standard codes followed in hazardous industries lpg storage and handling installations capacity...

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Standard Codes followed in Hazardous Industries Standard Codes followed in Hazardous Industries LPG Storage and Handling installations LPG Storage and Handling installations Capacity Building programme on Capacity Building programme on New Techniques and Strategies in New Techniques and Strategies in Prevention and Management of Industrial Prevention and Management of Industrial Disasters DisastersPresentation by – Presentation by – C. Vijay Kumar, C. Vijay Kumar, Senior Manager (LPG-Engg), IOCL, Karnataka Senior Manager (LPG-Engg), IOCL, Karnataka

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Page 1: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

Standard Codes followed in Hazardous Standard Codes followed in Hazardous Industries Industries

LPG Storage and Handling installationsLPG Storage and Handling installations

Capacity Building programme on Capacity Building programme on ““New Techniques and Strategies in New Techniques and Strategies in

Prevention and Management of Prevention and Management of Industrial DisastersIndustrial Disasters”

Presentation by –Presentation by –

C. Vijay Kumar, C. Vijay Kumar, Senior Manager (LPG-Engg), IOCL, KarnatakaSenior Manager (LPG-Engg), IOCL, Karnataka

Page 2: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

1.0 STATIC AND MOBILE PRESSURE VESSELS(UNFIRED) RULES:1981

TO REGULATE THE CONSTRUCTION, FITMENT,LOADING TRANSPORT AND INSPECTION OF UNFIRED VESSELS IN SERVICE OF COMPRESSED GAS(LPG) WITH CAPACITY EXCEEDING 1000 LTR.

PESO (CCOE) LICENSE FOR BULK STORAGE

2.0 GAS CYLINDER RULES: 1981 TO REGULATE POSSESSION, DELIVERY, STORAGE,

HANDLING AND EXAMINATION/TESTING OF CYLINDERS LIMITED UPTO CAPACITY 1000 L.

PRIOR APPROVAL FROM CCOE BEFORE CONSTRUCTING ANY NEW FACILITIES OR ALTERING THE EXISTING FACILITIES FOR FILLING CYLINDERS AND STORAGE AREA

PESO LICENSE FOR FILLLING OF CYLINDERS PESO LICENSE FOR STORAGE OF FILLED CYLINDERS

APPLICABLE STANDARDS & APPLICABLE STANDARDS & STATUTORY REGULATIONSSTATUTORY REGULATIONS

Page 3: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

3.0 FACTORIES ACT: 1948 APPROVAL FOR DRAWINGS FOR CONSTRUCTION OF

FACTORY/ INSTALLATION BY DIRECTOR, DEPARTMENT OF FACTORIES & BOILERS.

ADHERENCE TO FACTORIES ACT 1948 AND STATE FACTORIES RULES

WRITTEN SAFETY POLICY WRT HEALTH AND SAFETY OF WORKMEN

MAINTENANCE OF UPDATED ONSITE MANAGEMENT PLAN

4.0 WEIGHTS AND MEASURES RULES:1987 WEIGHTS AND MEASURE CERTIFICATE FOR WEIGH

BRIDGE, FILLING MACHINES AND CHECK SCALE PERMISSIBLE ERRORS ON NET QUANTITIES DECLARED BY

WEIGHT OR BY VOLUME AS PER ACT

APPLICABLE STANDARDS & APPLICABLE STANDARDS & STATUTORY REGULATIONSSTATUTORY REGULATIONS

Page 4: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

5.0 ENVIRONMENTAL REGULATIONS CONSENT OF STATE POLLUTION CONTROL BOARD FOR

DISCHARGE OF SEWAGE OR EFFLUENTS INTO A STREAM OR ON LAND

CONSENT OF STATE POLLUTION BOARD FOR DISCHARGE OR EMISSION OF AIR POLLUTANTS FOR OPERATION OF DG SET & FIRE ENGINES

6.0 INDIAN ELECTRICITY RULES - 1956

7.0 THE MOTOR VEHICLES ACT - 1988.

APPLICABLE STANDARDS & APPLICABLE STANDARDS & STATUTORY REGULATIONSSTATUTORY REGULATIONS

Page 5: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

OISD STD 144 – LIQUEFIED PETROLEUM GAS (LPG) INSTALLATIONS

OISD GDN 169 – OISD GUIDELINES ON SMALL LPG BOTTLING PLANTS (DESIGN & FIRE PROTECTION FACILITIES)

