Section 0 in Petroleum and Natural Gas Regulatory Board (Technical Standards and Specifications including Safety Standards for LPG Storage, Handling and Bottling Facilities) Regulations, 2019
0. LPG Tank Trucks (Requirements of Safety on Design or Fabrication and Fittings). - Transportation of LPG by road is regulated by Department of Explosives by applying the Petroleum Rules, 1976 and The Motor Vehicle Act 1988 (59 of 1988) and the transportation of LPG in bulk is regulated through the Static and Mobile Pressure Vessels (unfired) Rules, 1981 and The Motor Vehicle Act, 1988.
3.1Design Criteria. - Pressure vessels used for transportation of LPG shall be designed and fabricated in accordance with the Static and Mobile Pressure Vessels (Unfired) Rules 1981, IS: 2825 or equivalent codes.3.1.1Maximum Filling Volume. - Minimum vapour space or the maximum quantity of LPG filled in any vessel shall be limited to the filling density of LPG and shall be such that the vessel should not become liquid full due to expansion of the content with the rise in temperature to 55 deg. centigrade and such requirement shall be applicable irrespective of the ambient temperature of the product at the time of filling. (Generally, it is filled maximum up to 85% of the volume).3.2Vessel Design:3.2.1Design Pressure. - Vapour pressure of LPG conforming to IS:4576 at a maximum anticipated service temperature of 55 deg. C. to be considered and the minimum design pressure shall be 14.5 kg/sq.cmg and in addition, 3g effect to take into account acceleration or deceleration shall be considered while designing of the vessel.3.2.2Design Temperature. - The design temperature of the vessel shall be in line with the specification of LPG and as per statutory requirement.3.2.3Vessel Design Code. - i. Vessel shall be designed, fabricated and tested in accordance with requirements of Class I pressure vessels conforming to IS:2825, PD-5500, ASME SEC. VIII or equivalent codes accepted by Statutory Authority and the vessel shall be designed to withstand shocks normally encountered during transport including those set up by the movement of the contents of the vessel such as acceleration or deceleration of a minimum of 3g to be calculated considering that the vessel is full with LPG at 55 deg. C and saddle supports and other attachments shall also be designed according to the fabrication code;ii. Joints shall be as required by the code with all under cuttings in shell and head material fabricated as specified therein;iii. All longitudinal shell welds shall be located in upper half of the vessel and shall be staggered when assembling the cylindrical shell from two parts by means of a circumferential joint and the distance between two such staggered joints shall be at least 5 times the thickness of the thicker plate or as specified by code as adopted.3.2.4Material Specifications. - Material used in the manufacture of pressure parts of the vessel shall be in accordance with that specified in IS: 2825, PD-5500, ASME SEC. VIII or equivalent code as adopted and a single code shall be adopted for materials, fabrication, inspection and testing.3.2.5Vessel Plate Thickness. - The nominal thickness of the plate material used in fabrication shall not be less than the sum of minimum calculated thickness as per the fabrication Code and corrosion allowance (CA), if necessary and in addition, adequate thinning allowance in case of formed heads and for mobile vessels (for which CA may not be necessary) an allowance of at least 0.5 mm. shall be included in place of CA to safeguard against wear and tear and the nominal plate thickness shall also be not less than the minimum calculated thickness and the under-tolerance as allowed in material specification and in addition the thinning allowance as aforesaid and the minimum actual thickness of the finished formed head shall be physically verified by the Inspecting Authority to ensure that it is not less than the required thickness, as explained above and such minimum actual thickness shall be indicated in the final certificate issued.3.2.6Connecting Joints or Nozzles and Manhole. - Connecting joints or nozzles and manhole shall be constructed in accordance with the applicable design and fabrication code.3.2.7Baffle Plates. - Every vessel over 5 cu.m water capacity shall be fitted with baffle plates to minimize the surge, the design of which should facilitate complete internal inspection and the baffle plates shall be provided as follows, namely: -i. Over 230 cms in length shall be provided with baffles, the number of which shall be such that the linear distance between any two adjacent baffles or between any tank head and the baffle nearest it, shall in no case exceed 150 cms;ii. Each baffle shall have adequate strength to sustain without undue stress or any permanent set a horizontal force equal to the weight of so much of the contents of the tank as may come between it and any adjacent baffle or tank head, applied as a uniformly distributed load on the surface of the baffle or tank head and the baffles shall be formed with a curvature of 200 to 300 cms radius;iii. Each baffle shall have at least 2/3rd of the cross-sectional area of the