Std-151

7/31/2019 Std-151

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OISD-STD-151

First EditionJULY, 1999

FOR RESTRICTEDCIRCULATION ONLY

SAFETY IN DESIGN, FABRICATION AND FITTINGS :PROPANE TANK TRUCKS

PREPARED BY

FUNCTIONAL COMMITTEE ON LPG

OIL INDUSTRY SAFETY DIRECTORATE2ND FLOOR, KAILASH26, KASTURBA GANDHI MARG

NEW DELHI - 110001.

NOTE

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OISD publications are prepared for use in the oil and gas industryunder the Ministry of Petroleum and Natural Gas. These are theproperty of Ministry of Petroleum & Natural Gas and shall not bereproduced or copied or loaned or exhibited to others withoutwritten consent from OISD.

Though every effort has been made to assure the accuracy andreliability of data contained in these documents, OISD herebyexpressly disclaims any liability or responsibility for loss or damageresulting from their use.

These documents are intended only to supplement and not replacethe prevailing statutory requirements.

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FOREWORD

The Oil Industry in India is more than 100 years old. Because of various collaborationagreements, a variety of international codes, standards and practices have been in vogue.Standardisation in design philosophies, operating and maintenance practices at a national level was

hardly in existence. This coupled with feed back from some serious accidents that occurred in therecent past in India and abroad emphasized the need for the Industry to review the existing state of artin designing, operating and maintaining Oil and Gas Installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a SafetyCouncil assisted by an Oil Industry Safety Directorate (OISD) staffed from within the Industry informulating and implementing a series of self regulatory measures and aimed at removingobsolescence, standardizing and updating the existing standards to ensure safer operations. Accordingly , OISD constituted a number of Functional Committees of Experts nominated from theIndustry to draw up standards and guidelines on various subjects.

The present document " Safety in design, fabrication and fittings : Propane Tank Trucks" wasprepared by the Functional Committee on LPG. This document is based on accumulated knowledge

and experience of Industry members, explosive department and various national and internationalpractices.

It is hoped that provision of these document when adopted will go a long way to improve thesafety in transportation of Propane Gas. This document will be reviewed periodically for improvementsbased on the new experiences and better understanding. Suggestions from industry Members may beaddressed to :

The Member Coordinator Functional Committee on LPG.Oil Industry Safety Directorate

26 "Kailash" 2nd floor,Kasturba Gandhi Marg,

NEW DELHI - 110001.

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LIST OF MEMBERS

SR.NO. NAME POSITION IN

COMMITTEE

1. R. N. DAS BPCL LEADER

2. S.C. MESHRAM IOCL MEMBER

3. S.S.MUNDLE HPCL MEMBER

4. A.N. BISWAS Dept of Explosive MEMBER

5 S.C.GUPTA OISD MEMBER

6. S.K. PAL OISD MEMBERCO-ORDINATOR

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OISD STANDARD -151


I N D E X

SECTION I : INTRODUCTION & SCOPE

SECTION II : VESSEL DESIGN

SECTION III : VALVES AND ACCESSORIES

SECTION IV : VESSEL FILLING CONSIDERATIONS

SECTION V : VEHICLES - GENERAL SAFETY CONSIDERATIONS

SECTION VI : PRE-FABRICATION AND INSPECTION REQUIREMENTSDURING FABRICATION

SECTION VII : PERIODIC TESTING AND INSPECTION

ANNEXURES I - CERTIFICATE OF SAFETY FOR FIRST STAGEINSPECTION AFTER FABRICATION

II - LEVER OPERATED INTERNAL VALVES

III - TYPICAL DRAWING OF PROPANE TANK TRUCK

IV - TYPICAL ARRANGEMENT OF RELIEF VALVE

V - SCHEDULE OF NOZZLE

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1.0.0 SECTION I:INTRODUCTION & SCOPE

1.1.0 INTRODUCTION:

1.1.1 In view of envisaged growth in Propanein commercial & industrial use in thecountry a need was felt to standardisedesign of bulk PROPANE tank trucks.This standard has been prepared by aFunctional Committee comprising of

representatives of Oil Industry, Dept. of Explosives (Govt. of India) andConsultants, constituted for standardisation of the design of bulletsalong with material specifications,fittings, mounting etc for transportationof PROPANE in bulk by road.

