Compliance Requirements under the Rules

1. General Requirements for Installation of Pressure Vessels (Rule 21)

While installing pressure vessels, general requirements as mentioned under this rule shall be followed.

General Requirements:

1. 1. Above ground installation
   2. Open air placement
   3. Vessels must not be installed one above another
   4. Vessels in the same group must have their longitudinal axis aligned parallel to each other
   5. Vessels must not be located inside the bunded area of petroleum or other flammable liquid storage facilities
   6. Space for firefighting
   7. Earthquake proofing
   8. Storm water drains forming around vessels
   9. Underground or mounded LPG vessels
   10. Distance from certain above ground sources
   11. Construction materials should have minimum corrosion allowance of 1.5 mm
   12. Earthing and lightning protection
   13. Mounded underground vessels compliance – As per Schedule III
   14. Minimum distance from rail or public road
   15. Access road for fire-fighting
   16. Vessel capacity > 600 KL – Distance to be least 1 km

2. Minimum Safety Distance for Pressure Vessels (Rule 22(1))

Each vessel should be placed at the required minimum safety distance from adjoining buildings, property lines, process equipment, roads, railways, etc., as specified in the Rules.

Detailed table specifying vessel sizes based on the type of vessels mentioned in Rules.

3. Minimum Safety Distance for Multi-Vessel Installation (Rule 22(2))

In multi-vessel installation, adequate water capacity (>100 KL), minimum safety distance shall be maintained between vessels, as specified in Rules.

Minimum safety distances mentioned here is minimum distance between any two vessels and the boundary wall.

4. Safety Distance between Group Vessels (Rule 22(3))

Safety distance of group vessels shall be at least 1.5 times vessel diameter but not exceed 60 meters.

Minimum separation distance between two such groups of vessels shall be the distance from group vessel to nearest road or boundary of installation.

5. Maximum bottling quantity in LPG Bottling Plant (Rule 22(4))

Maximum quantity of LPG bottling shall not exceed 30 MT per hour or as approved by the Chief Controller.

Provisions of OISD (Oil Industry Safety Directorate) are to be complied with. OISD 150 are guidelines for LPG Bottling Plants.

6. Pressure Vessel Foundation (Rule 23(1))

The foundation, supports, saddles, anchors, pedestals and other supports of pressure vessels must be designed and constructed in accordance with approved standards.

Approved specifications, standards, or applicable rules as given or specified in Rules.

7. Ground condition for Pressure Vessel (Rule 23(2))

The installation ground under the vessel shall be firm and shall not be susceptible to subsidence, flooding, or erosion.

Ground condition refers to the location where vessel is to be installed.

8. Corrosion Protection for Pressure Vessel (Rule 23(3)

Corrosion protection measures shall be provided for the external surface of vessels to prevent deterioration. Choice of material shall be as specified under rules.

9. Loading for Pressure Vessel (Rule 23(4))

Loading conditions of pressure vessel shall include dead load, wind load, seismic load, and any other load which the vessel may experience. Greatest combined effect of static and imposed loads shall be used for design of pressure vessel.

10. Differential settlement of Pressure Vessel (Rule 23(5))

Differential settlement of pressure vessel shall be avoided and provisions shall be made in supports and foundations. Differential settlement may result in distortion or damage of vessel and connected pipelines.

11. Compliance Requirements for Vessel Support Structure (Rule 23(6))

Supports shall be designed as per the vessel’s construction code or standard and shall be designed to safely transfer all loads to ground.

12. Structure for Underground and Mounded Vessels (Rule 23(7))

Underground and mounded vessels shall be designed to withstand soil loads and loads arising from traffic, water table, and seismic forces. Schedule III shall be complied with in accordance with LPG Rules and amended rules.

13. Maintenance of safety area of Pressure Vessel (Rule 24(1), 24(2)& 24(3))

a.  The safety-distance area around installation must be kept clean & free from ignitable materials

b. Areas with vessels, pumps, loading facilities etc must be enclosed with industry type fence of 2 metres high.

c. Fenced area must have atleast 2 outward-opening exit gates that are not self-locking.

  14.Notice for prohibiting smoking in Safety area of Pressure Vessel (Rule 24(1))

Permanent notice with letters (at least 5 cm. in height) prohibiting smoking and naked lights shall be fixed to the fence surrounding the area where flammable or oxidising gases are stored. Such notice shall be visible from outside

15. Earthing Requirements for Vessels & Pipelines (Rule 25)

a. All vessels storing flammable compressed gases must be properly & effectively earthed.

b. Pipelines carrying flammable liquids must have proper electrical continuity & must be efficiently earthed. Bonded systems shall be grounded & resistance shall be<1 ohm to earth.

