
provided on the shore line / manifold of the tanker.
3. Samples before dispatch of product
a) The representative sample shall be drawn from the system after mercaptan dosing. In
case of mercaptan dosing before storage tank, sample is to be drawn from storage
vessel. In case, mercaptan dosing on line, representative samples shall be drawn from
the loading line.
March - 2006 7 of 9
V
SAMPLING PROCEDURES
Observance of correct sampling procedure is of utmost importance since the quality of product is
very much dependant on the test results of representative sample. The following procedures
should be followed when sampling
1. Sampling arrangement should be as per Fig. 1

2. Before taking sample, the product must be in equilibrium.
3. The sampling bomb should be properly closed ant it should be confirmed that there is no leak
4. Sample details should be entered in the form
5. Sampling and filing of sampling bomb should be personally supervised by an officer well
conversant with the procedures
PRECAUTIONS DURING SAMPLING
1. Careful testing and analysis is of little use if sufficient care is not exercised in sampling
2. Liquified petroleum gases present a hazard because they are heavier than air and are highly
flammable and appropriate precautions must, therefore be taken.
3. Sampling normally involves venting product into atmosphere and the absence of source of
ignition must always be checked before and during the sampling.
4. Liquid LPG causes serious cold burns on contact with the skin. Protective gloves and goggles
should therefore be worn during sampling.
5. Breathing of LPG vapours during sampling should be avoided.
6. If samples are to be sent by the public transport, the appropriate regulations must be complied
with.
7. The discharge of LPG from a sampling bomb can cause static electricity. Sample bomb must,
therefore , be earthed effectively before and during discharge.
8. The condition of sample bomb must be examined before use. They should be hydraulically
tested at 12 months intervals when its control valves should also be checked and serviced.
9. Each bomb should be marked with its tare weight , working pressure, test pressure and the
dates on which it was originally and last tested. The markings to be etched on the bomb or
stamped on a metal plate attached securely to it.
SAMPLE COLLECTION PROCEDURE
The size of the sample should be related to the test and analysis to be carried out on it and will
influence the size and type of sampling container used. For convenience, the sampling bomb is
used for describing the sampling procedure.
March - 2006 8 of 9
V
1. Vent the liquid content in the bomb after checking that there is no source of ignition in the
vicinity.
2. Holding the bomb vertically and connected to the sampling point, it should be atleast 10 cms
below liquid level. The connections should be made to the bottom of the bomb, which should
be at the end to which the ullage tube is connected.
3. Open the outlet and inlet valves on the bomb
4. Open the sample source valve and close the outlet on the bomb to minimize the boiling of
liquid LPG in the bomb
5. When liquid appears, close the liquid outlet valve followed by the inlet valve and the sample
source valve.
6. Loosen the connection sufficiently to enable the bomb to be inverted. After re-tightening
the connection , open the outlet valve and allow the LPG liquid contents to vent to ensure
that any contamination from the previous sample is removed and that the bomb is chilled.
7. When liquid ceases to flow, close the outlet valve and re-invert bomb by slackening and re-
tightening the connection.
8. Open sample source valve followed by the bomb inlet valve and allow liquid to flow into the
bomb
9. Open bomb outlet valve momentarily from time to time until liquid appears
10. Close outlet, inlet and sample source valve quickly in that order
11. Slacken union and invert bomb so that the ullage tube is at the top, tighten the union and
then crack the top needle valve until liquid ceases to emege, i.e, when appropriate ullage
has been made in the bomb. Close needle valve and slacken union to bleed off liquid from
bomb connection tube.
12. Disconnect bomb and connection tube and seal / plug sampling point
13. Remove sampling bomb to test / analysis point, ensuring that it is not over heated
March - 2006 9 of 9
VI
SQC FORMATS
QUALITY CHECKS ON NEW CYLINDERS AT PLANTS
Sr. No. Type of Checking Qty. to be checked Remarks
1. Tare Weight 5% of the consignment A deviation of +/- 50 gms.

between actual Tare weight &
stenciled / punched Tare weight
is permissible
2. Marking on Cylinder 1% of the consignment subject The requirement on cylinder

to min. of 3 cylinders. stay Plate, bung & footring are
available with the Plant (as per
drawing)
3. Visual Inspection 5% of the consignment To Check :
- Welding of halves, bung, stay

plate, footring
- General Workmanship
- Painting / stenciling including

quality of HP Gas Logos on
body & stay plate
- Legibility of various markings
4. Water Capacity 1 cylinder per supplier Water capacity to be checked by

weight method. Tolerances are
+3%/-0% for 14.2 kg, 19.0 kg &
47.5 kg cylinders & +5% / -0%
for 5 kg cylinders
5. Valve Tightening Torque 1% of the consignment subject Within range of 145 +/- 15 lbft
to min of 3 cylinders
6. Overall Height 05 out of each consignment Overall Height should be 397+5

mm for 5 kg capacity, 625+5
mm for 14.2 kg capacity, 725+5
mm for 19.0 kg capacity &
1270+5 mm for 47.5 kg capacity
March - 2006 1 of 6
VI
SQC FORMATS
QUALITY CHECKS ON NEW VALVES AT PLANTS
S.No. Type of Checing Quantity to be Remarks

Checked
1. Marking on the hexagon 1% of the consignment The marking requirements on
at the flat surface subject Valves are available with Plants
to minimum 10 nos. (As per drawing)
2. Visual Inspection of 0.1% of the consignment To Check :

Valves subject to minimum 10 nos - Crimping of Adjusting screw
- Presence of O’ring & internals
- Functioning of Safety cap
- Workmanship i.e. threads,

excess machining, damage
marks to collar/body, visible
cracks if any
3. Visual Inspection of 0.1% of the safety caps on No discolouring & visible cracks
Safety caps valves subject to minimum in the safety caps
10 nos.
March - 2006 2 of 6
VI
SQC FORMATS
QUALITY CHECKS ON NEW REGULATORS
S.No. Type of Checking Quantity to be Remarks

Checked
1 Markings on Body, 0.2% of the consignment The marking details are available
Cover and Marking Plates subject to min of 10 nos with the plants
2 Visual Inspection 0.2% of the consignment To Check :

- Functioning of operating knob /
tap.
- Functioning of clamping /
locking arrangement
- Presence of following
components
a) Tight Joint
b) Spacing Collar
c) 5 nos clamping steel balls ,
presence of foreign materials,
dust inside the nozzle, Quality
of dry powder coating / colour
- General Workmanship.
March - 2006 3 of 6
VI
SQC FORMATS
QUALITY CHECKS ON HOT REPAIR CYLINDERS / RETESTED CYLINDERS
Sr. No. Type of Checking Qty. to be checked Remarks
1. Visual Inspection 5% of the consignment To Check-
- General Workmanship
- Painting / stenciling and screen

printing
- Quality of HP Gas Logos on

body & stay plate
- Overall Workmanship
- Test Date
2. Tare Weight 5% of the consignment A deviation of +/- 50 gms.

between actual Tare weight &
stenciled / punched Tare weight
is permissible
3. Valve Tightening Torque 1% of the consignment Within range of 145 +/- 15 lbft
March - 2006 4 of 6
VI
SQC FORMATS
LPG FILLED CYLINDERS QUALITY CONTROL CHECKS FORMAT
Sr. No Cylinder Tare Observed Net Variation Next Test Sealed Leak Remarks Signature
No. Weight Tare Wt. Weight Date Yes/No Yes/ No
(O/PL)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
March - 2006 5 of 6
VI
SQC FORMATS
Name of the Bottling Plant DATE
MPa (25.00 kgf/cm2) OK/Rej

Internal & External Tare
Inspection Tare Weight
Weight
Hydrostatic Test at 2.45

Sr. No. of LPG Cylinders
Check
Accepted or Rejected
Name of Manufacture
Date of Manufacture
(i.e. first Test Date)
Old New
Previous Test Dates
Internal External OK/Rej
Pneumatic Test at
Inspection Inspection
OK/Rej. OK/Rej.
Bung Threads
Re-checked
Control No
12 kg/cm2
OK/Rej.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Name & Signature of Officer Supervising in house Testing :

Signature of Plant Manager :
March - 2006 6 of 6
VII
ASTM TABLES
TABLE 53
REDUCTION OF OBSERVED DENSITY TO DENSITY AT 15oC
(Density in this table is mass per unit volume at 15oC expressed in kilograme per litre)
This table gives values of density in kg per litre at 15oC corresponding to density observed with a glass
hydrometer or pyknometer at temperatures other than 15oC. The expression “observed density” appears
in Table 53 since it is the term most generally used in industry. For densities determined by hydrometer,
a more exact expression would be “hydrometer indication at the observed temperature”. This hydrometer
indication differs slightly from the true density at the observed temperature owing to the expansion on
contraction of the glass hydrometer when its temperature differs from its calibration temperature of
15oC. The same is true in the case of densities determined by a glass pyknometer.
It is generally impracticable to determine the density at exactly 15oC, although it is at this temperature
only that strictly correct results are obtained with a standard soft glass hydrometer or pyknometer. In
converting density from toC to 15oC, two corrections are necessary; the first arises from the change in
volume of the glass hydrometer or pyknometer with temperature, and the second from the change in
volume of the oil. For densities above 0.600 at15oC the table takes into account both the change in
volume of the hydrometer or pyknometer and the change in volume of the oil. For densities below, 0.600
at 15oC the table takes into account only the change in volume of the oil, because the change in volume
of the hydrometer or pyknometer is insignificant in comparison with the accuracy of the values for the
change in volume of the oil.
The table must be entered with densities measured with

a soft glass hydrometer or pyknometer calibrated at 15 oC
Example :
If the density of an oil is 0.7943 kg per litre at 24oC, what is its density at 15oC ?
Enter the table with the column headed “Observed Density”
0.794 kg per litre and note that against “Observed Temperature”
24oC, the corresponding density at 15oC is ……………… 0.8004 kg per litre
Likewise, note that for 0.795 kg per litre density at 24oC, the
corresponding value at 15oC is ………………………….. 0.8014 kg per litre
This represents an increase oil 0.0010 kg per litre at 15oC for

an increase of 0.001 in the value at 24oC. Therefore, by
simple proportion, an increase in density at 24oC from 0.794
to 0.7943 kg per litre increases the density at 15oC by
0.3 X 0.0010 or …………………………………………. 0.0003 kg per litre
Then, the density at 15oC corresponding to the density of