This standard has been formulatedbased on various engineering codes,standards

1.1.2 Notwithstanding above, all Propanetank trucks should meet therequirements of the Motor Vehicle Actsand Regulations and Static & MobilePressure Vessels (Unfired) Rules,1981 as amended from time to time.

1.2.0 SCOPE:

1.2.1 This standard covers basic requirementsof safety in design / fabrication of vessels with material specifications,fittings and mountings, for transportationof commercial Propane conforming toIS: 4576 - 1978 with Maximum vapour pressure at 65 deg. C not exceeding 26kg./cm sq. or 15.5 kg./cm sq. at 40 Deg.C. in bulk by road tank trucks. TheStandard is under revision and will beapplicable for all new Propane tanktrucks..

1.2.2 A single code shall be adopted for materials, fabrication, inspectionand testing.

2.0.0 SECTION II

2.1.0 VESSEL DESIGN:

2.1.1 Design Pressure:

Vessel should be designed based oncorresponding maximum vapour pressure at 55 deg. C of Propane (asper IS : 4576). 3g effect to take intoaccount acceleration/ deceleration shallbe considered while designing of thevessel.

2.1.2 Design Temperature:

The design temperature of the vesselshall be in line with the specification of Propane and as per requirementsstipulated by statutory authorities.

2.1.3 Vessel Design Code:

a) Vessel shall be designed, fabricated

and tested in accordance withrequirements of Class I pressurevessels conforming to IS:2825 (LatestEdition) BS-7124, ASME SEC. VIII or equivalent codes accepted by Statutory Authority. The vessel shall bedesigned to withstand shocks normallyencountered during transport includingthose set up by the movement of thecontents of the vessel such asacceleration / deceleration of aminimum of 3g to be calculatedconsidering that the vessel 95% liquid

full with propane at 55 deg. C. Saddlesupports and other attachments shallalso be designed according to thefabrication code.

b) Joints:

Joints shall be as required by the codewith all undercutting in shell and headmaterial fabricated as specified therein.

All longitudinal shell welds shall belocated in upper half of the vessel andshall be staggered when assemblingthe cylindrical shell from two parts bymeans of a circumferential joint. The

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distance between two such staggered joints shall be at least 5 times thethickness of the thicker plate or asspecified by code as adopted for design & fabrication

2.1.4 Material Specifications:

Material used in the manufacture of pressure parts of the vessel shall be inaccordance with that specified in IS:2825 (latest edition), BS-7124, ASMESEC. VIII or equivalent code asadopted.

2.1.5 Vessel Plate Thickness:

The nominal thickness of the platematerial used in fabrication shall not beless than the sum of minimumcalculated thickness as per thefabrication Code and 0.5 mm in lieu of corrosion allowance (CA), if necessaryand in addition, adequate thinningallowance in case of formed heads.

The nominal plate thickness shall alsobe not less than the minimumcalculated thickness and the under-

tolerance as allowed in materialspecification and in addition thethinning allowance as mentionedabove. The minimum actual thicknessof the finished-formed head shall bephysically verified by the Inspecting Authority to ensure that it is not lessthan the required thickness, asexplained above. This shall beindicated in the final certificate issued.

2.1.6 Connecting Joints/Nozzles andManhole:

Connecting joints / nozzles andmanhole shall be constructed inaccordance with the applicable designand fabrication code.

2.1.7 Baffle Plates:

Every vessel over 5 cum. water capacity shall be fitted with baffleplates to minimise the surge, thedesign of which should facilitatecomplete internal inspection.