OISD STD 150 – DESIGN AND SAFETY REQUIREMENTS FOR LIQUEFIED PETROLEUM GAS MOUNDED STORAGE FACILITY

OISD STD 105 – WORK PERMIT SYSTEM OISD STD 128 – INSPECTION OF UNFIRED PRESSURE VESSELS OISD STD 132 – INSPECTION OF PRESSURE RELIEVING DEVICES OISD STD 137 – INSPECTION OF ELECTRICAL EQUIPMENT OISD STD 154 – SAFETY ASPECTS IN FUNCTIONAL TRAINING

APPLICABLE OISD STANDARDS & APPLICABLE OISD STANDARDS & GUIDELINESGUIDELINES

Page 6: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

Minimum safety requirements on design, layout, storage, loading / unloading, operation, inspection & maintenance, fire protection, emergency planning and safety audit systems of LPG Installations.

Not applicable to bottling plants having a bulk LPG storage capacity not exceeding 300 MT (above ground) or 450 MT in case of mounded or in combination of above ground and mounded with total bottling quantity not exceeding 35MT per shift of eight hours. Such small bottling plants are covered under OISD GDN 169.

OISD STANDARD 144OISD STANDARD 144

Page 7: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

 Installation layout & design consideration Storage & Handling of Bulk LPG Bottling operations Maintenance and inspection Safety –

a) Fire Protection Facilitiesb) Gas Monitoring Systemc) Emergency Management Pland) Safety Audit

Page 8: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

TABLE –ITABLE –IOISD 144- INTER DISTANCES FOR LPG FACILITIESOISD 144- INTER DISTANCES FOR LPG FACILITIES

1 2 3 4 5 6 7

1. LPG STORAGE VESSELS * T-II 30 30 30 15 60

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

GROUP OF BLDGS NOT ASSO- CIATED WITH LPG PLANT3. SHED-LPG 30 30 15 30 30 15

60 4. TW/TT GANTRY-LPG 30 30 30 50 50

30 605. LPG/OTHER RAIL SPURS 30 30 30 50 50 30

60 6. PUMP HOUSE/COMPRESSOR 15 30 15 30 30

-- 60 HOUSE(LPG)7. FIRE PH 60 ** 60 60 60

60 --

Notes : ALL DISTANCES ARE IN METRES** ANY DISTANCE FOR OPERATIONAL CONVENIENCE* ¼ OF SUM OF DIA OF ADJACENT VESSELS

Page 9: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

OISD 144 -TABLE –IIOISD 144 -TABLE –IIDIST BETWEEN LPG STORAGE VESSELS & DIST BETWEEN LPG STORAGE VESSELS &

BOUNDARY LINE/GROUP OF BUILDINGS NOT BOUNDARY LINE/GROUP OF BUILDINGS NOT ASSOCIATED WITH THE PLANTASSOCIATED WITH THE PLANT

CAPACITY OF EACH VESSEL DISTANCE(CU. MT OF WATER) (M)

10-2015 21-4020 41-350 30 351-450 40 451-750 60 751-3800 90 > 3800 120

Page 10: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

1.0 LOCATION AND SAFETY DISTANCES OF FACILITIES

1.1 LOCATION

ACCESS FOR MOBILE FIRE FIGHTING EQUIPMENTS AVAILABILITY OF SPACE FOR FUTURE EXPANSION LONGITUDINAL AXIS OF BULLETS NOT POINTED

TOWARDS VESSELS, VITAL PROCESS EQUIPMENTS BUILDINGS AND FACILITIES STORAGE VESSELS LAID OUT IN A SINGLE ROW BULLETS AND SPHERES NOT GROUPED TOGETHER STORAGE VESSELS NOT LOCATED ONE ABOVE THE