0.7943 kg per litre at 24oC is 0.8004 + 0.0003 or ………. 0.8007 kg per litre
March - 2006 1 of 19
VII
ASTM TABLES
Table – 53
0.420 – 0.450 Density Reduction to 150C ASTM-IP
30 – 50 0C
Observed Observed Density
Temperature 0.420 0.425 0.430 0.435 0.440 0.445 0.450
0
C
0
Corresponding Density 15 C
25.0 --- --- --- --- --- --- ---
25.5 --- --- --- --- --- --- ---
26.0 --- --- --- --- --- --- ---
26.5 --- --- --- --- --- --- ---
27.0 --- --- --- --- --- --- ---
27.5 --- --- --- --- --- --- ---
28.0 --- --- --- --- --- --- ---
28.5 --- --- --- --- --- --- ---
29.0 --- --- --- --- --- --- ---
29.5 --- --- --- --- --- --- ---
30.0 --- --- --- --- --- --- 0.476
30.5 --- --- --- --- --- --- 0.477
31.0 --- --- --- --- --- --- 0.478
31.5 --- --- --- --- --- --- 0.478
32.0 --- --- --- --- --- --- 0.479
32.5 --- --- ---- ---- ---- --- 0.480
33.0 --- --- --- --- --- --- 0.481
33.5 --- --- --- --- --- --- 0.482
34.0 --- --- --- --- --- --- 0.482
34.5 --- --- --- --- --- --- 0.483
35.0 --- --- --- --- 0.476 0.480 0.484
35.5 --- --- --- --- 0.477 0.481 0.485
36.0 --- --- --- --- 0.478 0.482 0.486
36.5 --- --- --- --- 0.479 0.483 0.487
37.0 --- --- --- --- 0.480 0.484 0.488
37.5 --- --- --- --- 0.481 0.485 0.489
38.0 --- --- --- --- 0.482 0.486 0.489
38.5 --- --- --- --- 0.483 0.487 0.490
39.0 --- --- --- --- 0.484 0.488 0.491
39.5 --- --- --- --- 0.485 0.489 0.492
40.0 --- --- 0.477 0.481 0.485 0.489 0.493
40.5 --- --- 0.478 0.482 0.486 0.490 0.494
41.0 --- --- 0.478 0.482 0.486 0.490 0.494
41.5 --- ---- 0.479 0.483 0.487 0.491 0.495
42.0 --- --- 0.480 0.484 0.488 0.492 0.496
42.5 --- ---- 0.481 0.485 0.489 0.493 0.497
43.0 --- --- 0.481 0.485 0.489 0.493 0.497
43.5 --- --- 0.482 0.484 0.490 0.492 0.498
44.0 --- --- 0.483 0.485 0.491 0.493 0.499
44.5 --- --- 0.483 0.485 0.491 0.493 0.499
45.0 0.476 0.480 0.484 0.488 0.492 0.496 0.500
45.5 0.477 0.481 0.485 0.489 0.493 0.497 0.501
46.0 0.478 0.482 0.486 0.490 0.494 0.498 0.502
46.5 0.478 0.482 0.486 0.490 0.494 0.498 0.502
47.0 0.479 0.483 0.487 0.491 0.495 0.499 0.503
47.5 0.480 0.484 0.488 0.492 0.496 0.500 0.504
48.0 0.481 0.485 0.489 0.493 0.497 0.500 0.504
48.5 0.482 0.486 0.490 0.494 0.498 0.501 0.505
49.0 0.482 0.486 0.490 0.494 0.498 0.502 0.506
49.5 0.483 0.487 0.491 0.495 0.499 0.502 0.506
50.0 0.484 0.488 0.492 0.496 0.500 0.503 0.507
March - 2006 2 of 19
VII
ASTM TABLES
Table – 53
0 – 25 0C
Temperature 0.455 0.460 0.465 0.470 0.475 0.480 0.485 0.490 0.495 0.500
0
C Corresponding Density 15 0C
0.0 —- —- —- —- —- —- —- —- —- —-
0.5 —- —- —- —- —- —- —- —- —- —-
1.0 —- —- —- —- —- —- —- —- —- —-
1.5 —- —- —- —- —- —- —- —- —- —-
2.0 —- —- —- —- —- —- —- —- —- —-
2.5 —- —- —- —- —- —- —- —- —- —-
3.0 —- —- —- —- —- —- —- —- —- —-
3.5 —- —- —- —- —- —- —- —- —- —-
4.0 —- —- —- —- —- —- —- —- —- —-
4.5 —- —- —- —- —- —- —- —- —- —-
5.0 —- —- —- —- —- —- —- —- —- 0.485
5.5 —- —- —- —- —- —- —- —- —- 0.486
6.0 —- —- —- —- —- —- —- —- —- 0.486
6.5 —- —- —- —- —- —- —- —- —- 0.487
7.0 —- —- —- —- —- —- —- —- —- 0.488
7.5 —- —- —- —- —- —- —- —- —- 0.489
8.0 —- —- —- —- —- —- —- —- —- 0.489
8.5 —- —- —- —- —- —- —- —- —- 0.490
9.0 —- —- —- —- —- —- —- —- —- 0.491
9.5 —- —- —- —- —- —- —- —- —- 0.491
10.0 —- —- —- —- —- —- —- 0.481 0.486 0.492
10.5 —- —- —- —- —- —- —- 0.482 0.487 0.493
11.0 —- —- —- —- —- —- —- 0.483 0.488 0.494
11.5 —- —- —- —- —- —- —- 0.484 0.489 0.494
12.0 —- —- —- —- —- —- —- 0.485 0.490 0.495
12.5 —- —- —- —- —- —- —- 0.486 0.491 0.496
13.0 —- —- —- —- —- —- —- 0.486 0.491 0.497
13.5 —- —- —- —- —- —- —- 0.487 0.492 0.498
14.0 —- —- —- —- —- —- —- 0.488 0.493 0.498
14.5 —- —- —- —- —- —- —- 0.489 0.494 0.499
15.0 —- —- —- —- —- 0.480 0.485 0.490 0.495 0.500
15.5 —- —- —- —- —- 0.481 0.486 0.491 0.496 0.501
16.0 —- —- —- —- —- 0.482 0.487 0.492 0.497 0.502
16.5 —- —- —- —- —- 0.482 0.487 0.492 0.497 0.502
17.0 —- —- —- —- —- 0.483 0.488 0.493 0.498 0.503
17.5 —- —- —- —- —- 0.484 0.489 0.494 0.499 0.504
18.0 —- —- —- —- —- 0.485 0.490 0.495 0.500 0.505
18.5 —- —- —- —- —- 0.486 0.491 0.496 0.501 0.506
19.0 —- —- —- —- —- 0.486 0.491 0.496 0.501 0.506
19.5 —- —- —- —- —- 0.487 0.492 0.497 0.502 0.507
20.0 —- —- —- 0.478 0.483 0.488 0.493 0.498 0.503 0.508
20.5 —- —- —- 0.479 0.484 0.489 0.494 0.499 0.504 0.509
21.0 —- —- —- 0.480 0.485 0.490 0.495 0.499 0.504 0.509
21.5 —- —- —- 0.480 0.485 0.490 0.495 0.500 0.505 0.510
22.0 —- —- —- 0.481 0.486 0.491 0.496 0.501 0.506 0.511
22.5 —- —- —- 0.482 0.487 0.492 0.497 0.502 0.507 0.512
23.0 —- —- —- 0.483 0.487 0.493 0.498 0.502 0.507 0.512
23.5 —- —- —- 0.484 0.488 0.494 0.499 0.503 0.508 0.513
24.0 —- —- —- 0.484 0.488 0.495 0.499 0.504 0.509 0.514
24.5 —- —- —- 0.485 0.489 0.496 0.500 0.504 0.509 0.514
25.0 —- 0.477 0.438 0.486 0.490 0.497 0.501 0.505 0.510 0.515
March - 2006 3 of 19
VII
ASTM TABLES
Table – 53
25 – 50 0C
Temperature 0.455 0.460 0.465 0.470 0.475 0.480 0.485 0.490 0.495 0.500
0
25.0 —- 0.477 0.483 0.486 0.491 0.496 0.501 0.505 0.510 0.515
25.5 —- 0.478 0.484 0.487 0.492 0.497 0.502 0.506 0.511 0.516
26.0 —- 0.479 0.485 0.488 0.493 0.498 0.502 0.507 0.511 0.516
26.5 —- 0.480 0.486 0.488 0.493 0.498 0.503 0.507 0.512 0.517
27.0 —- 0.480 0.486 0.489 0.494 0.499 0.504 0.508 0.513 0.518
27.5 —- 0.481 0.487 0.490 0.495 0.500 0.505 0.509 0.514 0.519
28.0 —- 0.482 0.488 0.491 0.496 0.501 0.505 0.510 0.514 0.519
28.5 —- 0.483 0.489 0.492 0.497 0.502 0.506 0.511 0.515 0.520
29.0 —- 0.483 0.489 0.492 0.497 0.502 0.507 0.511 0.516 0.521
29.5 —- 0.484 0.490 0.493 0.498 0.503 0.507 0.512 0.516 0.521
30.0 0.482 0.485 0.491 0.494 0.499 0.504 0.508 0.513 0.517 0.522
30.5 0.482 0.486 0.492 0.495 0.500 0.505 0.509 0.514 0.518 0.523
31.0 0.483 0.487 0.492 0.496 0.501 0.505 0.509 0.514 0.518 0.523
31.5 0.484 0.487 0.493 0.496 0.501 0.506 0.510 0.515 0.519 0.524
32.0 0.485 0.488 0.494 0.497 0.502 0.507 0.511 0.516 0.520 0.525
32.5 0.485 0.489 0.495 0.498 0.503 0.508 0.512 0.517 0.521 0.526
33.0 0.486 0.490 0.495 0.499 0.504 0.508 0.512 0.517 0.521 0.526
33.5 0.487 0.491 0.496 0.500 0.505 0.509 0.513 0.518 0.522 0.527
34.0 0.488 0.491 0.497 0.500 0.505 0.510 0.514 0.519 0.523 0.528
34.5 0.488 0.492 0.497 0.501 0.506 0.510 0.514 0.519 0.523 0.528
35.0 0.489 0.493 0.498 0.502 0.507 0.511 0.515 0.520 0.524 0.529
35.5 0.490 0.494 0.499 0.503 0.508 0.512 0.516 0.521 0.525 0.530
36.0 0.491 0.495 0.499 0.504 0.508 0.512 0.516 0.521 0.525 0.530
36.5 0.491 0.496 0.500 0.504 0.509 0.513 0.517 0.522 0.526 0.531
37.0 0.492 0.497 0.501 0.505 0.510 0.514 0.518 0.523 0.527 0.531
37.5 0.493 0.498 0.502 0.506 0.511 0.515 0.519 0.524 0.528 0.532
38.0 0.494 0.498 0.502 0.507 0.511 0.515 0.519 0.524 0.528 0.533
38.5 0.495 0.499 0.503 0.508 0.512 0.516 0.520 0.525 0.529 0.533
39.0 0.495 0.500 0.504 0.508 0.513 0.517 0.521 0.526 0.530 0.534
39.5 0.496 0.501 0.504 0.509 0.513 0.517 0.521 0.526 0.530 0.534
40.0 0.497 0.502 0.505 0.510 0.514 0.518 0.522 0.527 0.531 0.535
40.5 0.498 0.503 0.506 0.511 0.515 0.519 0.523 0.528 0.532 0.536
41.0 0.498 0.503 0.507 0.511 0.515 0.519 0.523 0.528 0.532 0.536
41.5 0.499 0.504 0.507 0.512 0.516 0.520 0.524 0.529 0.533 0.537
42.0 0.500 0.505 0.508 0.513 0.517 0.521 0.525 0.529 0.533 0.538
42.5 0.501 0.506 0.509 0.514 0.518 0.522 0.526 0.530 0.534 0.539
43.0 0.501 0.506 0.510 0.514 0.518 0.522 0.526 0.531 0.535 0.539
43.5 0.502 0.507 0.511 0.515 0.519 0.523 0.527 0.531 0.535 0.540
44.0 0.503 0.508 0.511 0.516 0.520 0.524 0.528 0.532 0.536 0.541
44.5 0.503 0.508 0.512 0.516 0.520 0.524 0.528 0.532 0.536 0.541
45.0 0.504 0.509 0.513 0.517 0.521 0.525 0.529 0.533 0.537 0.542
45.5 0.505 0.510 0.514 0.518 0.522 0.526 0.530 0.534 0.538 0.543
46.0 0.505 0.510 0.514 0.518 0.522 0.526 0.530 0.534 0.539 0.543
46.5 0.506 0.511 0.515 0.519 0.523 0.527 0.531 0.535 0.539 0.544
47.0 0.507 0.511 0.515 0.519 0.523 0.527 0.532 0.536 0.540 0.544
47.5 0.508 0.512 0.516 0.520 0.524 0.528 0.533 0.537 0.541 0.545
48.0 0.508 0.513 0.517 0.521 0.525 0.529 0.533 0.537 0.541 0.546
48.5 0.509 0.513 0.517 0.521 0.525 0.529 0.534 0.538 0.542 0.546
49.0 0.510 0.514 0.518 0.522 0.526 0.530 0.535 0.539 0.543 0.547
49.5 0.510 0.514 0.518 0.522 0.526 0.530 0.535 0.539 0.543 0.547
50.0 0.511 0.515 0.519 0.523 0.527 0.531 0.536 0.540 0.544 0.548
March - 2006 4 of 19
VII
ASTM TABLES
Table – 53
0 – 25 0C
Temperature 0.505 0.510 0.515 0.520 0.525 0.530 0.535 0.540 0.545 0.550
0
0.0 —- 0.487 0.492 0.498 0.503 0.509 0.514 0.520 0.525 0.531
0.5 —- 0.488 0.493 0.499 0.504 0.510 0.515 0.521 0.526 0.532
1.0 —- 0.489 0.494 0.500 0.505 0.510 0.515 0.521 0.526 0.532
1.5 —- 0.489 0.494 0.500 0.505 0.511 0.516 0.522 0.527 0.533
2.0 —- 0.490 0.495 0.501 0.506 0.512 0.517 0.523 0.528 0.533
2.5 —- 0.491 0.496 0.502 0.507 0.513 0.518 0.524 0.529 0.534
3.0 —- 0.492 0.497 0.503 0.508 0.513 0.518 0.524 0.529 0.535
3.5 —- 0.493 0.498 0.504 0.509 0.514 0.519 0.525 0.530 0.535
4.0 —- 0.493 0.498 0.504 0.509 0.515 0.520 0.526 0.531 0.536
4.5 —- 0.494 0.499 0.505 0.510 0.515 0.520 0.526 0.531 0.536
5.0 0.490 0.495 0.500 0.506 0.511 0.516 0.521 0.527 0.532 0.537
5.5 0.491 0.496 0.501 0.507 0.512 0.517 0.522 0.528 0.533 0.538
6.0 0.491 0.497 0.502 0.507 0.512 0.517 0.522 0.528 0.533 0.538
6.5 0.492 0.497 0.502 0.508 0.513 0.518 0.523 0.529 0.534 0.539
7.0 0.493 0.498 0.503 0.509 0.514 0.519 0.524 0.529 0.534 0.540
7.5 0.494 0.499 0.504 0.510 0.515 0.520 0.525 0.530 0.535 0.541
8.0 0.494 0.500 0.505 0.510 0.515 0.520 0.525 0.531 0.536 0.541
8.5 0.495 0.501 0.506 0.511 0.516 0.521 0.526 0.531 0.536 0.542
9.0 0.496 0.501 0.506 0.512 0.517 0.522 0.527 0.532 0.537 0.543
9.5 0.496 0.502 0.507 0.512 0.517 0.522 0.527 0.532 0.537 0.543
10.0 0.497 0.503 0.508 0.513 0.518 0.523 0.528 0.533 0.538 0.544
10.5 0.498 0.504 0.509 0.514 0.519 0.524 0.529 0.534 0.539 0.545
11.0 0.499 0.504 0.509 0.514 0.519 0.524 0.529 0.534 0.539 0.545
11.5 0.499 0.505 0.510 0.515 0.520 0.525 0.530 0.535 0.540 0.546
12.0 0.500 0.506 0.511 0.516 0.521 0.526 0.531 0.536 0.541 0.546
12.5 0.501 0.507 0.512 0.517 0.522 0.527 0.532 0.537 0.542 0.547
13.0 0.502 0.507 0.512 0.517 0.522 0.527 0.532 0.537 0.542 0.548
13.5 0.503 0.508 0.513 0.518 0.523 0.528 0.533 0.538 0.543 0.548
14.0 0.503 0.509 0.514 0.519 0.524 0.529 0.534 0.539 0.544 0.549
14.5 0.504 0.509 0.514 0.519 0.524 0.529 0.534 0.539 0.544 0.549
15.0 0.505 0.510 0.515 0.520 0.525 0.530 0.535 0.540 0.545 0.550
15.5 0.506 0.511 0.516 0.521 0.526 0.531 0.536 0.541 0.546 0.551
16.0 0.507 0.512 0.516 0.521 0.526 0.531 0.536 0.541 0.546 0.551
16.5 0.507 0.512 0.517 0.522 0.527 0.532 0.537 0.542 0.547 0.552
17.0 0.508 0.513 0.518 0.523 0.528 0.533 0.538 0.543 0.548 0.553
17.5 0.509 0.514 0.519 0.524 0.529 0.534 0.539 0.544 0.549 0.554
18.0 0.510 0.515 0.519 0.524 0.529 0.534 0.539 0.544 0.549 0.554
18.5 0.511 0.516 0.520 0.525 0.530 0.535 0.540 0.545 0.550 0.555
19.0 0.511 0.516 0.521 0.526 0.531 0.536 0.541 0.546 0.551 0.556
19.5 0.512 0.517 0.521 0.526 0.531 0.536 0.541 0.546 0.551 0.556
20.0 0.513 0.518 0.522 0.527 0.532 0.537 0.542 0.547 0.552 0.557
20.5 0.514 0.519 0.523 0.528 0.533 0.538 0.543 0.548 0.553 0.558
21.0 0.514 0.519 0.523 0.528 0.533 0.538 0.543 0.548 0.553 0.558
21.5 0.515 0.520 0.524 0.529 0.534 0.539 0.544 0.549 0.554 0.559
22.0 0.516 0.520 0.525 0.530 0.535 0.540 0.544 0.549 0.554 0.559
22.5 0.517 0.521 0.526 0.531 0.536 0.541 0.545 0.550 0.555 0.560
23.0 0.517 0.522 0.526 0.531 0.536 0.541 0.546 0.551 0.556 0.561
23.5 0.518 0.522 0.527 0.532 0.537 0.542 0.546 0.551 0.556 0.561
24.0 0.519 0.523 0.528 0.533 0.538 0.543 0.547 0.552 0.557 0.562
24.5 0.519 0.523 0.528 0.533 0.538 0.543 0.547 0.552 0.557 0.562
25.0 0.520 0.524 0.529 0.534 0.539 0.544 0.548 0.553 0.558 0.563
March - 2006 5 of 19
VII
ASTM TABLES
Table – 53
25 – 50 0C
Temperature 0.505 0.510 0.515 0.520 0.525 0.530 0.535 0.540 0.545 0.550
- 0C Corresponding Density 150C
25.0 0.520 0.524 0.529 0.534 0.539 0.544 0.548 0.553 0.558 0.563
25.5 0.521 0.525 0.530 0.535 0.540 0.545 0.549 0.554 0.559 0.564
26.0 0.521 0.525 0.530 0.535 0.540 0.545 0.549 0.554 0.559 0.564
26.5 0.522 0.526 0531 0.536 0.541 0.546 0.550 0.555 0.560 0.565
27.0 0.523 0.527 0.532 0.537 0.541 0.546 0.550 0.555 0.560 0.565
27.5 0.524 0.528 0.533 0.538 0.542 0.547 0.551 0.556 0.561 0.566
28.0 0.524 0.528 0.533 0.538 0.543 0.548 0.552 0.557 0.562 0.567
28.5 0.525 0.529 0.534 0.539 0.543 0.548 0.552 0.557 0.562 0.567
29.0 0.526 0.530 0.535 0.540 0.544 0.549 0.553 0.558 0.563 0.568
29.5 0.526 0.530 0.535 0.540 0.544 0.549 0.553 0.558 0.563 0.568
30.0 0.527 0.531 0.536 0.541 0.545 0.550 0.554 0.559 0.564 0.569
30.5 0.528 0.532 0.537 0.542 0.546 0.551 0.555 0.560 0.565 0.570
31.0 0.528 0.532 0.537 0.542 0.546 0.551 0.555 0.560 0.565 0.570
31.5 0.529 0.533 0.538 0.543 0.547 0.552 0.556 0.561 0.566 0.571
32.0 0.529 0.534 0.538 0.543 0.547 0.552 0.557 0.561 0.566 0.571
32.5 0.530 0.535 0.539 0.544 0.548 0.553 0.558 0.562 0.567 0.572
33.0 0.531 0.535 0.540 0.545 0.549 0.554 0.558 0.563 0.567 0.572
33.5 0.531 0.536 0.540 0.545 0.549 0.554 0.559 0.563 0.568 0.573
34.0 0.532 0.537 0.541 0.546 0.550 0.555 0.560 0.564 0.568 0.573
34.5 0.532 0.537 0.541 0.546 0.550 0.555 0.560 0.564 0.569 0.574
35.0 0.533 0.538 0.542 0.547 0.551 0.556 0.561 0.565 0.569 0.574
35.5 0.534 0.539 0.543 0.548 0.552 0.557 0.562 0.566 0.570 0.575
36.0 0.534 0.539 0.543 0.548 0.552 0.557 0.562 0.566 0.570 0.575
36.5 0.535 0.540 0.544 0.549 0.553 0.558 0.563 0.567 0.571 0.576
37.0 0.536 0.540 0.544 0.549 0.553 0.558 0.563 0.567 0.571 0.576
37.5 0.537 0.541 0.545 0.550 0.554 0.559 0.564 0.568 0.572 0.577
38.0 0.537 0.542 0.546 0.551 0.555 0.560 0.564 0.569 0.573 0.578
38.5 0.538 0.542 0.546 0.551 0.555 0.560 0.565 0.569 0.573 0.578
39.0 0.539 0.543 0.547 0.552 0.556 0.561 0.565 0.570 0.574 0.579
39.5 0.539 0.543 0.547 0.552 0.556 0.561 0.566 0.570 0.574 0.579
40.0 0.540 0.544 0.548 0.553 0.557 0.562 0.566 0.571 0.575 0.580
40.5 0.541 0.545 0.549 0.554 0.558 0.563 0.567 0.572 0.576 0.581
41.0 0.541 0.545 0.549 0.554 0.558 0.563 0.567 0.572 0.576 0.581
41.5 0.542 0.546 0.550 0.555 0.559 0.564 0.568 0.573 0.577 0.582
42.0 0.542 0.546 0.550 0.555 0.559 0.564 0.568 0.573 0.577 0.582
42.5 0.543 0.547 0.551 0.556 0.560 0.565 0.569 0.574 0.578 0.583
43.0 0.544 0.548 0.552 0.557 0.561 0.565 0.570 0.574 0.579 0.583
43.5 0.544 0.548 0.552 0.557 0.561 0.566 0.570 0.575 0.579 0.584
44.0 0.545 0.549 0.553 0.558 0.562 0.566 0.571 0.575 0.580 0.584
44.5 0.545 0.549 0.553 0.558 0.562 0.567 0.571 0.576 0.580 0.585
45.0 0.546 0.550 0.554 0.559 0.563 0.567 0.572 0.576 0.581 0.585
45.5 0.547 0.551 0.555 0.560 0.564 0.568 0.573 0.577 0.582 0.586
46.0 0.547 0.551 0.555 0.560 0.564 0.568 0.573 0.577 0.582 0.586
46.5 0.548 0.552 0.556 0.561 0.565 0.569 0.574 0.578 0.583 0.587
47.0 0.548 0.552 0.557 0.561 0.565 0.569 0.574 0.578 0.583 0.587
47.5 0.549 0.553 0.558 0.562 0.566 0.570 0.575 0.579 0.584 0.588
48.0 0.550 0.554 0.558 0.563 0.567 0.571 0.576 0.580 0.585 0.589
48.5 0.550 0.554 0.559 0.563 0.567 0.571 0.576 0.580 0.585 0.589
49.0 0.551 0.555 0.560 0.564 0.568 0.572 0.577 0.581 0.586 0.590
49.5 0.551 0.555 0.560 0.564 0.568 0.572 0.577 0.581 0.586 0.590
50.0 0.552 0.556 0.561 0.565 0.569 0.573 0.578 0.582 0.587 0.591
March - 2006 6 of 19
VII
ASTM TABLES
Table – 53
0.555– 0.595 Density Reduction to 150C ASTM-IP
0 - 25 0C
Temperature 0.555 0.560 0.565 0.570 0.575 0.580 0.585 0.590 0.595
0 0.536 0.541 0.547 0.552 0.557 0.562 0.568 0.573 0.579
0.5 0.537 0.542 0.548 0.553 0.558 0.563 0.569 0.574 0.580
1.0 0.537 0.542 0.548 0.553 0.558 0.563 0.569 0.574 0.580
1.5 0.538 0.543 0.549 0.554 0.559 0.564 0.570 0.575 0.581
2.0 0.538 0.543 0.549 0.554 0.559 0.564 0.570 0.575 0.581
2.5 0.539 0.544 0.550 0.555 0.560 0.565 0.571 0.576 0.582
3.0 0.540 0.545 0.551 0.556 0.561 0.566 0.571 0.577 0.582
3.5 0.540 0.545 0.551 0.556 0.561 0.566 0.572 0.577 0.583
4.0 0.541 0.546 0.552 0.557 0.562 0.567 0.573 0.578 0.583
4.5 0.541 0.546 0.552 0.557 0.562 0.567 0.573 0.578 0.584
5.0 0.542 0.547 0.553 0.558 0.563 0.568 0.574 0.579 0.584
5.5 0.543 0.548 0.554 0.559 0.564 0.569 0.575 0.580 0.585
6.0 0.543 0.548 0.554 0.559 0.564 0.569 0.575 0.580 0.585
6.5 0.544 0.549 0.555 0.560 0.565 0.570 0.576 0.581 0.586
7.0 0.545 0.550 0.555 0.560 0.565 0.571 0.576 0.581 0.586
7.5 0.546 0.551 0.556 0.561 0.566 0.572 0.577 0.582 0.587
8.0 0.546 0.551 0.557 0.562 0.567 0.572 0.578 0.583 0.588
8.5 0.547 0.552 0.557 0.562 0.567 0.573 0.578 0.583 0.588
9.0 0.548 0.553 0.558 0.563 0.568 0.574 0.579 0.584 0.589
9.5 0.548 0.553 0.558 0.563 0.568 0.574 0.579 0.584 0.589
10.0 0.549 0.554 0.559 0.564 0.569 0.575 0.580 0.585 0.590
10.5 0.550 0.555 0.560 0.565 0.570 0.576 0.581 0.586 0.591
11.0 0.550 0.555 0.560 0.565 0.570 0.576 0.581 0.586 0.591
11.5 0.551 0.556 0.561 0.566 0.571 0.577 0.582 0.587 0.592
12.0 0.551 0.556 0.561 0.566 0.571 0.577 0.582 0.587 0.592
12.5 0.552 0.557 0.562 0.567 0.572 0.578 0.583 0.588 0.593
13.0 0.553 0.558 0.563 0.568 0.572 0.578 0.583 0.588 0.593
13.5 0.553 0.558 0.563 0.568 0.573 0.579 0.584 0.589 0.594
14.0 0.554 0.559 0.564 0.569 0.574 0.579 0.584 0.589 0.594
14.5 0.554 0.559 0.564 0.569 0.574 0.580 0.585 0.590 0.595
15.0 0.555 0.560 0.565 0.570 0.575 0.580 0.585 0.590 0.595
15.5 0.556 0.561 0.566 0.571 0.576 0.581 0.586 0.591 0.596
16.0 0.556 0.561 0.566 0.571 0.576 0.581 0.586 0.591 0.596
16.5 0.557 0.562 0.567 0.572 0.577 0.582 0.587 0.592 0.597
17.0 0.557 0.562 0.567 0.572 0.577 0.582 0.587 0.592 0.597
17.5 0.558 0.563 0.568 0.573 0.578 0.583 0.588 0.593 0.598
18.0 0.559 0.564 0.569 0.574 0.579 0.584 0.589 0.594 0.598
18.5 0.559 0.564 0.569 0.574 0.579 0.584 0.589 0.594 0.599
19.0 0.560 0.565 0.570 0.575 0.580 0.585 0.590 0.595 0.599
19.5 0.560 0.565 0.570 0.575 0.580 0.585 0.590 0.595 0.600
20.0 0.561 0.566 0.571 0.576 0.581 0.586 0.591 0.596 0.600
20.5 0.562 0.567 0.572 0.577 0.582 0.587 0.592 0.597 0.601
21.0 0.562 0.567 0.572 0.577 0.582 0.587 0.592 0.597 0.601
21.5 0.563 0.568 0.573 0.578 0.583 0.588 0.593 0.598 0.602
22.0 0.563 0.568 0.573 0.578 0.583 0.588 0.593 0.598 0.602
22.5 0.564 0.569 0.574 0.579 0.584 0.589 0.594 0.599 0.603
23.0 0.565 0.570 0.575 0.580 0.585 0.590 0.594 0.599 0.603
23.5 0.565 0.570 0.575 0.580 0.585 0.590 0.595 0.600 0.604
24.0 0.566 0.571 0.576 0.581 0.586 0.591 0.595 0.600 0.604
24.5 0.566 0.571 0.576 0.581 0.586 0.591 0.596 0.601 0.605
25.0 0.567 0.572 0.577 0.582 0.587 0.592 0.596 0.601 0.605
March - 2006 7 of 19
VII
ASTM TABLES
Table – 53
25 - 50 0C