Baffle plates shall be provided asfollows:

a) Over 230 cms in length shall beprovided with baffles, the number of which shall be such that the linear distance between any two adjacentbaffles or between any tank head

and the baffle nearest it shall in nocase exceed 150 cms.

b) Each baffle shall have adequatestrength to sustain without unduestress or any permanent set ahorizontal force equal to the weightof so much of the contents of thetank as may come between it andany adjacent baffle or tank head,applied as a uniformly distributedload on the surface of the baffle or tank head. Baffles shall be formed

with a curvature of 200 to 300 cmsradius.

c) Each baffle shall have at least 2/3rd

of the cross-sectional area of thetank. Baffles shall have suitableopenings at top and bottom,Openings at bottom should allowaccess to the other side. Bafflesshall be attached to the shell bymeans of suitably spaced cleats(min. 8 nos.) of minimum size 150 x150 x 6 mm thick. The weld

between baffle to cleat and cleat tothe shell shall meet the applicabledesign code requirements. Novessel supports or baffle or bafflecleat shall be welded directly to thevessel. All such supports shall beattached by means of pad of thesame material as the vessel. Thepad thickness shall not be less than6 mm and shall not exceed thethickness of the shell material.

Each pad shall extend atleast 4 times its

thickness in each direction beyond theweld attaching the support. Each padshall be formed to an inside radius notgreater than the outside radius of thevessel at the place of attachment. Eachpad corner shall be rounded to a radiusof at least 1/4th width of the pad and notgreater than ½ the width of the pad.Weep holes and telltale holes if usedshall be drilled or punched before thepads are attached to the tank. Eachpad shall be attached to the tank by filler material having the propertiesconforming to the similar filler materialused for welding of the vessel.

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Baffle shall be located away from SRVto facilitate ease of access for fitment /removal and safety of SRV.

2.1.8. Painting:

The external surface of the vessel shallbe prepared properly before painting. Itshall be painted with two coats of red-oxide primer and two coats of enamelpaint of the colour stipulated bystatutory authorities.

2.1.9 Marking:

Vessel Identification Plate:

Each vessel shall have a non-corrosivemetal plate permanently affixed by

brazing or welding on the rear dishedend in a place readily accessible for inspection and maintained legibly.Neither the plate itself nor the means of attachment to the vessel may besubjected to impingement by the tankcontents. The plate shall be plainlymarked by stamping or embossing or by other means of forming letters to themetal of the plate with the followinginformation in addition to that asrequired by local regulations:

1. Vessel Manufacturer 2. Vessel Manufacturer’s SerialNo.

3. Design code4. Radiography5. PWHT6. Design Pressure7. Design Temperature8. Hydrostatic test pressure9. First test date and subsequent

test dates10. Water capacity in litres11. Licensed Product capacity in

tonne and symbol or chemicalname.12. Name of the Inspection

Agency with their stamp.

13. Certificate number of

Inspecting Agency.

14. a) Shell thicknessb) Dish End Thickness

15. Next hydrotest date of the

vessel shall be painted on thebody of the vessel.

3.0.0 SECTION - III

3.1.0 Valves and Accessories:

The pipes, fittings and other

equipments mounted on the vesselshall be suitable for Propane servicei.e. corresponding to Vapour Pressureof Propane at 55 deg.C. and shall becapable of withstanding the mostsevere combined stresses set up bythe following:

a) Maximum vapour pressureof the product in service.b) Superimposed pumping

pressure.c) The shock loading during

transport movements.

3.2.0 Fittings:

Fittings to be provided on the vesselshall be as follows:

3.2.1 Safety Relief Valve:

There shall be minimum two safetyrelief valves with each one sized to suitthe full relieving capacity of the vessel.The design and operation of SafetyRelief Valves shall conform to the

provision of SMPV rules as amendedfrom time to time.

SRV shall be so installed that it doesnot project out of the top surface of thevessel. If necessary, recessed cupformation on vessel shall be made tohouse the SRV. (Refer OISD Std. 160).

3.2.2 The safety relief valves shall beinstalled at the top surface around thecentral portion of the vessel.

3.2.3 Safety relief valves shall have

following marking punched:

a) Manufacturer’s name andSerial No.

b) Set Pressurec) Rate of discharge in cum. per

minute of the gas at 15 deg. C.and at atmospheric pressure.

d) Date of first teste) Name of the Inspecting

Agency with their stamp.

3.3.0 Liquid / Vapour Connections:

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3.3.1 1 no. 50 mm size liquid inlet / outletand 1 no. 40 mm size vapour connection shall be provided at thebottom of the vessel. The vapour lineshall extend internally with a clearanceof 50 mm from the top of the vessel

surface. However, vessel capacityexceeding 30 Cu.M may be providedwith additional 1 no. 50 mm liquid inlet /outlet with internal valve.