OTHER

OISD 144OISD 144PLANT LAYOUTPLANT LAYOUT

Page 11: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

2.0 LPG BOTTLING FACILITIESSEPARATE SHEDS FOR -

• EMPTY CYLINDER STORAGE CUM FILLING SHED• FILLED CYLINDER STORAGE

ESCAPE ROUTES IDENTIFIED IN LPG SHEDS

3.0 PROTECTION OF FACILITIESPROVISION OF ROADS AROUND FACILITIES FOR ACCESSIBILITY OF FIRE FIGHTING OPERATIONEMERGENCY ESCAPE EXIT WITH PROPER GATELPG LORRY PARKING AREA(BULK/PACKED) WITH PROPER HYDRANTCOVERAGE

OISD 144OISD 144PLANT LAYOUTPLANT LAYOUT

Page 12: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

4.0 LPG STORAGE FACILITIESPROVISION OF KERB WALL AROUND STORAGE VESSELSPROVISION OF SPILLAGE SUMP WITH MIN DISTANCE NOT MORE THAN DIA OF THE NEAREST VESSEL OR 15M WHICHEVER IS HIGHERAREA UNDER SPHERE IS HAVING CONCRETE PAVEMENT WITH PROPER SLOPE TO SHALLOW SUMPGROUPING OF THE VESSEL NOT EXCEEDING 6 NO.S IN EACH GROUPTOP SURFACE OF ALL VESSELS IN ONE GROUP ON THE SAME PLANE

5.0 LPG BULK HANDLING FACILITIESMIN TURNING RADIUS FOR TT SHOULD BE 20MMAX NO. OF TANK LORRY BAYS IN A GROUP NOT TO EXCEED 8 NOS.SEPARATION BETWEEN TWO SETS OF BAYS MIN 50MPROVISION FOR ISLAND FOR PROTECTION OF PIPE LINEPIPELINE SYSTEM WITH THERMO SAFETY VALVES ROVs AND EFCVs TO BE PROVIDED

OISD 144OISD 144PLANT LAYOUTPLANT LAYOUT

Page 13: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

STORAGE VESSELS DESIGN CODES - ASME SEC. VIII or IS-2825 or PD- 5500 APPROVED BY PESO MATERIAL-SA537 Gr.1 OR SA 516 Gr. 70 DESIGN TEMPERATURE- -27DEG TO +55DEG DESIGN PRESSURE: 14.5 Kg/SQCM AT 55 DEG CELCIUS. CORROSSION ALLOWANCE: 1.5MM RADIOGRAPHY –FULL STRESS RELIEVING 100% IRRESEPCTIVE OF THICKNESS WIND PRESSURE AS PER IS 875 EARTH QUAKE PRESSURE AS PER IS:1893 HYDRO TEST PRESSURE AS PER DESIGN CODE

OISD 144OISD 144STORAGE VESSEL DESIGN STORAGE VESSEL DESIGN

CRITERIACRITERIA

Page 14: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in
Page 15: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in
Page 16: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in
Page 17: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

SPRINKLER SYSTEM - Automatic fire protection (Fixed) medium velocity sprinkler system - heat detection through quartzoid bulbs

In LPG storage area, detectors shall be provided encircling each vessel, equi-spaced.

Minimum 2 nos. detectors shall be provided at the top of the vessel and one near the liquid line ROV to take care of failure of flanges.

Upon actuation there shall be alarm in control panel, LPG pumps and compressors would trip, ROVs on LPG supply and return lines would trip and the deluge valves on fire water sprinkler system will get actuated.

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 18: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

DESIGN CRITERIA

ALL LPG STORAGE VESSELS, CYLINDER STORAGE/ FILLLING SHEDS, REPAIR SHEDS, LPG PHs, BULK LORRY AND TANK WAGON GANTRIES SHALL BE COVERED BY MEDIUM VELOCITY SPRAY SYSTEM

DETECTION OF FIRE FOR AUTOMATIC ACTUATION OF MV SPRAY SYSTEM SHALL BE PROVIDED AT ALL CRITICAL LOCATIONS LIKE LPG BULK STORAGE, TANK TRUCK/TANK WAGON GANTRY,NEAR CAROUSAL, LPG PUMP/COMPRESSOR HOUSE, EVACUATION, VALVE CHANGE AREAS