Temperature 0.555 0.560 0.565 0.570 0.575 0.580 0.585 0.590 0.595
0
C Corresponding Density 150C
25.0 0.567 0.572 0.577 0.582 0.587 0.592 0.596 0.601 0.605
25.5 0.568 0.573 0.578 0.583 0.588 0.593 0.597 0.602 0.606
26.0 0.568 0.573 0.578 0.583 0.588 0.593 0.597 0.602 0.606
26.5 0.569 0.574 0.579 0.584 0.589 0.594 0.598 0.603 0.607
27.0 0.569 0.574 0.579 0.584 0.589 0.594 0.598 0.603 0.607
27.5 0.570 0.575 0.580 0.585 0.590 0.595 0.599 0.604 0.608
28.0 0.571 0.576 0.581 0.585 0.590 0.595 0.600 0.604 0.609
28.5 0.571 0.576 0.581 0.586 0.591 0.596 0.600 0.605 0.609
29.0 0.572 0.577 0.582 0.586 0.591 0.596 0.601 0.605 0.610
29.5 0.572 0.577 0.582 0.587 0.592 0.597 0.601 0.606 0.610
30.0 0.573 0.578 0.583 0.587 0.592 0.597 0.602 0.606 0.611
30.5 0.574 0.579 0.584 0.588 0.593 0.598 0.603 0.606 0.611
31.0 0.574 0.579 0.584 0.588 0.593 0.598 0.603 0.607 0.612
31.5 0.575 0.580 0.585 0.589 0.594 0.599 0.604 0.607 0.612
32.0 0.575 0.580 0.585 0.589 0.594 0.599 0.604 0.608 0.613
32.5 0.576 0.581 0.586 0.590 0.595 0.600 0.605 0.608 0.613
33.0 0.577 0.582 0.586 0.591 0.595 0.600 0.605 0.608 0.613
33.5 0.577 0.582 0.587 0.591 0.596 0.601 0.606 0.609 0.614
34.0 0.578 0.583 0.587 0.592 0.596 0.601 0.606 0.609 0.614
34.5 0.578 0.583 0.588 0.592 0.597 0.602 0.607 0.610 0.615
35.0 0.579 0.584 0.588 0.593 0.597 0.602 0.607 0.610 0.615
35.5 0.580 0.585 0.589 0.594 0.598 0.603 0.608 0.611 0.616
36.0 0.580 0.585 0.589 0.594 0.598 0.603 0.608 0.611 0.616
36.5 0.581 0.586 0.590 0.595 0.599 0.604 0.609 0.612 0.617
37.0 0.581 0.586 0.590 0.595 0.599 0.604 0.609 0.612 0.617
37.5 0.582 0.587 0.591 0.596 0.600 0.605 0.610 0.613 0.618
38.0 0.582 0.587 0.591 0.596 0.601 0.605 0.610 0.614 0.619
38.5 0.583 0.588 0.592 0.597 0.601 0.606 0.611 0.614 0.619
39.0 0.583 0.588 0.592 0.597 0.602 0.606 0.611 0.615 0.620
39.5 0.584 0.589 0.593 0.598 0.602 0.607 0.612 0.615 0.620
40.0 0.584 0.589 0.593 0.598 0.603 0.607 0.612 0.616 0.621
40.5 0.585 0.590 0.594 - - - - - -
41.0 0.585 0.590 0.594 - - - - - -
41.5 0.586 0.591 0.595 - - - - - -
42.0 0.586 0.591 0.595 - - - - - -
42.5 0.587 0.592 0.596 - - - - - -
43.0 0.587 0.592 0.596 - - - - - -
43.5 0.588 0.593 0.597 - - - - - -
44.0 0.588 0.593 0.597 - - - - - -
44.5 0.589 0.594 0.598 - - - - - -
45.0 0.589 0.594 0.598 - - - - - -
45.5 0.590 0.595 0.599 - - - - - -
46.0 0.590 0.595 0.599 - - - - - -
46.5 0.591 0.596 0.600 - - - - - -
47.0 0.591 0.596 0.601 - - - - - -
47.5 0.592 0.597 0.602 - - - - - -
48.0 0.593 0.598 0.602 - - - - - -
48.5 0.593 0.598 0.603 - - - - - -
49.0 0.594 0.599 0.604 - - - - - -
49.5 0.594 0.599 0.604 - - - - - -
50.0 0.595 0.600 0.605 - - - - - -
March - 2006 8 of 19
VII
ASTM TABLES
Table – 53
0
0 - 25 C