3.4.0 Internal Valve with Excess FlowCheck Valve:

Internal valves with EFCV of appropriate ratings shall be installed onPropane liquid and vapour line. `Builtin’ internal valve shall be remotely

operable from drivers cabin/rear end of vehicle manually or pneumatically witha lever through a cable systemextending to driver’s cabin and fittedwith a thermal fuse link. This valveshall have an in-built internal excessflow check valve. (Refer Annexure II).

3.5.0 Liquid Level Gauging Device -Roto Gauge:

3.5.1 The vessel shall be equipped with aliquid level-gauging device for ready

determination of liquid level in thevessel at any time. The liquid levelgauging device shall be of the directlevel gauge type with zero leakage of product to atmosphere. The designshall be such that the unitencompasses a tough, durable steelshock absorber to prevent transfer of any vibrations sustained in transit.

3.5.2 This liquid level gauging device shallbe located on the shell near themidpoint /top upper half of the vessel in

a recessed cup formation.

3.5.3 To avoid damage to this liquid levelgauging device, a suitable hingedcover shall be provided.

3.6.0 Liquid Level Gauging Device:Maximum Level Indicator:

Suitable fixed level indicator shall beprovided.

3.7.0 Pressure Gauge:

3.7.1 1 no. dial type (100 mm) glycerine filled

pressure gauge with EFCV shall beprovided on the rear dished end in thevapour space. This shall be protectedby 10 mm thickness U-type shieldmetal plate.

3.7.2 The range of the pressure gaugeshall be from zero to 30 kg/sq. cm(min.) gauge.

3.8.0 Drain:

Suitable drain of maximum 40 mm NPTplug to be provided on the bottom sideof vessel with proper shield.

3.9.0 Manholes:

1 no. manhole of size as per IS 2825 or code followed for design andfabrication of vessel shall be providedon the upper rear dished at 45 deg.with the horizontal axis of the vessel.

3.10.0 Protection of Fittings:

a) All valves, fittings, safety relief devicesand other accessories to the vesselproper shall be protected against suchdamage as could be caused by

collision with other vehicles or objectsand due to overturning.

b) The protective devices or housing mustbe designed to withstand static loadingin any direction equal to twice theweight of the tank and attachmentswhen filled with the lading, using asafety factor of not less than 4 basedon the ultimate strength of the materialto be used without damage to thefittings protected, and must be made of metal at least 5 mm thick.

4.0.0 SECTION - IV

VESSEL FILLING CONSIDERATIONS :

4.1.0 Filling Capacity:

The maximum quantity of Propanefilled into any tank shall be such thatthe vessel shall not become liquid fulldue to the expansion of Propane andshall leave a vapour space equivalentto 5% or as stipulated by Statutory

authority of its volume with the rise of temperature of its contents to a

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maximum of 55 deg. C.

4.2.0 To arrive at the filling capacity, themaximum filling densities at 15 deg. C.for Propane (as per IS:4576) shall becalculated and effected by loadingbases as per IS:3710.

The RLW of the vehicle shall notexceed the authorised RegisteredWeight of the vehicle by the concernedtransport authority or chassismanufacturer, whichever is less. ThePayLoad filled should not exceed thelicensed capacity as permitted by thestatutory authority.

SECTION - V

5.0.0 VEHICLES - GENERAL SAFETY

CONSIDERATIONS:

5.1.0 General Safety Considerations:

5.1.1 Each tank truck shall be provided withat least one rear robust bumper,designed to protect the vessel andpiping in the event of a rear-endcollision and minimise the possibility of any part of the colliding vehicle strikingthe vessel. The design shall be suchas to transmit the force of a rear endcollision in a horizontal line to the

chassis of the vehicle. The bumper shall be designed to withstand theimpact of the fully loaded vehicle with adeceleration of 2 “g” using a safetyfactor of 4 based on the ultimatestrength of the bumper material.

5.1.2 Extension to chassis if any shall not bemore than 300 mm.

5.1.3 The maximum width and height of vessel and its service equipment shallbe such that these do not project

beyond the overall width and height of the rest of the vehicle. The max. heightof the vehicle shall be in accordancewith Motor Vehicles Act, 1989 asamended from time to time.