tank and the baffles shall have suitable openings at top and bottom and the openings at bottom should allow access to the other side and the baffles shall be attached to the shell by means of suitably spaced cleats (min. 8 nos.) of minimum size 150 x 150 x 6 mm thick and the weld between baffle to cleat and cleat to the shell shall meet the applicable design code requirements And no vessel supports or baffle or baffle cleat shall be welded directly to the vessel and all such supports shall be attached by means of pad of the same material of which the vessel is made and the pad thickness shall not be less than 6 mm and shall not exceed the thickness of the shell material.iv. Each pad shall extend at least 4 times its thickness in each direction beyond the weld attaching the support and each pad shall be formed to an inside radius not greater than the outside radius of the vessel at the place of attachment and each pad corner shall be rounded to a radius of at least 1/4th width of the pad and not greater than ½ the width of the pad and the weep holes and tell-tale holes if used shall be drilled or punched before the pads are attached to the tank and each pad shall be attached to the tank by filler material having the properties conforming to the similar filler material used for welding of the vessel and the baffle shall be located away from SRV to facilitate ease of access for fitment / removal and safety of SRV.3.2.8Safety Appurtenances. - LPG tank truck is provided with them following openings or nozzles, namely: -(i)Safety Relief valves;(ii)Excess flow check valves in the liquid and vapour lines and pressure gauge nozzle;(iii)Pressure gauge (Provided in the vapour space of the vessel);(iv)Temperature gauge (Provided in the liquid space);(v)Roto-gauge (to measure the percentage of liquid in the vessel;(vi)Manhole with cover;(vii)Fixed level gauge;(viii)Drain point at the bottom; and(ix)Liquid or Vapour manifold3.2.8.1Safety Relief Valve (SRV). - Each tank truck is provided with two or more SRVs for providing the relieving capacity under excess pressure and the SRVs are mounted on the top surface of the vessel either in the recessed fittings or at the shell level with head projecting out and in the event of an accident causing the tank truck to fall off the road and topple, there is a possibility that Safety Relief Valves which projects out can hit against a hard surface and get damaged or even come out of the nozzles as adequate protection as envisaged in the rules has not been provided and to prevent this from happening, the following measures shall be adopted, namely: -i. The SRV of an LPG tank truck shall be provided in a recessed cup formation and alternatively, it may be equally protected by providing a guard all rounds as per the CCE approved procedure for modification;ii. SRV shall be replaced by a new SRV every ten years and if found defective during any of the earlier yearly inspections, it shall be replaced earlier;iii. Unstamped (Uncertified) SRVs shall not be used;iv. At the time of yearly inspection or each opening, the threads of the valve and coupling shall be checked by an Inspection Agency or Competent Person using "Go" or "No Go" gauges and SRV shall be tightened to the required torque specified for its size so as to obtain minimum engagement of 5-6 threads by hand tightening and another 1-2 threads by spanner tightening and LPG tank trucks shall carry SRV certificates issued by Inspection Agency or Competent Persons which apart from test date and set pressures shall also include the following information: -(a)The number of threads engaged in its coupling;(b)The number of threads outside its coupling;(c)Torque applied for tightening; and(d)Identification mark of SRVs3.2.8.2Internal Excess Flow Check Valves (IEFCVs.). - i. Each liquid or vapour pipeline and pressure gauge nozzle shall be provided with internal excess flow check valve duly type approved by PESO;ii. IEFCVs before fitment, shall be checked using "Go" or "No Go", gauges and shall be tightened to the required torque specified for the size to obtain minimum engagement of 5-6 threads through hand tightening and another 1-2 threads by spanner tightening;iii. IEFCV shall be examined for its proper operation along with SRV, once a year by competent person;iv. IEFCV shall be checked for its rated capacity every five years; andv. Each IEFCV shall be replaced by a new IEFCV every ten years and if found defective during operation or any of the earlier inspection, it shall be replaced at that time itself i.e., earlier than ten years.3.2.8.3Pressure Gauge. - The functional parts of EFCV of pressure gauge shall remain within its coupling and in addition, the pressure gauge should be provided with isolation valve with lock open arrangement.3.2.8.4Fixed Level Gauge or Drain Nozzles. - The fittings have been found to be redundant and to minimize the openings in the tanker, these fittings shall be plugged (After necessary amendment to the SMPV Rules, 1981) and such plugging shall be approved by Competent Persons or Inspection Agency.3.2.8.5Roto Gauge. - These fittings shall be housed in a recessed cup formation, when fitted on longitudinal sides of vessel