   16. Adequate Fire Water Supply to Vessel (Rule 26 (i)

Adequate fire water supply shall be provided for cooling and fire-fighting purposes in case of emergency. Fire water supply shall be adequate as per OISD standards.

17. Hydrants on Vessels (Rule 26(ii))

Hydrants shall be installed and readily accessible for fire-fighting. Outlet of hydrants shall be easily accessible with connection to fire mains.

18. Availability of Fire Extinguishers (Rule 26(iii))

Portable and fixed fire extinguishers of suitable type shall be provided near pressure vessels. Guidelines for number and type of fire extinguishers shall be as per relevant standards.

19. Adequate Water Application Over Vessel Surface (Rule 26(iv))
    Mobile equipment, fixed monitors, or spray systems in vessel shall be so designed to discharge water at a rate ensuring a continuous water film over vessels and supports under fire conditions. Mobile equipment, fixed monitors, or spray systems in vessel shall be so designed to discharge water at a rate ensuring a continuous water film over vessels and supports under fire conditions.
20. Water Spray Protection for Loading/Unloading Areas of Vessel (Rule 26(v))

Suitable mobile or fixed water spray systems must be provided for vehicle loading and unloading zones

21. Dry Chemical Extinguishers at Access Points of Vessel (Rule 26(vi))

At each point of access to the installations, atleast 2 dry chemical powder type fire extinguishers (of 9 kg. capacity each) shall be installed.

22. Fire Protection for LPG Dispensing Stations (Rule 26(vii))

LPG Dispensing Stations should comply with following fire safety measure:

• • For Underground/mounded LPG vessels: Two 70-kg DCP extinguishers.
  • For Above-ground LPG vessels: Hydrants with min.7 kg/cm² pressure, water sprinklers with 10 L/min/m²
  • Fire-water storage with atleast 1 hour fire fighting”
    
    

23. Pump Design and Safety Requirements (Rule 27(1))

a. Pump design, materials, and construction must be suitable for the specific gas handled and capable of withstanding the maximum outlet pressure during operation.

b. Also, Positive displacement Pumps must be equipped with a bypass valve or other effective over-pressure protection.

   24. Requirements for Compressor Design (Rule 27(2))

a. Compressors must be designed, constructed, and made of materials suitable for the specific gas handled, and must safely withstand maximum outlet pressure during operation

b. All compressors (except multi-stage compressors) must take suction from vapour space of the vessel being filled

   25. Transfer System Design and Safety Requirements (Rule 27(3))

Transfer systems must be designed to prevent gases with higher vapour pressure from being transferred into equipment meant for lower-vapour-pressure gases.

A reliable, rapid shut-off mechanism must be provided at a safe distance from the vessel being filled/emptied.

26. Automatic alarm system in Transfer System (Rule 27(3))

Automatic Alarm Device shall be used in used in Transfer Systems to indicate the approach to maximum permissible height OR Automatic Shut-off Valves shall be used to prevent over filling.

27. Requirement for Hoses Design (Rule 27(4))

Hoses shall be mechanically and electrically continuous. Further, Hoses for liquid transfer shall be designed to withstand atleast 4 times of maximum operating pressure they will carry in service.

28. Gantry and Bay Limits for Tank-Trucks (Rule 27(5)(i))

Maximum no. of bays for parking tank-trucks (loading unloading), can be 8 and maximum 2 gantries can be in a premise.

29. Safety distance of Tank Truck Loading / Unloading (Rule 27(5)(ii))

Safety distance of Tank Truck Loading /Unloading gantry from property line and as well as from vessel should be as per specified in rules.

Safety distance of Tank Truck Loading /Unloading should be as below:

• • LPG bottling plants and terminals : As per Table 4(A) & (B)
  • LPG, LNG and other flammable or toxic or corrosive gas installations : 9 mtr from property line and storage vessel
  • Non-toxic, non-flammable gas installation : 4.5 mtr from property line, and 3 mts in case of liquid installation
  • Mounded installations consisting of vessel of water capacity upto 100 KL each: 4.5 mtr from Vessel & 9 mtr from property line

30. Safety distance Rail Tank Wagon Loading/ Unloading (Rule 27(6))

Rail Tank Wagon loading or unloading shall be maximum of half a rake (600 tonnes). And full rake handling is required, it shall be placed in 2 separate gantries with 50 mtr distance in between them.
Safety distances for rail tank wagon loading or unloading shall be as per table 4(A) under rule 22

   31. Marking of Valves on the Vessel and Pipelines (Rule 27(7))

All valves on the vessel and pipelines in the premises shall be permanently marked in a manner clearly indicating the direction of opening and closing.