Each vessel shall be provided with aheight barrier and designed asstipulated in OISD Std. 160.

5.2.0 Stability Considerations:

Provided the distance from the centreof the vessel to the road surface is lessthan the distance between the centre of

the outer wheels of the rear axle thenthe tank truck will be reasonably stable.This is also essential in order to ensuremaximum stability especially where thetank truck is to operate in areas wherethere are numerous hurdles and the

roads are bad. In accordance with IS :9618, 1969 (latest) the ratio of H/Wshall be kept less than 1. (where `H’ isthe height of the centre of gravity of thevessel from the road level and `W’ isthe distance between the centre of theouter tyres of the rear axle).

5.3.0 Safety Equipment:

5.3.1 The vehicles shall carry the following:

a) A First Aid box.b) 2 nos. 10 Kg DCP (ISI marked)

and 1 no. 2 Kg CO2 fireextinguishers (ISI marked).Periodicity of testing to befollowed as per OISD Std. 142.

c) Low temperature hand glovessuitable for propane and heatresistant hand gloves.

d) Safety Gogglese) 2 nos. red flags

The above equipment should be ingood working condition.

In addition, each vehicle must carrynon-metallic tools, wooden plugs of appropriate size and sealing compoundfor any emergency.

5.3.2 An emergency information boardshould be displayed on the vehiclementioning the important telephonenos. of contractor, Oil company’sloading base, attached Bottling Plantsand easier contact nos. in the event of accident in addition to other detailsenumerated as above (Ref. OISD Std.

161).

5.4.0 Mountings:

5.4.1 Vessel should be securely attached tothe chassis.

5.4.2 It is recommended to adopt the designof the mountings / drawings asrecommended by the manufacturers of the chassis.

5.5.0 Design Safety Requirements -

Mechanical:

5.5.1 Where the fuel system is gravity-fed, a

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quick action cut-off valve shall be fittedto the fuel feed pipe in an easilyaccessible and clearly marked position.

5.5.2 The engine and exhaust systemtogether with all electrical generators,

motors, batteries, switch-gears, andfuses shall be efficiently screened fromthe vessel or the body of the vehicle bya fire-resistant shield or by anenclosure within an approved fireresistant compartment. All vehiclescarrying Propane should be equippedwith a spark arrestor of approveddesign from approved manufacturer. As per Static and Mobile PressureVessel Rules 1981 and PetroleumRules 1976, the exhaust of all suchvehicles is required to be routed on the

front side of the vehicle. The exhaustis to be fitted with an approved sparkarrestor.

5.5.3 When the equipment referred to in

Clauses 5.5.1 & 5.5.2 are mountedforward of driving cab, the cab can beconsidered to act as an acceptableshield, provided the back, the roof andthe floor of the cab, are of fire-resistingtype construction for the full width of the cab, without any openings in theback or roof, and that the back extends

downwards to the top of the chassis.For rear view, in case of trailers,toughened reinforced glass may beprovided.

5.5.4 When the equipment referred to inclauses 5.4.1 & 5.4.2 are mounted tothe rear of the cab, it shall be containedwholly within an approved fire-resistingcompartment.

5.5.5 In such cases where the fuel used topropel a vehicle gives off a flammable

vapour at a temperature less than 65deg. C, the fuel tank shall not bemounted behind the shield unless thefollowing requirements are compliedwith namely,

a) the fuel tank is protected fromexternal blows by stout steelguards or by the under framesof 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 andpreventing spillage of fuel in the event of over turning of vehicleand

ii) suitable lockingarrangement.

c) the fuel-feed apparatus placedin front of the fire-resistingshield is used to lift thecontents of the fuel tank.

5.5.6 The cabin shall be painted with color scheme as stipulated by the Transport Authority.

5.5.7 The overall height of the vessel shall

not exceed the height of the driver cabin including the height barrier if any.