Temperature 0.600 0.601 0.602 0.603 0.604 0.605 0.606 0.607 0.608 0.609
0 0.5838 0.5849 0.5859 0.5870 0.5880 0.5891 0.5901 0.5912 0.5922 0.5933
0.5 0.5844 0.5854 0.5865 0.5875 0.5886 0.5896 0.5907 0.5917 0.5928 0.5938
1.0 0.5850 0.5860 0.5871 0.5881 0.5892 0.5902 0.5912 0.5923 0.5933 0.5944
1.5 0.5855 0.5866 0.5876 0.5887 0.5897 0.5907 0.5918 0.5928 0.5939 0.5949
2.0 0.5861 0.5871 0.5882 0.5892 0.5903 0.5913 0.5923 0.5934 0.5944 0.5955
2.5 0.5866 0.5877 0.5887 0.5898 0.5908 0.5918 0.5929 0.5939 0.5950 0.5960
3.0 0.5872 0.5882 0.5893 0.5903 0.5913 0.5924 0.5934 0.5945 0.5955 0.5966
3.5 0.5877 0.5888 0.5898 0.5909 0.5919 0.5929 0.5940 0.5950 0.5961 0.5971
4.0 0.5883 0.5893 0.5904 0.5914 0.5924 0.5935 0.5945 0.5956 0.5966 0.5976
4.5 0.5888 0.5899 0.5909 0.5919 0.5930 0.5940 0.5951 0.5961 0.5971 0.5982
5.0 0.5894 0.5904 0.5915 0.5925 0.5935 0.5946 0.5956 0.5966 0.5977 0.5987
5.5 0.5899 0.5910 0.5920 0.5930 0.5941 0.5951 0.5961 0.5972 0.5982 0.5992
6.0 0.5905 0.5915 0.5925 0.5936 0.5946 0.5956 0.5967 0.5977 0.5987 0.5998
6.5 0.5910 0.5920 0.5931 0.5941 0.5951 0.5962 0.5972 0.5982 0.5992 0.6003
7.0 0.5916 0.5926 0.5936 0.5946 0.5957 0.5967 0.5977 0.5987 0.5998 0.6008
7.5 0.5921 0.5931 0.5941 0.5952 0.5962 0.5972 0.5983 0.5993 0.6003 0.6013
8.0 0.5926 0.5937 0.5947 0.5957 0.5967 0.5978 0.5988 0.5998 0.6008 0.6018
8.5 0.5932 0.5942 0.5952 0.5962 0.5973 0.5983 0.5993 0.6003 0.6013 0.6024
9.0 0.5937 0.5947 0.5957 0.5968 0.5978 0.5988 0.5998 0.6008 0.6019 0.6029
9.5 0.5942 0.5953 0.5963 0.5973 0.5983 0.5993 0.6003 0.6014 0.6024 0.6034
10.0 0.5948 0.5958 0.5968 0.5978 0.5988 0.5999 0.6009 0.6019 0.6029 0.6039
10.5 0.5953 0.5963 0.5973 0.5983 0.5994 0.6004 0.6014 0.6024 0.6034 0.6044
11.0 0.5958 0.5968 0.5979 0.5989 0.5999 0.6009 0.6019 0.6029 0.6039 0.6049
11.5 0.5964 0.5974 0.5984 0.5994 0.6004 0.6014 0.6024 0.6034 0.6044 0.6054
12.0 0.5969 0.5979 0.5989 0.5999 0.6009 0.6019 0.6029 0.6039 0.6049 0.6060
12.5 0.5974 0.5984 0.5994 0.6004 0.6014 0.6024 0.6034 0.6045 0.6055 0.6055
13.0 0.5979 0.5989 0.5999 0.6009 0.6019 0.6030 0.6040 0.6050 0.6060 0.6070
13.5 0.5984 0.5995 0.6005 0.6015 0.6025 0.6035 0.6045 0.6055 0.6065 0.6075
14.0 0.5990 0.6000 0.6010 0.6020 0.6030 0.6040 0.6050 0.6060 0.6070 0.6080
14.5 0.5995 0.6005 0.6015 0.6025 0.6035 0.6045 0.6055 0.6065 0.6075 0.6085
15.0 0.6000 0.6010 0.6020 0.6030 0.6040 0.6050 0.6060 0.6070 0.6080 0.6090
15.5 0.6005 0.6015 0.6025 0.6035 0.6045 0.6055 0.6065 0.6075 0.6085 0.6095
16.0 0.6010 0.6020 0.6030 0.6040 0.6050 0.6060 0.6070 0.6080 0.6090 0.6100
16.5 0.6015 0.6025 0.6035 0.6045 0.6055 0.6065 0.6075 0.6085 0.6095 0.6105
17.0 0.6021 0.6030 0.6040 0.6050 0.6060 0.6070 0.6080 0.6090 0.6100 0.6110
17.5 0.6026 0.6036 0.6046 0.6055 0.6065 0.6075 0.6085 0.6095 0.6105 0.6115
18.0 0.6031 0.6041 0.6051 0.6061 0.6070 0.6080 0.6090 0.6100 0.6110 0.6120
18.5 0.6036 0.6046 0.6056 0.6066 0.6075 0.6085 0.6095 0.6105 0.6115 0.6125
19.0 0.6041 0.6051 0.6061 0.6071 0.6081 0.6090 0.6100 0.6110 0.6120 0.6130
19.5 0.6046 0.6056 0.6066 0.6076 0.6086 0.6095 0.6105 0.6115 0.6125 0.6135
20.0 0.6051 0.6061 0.6071 0.6081 0.6091 0.6100 0.6110 0.6120 0.6130 0.6140
20.5 0.6056 0.6066 0.6076 0.6086 0.6096 0.6105 0.6115 0.6125 0.6135 0.6145
21.0 0.6061 0.6071 0.6081 0.6091 0.6101 0.6110 0.6120 0.6130 0.6140 0.6150
21.5 0.6066 0.6076 0.6086 0.6096 0.6106 0.6115 0.6125 0.6135 0.6145 0.6155
22.0 0.6071 0.6081 0.6091 0.6101 0.6110 0.6120 0.6130 0.6140 0.6150 0.6160
22.5 0.6076 0.6086 0.6096 0.6106 0.6115 0.6125 0.6135 0.6145 0.6155 0.6165
23.0 0.6081 0.6091 0.6101 0.6111 0.6120 0.6130 0.6140 0.6150 0.6160 0.6169
23.5 0.6086 0.6096 0.6106 0.6116 0.6125 0.6135 0.6145 0.6155 0.6165 0.6174
24.0 0.6091 0.6101 0.6111 0.6120 0.6130 0.6140 0.6150 0.6160 0.6169 0.6179
24.5 0.6096 0.6106 0.6116 0.6125 0.6135 0.6145 0.6155 0.6165 0.6174 0.6184
25.0 0.6101 0.6111 0.6121 0.6130 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189
March - 2006 9 of 19
VII
ASTM TABLES
Table – 53
25 - 50 0C
Temperature 0.600 0.601 0.602 0.603 0.604 0.605 0.606 0.607 0.608 0.609
25.0 0.6101 0.6111 0.6121 0.6130 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189
25.5 0.6106 0.6116 0.6125 0.6135 0.6145 0.6155 0.6165 0.6174 0.6184 0.6194
26.0 0.6111 0.6121 0.6130 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189 0.6199
26.5 0.6116 0.6126 0.6135 0.6145 0.6155 0.6165 0.6174 0.6184 0.6194 0.6203
27.0 0.6121 0.6130 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189 0.6199 0.6208
27.5 0.6126 0.6135 0.6145 0.6155 0.6165 0.6174 0.6184 0.6194 0.6203 0.6213
28.0 0.6131 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189 0.6198 0.6208 0.6218
28.5 0.6135 0.6145 0.6155 0.6165 0.6174 0.6184 0.6194 0.6203 0.6213 0.6223
29.0 0.6140 0.6150 0.6160 0.6169 0.6179 0.6189 0.6198 0.6208 0.6218 0.6228
29.5 0.6145 0.6155 0.6165 0.6174 0.6184 0.6194 0.6203 0.6213 0.6223 0.6232
30.0 0.6150 0.6160 0.6169 0.6179 0.6189 0.6198 0.6208 0.6218 0.6227 0.6237
30.5 0.6155 0.6165 0.6174 0.6184 0.6193 0.6203 0.6213 0.6222 0.6232 0.6242
31.0 0.6160 0.6169 0.6179 0.6189 0.6198 0.6208 0.6218 0.6227 0.6237 0.6247
31.5 0.6165 0.6174 0.6184 0.6193 0.6203 0.6213 0.6222 0.6232 0.6242 0.6251
32.0 0.6169 0.6179 0.6189 0.6193 0.6208 0.6218 0.6227 0.6237 0.6247 0.6256
32.5 0.6174 0.6184 0.6193 0.6203 0.6213 0.6222 0.6232 0.6242 0.6251 0.6261
33.0 0.6179 0.6189 0.6198 0.6208 0.6217 0.6227 0.6237 0.6246 0.6256 0.6266
33.5 0.6184 0.6193 0.6203 0.6213 0.6222 0.6232 0.6241 0.6251 0.6261 0.6270
34.0 0.6189 0.6198 0.6208 0.6217 0.6227 0.6237 0.6246 0.6256 0.6265 0.6275
34.5 0.6193 0.6203 0.6213 0.6222 0.6232 0.6241 0.6251 0.6261 0.6270 0.6280
35.0 0.6198 0.6208 0.6217 0.6227 0.6236 0.6246 0.6256 0.6265 0.6275 0.6285
35.5 0.6203 0.6212 0.6222 0.6232 0.6241 0.6251 0.6260 0.6270 0.6280 0.6289
36.0 0.6208 0.6217 0.6227 0.6236 0.6246 0.6256 0.6265 0.6275 0.6284 0.6294
36.5 0.6212 0.6222 0.6232 0.6241 0.6251 0.6260 0.6270 0.6279 0.6289 0.6299
37.0 0.6217 0.6227 0.6236 0.6246 0.6255 0.6265 0.6275 0.6284 0.6294 0.6303
37.5 0.6222 0.6231 0.6241 0.6251 0.6260 0.6270 0.6279 0.6289 0.6298 0.6308
38.0 0.6227 0.6236 0.6246 0.6255 0.6265 0.6274 0.6284 0.6294 0.6303 0.6313
38.5 0.6231 0.6241 0.6250 0.6260 0.6270 0.6279 0.6289 0.6298 0.6308 0.6317
39.0 0.6236 0.6246 0.6255 0.6265 0.6274 0.6284 0.6293 0.6303 0.6312 0.6322
39.5 0.6241 0.6250 0.6260 0.6269 0.6279 0.6288 0.6298 0.6308 0.6317 0.6327
40.0 0.6246 0.6255 0.6265 0.6274 0.6284 0.6293 0.6303 0.6312 0.6322 0.6331
40.5 0.6250 0.6260 0.6269 0.6279 0.6288 0.6298 0.6307 0.6317 0.6326 0.6336
41.0 0.6255 0.6264 0.6274 0.6283 0.6293 0.6302 0.6312 0.6321 0.6331 0.6340
41.5 0.6260 0.6269 0.6279 0.6288 0.6208 0.6307 0.6317 0.6326 0.6336 0.6345
42.0 0.6264 0.6274 0.6283 0.6293 0.6302 0.6312 0.6321 0.6331 0.6340 0.6350
42.5 0.6269 0.6278 0.6288 0.6297 0.6307 0.6316 0.6326 0.6335 0.6345 0.6354
43.0 0.6274 0.6283 0.6293 0.6302 0.6312 0.6321 0.6330 0.6340 0.6349 0.6359
43.5 0.6278 0.6288 0.6297 0.6307 0.6316 0.6326 0.6335 0.6344 0.6354 0.6363
44.0 0.6283 0.6292 0.6302 0.6311 0.6321 0.6330 0.6340 0.6349 0.6358 0.6368
44.5 0.6288 0.6297 0.6306 0.6316 0.6325 0.6335 0.6344 0.6354 0.6363 0.6372
45.0 0.6292 0.6302 0.6311 0.6321 0.6330 0.6339 0.6349 0.6358 0.6368 0.6377
45.5 0.6297 0.6306 0.6316 0.6325 0.6335 0.6344 0.6353 0.6363 0.6372 0.6382
46.0 0.6302 0.6311 0.6320 0.6330 0.6339 0.6349 0.6358 0.6367 0.6377 0.6386
46.5 0.6306 0.6316 0.6325 0.6334 0.6344 0.6353 0.6362 0.6372 0.6381 0.6391
47.0 0.6311 0.6320 0.6330 0.6339 0.6348 0.6358 0.6367 0.6376 0.6386 0.6395
47.5 0.6315 0.6325 0.6334 0.6343 0.6353 0.6362 0.6372 0.6381 0.6390 0.6400
48.0 0.6320 0.6329 0.6339 0.6348 0.6357 0.6367 0.6376 0.6385 0.6395 0.6405
48.5 0.6325 0.6334 0.6343 0.6353 0.6362 0.6371 0.6381 0.6390 0.6399 0.6409
49.0 0.6329 0.6338 0.6348 0.6357 0.6366 0.6376 0.6385 0.6394 0.6404 0.6414
49.5 0.6334 0.6343 0.6352 0.6362 0.6371 0.6380 0.6390 0.6399 0.6409 0.6418
50.0 0.6338 0.6348 0.6357 0.6366 0.6376 0.6385 0.6394 0.6404 0.6413 0.6423
March - 2006 10 of 19
VII
ASTM TABLES
TABLE 54
REDUCTION OF VOLUME TO 15oC AGAINST DENSITY AT 15oC
(Density in this table is mass per unit volume at 15oC expressed in kilograme per litre)
This table gives the factors for converting oil volumes observed at temperatures other than 15oC to the
corresponding volumes at 15oC for values of density in the range 0,500 to 1,100 kg per litre.
It is emphasized that the volume correction factors in this table make no allowance for the thermal
expansion of tanks and other types of containers. In order to facilitate interpolation in density, differences
are provided between adjacent density values.
The table must be entered with density at 15oC and

volumes measured at Centigrade temperatures.
Example :
What is the volume at 15oC of 63,162 litres at 1,0oC of an oil whose density at 15oC is 0,7237 kg per
litre?
Enter the table with the column headed “Density at 15oC” 0,720 kg
per litre, note that against “Observed Temperature” 1,0oC the
factor is …………………………………………………... 1,0165 kg per litre
Likewise at the same temperature note that the difference between

the factor for 0,720 kg per litre density and the factor for 0,725 kg
per litre density is ……………………………………….. 0,0003
This represents a decrease of 0,0003 units in the factor for an increase

of 0,005 kg per litre in density. Therefore, by simple proportion,
an increase in density from 0,720 to 0,7237 kg per litre decreases
the factor by 0,0037/0,0050 X 0,0003 or ……………….. 0,0002
Hence, one litre of oil having a density of 0,7237 kg per litre at 15oC
and measured 1,0oC occupies a volume at 15oC of 1,0165 – 0,0002
or ………………………………………………………… 1,0163 litres
Then 63,162 litres measured at 1,0oC occupy a volume at 15oC of