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 19: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

FIRE WATER STORAGE

EFFECTIVE WATER STORAGE CAPACITY IS NOT LESS THAN 4 HRS AGGREGATE WORKING CAPACITY OF MAIN FIRE WATER PUMP

MIN 2 STORAGE TANKS ARE PROVIDED IF STEEL TANKS ARE PROVIDED

FIRE WATER PUMPS TO MEET INSTALLED RATE OF FLOW AND HEAD SHALL BE CENTRIFUGAL TYPE DIESEL ENGINE DRIVEN

THERE SHALL BE A JOCKEY PUMP NOT LESS THAN 10M3/HR PER 100 HYDRANT POINTS WHICH MAINTAINS THE SYSTEM PRESSURE AT 7KG/CM2 BY STARTING AND STOPPING AUTOMATCALLY BASED ON THE SYSTEM PRESSURE

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 20: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

AT LEAST ONE STANDBY FIRE WATER PUMP SHALL BE PROVIDED UPTO 2 NOS OF MAIN PUMPS.

FOR MAIN PUMPS 3 AND MORE, MINIMUM TWO STANDBY PUMPS OF THE SAME CAPACITY AS THE MAIN PUMPS SHALL BE PROVIDED.

FIRE HYDRANT NETWORK• FIRE WATER RING MAIN LAID ABOVE GROUND• FIRE WATER RING MAIN LAID UNDERGROUND IF ANY ,

CONFORMS TO THE FOLLOWING: - RING MAIN LAID 1 MTR BELOW GROUND

- IN ROAD CROSSING, RING MAIN LAID 1.2 MTR BELOW

GROUND FIRE WATER RING MAIN KEPT PRESSURISED MIN. 7KG/CM2

FIRE WATER MONITOR PROVIDED WITH INDEPENDENT ISOLATION VALVE

BETWEEN HYDRANT POINTS HOSE BOXES ARE KEPT WITH 2 NOS HOSES AND A NOZZLE

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 21: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

FIRST AID PORTABLE FIRE FIGHTING EQUIPMENTS

FIRE EXTINGUISHERS SHALL BE PROVIDED AT VARIOUSLOCATIONS AS UNDER:

AREA PORTABLE FIRE EXTINGUISHER

LPG STORAGE VESSEL 2 NO.S 10KG DCPLPG CYL SHED 2 NO.s 10KG DCP PER 200 SQM

AREALPG PUMP HOUSES 2 NO.S 10KG DCP PER 50SQMTT LOADING/UNLOADING 1 NO. 10KG DCP PER BAYTW LOADING/UNLOADING 1 NO. 10KG DCP FOR EVERY

15/20 MTRS OF GANTRYOTHER PUMP HOUSES 2 NO.S 10KG DCP

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 22: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

FIRST AID PORTABLE FIRE FIGHTING EQUIPMENTS

AREA NO. OF FIRE EXTINGUISHER

MCC/DG ROOM/HT ROOM ATLEAST 2 NO.S 4.5KG CO2 EXTINGUISHERS IN EACH ROOM

100% SPARE CARTRIDGES 50% MIN SPARE DCP BAGS AS PER FIRE EXTINGHUISHER

CAPACITYMOBILE FIRE FIGHTING EQUIPMENT1 NO. 75 KG DCP IN FILLING SHED , LPG STORAGE VESSELS, LPG PUMP HOUSE AREA, TANK TRUCK LOADING/UNLOADING GANTRY AREA, TANK WAGON LOADING/UNLOADING GANTRY AREA

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 23: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

HOSES NOZZLES AND ACCESSORIES 50% SPARE SHALL BE STORED IN THE LPG PLANT 2 NO.S NOZZLES SPARE OF EACH KIND

FIRE ALARM SYSTEM SUFFICIENT NO. OF MANUAL CALL POINTS TWO ELECTRICALLY OPERATED FIRE SIREN WITH 1 KM AND 3 KM

RADIUS COVERING THE ENTIRE PLANT AND SORROUNDING PLACES MANUALLY OPERATED SIREN AT STRATEGIC PLACES

COMMUNICATION SYSTEM AVAILABILITY OF EFFECTIVE COMMUNICATION COMMUNICATION SYSTEM LIKE TELEPHONE, PA/PAGING IN

HAZARDOUS AREA TO BE FLAMEPROOF / INTRINSICALLY SAFE

OISD 144OISD 144FIRE PROTECTION FACILITIESFIRE PROTECTION FACILITIES

Page 24: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

The Gas Monitoring system - early warning for gas concentration below the LEL (lower explosive limit).

