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: ..16:1

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.. 16 (1024) -

(23.020.30).. 16 (1067) 1

[ 6044 1] ( 75.200)

.. 16 (1068) (43.060.40)

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: 15-10-2009

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Ref: ME 16:2/T-43,16 :3/T-45

16 :3/T-38

12-08-2009

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Please correspond at: Phone / Fax: 011-23232509 E-mail: vtomer@bis.org.in /med@bis.org.in

Gas Cylinders, Sectional Committee, ME 16

TO:

a) The interested members of Mechanical Engineering Division Council, MEDCb) All members of Gas Cylinders Sectional Committee, ME 16, Low Pressure Gas Cylinders Subcommittee,

ME 16:2

and Dissolved Acetylene Cylinders, Generators, Acetylene Pipe lines and High Pressure Gas Cylinders

Subcommittee,e, ME 16:3

c) All others Interested

Dear Sirs,

Please find enclosed the following document:

Doc. No. TITLE

Doc: ME 16(1024) Draft Indian Standard Procedure for checking before during and after filling of refillable welded steel

cylinder for liquefied petroleum gas (LPG) (ICS 23.020.30)

Doc: ME 16(1067) Draft Indian Standard Code of practice for liquefied petroleum gas storage installations Part 1

Commercial and industrial cylinder installations [second revision of IS 6044(Part 1)] (ICS 75.200)

ME 16 (1068) Draft Indian Standard Gaseous hydrogen and hydrogen blends Land vehicle fuel tanks

(ICS 43.060.40)

Kindly examine the Draft Standard and forward your views stating any difficulties which you are likely to experience inyour business or profession, if this is finally adopted.

Last date for receipt of comments: 15 October 2009.

Comments, if any, may please be made in the format as given overleaf and mailed to the undersigned atthe above address.

In case no comments are received or comments received are of editorial nature, you will kindly permit us to presume yourapproval for the above document as finalized. However, in case of comments of technical in nature are received then it may be

finalized either in consultation with the Chairman, Sectional Committee or referred to the Sectional committee for further

necessary action if so desired by the Chairman, Sectional Committee.

This document is hosted on BIS website: www.bis.org.in.

Thanking you,

Yours faithfully

(C.K. Veda)

Encl: As above Scientist F & Head (Mech Engg)

NOTE-WHERE PRINCIPAL AND ALTERNATE MEMBERS OF AN ORGANISATION ARE FROM THE SAME

STATION, ONE COPY OF THE DOCUMENT IS SENT ONLY TO THE PRINCIPAL MEMBER WHO MAY

KINDLY SHARE THIS WITH HIS ALTERNATE AS WELL.

DRAFT STANDARD IN

WIDE CIRCULATION

DOCUMENT DESPATCH ADVICE

Ref: ME 16:2/T-43,16 :3/T-45 Date: 12-08-2009

16 :3/T-38

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For Comments Only

Draft Indian StandardCODE OF PRACTICE FOR LIQUEFIED PETROLEUM GAS

STORAGE INSTALLATIONSPART 1 COMMERCIAL AND INDUSTRIAL CYLINDER INSTALLATIONS

(Second Revision)

ICS 75.200_________________________________________________________________________Not to be reproduced without the permission of Last date for receipt ofBIS or used as a STANDARD comments is: 15 October 2009_________________________________________________________________________

FOREWORD

Adoption clause will be added later on.

This standard was first published in 1971 and subsequently revised in 2000. In thisrevision scope has been enlarged to include the liquid withdrawal from the cylinder.New clauses for point of delivery, maintenance and handling & use have beenadded.

Cylinder location, cylinder manifolds, pressure regulators and piping, tubes andfittings have been modified. A new Annex A has been added to include requirementsof liquid off take valve multi cylinder installation.

For the purpose of deciding whether a particular requirement of this standard iscomplied with, the final value, observed or calculated, expressing the result of a testor analysis, shall be rounded off in accordance with IS 2:1960 Rules for rounding off

numerical values ( revised). The number of significant places retained in therounded off value should be the same as that of the specified value in this standard.