63 162 X 1,0163 or …………………………………….. 64 192 litres
March - 2006 11 of 19
VII
ASTM TABLES
Table 54
ASTM-IP Volume Reduction to 15ºC. 0.500-0.510
0-50ºC
* Density 15ºC. * Density 15ºC.
Observed Observed
0.500 0.505 0.510 0.500 0.505 0.510
Temperature Temperature
0
- C Factor for Reducing Volume to 15ºC. - 0C Factor for Reducing Volume to 15ºC.
0 1.044 1 1.043 1 1.042 25.0 0.969 0 0.969 1 0.970
0.5 1.043 1 1.042 2 1.040 25.5 0.967 1 0.968 1 0.969
1.0 1.041 1 1.040 1 1.039 26.0 0.965 1 0.966 1 0.967
1.5 1.040 1 1.039 2 1.037 26.5 0.964 1 0.965 1 0.966
2.0 1.038 0 1.038 2 1.036 27.0 0.962 1 0.963 1 0.964
2.5 1.037 1 1.036 1 1.035 27.5 0.960 1 0.961 1 0.962
3.0 1.036 1 1.035 2 1.033 28.0 0.958 2 0.960 1 0.961
3.5 1.034 1 1.033 1 1.032 28.5 0.957 1 0.958 1 0.959
4.0 1.033 1 1.032 1 1.031 29.0 0.955 2 0.957 1 0.958
4.5 1.031 1 1.030 1 1.029 29.5 0.953 2 0.955 1 0.956
5.0 1.030 1 1.029 1 1.028 30.0 0.952 1 0.953 1 0.954
5.5 1.028 0 1.028 1 1.027 30.5 0.950 2 0.952 1 0.953
6.0 1.027 1 1.026 1 1.025 31.0 0.948 2 0.950 1 0.951
6.5 1.025 0 1.025 1 1.024 31.5 0.947 1 0.948 2 0.950
7.0 1.024 0 1.024 1 1.023 32.0 0.945 2 0.947 1 0.948
7.5 1.023 1 1.022 1 1.021 32.5 0.943 2 0.945 2 0.947
8.0 1.021 0 1.021 1 1.020 33.0 0.941 2 0.943 2 0.945
8.5 1.020 1 1.019 1 1.018 33.5 0.940 2 0.942 1 0.943
9.0 1.018 0 1.018 1 1.017 34.0 0.938 2 0.940 2 0.942
9.5 1.017 0 1.017 1 1.016 34.5 0.936 2 0.938 2 0.940
10.0 1.015 0 1.015 1 1.014 35.0 0.935 2 0.937 2 0.939
10.5 1.014 0 1.014 1 1.013 35.5 0.933 2 0.935 2 0.937
11.0 1.012 0 1.012 0 1.012 36.0 0.931 2 0.933 3 0.936
11.5 1.011 0 1.011 1 1.010 36.5 0.929 2 0.931 3 0.934
12.0 1.000 0 1.009 0 1.009 37.0 0.928 2 0.930 2 0.932
12.5 1.008 0 1.008 1 1.007 37.5 0.926 2 0.928 3 0.931
13.0 1.006 0 1.006 0 1.006 38.0 0.924 2 0.926 3 0.929
13.5 1.005 0 1.005 1 1.004 38.5 0.922 3 0.925 2 0.927
14.0 1.003 0 1.003 0 1.003 39.0 0.921 2 0.923 3 0.926
14.5 1.002 0 1.002 1 1.001 39.5 0.919 2 0.921 3 0.924
15.0 1.000 0 1.000 0 1.000 40.0 0.917 3 0.920 3 0.923
15.5 0.998 0 0.998 1 0.999 40.5 0.915 3 0.918 3 0.921
16.0 0.997 0 0.997 0 0.997 41.0 0.913 3 0.916 3 0.919
16.5 0.995 0 0.995 1 0.996 41.5 0.912 2 0.914 3 0.917
17.0 0.994 0 0.994 0 0.994 42.0 0.910 3 0.913 3 0.916
17.5 0.992 0 0.992 1 0.993 42.5 0.908 3 0.911 3 0.914
18.0 0.991 0 0.991 0 0.991 43.0 0.906 3 0.909 3 0.912
18.5 0.989 0 0.989 1 0.990 43.5 0.904 3 0.907 4 0.911
19.0 0.988 0 0.988 0 0.988 44.0 0.903 3 0.906 3 0.909
19.5 0.986 0 0.986 1 0.987 44.5 0.901 3 0.904 3 0.907
20.0 0.985 0 0.985 1 0.986 45.0 0.899 3 0.902 3 0.905
20.5 0.983 0 0.983 1 0.984 45.5 0.897 3 0.900 4 0.904
21.0 0.981 1 0.982 1 0.983 46.0 0.895 3 0.898 4 0.902
21.5 0.980 0 0.980 1 0.981 46.5 0.893 4 0.897 3 0.900
22.0 0.978 1 0.979 1 0.980 47.0 0.892 3 0.895 3 0.898
22.5 0.977 0 0.977 1 0.978 47.5 0.890 3 0.893 4 0.897
23.0 0.975 1 0.976 0 0.976 48.0 0.888 3 0.891 4 0.895
23.5 0.973 1 0.974 1 0.975 48.5 0.886 3 0.889 4 0.893
24.0 0.972 0 0.972 1 0.973 49.0 0.884 3 0.887 4 0.891
24.5 0.970 1 0.971 1 0.972 49.5 0.882 4 0.886 3 0.889
25.0 0.969 0 0.969 1 0.970 50.0 0.880 4 0.884 4 0.888
March - 2006 12 of 19
VII
ASTM TABLES
Table 54
ASTM-IP Volume Reduction to 15ºC. 0.510-0.540
0-25ºC.
* Density 15ºC.
Observed
0.510 0.515 0.520 0.525 0.530 0.535 0.540
Temperature
- 0C Factor for Reducing Volume to 15ºC.
0 1.042 1 1.041 1 1.040 2 1.038 1 1.037 1 1.036 1 1.035
0.5 1.040 1 1.039 1 1.038 1 1.037 1 1.036 1 1.035 1 1.034
1.0 1.039 1 1.038 1 1.037 1 1.036 1 1.035 1 1.034 1 1.033
1.5 1.037 0 1.037 1 1.036 1 1.035 1 1.034 1 1.033 1 1.032
2.0 1.036 1 1.035 1 1.034 1 1.033 1 1.032 1 1.031 1 1.030
2.5 1.035 1 1.034 1 1.033 1 1.032 1 1.031 1 1.030 1 1.029
3.0 1.033 0 1.033 1 1.032 1 1.031 1 1.030 1 1.029 1 1.028
3.5 1.032 1 1.031 1 1.030 0 1.030 1 1.029 1 1.028 1 1.027
4.0 1.031 1 1.030 1 1.029 0 1.029 1 1.028 1 1.027 1 1.026
4.5 1.029 0 1.029 1 1.028 1 1.027 1 1.026 0 1.026 1 1.025
5.0 1.028 1 1.027 0 1.027 1 1.026 1 1.025 0 1.025 1 1.024
5.5 1.027 1 1.026 1 1.025 0 1.025 1 1.024 1 1.023 1 1.022
6.0 1.025 0 1.025 1 1.024 1 1.023 0 1.023 1 1.022 1 1.021
6.5 1.024 1 1.023 1 1.022 0 1.022 1 1.021 0 1.021 1 1.020
7.0 1.023 1 1.022 1 1.021 0 1.021 1 1.020 0 1.020 1 1.019
7.5 1.021 0 1.021 1 1.020 1 1.010 0 1.019 0 1.019 1 1.018
8.0 1.020 0 1.020 1 1.019 1 1.018 0 1.018 1 1.017 1 1.016
8.5 1.018 0 1.018 1 1.017 0 1.017 1 1.016 0 1.016 1 1.015
9.0 1.017 0 1.017 1 1.016 1 1.015 0 1.015 0 1.015 1 1.014
9.5 1.016 0 1.016 1 1.015 1 1.014 0 1.014 0 1.014 1 1.013
10.0 1.014 0 1.014 1 1.013 0 1.013 0 1.013 1 1.012 0 1.012
10.5 1.013 0 1.013 1 1.012 1 1.011 0 1.011 0 1.011 0 1.011
11.0 1.012 0 1.012 1 1.011 1 1.010 0 1.010 0 1.010 1 1.009
11.5 1.010 0 1.010 1 1.009 0 1.009 0 1.009 0 1.009 1 1.008
12.0 1.009 0 1.000 1 1.008 0 1.008 0 1.008 0 1.008 1 1.007
12.5 1.007 0 1.007 0 1.007 1 1.006 0 1.006 0 1.006 0 1.006
13.0 1.006 0 1.006 1 1.005 0 1.005 0 1.005 0 1.005 0 1.005
13.5 1.004 0 1.004 0 1.004 0 1.004 0 1.004 0 1.004 0 1.004
14.0 1.003 0 1.003 0 1.003 0 1.003 0 1.003 0 1.003 1 1.002
14.5 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001
15.0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000
15.5 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999
16.0 0.997 0 0.997 0 0.997 0 0.997 0 0.997 0 0.997 0 0.987
16.5 0.996 0 0.996 0 0.996 0 0.996 0 0.996 0 0.996 0 0.986
17.0 0.994 0 0.994 0 0.994 1 0.995 0 0.995 0 0.995 0 0.995
17.5 0.993 0 0.993 0 0.993 0 0.993 0 0.993 1 0.994 0 0.994
18.0 0.991 0 0.991 0 0.991 1 0.992 0 0.992 0 0.992 0 0.992
18.5 0.990 0 0.990 0 0.990 1 0.991 0 0.991 0 0.991 0 0.991
19.0 0.988 0 0.988 0 0.988 1 0.989 0 0.989 1 0.990 0 0.990
19.5 0.987 0 0.987 0 0.987 1 0.988 0 0.988 1 0.989 0 0.989
20.0 0.986 0 0.986 0 0.986 0 0.986 1 0.987 0 0.987 0 0.987
20.5 0.984 0 0.984 0 0.984 1 0.985 0 0.985 1 0.986 0 0.986
21.0 0.983 0 0.983 0 0.983 1 0.984 0 0.984 1 0.985 0 0.985
21.5 0.981 0 0.981 1 0.982 0 0.982 1 0.983 0 0.983 1 0.984
22.0 0.980 0 0.980 0 0.980 1 0.981 0 0.981 1 0.982 0 0.982
22.5 0.978 0 0.978 1 0.979 1 0.980 0 0.980 1 0.981 0 0.981
23.0 0.976 1 0.977 0 0.977 1 0.979 1 0.979 0 0.979 1 0.980
23.5 0.975 1 0.976 0 0.976 1 0.978 1 0.978 0 0.978 1 0.979
24.0 0.973 1 0.974 1 0.975 1 0.976 0 0.976 1 0.977 0 0.977
24.5 0.972 1 0.973 0 0.973 1 0.975 1 0.975 0 0.975 1 0.976
25.0 0.970 1 0.971 1 0.972 1 0.974 1 0.974 0 0.974 1 0.975
March - 2006 13 of 19
VII
Table 54
0.510-0.540 Volume Reduction to 15ºC. ASTM-IP
25-50ºC
* Density 15ºC.
Observed
0.510 0.515 0.520 0.525 0.530 0.535 0.540
Temperature
25.0 0.970 1 0.971 1 0.972 1 0.973 1 0.974 0 0.974 1 0.975
25.5 0.969 1 0.970 1 0.971 1 0.972 0 0.972 1 0.973 1 0.974
26.0 0.967 1 0.968 1 0.969 1 0.970 1 0.971 0 0.971 1 0.972
26.5 0.966 1 0.967 1 0.968 1 0.969 1 0.970 0 0.970 1 0.971
27.0 0.964 1 0.965 1 0.966 1 0.967 1 0.968 1 0.969 1 0.970
27.5 0.962 2 0.964 1 0.965 1 0.966 1 0.967 1 0.968 1 0.969
28.0 0.961 1 0.962 1 0.963 1 0.964 1 0.965 1 0.966 1 0.967
28.5 0.959 2 0.961 1 0.962 1 0.963 1 0.964 1 0.965 1 0.966
29.0 0.958 1 0.959 1 0.960 2 0.962 1 0.963 1 0.964 1 0.965
29.5 0.956 2 0.958 1 0.959 1 0.960 1 0.961 1 0.962 1 0.963
30.0 0.954 2 0.956 1 0.957 1 0.958 2 0.960 1 0.961 1 0.962
30.5 0.953 2 0.955 1 0.956 1 0.957 1 0.958 1 0.959 2 0.961
31.0 0.951 2 0.953 1 0.954 2 0.956 1 0.957 1 0.958 2 0.960
31.5 0.950 2 0.952 1 0.953 1 0.954 2 0.956 1 0.957 1 0.958
32.0 0.948 2 0.950 1 0.951 2 0.953 1 0.954 1 0.955 2 0.957
32.5 0.947 1 0.948 2 0.950 2 0.952 1 0.953 1 0.954 2 0.956
33.0 0.945 2 0.947 1 0.948 2 0.950 2 0.952 1 0.953 1 0.954
33.5 0.943 2 0.945 2 0.947 2 0.949 1 0.950 1 0.951 2 0.953
34.0 0.942 2 0.944 1 0.945 2 0.947 2 0.949 1 0.950 2 0.952
34.5 0.940 2 0.942 2 0.944 2 0.946 1 0.947 1 0.948 2 0.950
35.0 0.930 1 0.940 2 0.942 2 0.944 2 0.946 1 0.947 2 0.949
35.5 0.937 2 0.939 2 0.941 2 0.943 2 0.945 1 0.946 2 0.948
36.0 0.936 2 0.938 1 0.939 2 0.941 2 0.943 1 0.944 2 0.946
36.5 0.934 2 0.936 2 0.938 2 0.940 2 0.942 1 0.943 2 0.945
37.0 0.932 2 0.934 2 0.936 2 0.938 2 0.940 1 0.941 2 0.943
37.5 0.931 2 0.933 2 0.935 2 0.937 2 0.939 1 0.940 2 0.942
38.0 0.929 2 0.931 2 0.933 2 0.936 2 0.937 2 0.939 2 0.941
38.5 0.927 2 0.929 3 0.932 2 0.934 2 0.936 1 0.937 2 0.939
39.0 0.926 2 0.928 2 0.930 2 0.932 2 0.934 2 0.936 2 0.938
39.5 0.924 2 0.926 3 0.929 2 0.931 2 0.933 1 0.934 2 0.936
40.0 0.923 2 0.925 2 0.927 2 0.929 2 0.931 2 0.933 2 0.935
40.5 0.921 2 0.923 2 0.925 3 0.928 2 0.930 2 0.932 2 0.934
41.0 0.919 2 0.921 3 0.924 2 0.926 3 0.929 1 0.930 2 0.932
41.5 0.917 2 0.919 3 0.922 3 0.925 2 0.927 2 0.929 2 0.931
42.0 0.916 2 0.918 3 0.921 2 0.923 3 0.926 1 0.927 2 0.929
42.5 0.914 2 0.916 3 0.919 3 0.922 2 0.924 2 0.926 2 0.928
43.0 0.912 2 0.914 3 0.917 3 0.920 3 0.923 1 0.924 3 0.927
43.5 0.911 2 0.913 3 0.916 3 0.919 2 0.921 2 0.923 2 0.925
44.0 0.909 2 0.911 3 0.914 3 0.917 3 0.920 1 0.921 3 0.924
44.5 0.907 2 0.909 3 0.912 3 0.915 3 0.918 2 0.920 2 0.922
45.0 0.905 3 0.908 3 0.911 3 0.914 3 0.917 2 0.919 2 0.921
45.5 0.904 2 0.906 3 0.909 3 0.912 3 0.915 2 0.917 3 0.920
46.0 0.902 2 0.904 3 0.907 4 0.911 3 0.914 2 0.916 2 0.918
46.5 0.900 3 0.903 3 0.906 3 0.909 3 0.912 2 0.914 3 0.917
47.0 0.898 3 0.901 3 0.904 3 0.907 3 0.910 3 0.913 2 0.915
47.5 0.897 2 0.899 3 0.902 4 0.906 3 0.909 2 0.911 3 0.914
48.0 0.895 3 0.898 3 0.901 3 0.904 2 0.907 3 0.910 3 0.913
48.5 0.893 3 0.896 3 0.899 3 0.902 4 0.906 2 0.908 3 0.911
49.0 0.891 3 0.894 3 0.897 4 0.901 3 0.904 3 0.907 3 0.910
49.5 0.889 4 0.893 3 0.896 3 0.899 4 0.903 2 0.905 3 0.908
50.0 0.888 3 0.891 3 0.894 4 0.898 4 0.902 2 0.904 3 0.907
March - 2006 14 of 19
VII
Table – 54
0.540 – 0.570 Volume Reduction to 150C ASTM-IP
0 – 25 0C
* Density 15ºC.
Observed
0.540 0.545 0.550 0.555 0.560 0.565 0.570
Temperature
0.0 1.035 0 1.035 1 1.034 1 1.033 1 1.032 1 1.031 1 1.030
0.5 1.034 1 1.033 1 1.032 1 1.031 0 1.031 1 1.030 1 1.029
1.0 1.033 1 1.032 1 1.031 1 1.030 0 1.030 1 1.029 1 1.028
1.5 1.032 1 1.031 1 1.030 1 1.029 0 1.029 1 1.028 1 1.027
2.0 1.030 0 1.030 1 1.029 1 1.028 0 1.028 1 1.027 1 1.026
2.5 1.029 0 1.029 1 1.028 1 1.027 0 1.027 1 1.026 1 1.025
3.0 1.028 0 1.028 1 1.027 1 1.026 0 1.026 1 1.025 1 1.024
3.5 1.027 0 1.027 1 1.026 1 1.025 0 1.025 1 1.024 1 1.023
4.0 1.026 0 1.026 1 1.025 1 1.024 0 1.024 1 1.023 1 1.022
4.5 1.025 0 1.025 1 1.024 1 1.023 0 1.023 1 1.022 0 1.022
5.0 1.024 1 1.023 0 1.023 1 1.022 0 1.022 1 1.021 0 1.021
5.5 1.022 0 1.022 0 1.022 1 1.021 0 1.021 1 1.020 0 1.020
6.0 1.021 0 1.021 1 1.020 1 1.019 0 1.019 0 1.019 1 1.018
6.5 1.020 0 1.020 1 1.019 1 1.018 0 1.018 0 1.018 1 1.017
7.0 1.019 0 1.019 1 1.018 1 1.017 0 1.017 0 1.017 1 1.016
7.5 1.018 0 1.018 1 1.017 1 1.016 0 1.016 0 1.016 1 1.015
8.0 1.016 0 1.016 0 1.016 1 1.015 0 1.015 0 1.015 1 1.014
8.5 1.015 0 1.015 0 1.015 1 1.014 0 1.014 0 1.014 1 1.013
9.0 1.014 0 1.014 0 1.014 1 1.013 0 1.013 0 1.013 1 1.012
9.5 1.013 0 1.013 0 1.013 1 1.012 0 1.012 0 1.012 1 1.011
10.0 1.012 0 1.012 1 1.011 0 1.011 0 1.011 1 1.010 0 1.010
10.5 1.011 0 1.011 1 1.010 0 1.010 0 1.010 1 1.009 0 1.009
11.0 1.009 0 1.009 0 1.009 0 1.009 0 1.009 1 1.008 0 1.008
11.5 1.008 0 1.008 0 1.008 0 1.008 0 1.008 1 1.007 0 1.007
12.0 1.007 0 1.007 0 1.007 1 1.006 0 1.006 0 1.006 0 1.006
12.5 1.006 0 1.006 0 1.006 1 1.005 0 1.005 0 1.005 0 1.005
13.0 1.005 0 1.005 0 1.005 1 1.004 0 1.004 0 1.004 0 1.004
13.5 1.004 0 1.004 0 1.004 1 1.003 0 1.003 0 1.003 0 1.003
14.0 1.002 0 1.002 0 1.002 0 1.002 0 1.002 0 1.002 0 1.002
14.5 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001
15.0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000
15.5 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999
16.0 0.997 0 0.997 1 0.998 0 0.998 0 0.998 0 0.998 0 0.998
16.5 0.996 0 0.996 0 0.996 0 0.996 1 0.997 0 0.997 0 0.997
17.0 0.995 0 0.995 0 0.995 0 0.995 1 0.996 0 0.996 0 0.996
17.5 0.994 0 0.994 0 0.994 0 0.994 1 0.995 0 0.995 0 0.995
18.0 0.992 0 0.992 1 0.993 0 0.993 1 0.994 0 0.994 0 0.994
18.5 0.991 0 0.991 1 0.992 0 0.992 0 0.992 0 0.992 0 0.992
19.0 0.990 0 0.990 1 0.991 0 0.991 0 0.991 0 0.991 0 0.991
19.5 0.989 0 0.989 0 0.989 1 0.990 0 0.990 0 0.990 0 0.990
20.0 0.987 1 0.988 0 0.988 1 0.989 0 0.989 0 0.989 0 0.989
20.5 0.986 0 0.986 1 0.987 0 0.987 1 0.988 0 0.988 0 0.988
21.0 0.985 0 0.985 1 0.986 0 0.986 1 0.987 0 0.987 0 0.987
21.5 0.984 0 0.984 1 0.985 0 0.985 1 0.986 0 0.986 0 0.986
22.0 0.982 1 0.983 1 0.984 0 0.984 1 0.985 0 0.985 0 0.985
22.5 0.981 1 0.982 0 0.982 1 0.983 0 0.983 1 0.984 0 0.984
23.0 0.980 0 0.980 1 0.981 1 0.982 0 0.982 1 0.983 0 0.983
23.5 0.979 0 0.979 1 0.980 1 0.981 0 0.981 1 0.982 0 0.982
24.0 0.977 1 0.978 1 0.979 1 0.980 0 0.980 1 0.981 0 0.981
24.5 0.976 1 0.977 1 0.978 0 0.978 1 0.979 0 0.979 1 0.980
25.0 0.975 1 0.976 1 0.977 0 0.977 1 0.978 0 0.978 1 0.979
March - 2006 15 of 19
VII
Table – 54
0.540 – 0.570 Volume Reduction to 150C ASTM-IP
25 – 50 0C
* Density 15ºC.
Observed
0.540 0.545 0.550 0.555 0.560 0.565 0.570
Temperature
25.0 0.975 1 0.976 1 0.977 0 0.977 1 0.978 0 0.978 1 0.979
25.5 0.974 0 0.974 1 0.975 1 0.976 0 0.976 1 0.977 1 0.978
26.0 0.972 1 0.973 1 0.974 1 0.975 0 0.975 1 0.976 1 0.977
26.5 0.971 1 0.972 1 0.973 1 0.974 0 0.974 1 0.975 1 0.976
27.0 0.970 1 0.971 1 0.972 1 0.973 0 0.973 1 0.974 1 0.975
27.5 0.969 0 0.969 1 0.970 1 0.971 1 0.972 1 0.973 1 0.974
28.0 0.967 1 0.968 1 0.969 1 0.970 1 0.971 1 0.972 0 0.972
28.5 0.966 1 0.967 1 0.968 1 0.969 0 0.969 1 0.970 1 0.971
29.0 0.965 1 0.966 1 0.967 1 0.968 0 0.968 1 0.969 1 0.970
29.5 0.963 1 0.964 1 0.965 1 0.966 1 0.967 1 0.968 1 0.969
30.0 0.962 1 0.963 1 0.964 1 0.965 1 0.966 1 0.967 1 0.968
30.5 0.961 1 0.962 1 0.963 1 0.964 1 0.965 1 0.966 1 0.967
31.0 0.960 1 0.961 1 0.962 1 0.963 1 0.964 1 0.965 1 0.966
31.5 0.958 1 0.959 1 0.960 2 0.962 0 0.962 2 0.964 1 0.965
32.0 0.957 1 0.958 1 0.959 1 0.960 1 0.961 1 0.962 1 0.963
32.5 0.956 1 0.957 1 0.958 1 0.959 1 0.960 1 0.961 1 0.962
33.0 0.954 2 0.956 1 0.957 1 0.958 1 0.959 1 0.960 1 0.961
33.5 0.953 1 0.954 1 0.955 2 0.957 1 0.958 1 0.959 1 0.960
34.0 0.952 1 0.953 1 0.954 2 0.956 1 0.957 1 0.958 1 0.959
34.5 0.950 2 0.952 1 0.953 1 0.954 1 0.955 2 0.957 1 0.958
35.0 0.949 1 0.950 2 0.952 1 0.953 1 0.954 2 0.956 1 0.957
35.5 0.948 1 0.949 1 0.950 2 0.952 1 0.953 2 0.955 1 0.956
36.0 0.946 2 0.948 1 0.949 2 0.951 1 0.952 2 0.954 1 0.955
36.5 0.945 2 0.947 1 0.948 2 0.950 1 0.951 1 0.952 1 0.953
37.0 0.943 2 0.945 2 0.947 1 0.948 2 0.950 1 0.951 1 0.952
37.5 0.942 2 0.944 1 0.945 2 0.947 1 0.948 2 0.950 1 0.951
38.0 0.941 2 0.943 1 0.944 2 0.946 1 0.947 2 0.949 1 0.950
38.5 0.939 2 0.941 2 0.943 2 0.945 1 0.946 2 0.948 1 0.949
39.0 0.938 2 0.940 2 0.942 1 0.943 2 0.945 2 0.947 1 0.948
39.5 0.936 3 0.939 1 0.940 2 0.942 2 0.944 2 0.946 1 0.947
40.0 0.935 2 0.937 2 0.939 2 0.941 2 0.943 1 0.944 2 0.946
40.5 0.934 2 0.936 2 0.938 2 0.940 1 0.941 2 0.943 1 0.944
41.0 0.932 3 0.935 1 0.936 2 0.938 2 0.940 2 0.942 1 0.943
41.5 0.931 2 0.933 2 0.935 2 0.937 2 0.939 2 0.941 1 0.942
42.0 0.929 3 0.932 2 0.934 2 0.936 2 0.938 2 0.940 1 0.941
42.5 0.928 3 0.931 2 0.933 2 0.935 2 0.937 2 0.939 1 0.940
43.0 0.927 2 0.929 2 0.931 2 0.933 2 0.935 2 0.937 2 0.939
43.5 0.925 3 0.928 2 0.930 2 0.932 2 0.934 2 0.936 2 0.938
44.0 0.924 3 0.927 2 0.929 2 0.931 2 0.933 2 0.935 1 0.936
44.5 0.922 3 0.925 3 0.928 2 0.930 2 0.932 2 0.934 1 0.935
45.0 0.921 3 0.924 2 0.926 2 0.928 3 0.931 1 0.932 2 0.934
45.5 0.920 3 0.923 2 0.925 2 0.927 3 0.930 1 0.931 2 0.933
46.0 0.918 3 0.921 3 0.924 2 0.926 2 0.928 2 0.930 2 0.932
46.5 0.917 3 0.920 2 0.922 3 0.925 2 0.927 2 0.929 2 0.931
47.0 0.915 3 0.918 3 0.921 2 0.923 3 0.926 2 0.928 2 0.930
47.5 0.914 2 0.917 3 0.920 2 0.922 3 0.925 2 0.927 2 0.929
48.0 0.913 3 0.916 2 0.918 3 0.921 2 0.923 3 0.926 1 0.927
48.5 0.911 3 0.914 3 0.917 2 0.919 3 0.922 2 0.924 2 0.926
49.0 0.910 3 0.913 3 0.916 2 0.918 3 0.921 2 0.923 2 0.925
49.5 0.908 3 0.911 3 0.914 3 0.917 3 0.920 2 0.922 2 0.924
50.0 0.907 3 0.910 3 0.913 2 0.915 4 0.919 2 0.921 2 0.923
March - 2006 16 of 19
VII
ASTM-IP Table-54 0.570 – 0.600