The detectors for the gas monitoring system strategically located at all facilities close to potential source of leakage.

The detection control equipment provided in the control room for continuous monitoring even during power failure.

The control equipment to generate at least two alarms at different levels of concentration of gas below LEL.

OISD 144OISD 144GAS MONITORING SYSTEMGAS MONITORING SYSTEM

Page 25: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

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.

The height of the detector should not be more than 0.3 M from the mounting level.

The detectors should be located at least 0.3 mtrs. away from the potential source of leakage

The gas monitoring system shall be kept in good operating condition all the time.

OISD 144OISD 144GAS MONITORING SYSTEMGAS MONITORING SYSTEM

Page 26: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

The minimum detectors are given below: Storage vessels (above ground) – 1 No. top and 1 No.

near bottom ROV. LPG pump house 1 No. in pump house and 1 No. in

manifold. Filled cylinder shed - 2 No. Valve change shed – 1 No. Empty-cum-filling shed – 2 Nos. near carousel, 1 No.

near evacuation unit tank, 1 No. weight correction unit. TLD – one at each manifold and at ends. Tank wagon gantry – 1 no. for every two bays or 30 m

whichever is less at bottom. Additionally, some detectors at selected locations shall be provided at the top of platform.

OISD 144OISD 144GAS MONITORING SYSTEMGAS MONITORING SYSTEM

Page 27: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

GUIDELINES FOR EMERGENCY PREVENTION - Sound engineering practice in the design,

fabrication, installation and maintenance of facilities.

Careful selection and correct use of equipment. Observance of safety and security regulations. Proper and constant training and guidance to all

personnel on product knowledge and maintenance practices.

Good House-keeping. Constant supervision and alertness

OISD 144OISD 144EMERGENCY MANAGEMENT EMERGENCY MANAGEMENT

SYSTEMSYSTEM

Page 28: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

Instructions to both corporation and contractor’s employee identifying the action to be taken by each one in an emergency.

Availability of fire fighting organization plan including plan for holidays and off shifts

Availability of approved onsite disaster management plan(DMP)

Mock fire drills to be conducted in coordination local administration, Police authorities, Fire Brigade, hospital authorities, home guards, neighbouring industries

Offsite DMP will be formulated by District Administration

OISD 144OISD 144EMERGENCY MANAGEMENT EMERGENCY MANAGEMENT

SYSTEMSYSTEM

Page 29: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

SOURCE OF LPG LEAKAGES - Through water drain valve while draining. Leaking sample valve. Breakage of glass on Sight Flow Indicator on the

pipeline. Opening of pop-off valve, gland/packing etc. Leakage through LPG compressor/pump. Leakage due to bursting/ rupture of hose or

through swivel joints of body arms. Leakage from the filling guns. Escape of liquid/ vapour LPG during maintenance/

repairs.

OISD 144OISD 144EMERGENCY MANAGEMENT EMERGENCY MANAGEMENT

SYSTEMSYSTEM

Page 30: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

A structured and systematic safety audit of any plant / facility to be done

Check lists should cover all the operational areas, major equipments, operating/ maintenance procedures, safety practices, fire prevention/ protection systems etc.

OISD 144OISD 144SAFETY AUDITSAFETY AUDIT

Page 31: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

Daily safety audit of LPG Installation by Safety Officer – reviewed by PM on daily basis.

Monthly safety audit by Plant Manager Electrical audit by Internal & External Auditors

annually Detailed safety audit by Multi disciplinary

team annually with members from region / HQ Maintenance & Inspection audit annually Surprise audit by Regional Safety Team External safety audit by OISD – scheduled as

well as surprise

OISD 144OISD 144SAFETY AUDITSAFETY AUDIT

Page 32: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

The safety audit will cover the following points –

Safety Organisation Security System Fire prevention/ protection system Preparedness to handle any emergency --

Disaster control plan and mock drills. Skill level and training needs for HRD. Operating manual/ instructions, display of

Do's/ Don'ts etc.