to avoid any accidental damage to bleed valve or seal and the roto gauge shall also be protected with a provision of hinged cover of 5 mm thick plate.3.2.8.6Liquid or Vapour Piping. - The pipes shall conform to the ASTM A-106B, schedule 80 standards and liquid or vapour piping shall be single piece and the end flanges shall be of ASA-300 rating and metal jacketed gasket shall be used for the piping system and in addition, sturdy guard shall be provided between the propeller shaft and the elbow of the piping and adequately strong arrangement shall be provided to fix the piping rigidly to the bullet or chassis to minimize the effect of vibrations.3.2.8.7Height Barrier. - Whenever cabin height is less than the height of the vessel and fittings on top of it, a height barrier shall be provided all along the width of the cabin in the form of a cage either 50mm diameter pipe or 50 X 50 X 3 MM angle frame on the top of vessel and within the height regulation of Road Transport Authority (with whatsoever name it is called).3.2.8.8Mounting. - U-Bolts used for mounting of the pressure vessel on the chassis shall conform to ASTM 193 B7 and the nuts to A194 Gr.2H and the number and size of bolts should be as per the design requirements for the particular chassis and load thereon.3.2.9Other Considerations. - i. Openings for liquid and vapour low and pressure gauge and like other purposes in the truck shall be protected by suitable excess flow check valves mounted in the openings of the vessel and openings of less than 1.5 mm need not have such a valve;ii. Valves or accessories situated at the rear of a vehicle shall be protected by the rear cross member of the frame of the vehicle against damage;iii. All piping, fittings, pumps and meters permanently mounted on the vehicle shall be designed to withstand the most severe combined stresses imposed by the following, namely:(a)The maximum design pressure of the vessel;(b)The superimposed pressure of the shock loading caused by road movements;iv. All piping, fittings and equipment shall be adequately protected to minimize accidental damage which may be caused by road accidents or overturning and all trucks should be provided with suitable height barriers on the drivers cabin if the height of the bullet exceeds the cabin height;v. The engine and exhaust system together with all electrical generators, motors, batteries, switch gears and circuit breakers shall be efficiently screened from the vessel or the body of the vehicle by a fire-resisting shield or by enclosure within an approved fire resisting compartment;vi. When any of the safety appurtenances referred to in paragraph 3.3.8 is mounted forward of the rear of the driving cabin the cabin can be considered to act as an acceptable shield, provided the back, the roof and the floor of the cabin are of fire resisting construction for the full width of the cabin, without any openings in the back or roof, and that the back extends downwards to the top of the chassis;vii. When the cabin construction does not conform to the requirements mentioned clause (vi), a separate fire resistant shield should be installed extending upwards without any openings from the top of the chassis to the top of the vessel;viii. In any case where windows are provided in the shield, they should be fitted in fire-resistant framing with wired glass or other heat resistant material and shall not be capable of being opened;ix. When any of the safety appurtenances referred to in paragraph 3.3.8 is mounted to the rear of the cabin, it shall be contained wholly within an approved fire-resistant compartment;x. In any case where the fuel used to propel a vehicle gives off a flammable vapour at a temperature less than 65-degree C, the fuel tank shall not be behind the shield unless the following requirements are complied with, namely -(a)The fuel tank is protected from external blows by stout steel guards or by the under frames of the vehicle;(b)The fill pipe of the fuel tank of the vehicle is provided with:i. an arrangement facilitating breathing of the fuel tank and preventing spillage of fuel in the event of overturning of vehicle; andii. suitable locking arrangement;(c)The fuel-feed apparatus placed in front of the fire resisting shield is used to lift the contents of the fuel tank;xi. The fuel tank is protected by stout steel guards or by the frames of the vehicle;xii. The fill pipe of the fuel tank of the vehicle is provided with a cover having locking arrangements;xiii. Fuel feed apparatus placed in front of the fire-resisting shield is used to lift the contents of the fuel tank;xiv. The electrical systems shall have, as far as may be applicable, the same safety features as detailed in preceding clause;xv. Tyres shall be of the "anti-skid" type;xvi. There shall be a clear space of at least 15 cm. between the rear of the cabin and the front of the vessel;xvii. The rear of the vessel shall be protected by a robust steel bumper and such bumper shall be -(a)attached so that collision stresses will be transmitted to the frame work of the vehicle or, in the case of an articulated vehicle to the frame work carrying the wheels of the vessel;(b)situated at least 7.5 cm to the