Volume Reduction to 15 0C 0 – 25 0C
* Density 15ºC.
Observed
0.570 0.575 0.580 0.585 0.590 0.595 0.600
Temperature
0 1.030 1 1.029 0 1.029 1 1.028 1 1.027 0 1.027 1 1.026
0.5 1.029 0 1.029 1 1.028 1 1.027 1 1.026 0 1.026 1 1.025
1.0 1.028 0 1.028 1 1.027 1 1.026 1 1.025 0 1.025 1 1.024
1.5 1.027 0 1.027 1 1.026 1 1.025 1 1.024 0 1.024 1 1.023
2.0 1.026 0 1.026 1 1.025 1 1.024 1 1.023 0 1.023 0 1.023
2.5 1.025 0 1.025 1 1.024 0 1.024 1 1.023 0 1.023 1 1.022
3.0 1.024 0 1.024 1 1.023 0 1.023 1 1.022 0 1.022 1 1.021
3.5 1.023 0 1.023 1 1.022 0 1.022 1 1.021 0 1.021 1 1.020
4.0 1.022 0 1.022 1 1.021 0 1.021 1 1.020 0 1.020 1 1.019
4.5 1.022 1 1.021 1 1.020 0 1.020 1 1.019 0 1.019 1 1.018
5.0 1.021 1 1.020 1 1.019 0 1.019 1 1.018 0 1.018 1 1.017
5.5 1.020 1 1.019 1 1.018 0 1.018 1 1.017 0 1.017 0 1.017
6.0 1.018 0 1.018 1 1.017 0 1.017 1 1.016 0 1.016 0 1.016
6.5 1.017 0 1.017 1 1.016 0 1.016 1 1.015 0 1.015 0 1.015
7.0 1.016 0 1.016 1 1.015 0 1.015 1 1.014 0 1.014 0 1.014
7.5 1.015 0 1.015 1 1.014 0 1.014 0 1.014 0 1.014 1 1.013
8.0 1.014 0 1.014 0 1.014 0 1.014 1 1.013 0 1.013 1 1.012
8.5 1.013 0 1.013 0 1.013 0 1.013 1 1.012 0 1.012 1 1.011
9.0 1.012 0 1.012 0 1.012 0 1.012 1 1.011 0 1.011 1 1.010
9.5 1.011 0 1.011 0 1.011 0 1.011 1 1.010 0 1.010 0 1.010
10.0 1.010 0 1.010 0 1.010 0 1.010 1 1.009 0 1.009 0 1.009
10.5 1.009 0 1.009 0 1.009 0 1.009 1 1.008 0 1.008 0 1.008
11.0 1.008 0 1.008 0 1.008 0 1.008 1 1.007 0 1.007 0 1.007
11.5 1.007 0 1.007 0 1.007 0 1.007 1 1.006 0 1.006 0 1.006
12.0 1.006 0 1.006 0 1.006 0 1.006 1 1.005 0 1.005 0 1.005
12.5 1.005 0 1.005 0 1.005 0 1.005 0 1.005 0 1.005 1 1.005
13.0 1.004 0 1.004 0 1.004 0 1.004 0 1.004 0 1.004 0 1.004
13.5 1.003 0 1.003 0 1.003 0 1.003 0 1.003 0 1.003 0 1.003
14.0 1.002 0 1.002 0 1.002 0 1.002 0 1.002 0 1.002 0 1.002
14.5 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001 0 1.001
15.0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000 0 1.000
15.5 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999 0 0.999
16.0 0.998 0 0.998 0 0.998 0 0.998 0 0.998 0 0.998 0 0.998
16.5 0.997 0 0.997 0 0.997 0 0.997 0 0.997 0 0.997 0 0.997
17.0 0.996 0 0.996 0 0.996 0 0.996 0 0.996 0 0.996 1 0.997
17.5 0.995 0 0.995 0 0.995 0 0.995 0 0.995 1 0.996 0 0.996
18.0 0.994 0 0.994 0 0.994 0 0.994 0 0.994 1 0.995 0 0.995
18.5 0.992 1 0.993 0 0.993 0 0.993 0 0.993 1 0.994 0 0.994
19.0 0.991 1 0.992 0 0.992 0 0.992 0 0.992 1 0.993 0 0.993
19.5 0.990 1 0.991 0 0.991 0 0.991 0 0.991 1 0.992 0 0.992
20.0 0.989 1 0.990 0 0.990 0 0.990 0 0.990 1 0.991 0 0.991
20.5 0.988 0 0.988 1 0.989 0 0.989 0 0.989 1 0.990 0 0.990
21.0 0.987 0 0.987 1 0.988 0 0.988 0 0.988 1 0.989 0 0.989
21.5 0.986 0 0.986 1 0.987 0 0.987 0 0.987 1 0.988 1 0.989
22.0 0.985 0 0.985 1 0.986 0 0.986 0 0.986 1 0.987 1 0.988
22.5 0.984 0 0.984 1 0.985 0 0.985 1 0.986 1 0.987 0 0.987
23.0 0.983 0 0.983 1 0.984 0 0.984 1 0.985 1 0.986 0 0.986
23.5 0.982 0 0.982 1 0.983 0 0.983 1 0.984 1 0.985 0 0.985
24.0 0.981 0 0.981 1 0.982 0 0.982 1 0.983 1 0.984 0 0.984
24.5 0.980 0 0.980 1 0.981 0 0.981 1 0.982 1 0.983 0 0.983
25.0 0.979 0 0.979 1 0.980 0 0.980 1 0.981 1 0.982 0 0.982
March - 2006 17 of 19
VII
ASTM-IP Table-54 0.570 – 0.600