5.6.0 Design Safety Requirements -Electrical:

The following requirements shall becomplied with in connection with theelectrical and anti-static properties of the vehicle, namely:

a) The electrical system:

i) The battery shall bemounted inside thecabin within a metalliccover with openings inan easily accessibleposition.

ii) A readily accessiblecut-off switch of notless than 300 Ampsrating.

iii) Electrical wiring shall

be heavily insulatedand be adequate for maximum currentloads to be carried.Electrical wirings shallbe provided withsuitable over currentprotection in the formof fuses or automaticcircuit-breakers andinstalled so as to beprotected fromphysical and chemical

damage on contactwith possible product

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spill either at locationor on road beingencased in the metalconduit.

iv) Have all junction

boxes sealed.

v) Normal/emergencylighting other than thatpermitted by theTransport Authorityshall not be allowed.

b) Earthing boss on the saddle of the vessel shall be provided onboth sides.

c) The vehicle should carry

minimum six reflector coneshaving base of 300mm dia andheight of 750 mm. Thesecones should be used for marking out the area wheretruck is parked or in the eventof an accident segregating itfrom other portion of the road.

6.0.0 SECTION - VI

6.1.0 PRE-FABRICATION ANDINSPECTION REQUIREMENTSDURING FABRICATION:

6.1.1 The inspection shall be in twostages:

a) The first stage inspection shallconstitute of completeinspection from design stage tocomplete fabrication and testas per appropriate codeincluding material identification

and the final hydro-test as per Annexure-I. However, anyadditional information requiredby statutory authorities may beincorporated in the Annexurefor issuing the licence.

b) The second stage inspectionwould be carried out by acompetent person recognisedby statutory authorities. Thecompetent person shall checkthe vehicle for overallconformity to the standard andissue the certificate of safety

as per SMPV Rules.

6.1.2 Vessel should be fabricated by theparty approved by Statutory Authoritiesaccording to design as per SMPVRules and IS : 2825 or equivalent as

approved by Statutory Authorities.Fabrication shall progress under stagewise inspection by an independentInspecting Agency (approved byStatutory authorities). Stage Inspectionshould include the following:

a) Appraisal of the design anddrawing.

b) Appraisal of fabricationprocedure.

c) Qualification of weldingprocedure and performances.

d) Identification of Raw Materialsto the specification and sizeeg. plates/forging/ couplingstuds etc.

e) Counter testing of thematerials and matching withoriginal Test Certificates. Inother words, Inspection agencyshall be involved duringmanufacturing of thecomponents at componentmanufacturer’s premises.

f) Inspection of weld set ups in

accordance with the fabricationcodes.

g) Witnessing of NDT tests i.e.Radiography, LiquidPenetration test, Ultra SonicFlaw detection.

h) Inspection of formed heads.i) Witnessing of destructive

testing. j) Witnessing of stress relieving.k) Final visual inspection and

dimensional checks.l) After satisfying the above,

hydrotest to be carried out atthe required test pressure for min. 30 minutes.

m) Stamping the vessel on apermanently welded plate asmark of certification.

n) Documentation andCertification.

6.2.0 Mounting and Inspection:

6.2.1 Mounting drawing of the vehicle shallbe approved by Statutory authority.

The drawing should clearly specify themake and model of the vehicle

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alongwith fabrication drawing of thevessel. It should also specify the loaddistribution on the various axles, centreof gravity and stability ratio in bothladen and unladen conditions. Thedrawing shall have a general assembly

drawing indicating all the major dimensions and the positions of thevarious fittings and all accessories.

6.2.2 The vessel should be securelymounted as per the approved drawingspecified in 6.2.1. After mounting all thefittings on the vessel, the vessel shallbe leak-tested with water andsubsequently pneumatically by arecognised competent person at thepressures based on the vapour pressure of the Propane. During

leakage test with water the chassisshall be adequately supported to avoidpossible damage to the under carriage.Pneumatic testing shall beaccompanied by soap bubble test.

6.2.3 After satisfying the test as stated aboveand ensuring conformity of the vesseland the vehicle in terms of mountingdrawing, the competent person shallissue certificate of safety in thespecified format as per SMPV Rules,1981.

6.3.0 Purging:

After completion of hydro and pneumatictests, the bullet shall be purged safelywith nitrogen & Propane Vapour respectively.