rear of the rearmost part of the vessel providing complete cover to the body; and(c)extended on each side of the vehicle to, at least, cover the maximum width of the vessel;xviii. The maximum weight of the liquefied gas for which the vehicle is designed should not exceed the difference in weight between the unladden weight of the vehicle and the maximum gross weight permitted for that class of vehicle under the applicable transport laws or CCOE licensed capacity; when such law is applicable;xix. The vessel shall be conspicuously marked to show the product which is being carried;xx. Two portable ISI marked 9 kg. DCP fire extinguishers shall be provided on each vehicle, one on each side and should be accessible from outside the cabin and another DCP extinguisher should be kept in the driver's cabin and all extinguishers (minimum 3 nos) should have the marking indicating next due date for pressure testing;xxi. Pressure relief valves shall be tested every year by competent person and certificates or records maintained and the functioning of excess flow check valves should also be checked once a year;xxii. All pressure gauges, level gauges and temperature gauges should be calibrated once a year;xxiii. Tank or bullet mounted on the chassis shall be hydrostatically tested every 5 years through competent person and Certificates or records maintained In this regard and if the chassis is not suitable for taking the load the tank or bullet should be removed and tested separately;xxiv. After maintenance or repair job the LPG tank trucks are to be purged by water displacement by LPG or inert gas;xxv. Driver of the vehicle should carry TREM card and route-map with detail locations and contact agencies in case of an emergency;xxvi. Checklists for Bulk LPG tank trucks are given in Annexure - I To Chapter IV of this Schedule; andxxvii. The spark arrestor shall be welded to the exhaust pipe of the prime movers or horse and spark arrester shall be of a type approved by the CCOE Any alternate spark elimination system duly approved by CCOE shall also be accepted e.g.in case exhaust of diesel engine is based on design having electronic fuel management with unit injectors and electronic control unit coupled with turbo charger and intercooler arrangement, no separate spark arrester to be provided.3.2.10Painting. - Vessel external surface shall be sand blasted and painted with two coats of red-oxide primer (as per IS: 2074 Part I) and two coats of enamel paint (as per IS: 2932 Part I), of the colour stipulated by statutory authorities.3.3Safety of Tank Trucks In Transit. - (i) Except for driving crew and oil companies officials during emergencies or leaks or accidents, no other person shall be carried on the tank truck;(ii)Vehicle shall be constantly attended by the driver or his assistant;(iii)The vehicle shall be halted at a safe place;(iv)Vehicle shall be equipped with Anti-lock Braking System (ABS) as per Central Motor Vehicle Rules,1989;(v)The vehicle should be parked with the consent of the Occupier in an open yard or enclosed premises subject to the Factories Act, 1947 (......of 1947);(vi)The driver should take all reasonable precaution to ensure that the vehicle is parked in safe environment;(vii)The driver of a vehicle carrying petroleum product shall be trained in the properties of the material carried, the handling method applicable to the grades being carried, in the use of the fire extinguishing equipment carried on the vehicle and in the emergency procedure to be followed and the training to drivers should be in line with syllabus under rule 9 of The Central Motor Vehicle Rules, 1989 and such training should be provided by any Government approved agencies for this purpose;(viii)All necessary steps shall be taken by the owner or loader of the vehicle to ensure that the driver is fully aware of, and understands, all instructions;(ix)As a precaution against any accident or emergency that may Occur during carriage, the driver shall be supplied with instructions in writing in the form of a safety instruction booklet;(x)The nature of the danger presented by the dangerous substances carried safety precaution to avert such nature of the danger shall positively be ensured;(xi)The appropriate action shall be taken and medical treatment shall be given in the event of persons coming in contact with the dangerous substances being carried or with any substances which might escape there from;(xii)The measures to be taken in case of fire and in particular the extinguishing methods or agents or groups of extinguishing methods or agents not to be used shall be ensured;(xiii)The measures to be taken in case of breakage or deterioration of packaging or spillage of the dangerous substances, particularly on the road shall be ensured;(xiv)The instructions relating to this paragraph should be in local language, Hindi and English;(xv)The system of Transport Emergency Cards (TREM) shall meet the requirements; and(xvi)The emergency kit to be carried with tank truck shall contain wooden wedges of various sizes, Teflon tapes, non-sparking tool, sealant compound, low temperatures gloves, goggles, threaded brass caps, first aid box, flameproof