OISD 144OISD 144SAFETY AUDITSAFETY AUDIT

Page 33: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

1.0 STORAGE AND HANDLING OF BULKUNLOADING OF BULK LPG TANK TRUCKS/ TANK

WAGONS UNLOADING OF BULK TTs & TWs TO BE CARRIED OUT ONLY AT LOCATIONS APPROVED BY PESO

SAFETY PRECAUTIONS ELECTRICAL EQUIPMENTS/ LIGHTING FLAME

PROOF VAPOUR VENTLINE FOR INDUIVIDUAL BAY AT

1.5M HEIGHT ABOVE THE EAVES OF THE SHED FIRE EXTINGUISHERS SHALL BE POSITIONED AS

AN IMMEDIATE AID FOR FIRE FIGHTING - 1 NO 10 KG DCP EXTINGUISHER PER BAY

OISD 144OISD 144OPERATING PRACTICESOPERATING PRACTICES

Page 34: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in
Page 35: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

CHECKS TO BE CARRIED OUT FOR EACH TT BEFORE UNLOADING –

• VALID LICENSE FROM PESO, NAGPUR• 2 NO.S 10KG DCP FIRE EXTINGUISHERS• QUICK CLOSING MANIFOLD VALVE WITH LEVER

INDICATING CLOSE/OPEN STATUS

• MASTER CUT OFF SWITCH FOR SWITCHING OFF ENGINE IS PROVIDED

• AVAILABILITY OF TREM CARD, ROUTE MAP, INSTRUCTION BOOKLET, RTO PERMIT

OISD 144OISD 144OPERATING PRACTICESOPERATING PRACTICES

Page 36: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

LPG CYLINDER STORAGESTACKING VERTICAL WITH VALVE IN UPRIGHT POSITION HEIGHT SHOULD NOT EXCEED 2 STACKS DIFFERENT TYPE AND CAPACITY TO BE STACKE SEPARATELY (SEPARATE

STACKING OF OMC CYLINDERS –COMPANY WISE)

STACKING PATTERN SMALL LOTS OF 4 ROWS AND 25 CYL LENGTH WITH MAX 2

STACKS HIGH MIN ACCESS PATH OF 1M ON BOTH SIDES OF STACK 2M ACCESS

AFTER 5 LOTS AFTER EACH LENGTH OF 25 CYLINDERS, PASSAGE OF 2M

CYLINDER STORAGE SPACE TO BE MARKED AND PAINTED ON FLOORING DEMARCATED

MINIMUM DISTANCE OF 15M FROM CYLINDER LOADING MIN DISTANCE OF 10M FROM FILLING POINT

OISD 144OISD 144OPERATING PRACTICESOPERATING PRACTICES

Page 37: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

INSPECTION/ TEST CERTIFICATE AT THE TIME OF ORIGINAL FABRICATION SHOULD BE AVAILABLE AND SUBSEQUENT INSPECTION / HYDRAULIC TEST CARRIED OUT AS PER SMPV RULES 1981 AND RECORDS MAINTAINED.

GUIDELINES OF OISD STANDARD-128 TO BE FOLLOWED FOR DETAILED INSPECTION OF PRESSURE VESSELS.

ANNUAL INSPECTION AND TESTING OF SAFETY VALVES CARRIED OUT AT PROPER SET PRESSURE AND RECORDS MAINTAINED.