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7.0.0 SECTION - VII

7.1.0 PERIODIC TESTING & INSPECTION:

The inspection and testing of service vessels and its accessories shall be carried out by theparties approved by Statutory Authorities as per the following schedule:

EQUIPMENT DETAILS OF CHECKS/ PERIODICITY

TESTING

1. Vessel a) Non-destructive test Once in 5 yrs(NDT)

b) Hydrotest at original Once in 5 yrstest pressure, internal and

external detailed inspection.c) Condition of external Once in 2 yrs

painting.

2. Safety Relief Set pressure As stipulated by ValveStatutory authorities

3. Internal Valves a) Condition of valve Once in 1 yr b) Checking on working of EFCV Once in 1 yr

4. Liquid Level Condition of gauge/ Once in 5 yrsGauges proper functioning &

calibration.

5. Pressure Accuracy within Once in 1 yr

Gauges original range

6. Vehicles in Overall check on the Once in 6 monthsGeneral general condition of

the vehicle.(visual inspection )

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ANNEXURE - I

CERTIFICATE OF SAFETY

(Under rule 43 of SMPV (U) RULES)

CERTIFICATE NO .

DATE

VALID UPTO :

NAME OF COMPETENT PERSON :

REGISTRATION NO:

I hereby certify that the compressed gas transport vehicle of M/S ---------------------- having theparticulars noted below has been examined by me and found to meet the requirements of the standards

for bulk PROPANE tank trucks in the Indian petroleum industry.1. NO. AND DATE OF APPROVAL BY CCOE :

i) Fabrication drawingii) Mounting

2. VEHICLE REGISTRATION DETAILS:

Registration No.Make and ModelEngine NoChassis NoUnladen weight ULW in kg

Maximum laden weight RLW in kgas certified by RTA

Recheck on Unladen weight : Witnessed on ………………….at-------

ULW as witnessed above : …………………………….

3. PRESSURE VESSELS:

Identification No.Fabricator’s NameDesign CodeDesign PressureDesign Temperature

Water CapacityName of the gasFirst stage hydraulic test pressureas per IS:2825 : kg/sq.cm g

Name of Inspecting agency who conducted

First stage test :

Particulars of Inspection Certificates:

a) External condition of painting :

b) Internal visual inspection of vessel done : Yes/No

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c) Details of foreign matter like dirt/sludge

inside the vessel (Please specify) :

d) Second stage Hydraulic Test Pressure( to ensure tightness of fittings minimum 12 kg./sq.cm.):

e) Second stage Hydraulic Test date :

f) Witnessed by :

g) Pneumatic test pressure after installation

of fittings (6 Kg/sq.cm.g) :

h) Pneumatic test date :

i) Witnessed by :

j) Any leaks in the above tests ? : Yes/No

4. VALVES AND ACCESSORIES :

A) SAFETY RELIEF VALVE Safety valve identification No.MakeFitted with vessel no.Mounted on Vehicle no .SizeSet pressure ,Kg/cm2g :Discharge flow rate ,Nm3/Hr :

Calculations for size and flow rate checked : Yes/NoTested on:Tested at (place ) :Test Pressure :(To be checked by Competent Authority )

Does valve open at set pressure ? : Yes/NoIs any leakage observed after reseating ? : Yes/No Are size and flow rate adequate for the vessel ?: Yes/No

Inspection mark on the safety relief valve been

complied with ? (To be embossed by competent : Yes/No

person after SRV test )

B) LIQUID/VAPOUR CONNECTIONS:

Are seamless Pipe used as per code? : Yes/NoSingle piece line used between fittigs? : Yes/NoMethod of securing vessel to chassis :Shortest distance of drive shaft to centre of pipelines .

Shortest distance of rear wheels from centre of pipelines .

Are liquid/vapour connections in a protective enclosure ? : Yes/No

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C INTERNAL VALVE:

Valve no for liquid and vapour :

Location and type :

Make :

Size :

Closing flow ,Nm3/Hr :

Date of last test :

Whether size and closing flow rate adequate : Yes/No

Whether remote operated levers provided with

thermal fuselink: Yes/No

D. LIQUID LEVEL GAUGE :

Type:

Make:

Whether in working condition: Yes/No

E. PRESSURE GAUGE :

Pressure range :

Whether excess flow valve provided :

Particulars thereof :

F. DRAIN NOZZLE :

Location and size :Whether fitted with plug :

5. VEHICLE DESIGN PARTICULARS:

Fire resisting shield : Yes/No

Fuel tank with spillage proof cap. capacity of fuel : Yes/Notank:...... litres.