   32. Safety Requirements for Gas Transmission Operation (Rule 28(1))

Following safety checks shall be performed before transmission of gas:

• • Visual check of the surroundings
  • Display of all necessary warning signs
  • Checking all inter connecting systems & gas receiving vessel
  • Each vehicle to be completely emptied and checked to ensure compliance with regulations”
    It shall be checked that receiving vessel has sufficient ullage to receive quantity of gas being transferred to it. Further, Inter-connecting system (i.e. pipe work-fittings, valves or hoses) shall be checked to ensure that it is in safe working condition and that only valves and other fittings required in the transfer operations or any other operations proceeding simultaneously, are open.

   33. Safety Requirements Prior to Gas Transmission (Rule 28(2) & 28(3))

Following safety checks shall be performed during/after transmission of gas:

• • Receiving vessel shall be checked to ensure that its not filled above its safe filling capacity/ its design pressure.
  • After transfer of gas, vehicle shall be weighed to ascertain the qty of the compressed gas.

Vehicle shall be weighed to ascertain the quantity only if if the vehicle is filled with a
liquefiable gas

   34. Procedure for Filling Gas in Vessel (Rule 28(4))

While filling the vessels with compressed gas, following procedure shall be complied:

• • Parking the vehicle on ground level
  • Preventing accidental movement using parking brake
  • Isolating non-essential driving units
  • Electrically bonding the vessel to fixed installation etc”

Before moving a vehicle, the electrical, liquid and vapour connections shall be disconnected, exercising care to avoid spillage. Where wheel chock blocks have been used, shall be removed. The vehicle shall be checked to ensure that its in safe working order and surrounding areas checked to ensure that any liquefied flammable gas that may have leaked or has to be vented has safely dispersed.

   35. Supervision of Vehicle Gas Transfer (Rule 28(5))

Skilled and trained person with requisite knowledge & experience be available during all the operations of transfer to ensure that all the rules are complied with.

Where its necessary to discontinue a vehicle loading operation temporarily, the loading hose shall be disconnected from the vehicle for the period of such discontinuance.

 36. Stoppage of Gas Transfer operations (Rule 28(6))

Gas transfer operations shall ensure be stopped in following cases:

(i) any leakage or

(ii) a fire occurring in the vicinity or

(iii) a severe electrical storm occurring in the vicinity in the case of an operation which involves venting of flammable gas

Person in-charge of transfer operations shall ensure that operations have been stopped as mentioned here.

   37. Design requirements of Dispenser (used for dispensing auto LPG station) (Rule 29)

Dispenser equipment used at auto-LPG dispensing stations must be designed, built, tested, and maintained according to the standards in Schedule II of the rules. The dispenser type must also have written approval from the Chief Controller.
Compressed Hydrogen Gas dispensing station shall be designed, constructed, operated and maintained in accordance with NFPA-2 and ISO 19880- Part 1, Part 3, Part 5, Part 8 as amended from time to time or any other standard accepted by the Chief Controller. However, dispenser for dispensing of LH2or compressed hydrogen gas (CHG), shall be designed, constructed, tested and maintained as per provisions of the Schedule V of the rules and ISO 19880 or NFPA-

   38. Safety Compliance for Auto-LPG Refuelling and Unloading (Rule 30)

Following shall be ensured while filling fuel tanks & unloading tank-truck :

1. 1. Auto LPG/Auto LNG/LH2 /CHG must not be filled in a vehicle’s fuel tank when engine is running.
   2. Auto-LPG/Auto LNG/LH2 /CHG must not be dispensed to vehicles during unloading of Auto-LPG from a tank-truck to vessels.

   39. Compliance for Safety of Electrical Installations (Rule 31(1), (2),(4))

Electrical wires must not pass over any storage vessel/licensed premises

• • Electrical wiring within the safety zone of storage vessels must use approved insulated cables
  • Portable electrical & instruments must be approved by Chief Controller”
    All time

For pumping flammable compressed gases –

(i) all electrical motors, distribution boards, switches, fuses, plugs, sockets and other instrumentation shall be of explosion protection construction complying with the requirements of IS/IEC or IEC or EN 60079 as amended from time to time and the frames shall be effectively earthed;

(ii) all electrical fixed lamps shall be enclosed in a well glass flameproof fitting conforming to IS/IEC or IEC or EN 60079-1 amended from time to time.”

   40. Compliance for Safety of Pump-rooms (Rule 31(3) & (5))

In pump rooms handling flammable compressed gases:

• • All electrical equipment must be explosion-protected as per IS/IEC 60079 standards and effectively earthed.
  • Fixed lamps must be enclosed in flameproof fittings as per IS/IEC 60079.
    Further, Vaporisers must be indirect/atmospheric heating type”

Electrical equipments in Pump-rooms include: motors, switches, boards, plugs, etc.