torch, gaskets, studs, and such equipment;3.4Labelling of Containers or Vehicles Carrying LPG. - i. To ensure that any package or truck carrying dangerous goods is recognized from a distance, the recommendations include a labelling system and the recommended labels are diamond shaped i.e. they are in the form of square (25 cm x 25 cm) set at an angle of 45 degrees and the upper half of the label is reserved for the pictorial symbol representing the nature of the risk, different symbols being provided for each of the classes and the number of the class or division should be shown in block in the bottom corner of the label unless the substance in question presents more than one risk and any other text inserted optionally in the lower half of the label should be printed in black and should be confined to particulars indicating the nature of the risk and precautions to be taken in handling;ii. Every goods carriage carrying any dangerous or hazardous goods shall display the class label both in front and in the rear in a conspicuous place;iii. Every goods carriage used for transporting any dangerous or hazardous goods shall be legibly and conspicuously marked with an emergency information panel;iv. The display on vehicles of the descriptive names or prescribed "correct technical names" at national and international level of the chemicals or petroleum products in letters not less than 50 mm high;v. The display on vehicle of special signs or plates denoting that dangerous goods are being conveyed or plates bearing special code numbers (HAZCHEM) which may identify the substances or reveal its hazardous property or indicate what action should be taken in emergencies;vi. The name and telephone numbers of the emergency services to be contacted in the event of any fire or any other accident in letters and numerals that are not less than 50 mm high and the name and telephone number of the consignor of the dangerous or hazardous goods or of some other person from whom expert information and advice can be obtained concerning the measures that should be taken in the event of an emergency involving such goods; andvii. Every class label and emergency information panel shall be marked on the goods, carriage as stipulated in the Motor Vehicle Rules, 1989 and shall be kept free and clean from instructions at all the times.3.4.1Marking. - Vessel Identification Plate:Each vessel shall have a non-corrosive metal plate permanently affixed by brazing or welding on the rear dished end in a place readily accessible for inspection and maintained legibly and neither the plate itself nor the means of attachment to the vessel may be subjected to impingement by the tank contents and the plate shall be plainly marked by stamping or embossing or by other means of forming letters to the metal of the plate with the following information in addition to that as required by local regulations, namely:(1)Vessel Manufacturer;(2)Chief Controller of Explosives (CCOE) approval number(3)Vessel Manufacturer's Serial No.;(4)Design code;(5)Radiography;(6)PWHT;(7)Design Pressure;(8)Design Temperature;(9)Hydrostatic test pressure;(10)First test date and subsequent test dates;(11)Water capacity in liters;(12)Licensed Product capacity in tons and symbol or chemical name;(13)Name of the Inspection Agency with their stamp;(14)Certificate number of Inspecting Agency in respect of -(a)Shell thickness; and(b)Dish End Thickness; and(15)Next hydrotest date of the vessel shall be painted on the body of the vessel.3.5Transportation By Rail. - Railway Administration, acting as a carrier of Petroleum Products, is exempted from taking any licence for transporting it under Petroleum Rules, 1976 and Railway Administration have elaborate rules for the carriage of petroleum by rail as provided in the,1989 (24 of 1989) Railways Act and Red Tariff No.19 of Indian Railways Conference Association.3.5.1Design Criterion. - All tank wagons used for the conveyance of petroleum products and LPG shall be of a design approved by RDSO and the design parameters for tank wagons used for transportation by rail are issued by the Wagon directorate, Research, Design, and Standards Organisation of Indian Railways.3.5.2Safety Appurtenances and other Safety Features. - i. Tank wagons for petroleum class A: These wagons are marked as "TP" as per Railway Code, except Hexane which is loaded in TH tank wagon;ii. Each tank wagon is provided with an effective pressure valve as per approved design;iii. All openings of fill pipe and dip pipe are provided with air tight caps;iv. A master valve set at the bottom inside the body with control from the top of tank wagon;v. A block valve at bottom of the wagon to which unloading hose is connected;vi. The top fittings are protected by a dome cover;vii. Tank wagons designed by RDSO are provided with safety valve with Discharge Capacity: 10.3 cum/sec;viii. All other fittings such as liquid valves, vapour valves, magnetic gauging device, thermowell, sample valve, safety valves and pressure gauges are provided on top of the pressure vessel in a protective housing known as 'dome' with a cover; andix. After repair or maintenance tank wagons are required to be purged with LPG or inert gases.