ALL INSTRUMENTS, LEVEL INDICATORS, PRESSURE AND TEMPERATURE GAUGES, ROVS ARE MAINTAINED IN WORKING CONDITION AND DAILY SCHEDULED CHECKS, PERIODIC CALIBRATION AND PREVENTING MAINTENANCE SCHEDULE

RELIEF VALVES - ISOLATION VALVES LOCKED IN OPEN CONDITION EARTHING SHOULD HAVE CONTINUITY AND CONDITION OF EARTH

PIT TO BE CHECKED AND RESISTANCE MEASURED

OISD 144OISD 144MAINTENANCE & INSPECTIONMAINTENANCE & INSPECTION

Page 38: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

INSTRUMENTATION TEMP INDICATING DEVICES TO BE CHECKED, CALIBRATED ONCE

IN 6 MONTHS USING STD GAUGE LEVEL GAUGE SHALLBE CHECKED DAILY FOR PROPER

FUNCTIONING ZERO LEVEL CHECK AND CALIBRATION TO BE CARRIED OUT

MONTHLY PRESSURE GAUGES TO BE CHECKED DAILY FOR CORRECT

FUNCTIONING AND CALIBRATED ONCE IN 6 MONTHS USING STD. GAUGE

FLOW MEASURING DEVICES TO BE CHECKED DAILY AND CALIBRATED ONCE IN A MONTH

INSPECTION OF LOADING/UNLOADING HOSES UNLOADING ARMS ARE PREFERABLE TO HOSES HOSES TO BE STORED PROPERLY WITH ENDS CLOSED BLINDS NO HOSE HAVING KINKS OR CRACKS

OISD 144OISD 144MAINTENANCE & INSPECTIONMAINTENANCE & INSPECTION

Page 39: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

ENTRANCE TO AUTHORISED PERSONNEL ONLY WITH IDENTIFICATION WITH PHOTO ID CARDS

FRISKING OF ALL PERSONAL DONE BEFORE ENTRANCE PHYSICALLY AS WELL AS HAND HELD METAL DETECTORS. FURTHER THE PERSON HAS TO PASS THROUGH DOOR FRAME METAL DETECTORS

VISITORS ALLOWED INSIDE ONLY AFTER AUTHORISATION BY PLANT MANAGER / AUTHORISED OFFICER

MONITORING OF MOVEMENT OF VISITORS AND LOGGING THEM OUT AFTER EXIT.

VISITORS FACE CAPTURED USING A WEB CAMERA VEHICLES ENTERING ARE CHECKED FOR PRESENCE OF BOMBS,

ETC., PHYSICALLY AS WELL AS UNDER BODY MIRRORS NO INFLAMMABLE OBJECT ALLOWED INSIDE VISITORS VEHICLE CHECKED THOROUGHLY DICKIE, BONNET AND

UNDER BODY ADEQUATE SECURITY PERSONNEL FOR ROUND THE CLOCK FOR

PETROLING AND SECURITY OF INSTALLATION SECURITY TOWERS FOR MONITORING OUTSIDE AREAS CO-ORDINATION WITH LOCAL POLICE AND INTELLIGENCE BUREAU

FOR SUSPICIOUS PERSONS AND MOVEMENT

SECURITYSECURITY

Page 40: Standard Codes followed in Hazardous Industries LPG Storage and Handling installations Capacity Building programme on “New Techniques and Strategies in

SAFETY EDUCATION AND TRAINING RECEIVES GREAT ATTENTION A VARIETY OF TRAINING COURSES ARE CONDUCTED INTENDED TO

DEVELOP THE SKILLS AND SAFETY CONSCIOUSNESS OF EMPLOYEES.

TRAINING IS GIVEN TO IOCL EMPLOYEES, HANDLING & HOUSE KEEPING CONTRACT LABOUR, TRUCK CREW AND SECURITY AS PER THE SYLLABUS GIVEN IN OISD 154.

TRAINING ALSO GIVEN DURING MONTHLY FIRE DRILL AND HALF YEARLY FIRE DRILL INVOLVING OUTSIDE AGENCIES.

FIRST AID TRAINING IS GIVEN TO EMPLOYEES WITH THE ASSISTANCE OF OUTSIDE AGENCIES LIKE ST. JOHNS, ETC.,

TRAINING IS GIVEN AS PER MV RULE 9 TO TRUCK CREW WITH THE HELP OF INHOUSE PERSONNEL AND OUTSIDE AGENCIES.

TRAINING DATA AND QUALITY REVIEWED BY HIGHER MANAGEMENT

REFRESHER COURSES ARE GIVEN PERIODICALLY AS SPECIFIED OISD 154 / INTERNAL COMPANY REGULATIONS.

TRAININGTRAINING

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