Volume Reduction to 15 0C 25 – 50 0C
* Density 15ºC.
Observed
0.570 0.575 0.580 0.585 0.590 0.595 0.600
Temperature
25.0 0.979 0 0.979 1 0.980 0 0.980 1 0.981 1 0.982 0 0.982
25.5 0.978 0 0.978 1 0.979 0 0.979 1 0.980 1 0.981 1 0.982
26.0 0.977 0 0.977 1 0.978 0 0.978 1 0.979 1 0.980 1 0.981
26.5 0.976 0 0.976 1 0.977 0 0.977 1 0.978 1 0.979 1 0.980
27.0 0.975 0 0.975 1 0.976 0 0.976 1 0.977 1 0.978 1 0.979
27.5 0.974 0 0.974 1 0.975 0 0.975 1 0.976 1 0.977 1 0.978
28.0 0.972 1 0.973 1 0.974 0 0.974 1 0.975 1 0.976 1 0.977
28.5 0.971 1 0.972 1 0.973 0 0.973 1 0.974 2 0.976 1 0.977
29.0 0.970 1 0.971 1 0.972 0 0.972 1 0.973 2 0.975 1 0.976
29.5 0.969 1 0.970 1 0.971 0 0.971 1 0.972 2 0.974 1 0.975
30.0 0.968 1 0.969 1 0.970 1 0.971 1 0.972 1 0.973 1 0.974
30.5 0.967 1 0.968 1 0.969 1 0.970 1 0.971 1 0.972 1 0.973
31.0 0.966 1 0.967 1 0.968 1 0.969 1 0.970 1 0.971 1 0.972
31.5 0.965 1 0.966 1 0.967 1 0.968 1 0.969 1 0.970 1 0.971
32.0 0.963 2 0.965 1 0.966 1 0.967 1 0.968 1 0.969 1 0.970
32.5 0.962 2 0.964 1 0.965 1 0.966 1 0.967 1 0.968 1 0.969
33.0 0.961 2 0.963 1 0.964 1 0.965 1 0.966 1 0.967 1 0.968
33.5 0.960 2 0.962 1 0.963 1 0.964 1 0.965 2 0.967 1 0.968
34.0 0.959 1 0.960 1 0.961 1 0.962 2 0.964 2 0.966 1 0.967
34.5 0.958 1 0.959 1 0.960 1 0.961 2 0.963 2 0.965 1 0.966
35.0 0.957 1 0.958 1 0.959 1 0.960 2 0.962 2 0.964 1 0.965
35.5 0.956 1 0.957 1 0.958 1 0.959 2 0.961 2 0.963 1 0.964
36.0 0.955 1 0.956 1 0.957 1 0.958 2 0.960 2 0.962 1 0.963
36.5 0.953 2 0.955 1 0.956 1 0.957 2 0.959 2 0.961 1 0.962
37.0 0.952 2 0.954 1 0.955 1 0.956 2 0.958 2 0.960 1 0.961
37.5 0.951 2 0.953 1 0.954 1 0.955 2 0.957 2 0.959 2 0.961
38.0 0.950 1 0.951 2 0.953 1 0.954 2 0.956 2 0.958 2 0.960
38.5 0.949 1 0.950 2 0.952 1 0.953 2 0.955 2 0.957 2 0.959
39.0 0.948 1 0.949 2 0.951 1 0.952 2 0.954 2 0.956 2 0.958
39.5 0.947 1 0.948 2 0.950 1 0.951 2 0.953 2 0.955 2 0.957
40.0 0.946 1 0.947 2 0.949 1 0.950 2 0.952 2 0.954 2 0.956
40.5 0.944 2 0.946 1 0.947 2 0.949 2 0.951 2 0.953 2 0.955
41.0 0.943 2 0.945 1 0.946 2 0.948 2 0.950 2 0.952 2 0.954
41.5 0.942 2 0.944 1 0.945 2 0.947 2 0.949 2 0.951 2 0.953
42.0 0.941 2 0.943 1 0.944 2 0.946 2 0.948 2 0.950 3 0.953
42.5 0.940 2 0.942 1 0.943 2 0.945 2 0.947 2 0.949 3 0.952
43.0 0.939 2 0.941 1 0.942 2 0.944 2 0.946 2 0.948 3 0.951
43.5 0.938 1 0.939 2 0.941 2 0.943 2 0.945 2 0.947 3 0.950
44.0 0.936 2 0.938 2 0.940 2 0.942 2 0.944 2 0.946 3 0.949
44.5 0.935 2 0.937 2 0.939 2 0.941 2 0.943 3 0.946 2 0.948
45.0 0.934 2 0.936 2 0.938 2 0.940 2 0.942 3 0.945 2 0.947
45.5 0.933 2 0.935 2 0.937 2 0.939 2 0.941 3 0.944 2 0.946
46.0 0.932 2 0.934 2 0.936 2 0.938 2 0.940 3 0.943 2 0.945
46.5 0.931 2 0.933 2 0.935 2 0.937 2 0.939 3 0.942 3 0.945
47.0 0.930 2 0.932 2 0.934 2 0.936 2 0.938 3 0.941 3 0.944
47.5 0.929 2 0.931 2 0.933 2 0.935 2 0.937 3 0.940 3 0.943
48.0 0.927 3 0.930 2 0.932 2 0.934 2 0.936 3 0.939 3 0.942
48.5 0.926 2 0.928 2 0.930 3 0.933 2 0.935 3 0.938 3 0.941
49.0 0.925 2 0.927 2 0.929 3 0.932 2 0.934 3 0.937 3 0.940
49.5 0.924 2 0.926 2 0.928 2 0.930 3 0.933 3 0.936 3 0.939
50.0 0.923 2 0.925 2 0.927 2 0.929 3 0.932 3 0.935 3 0.938
March - 2006 18 of 19
VII
Table 54
0.570-0.600 Volume Reduction to 15ºC. ASTM-IP
-25 to 0ºC
* Density 15ºC.
Observed
0.570 0.575 0.580 0.585 0.590 0.595 0.600
Temperature
-25.0 1.077 1 1.076 2 1.074 1 1.073 2 1.071 1 1.070 2 1.068
-24.5 1.076 1 1.075 2 1.073 1 1.072 2 1.070 1 1.069 1 1.068
-24.0 1.076 2 1.074 2 1.072 1 1.071 2 1.069 1 1.068 1 1.067
-23.5 1.075 2 1.073 1 1.072 2 1.070 1 1.069 2 1.067 1 1.066
-23.0 1.074 2 1.072 1 1.071 1 1.070 2 1.068 2 1.066 1 1.065
-22.5 1.073 1 1.072 2 1.070 1 1.069 2 1.067 1 1.066 2 1.064
-22.0 1.072 1 1.071 2 1.069 1 1.068 2 1.066 1 1.065 1 1.064
-21.5 1.071 1 1.070 2 1.068 1 1.067 2 1.065 1 1.064 1 1.063
-21.0 1.070 1 1.069 2 1.067 1 1.066 1 1.065 2 1.063 1 1.062
-20.5 1.069 1 1.068 2 1.066 1 1.065 1 1.064 2 1.062 1 1.061
-20.0 1.068 1 1.067 2 1.065 1 1.064 1 1.063 2 1.061 1 1.060
-19.5 1.068 2 1.066 1 1.065 1 1.064 2 1.062 2 1.060 1 1.059
-19.0 1.067 2 1.065 1 1.064 1 1.063 2 1.061 2 1.059 1 1.058
-18.5 1.066 2 1.064 1 1.063 1 1.062 2 1.060 1 1.059 1 1.058
-18.0 1.065 2 1.063 1 1.062 1 1.061 2 1.059 1 1.058 1 1.057
-17.5 1.064 1 1.063 2 1.061 1 1.060 1 1.059 2 1.057 1 1.056
-17.0 1.063 1 1.062 2 1.060 1 1.059 1 1.058 2 1.056 1 1.055
-16.5 1.062 1 1.061 1 1.060 2 1.058 1 1.057 2 1.055 1 1.054
-16.0 1.061 1 1.060 1 1.059 2 1.057 1 1.056 1 1.055 2 1.053
-15.5 1.060 1 1.059 1 1.058 2 1.056 1 1.055 1 1.054 2 1.052
-15.0 1.059 1 1.058 1 1.057 2 1.055 1 1.054 1 1.053 1 1.052
-14.5 1.058 1 1.057 1 1.056 2 1.054 1 1.053 1 1.052 1 1.051
-14.0 1.057 1 1.056 1 1.055 1 1.054 2 1.052 1 1.051 1 1.050
-13.5 1.056 1 1.055 1 1.054 1 1.053 2 1.051 1 1.050 1 1.049
-13.0 1.055 1 1.054 1 1.053 1 1.052 2 1.050 1 1.049 1 1.048
-12.5 1.054 1 1.053 1 1.052 1 1.051 1 1.050 1 1.049 2 1.047
-12.0 1.053 1 1.052 1 1.051 1 1.050 1 1.049 1 1.048 1 1.047
-11.5 1.052 1 1.051 1 1.050 1 1.049 1 1.048 1 1.047 1 1.046
-11.0 1.051 1 1.050 1 1.049 1 1.048 1 1.047 1 1.046 1 1.045
-10.5 1.050 1 1.049 1 1.048 1 1.047 1 1.046 1 1.045 1 1.044
-10.0 1.050 2 1.048 1 1.047 1 1.046 1 1.045 1 1.044 1 1.043
-9.5 1.049 2 1.047 1 1.046 1 1.045 1 1.044 1 1.043 1 1.042
-9.0 1.048 2 1.046 1 1.045 1 1.044 1 1.043 1 1.042 1 1.041
-8.5 1.047 2 1.045 1 1.044 1 1.043 1 1.042 1 1.041 0 1.041
-8.0 1.046 2 1.044 1 1.043 1 1.042 1 1.041 1 1.040 0 1.040
-7.5 1.045 1 1.044 1 1.043 1 1.042 1 1.041 1 1.040 1 1.039
-7.0 1.044 1 1.043 1 1.042 1 1.041 1 1.040 1 1.039 1 1.038
-6.5 1.043 1 1.042 1 1.041 1 1.040 1 1.039 1 1.038 1 1.037
-6.0 1.042 1 1.041 1 1.040 1 1.039 1 1.038 1 1.037 1 1.036
-5.5 1.041 1 1.040 1 1.039 1 1.038 1 1.037 1 1.036 1 1.035
-5.0 1.040 1 1.039 1 1.038 1 1.037 1 1.036 1 1.035 0 1.035
-4.5 1.039 1 1.038 1 1.037 1 1.036 1 1.035 1 1.034 0 1.034
-4.0 1.038 1 1.037 1 1.036 1 1.035 1 1.034 1 1.033 0 1.033
-3.5 1.037 1 1.036 1 1.035 1 1.034 1 1.033 0 1.033 1 1.032
-3.0 1.036 1 1.035 1 1.034 1 1.033 1 1.032 0 1.032 1 1.031
-2.5 1.035 1 1.034 1 1.033 0 1.033 1 1.032 1 1.031 1 1.030
-2.0 1.034 1 1.033 1 1.032 0 1.032 1 1.031 1 1.030 1 1.029
-1.5 1.033 1 1.032 1 1.031 0 1.031 1 1.030 1 1.029 0 1.029
-1.0 1.032 1 1.031 0 1.031 1 1.030 1 1.029 0 1.029 1 1.028
-0.5 1.031 1 1.030 0 1.030 1 1.029 1 1.028 0 1.028 1 1.027
0 1.030 1 1.029 0 1.029 1 1.028 1 1.027 0 1.027 1 1.026
March - 2006 19 of 19
VIII
FILLING RATIO
1.0 FILLING DENSITIES