Has the capacity been changed after original : Yes/Nocertification ?If yes, is the new tank of safe design and with : Yes/Nospillage proof cap ?

*Overturn spill protection

Whether transfer pump driven by engine of vehicle : Yes/Noprovided. If yes, whether provision for stoppingengine from outside made.

Battery and cut-off switch (Nature, capacity & : Yes/Nolocation)

Whether the switch is readily accessible.

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Particulars of wiring : Yes/NoWhether properly fixed and protected and wiringheavy insulated type.

Whether non-conduited and protected suitably from : Yes/Nophysical and chemical damage.

Earthing wire/reel assembly with strong flexible cable : Yes/Nofor electrical bonding atleast 5 m long and with suitablecrocodile clip at end, provided.Whether earthing boss provided : Yes/No

Electrical wiring particulars:

Whether all junction boxes are sealed : Yes/No

Gap between cabin and vessel to be min. 150 mm : Yes/NoClearance between end of vessel and end of rear : Yes/Nobumper is 75 mm min.

Whether the gaps are as per as-built drawing. : Yes/No

Details of rear bumper : Length..... Width....... Height.....Type of section is:Is above design adequate to protect vessel against : Yes/Norear end collision ?

Fastening of vessel with chassis. Particulars of : Yes/Nofastening bolts and padding (if any) with remarksas to whether secured well to the chassis.

Is above fastening designed to withstand severe : Yes/No

combined stress set up while the vehicle is inmotion ?

Is above as per chassis manufacturers : Yes/Norecommendations

Whether chassis is extended - : Yes/No

a) If yes, the length extendedb) Nature of connection to the chassisc) Condition of chassis and fittings -

Note: No welding/drilling of chassis other than specified

by chassis manufacturer is permissible.

Manhole diameter - : Yes/NoNature of protection cover over manhole, thicknessdiameter & height. (Manhole cover or flange)

Particulars of fire extinguishers provided :

Height and type of barrier on top of driver’s cabin,:if provided.

Condition of tyres: Front Rear Left Right Left Right

Size

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Is ply rating as per manufacturer’s recommendations : Yes/No

Stability :Height of C.G. of laden :Vehicle from ground level :Stability ratio :

Calculations for stability ratio checked : Yes/No

6. RECORD OF CHANGES MADE DURING VALIDITYOF THE CERTIFICATE:

SIGNATURE OF COMPTENT PERSON

PLACE

DATE

NOTE:

This certificate is being issued as part of the rigorous safety requirements for bulk PROPANE tank trucks asper the standards of Indian Petroleum Industry and meets the approval of Chief Controller of Explosives,Nagpur. No attachments / modifications / changes of fittings shall be done when the bulk PROPANEtruck is in service during the period of validity of this certificate without prior written permission from thecomptent person. Any such change shall be recertified. Violation of above may lead to withdrawal of Certificate of Safety.

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ANNEUXRE - II

INTERNAL VALVE WITH EXCESS FLOW CHECK VALVE

• Manually operated stem positively connected to valve stem so operator knows if valves is closed.

• Manually operated - spring loaded to automatically return to closed position.

• All springs and controls designed within body of valve for protection of parts and to provide a clean,smooth, easy operative valve.

• Emergency opening of valve provided to allow the valve stem to engage the excess flow chekc disc soit can be partially lifted manually for emergency evacuation of container product.

The valve can be arranged for automatic closing through operation of feasible elements (fire exposure) andfor remote manual closing.

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ANNEXURE - III

INTERNAL TYPE SAFETY RELIEF VALVE

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ANNEXURE IV

SCHEDULE OF NOZZLE

Service Quantity Size Remarks

Manhole 1 450 mm With cover

Safety Relief Valve 2 50 mm With full relievingcapacity

Liquid inlet/outlet 1 50 mm EFCV with internal valveremote operated.

Vapour connection 1 40 mm With EFCV

Drain 1 40 mm With plug and shield.

Rotogauge 1 25 mm

Pressure gauge 1 25 mm With EFCV and cover

Fix level gauge 1 6 mm

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Std-151

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