1.1 Definition
The “filling density” is defined as the percent ratio of the weight of the gas allowed ©©©to
be filled in a container to the weight of water the container will hold at 15.6 oC. All containers
shall be filled according to the filling densities shown in the table below :
1.2 Method of Calculating Maximum Liquid Volume Which Can Be Placed in a Container at Any Liquid
Temperature
The quantity of gas which may be placed in a container is dependent upon the temperature of
the liquid in the container and the maximum permitted filling density in addition to the size
of the container.
The filling density depends on : The size of the container whether it is installed aboveground or
underground and the specific gravity at 15.6 oC of the LPG placed in the container. Filling
density values for these conditions are given in Table 1.
TABLE 1
MAXIMUM PERMITTED FILLING DENSITY
Specific Gravity at 0 to 1000 Imp. Gal. Over 1000 Imp. Underground

15.6 OC Or 450 Litres Total Gal. Or 4550 Litres Containers All
Water Cap. Total Water Cap. Capacities
.504-.510 42 45 46
.511-.519 43 46 47
.496-.503 41 44 45
.528-.536 45 48 49
.520-.527 44 47 48
.537-.544 46 49 50
.545-.552 47 50 51
.553-.560 48 51 52
.561-.568 49 52 53
.569-.576 50 53 54
.577-.584 51 54 55
.585-.592 52 55 56
.593-.600 53 56 57
March - 2006 1 of 7
VIII
FILLING RATIO
Since the temperature of the liquid in the container is seldom exactly 15.6 oC, it is necessary
to measure the actual liquid temperature and then obtain a correction factor from the attached
Table and insert this in the following formula. The average liquid temperature may be obtained
by one of two ways. One procedure is to measure the liquid temperature in the container after
the container is almost filled to its permissible liquid content. This is secured by inserting a
thermometer into a thermometer well installed in the container so as to be in the liquid.
The other procedure can only be used if the container is essentially empty prior to filling. In this
case, the liquid temperature is measured by a thermometer placed in a thermometer well or
other device installed in the filling line at a place near the container. The temperature should be
read at intervals and averaged.
Knowing the filling density, the liquid specific gravity at 15.6 oC of the product to be placed in
the container, the correction factor for the temperature of the liquid in the container, and the
container capacity, the maximum quantity that can be placed in a container is determined as
follows :
V = D__
GxF
Where
V = Maximum liquid volume ( in percent of total container capacity ) which shall be

placed in a container when the liquid temperature is T.
D = Filling density from Table 1 in percent
G = specific gravity of LPG at 15.6 oC placed in container
F = Correction factor from following table (2) for correcting liquid volumes from 15.6oC to volume
at temperature T. The correction factor is obtained by finding the specific gravity at 15.6 oC (G)
in the column at the top of the table and coming down this column till the actual liquid temperature
T is found. The correction factor corresponding to this specific gravity and temperature is then
read. Interpolation is permitted.
T = Temperature of liquid LPG in container in degrees centigrade.
March - 2006 2 of 7
VIII
FILLING RATIO
March - 2006 3 of 7
VIII
FILLING RATIO
March - 2006 4 of 7
VIII
FILLING RATIO
After obtaining V from the above formula the actual maximum litres, Qtm, of LPG which may be
placed in a container is obtained by multiplying the water capacity of the container by V
100
where, Qtm = actual litres at liquid temperature, T.
Maximum liquid volume can be place in storage vessel given in Table # 3 basis type of storage i.e,
aboveground or underground
TABLE 3
MAXIMUM LIQUID VOLUME PERCENT
Aboveground Containers Liq. Underground Containres

Temp. Assumed to be Liq. Temp. Assumed to be
4.4 oC 10.0 oC
Propane (Approx. sp. Gr. 0.51 ) 80 89
Mixtures (Approx. sp. Gr. 0.55 ) 83 91
Butane (Approx. sp. Gr. 0.58 ) 86 93
EXAMPLE :
Assume an aboveground container with 10,000 litres water capacity. Propane with a specific gravity
of 0.508 at 15.6 oC to be placed in container Filing Density from Table 1 for aboveground container
having a capacity greater than 4550 litres in which a product having a specific gravity at 15.6 oC of
0.508 is to be placed is 45%
To determine maximum quantity that may be placed in container when liquid temperature is 15.6oC.
Q at 15.6 oC = 45 x 10,000 = 8,860 liters

0.508 x 100
When liquid temperature is 27.8 oC find correction factor in the Table 2 for specific gravity at 15.6
o
C of 0.508 and a liquid temperature of 27.8 oC which is 0.963.
Q at 27.8 oC = 45 x 10,000 = 9200 litres

0.508 x 0.963 x 100
March - 2006 5 of 7
VIII
FILLING RATIO
Alternate Permitted Maximum Liquid Volumes in Percentage of Total Container Capacity for
Filling Containers up to 4550 Litres Total Water Capacity as Specified in Table 1.
1.3 Formula for determining maximum volume of Liquified Petroleum Gas in a container.
= Water capacity (Litres) of container at 15.6 0C x Filling Density in Table 1

Sp gravity of LPG x Volume correction factor in Table 4 x 100
For aboveground containers the liquid temperature is assumed to be 4.4 0C and for underground
containers the liquid temperature is assumed to be 10.0 0C. to correct the liquid volume at
these temperatures to 15.6 0C the following factors shall be used.
TABLE 4 - VOLUME CORRECTION FACTORS
Specific Gravity Aboveground Underground

0.500 1.033 1.017
0.510 1.031 1.016
0.520 1.029 1.015
0.530 1.028 1.014
0.540 1.026 1.013
0.550 1.025 1.013
0.560 1.024 1.012
0.570 1.023 1.011
0.580 1.021 1.011
0.590 1.020 1.010
EXAPMLE : Assume a 1000 litres total water capacity tank for aboveground storage of
Propane having a specific gravity of 0.510 at 15.6 oC.
= 1000 (Litres ) x 42 (Filling Density from Table 1 )

0.510 x 1.031 (Correction Factor from Table 4 ) x 100
= 42000
52.6
42000 = 798 liters propane ( the maximum amount permitted to be placed in a 1000
52.6 liters total water capacity aboveground container )
The maximum volume of LPG which can be placed in a container expressed as a percentage of
total water content of the container is calculated by the following formula :
Maximum % of LPG = Max Vol. of LPG (As mentioned in 1.3 above) x 100
Total water content of container in litres
March - 2006 6 of 7
VIII
FILLING RATIO
1.4 Filling Capacity and Filling Pressure - ( 1 ) the maximum quantity of liquefiable gas filled into
any vessel shall be limited to the filling density of the gas and shall be such that the vessel shall
not be liquid-full due to expansion of the contents with rise of the temperature to 55 oC. This
requirement shall be applicable irrespective of the ambient temperature of the product at the
time of filling.
March - 2006 7 of 7
IX
FIRE WATER CALCULATION
FIRE WATER CALCULATION
Sr.No. RISK AREA ArREA WATER WATER ADD 288 TOTAL

REQUIRED REQUIRED KL/HR FOR WATER
( LPM/SQM) THRU 2 NOS REQUIRED
SPRINKLER MONITORS (KL/HR)
KL/HR)
1 Filling Shed(50X50 SQM) 2500.00 10.2 1530 288 1818
2 Filled Storage(50X30) 1500.00 10.2 918 288 1206
3 LPG Pump and 300.00 20.4 367 288 655

Comp.Shed(15X20 SQM)
4 TT Gantry(50X20) 1000.00 10.2 612 288 900
5 Bulk Storage 3052.08 10.2 1868 288 2156

(3NOS SPHERES-18MDIA)
(3*3.14*9*9)
(LARGEST RISK AREA)
WATER REQUIREMENT FOR LARGEST RISK AREA FOR 4 HRS.(KL) 8624

=(2156*4)
NO.OF FIRE PUMPS REQUIRED(CAP 410 KL/HR) 5.2
= 2156/410
ACTUAL NO OF PUMPS REQUIRED 6
NO OF STANDBY PUMPS 2
( 6/2 = 3, BUT MAXIMUM REQUIRED STANDBY IS 2)
TOTAL PUMPS REQUIRED 8
FIRE WATER REQUIRED TO OPERATE 6 PUMPS FOR 4 HRS(KL) 9840

6*410*4)
TANKAGE REQUIRED (KL) 9840
March - 2006 1 of 1

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FOREWORD

LPG operation manual for operational ease.

installations & bottling plants.

towards operational excellence to achieve Customer delight.

efficiency and service quality.

SECTIONS DESCRIPTION PAGE NOS.

1 Properties & Characteristics of LPG 1 - 39

2 Important statutes applicable to LPG Plants/Installations 2 - 20

3 Receipt & dispatch of Bulk LPG 3 - 77

4 Storage of Bulk LPG 4 - 48

5 LPG Terminals / Plant Operations 5 - 47

6 Bulk Stock Monitoring & Inventory Management 6 - 39

7 Design, Manufacturing & Maintenance of CVR 7 - 30

8 Fire Prevention & Safety 8 - 21

CHAPTER DESCRIPTION PAGE NO.

1.1 Specification as per Indian Standards 4

1.2 Physical/Chemical properties & characteristics 9

1.4 Solubility of water in LPG 20

1.5 Flame Propagation 20

1.6 Presence of sulphur 20

1.7 Pyroferic Iron 21

1.8 Presence of caustic soda (NAOH) residue 21

1.9 Explosion property of LPG 21

1.10 Testing procedures as per IS:1448 22

1.10.1 Testing procedure for odour of LPG (IS:1448) 23

1.10.2 Volatility of Liquified Petroleum Gas 24

1.10.3 Vapour presence of liquefied petroleum gases 28

1.10.4 Specific gravity test – Hydrometer test 30

1.10.5 Copper corrosion test 31

1.10.6 Hydrogen sulphide test 33

1.10.7 Dryness test 34

1.10.8 Composition test – Gas Chromatograph (ASTM D 2163) 36

Commercial Propane predominantly consists of hydrocarbons containing three carbon atoms,

Butane is usually supplied to customers in cylinders. Propane can be supplied in cylinders or in

1.1 SPECIFICATIONS AS PER INDIAN STANDARDS :

Sr. Characteristics Butane Butane – Propane Method of Test

i) Vapour pressure at 40 C in 520 1050 (Note 2) 1550 D 1267

ii) Composition, liquid mole D 2163

Sr. No. Characteristics Requirement Method of Test

5. 5ml Doctor Solution + 8 ml Iso-Octane + Pinch of Flower Sulphur in 25 ml stoppered cylinder.

IS 1448 [ P : 75 ], Odour test method is also acceptable as an alternate method.

Comparison of ‘Auto-LPG’ and ‘Domestic/Industrial-LPG’ Standards

Sl.No. Requirement Auto LPG- IS 14861-2000 Domestic LPG

9 Motor Octane Number 88 ISO 7941 Motor Octane Not

COMPARISON BETWEEN LPG, LNG, NG AND CNG

Parameter LPG LNG NG CNG

Pressures Max 16 bar Atmospheric 10-12 bar 200-240 bar

1.2 PHYSICAL/CHEMICAL PROPERTIES & CHARACTERISTICS

1.2.4 COLD BURN

0-50 deg. centigrade 0.522 to 0.454 0.587 to 0.537

1.2.8 COEFFICIENT OF VOLUMETRIC EXPANSION

1.2.9 VOLUMETRIC EXPANSION OF LPG

1.2.10 MELTING OR FREEZING POINT

1.2.11 CRITICAL TEMPERATURE

1.2.12 CRITICAL PRESSURE

1.2.13 BOILING POINT

This temperature differs for the liquid under different pressures.

Considering liquid in an container exposed to the atmosphere, a pressure equivalent to atmospheric

1.2.14 VAPOUR PRESSURE

VAPOUR PRESSURE CHARTS FOR DIFFERENT HYDROCARBONS

VAPOR PRESSURE CHART FOR LPG AT DIFFERENT COMPOSITIONS

1.2.15 LATENT HEAT OF VAPQURIZATION

1.2.16 SPECIFIC HEAT

1.2.18 AUTO IGNITION TEMPERATURE