1 SCOPE

1.1 This standard (Part 1) lays down the code of practice for the installations of LPGcylinders (both for liquid and vapour withdrawal from cylinders), piping andequipment in commercial and industrial premises.

1.2 This code also applies to installations in commercial, industrial, educational,institutional premises and domestic/ residential complexes installations includingwherever cylinder manifold is provided for liquid or vapour withdrawl. The specificrequirements for installation of Liquid Off take valves are covered in Annex A.

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2 REFERENCES

The following Indian Standards contain provisions which, through reference in thistext, constitute provisions of this standard. At the time of publication the editionsindicated were valid. All standards are subject to revision, and parties to agreementsbased on this standard are encouraged to investigate the possibility of applying themost recent editions of the standards indicated below:

IS No. Title

1239 (Part 1):1990 Mild steel tubes, tubulars and other wrought steelfittings:

Part 1 Mild steel tubes (fifth revision)2171:1995 Portable fire extinguishers, dry powder (cartridge type)

(third revision)2148:2004 Electrical apparatus for explosive gas atmospheres

Flameproof enclosures d (third revision)2501:1995 Solid drum Copper tubes for general engineering

purposes (third revision)2878:1986 Fire extinguisher, carbon dioxide type portable and

trolley

mounted (second revision)3043:1987 Code of practice for earthing (first revision)3601:1984 Steel tubes for mechanical and general engineering

purposes (revision)4576:1999 Liquefied petroleum gases Specification (second

revision)4786:1968 Variable high pressure regulators for use with liquefied

petroleum gas6044(Part 2):2001 Code of practice for liquefied petroleum gas storage

installations Part 2 Commercial, industrial anddomestic bulk

storage installations (first revision)9573:1998 Rubber hose for liquefied petroleum gas (LPG)

Specification(second revision)

3 GENERAL RECOMMENDATIONS

3.1 Those responsible for the installation of cylinders, equipment and piping shouldunderstand the characteristics of LPG and be trained in good practice of handling,installing and maintaining installations.

3.2 The complete installation shall conform to approved layout (approved by thedistributing company or by local authorities where ever applicable) and otherspecifications as stated in the subsequent paragraphs of the code.

3.3 The maintenance, inspection, repair etc. of the system shall be done by agenciesapproved by the distribution company.

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3.4 Cylinders and cylinder valves shall comply with the standard approved by theChief Controller of Explosives. All other equipment such as pressure regulators andother installation material shall comply with the statutory provisions or relevant Indianstandards. In absence of any such provisions or Indian standards, equivalentinternational norms shall be followed. For LPG lines threaded joints shall be avoidedas far as possible and should be provided if welded joint is not possible. For LiquidLPG lines threaded joints shall not be provided. Wherever any threaded joint isprovided, a suitable jointing compound be used on male thread.

3.5 Gas piping shall be of the colour as stipulated (for vapour Green, for liquid Golden Yellow ). to distinguish it from other piping. The direction of flow shall beindicated on the pipeline with a black colour paint.

3.6 Fire extinguishers of powder type (seeIS 2171) or carbon-dioxide (seeIS 2878)type shall be provided in places where LPG cylinder installations are situated andshall be located near such installations. Two buckets filled with sand and two withwater shall also be installed nearby. The number, type and size of the fireextinguishers shall be as follows:

Number TypeCapacity

a) For installations with LPG 40 to 200 kg 2 Dry powder 10kgb) For installations with LPG more than 2 Dry powder 10kg

200 and up to 320 kgc) For installations with LPG more than 3 Dry powder 10kg

320 and up to 1000 kg

For electrical installation 1No. C02 (4.5 kg capacity) fire extinguisher shall beprovided.

3.7 Safety cap shall be put on all cylinders not in use, whether empty or filled.

3.8 The storage room shall have caution signs such as DANGER, HIGHLY

INFLAMMABLE GAS SHED. NO SMOKING etc. painted in luminous red paintoutside at a prominent place.

4 CYLINDER LOCATION

4.1 Stationary Installations

4.1.1 Stationary installation not exceeding 50 kg of LPG may be installed indoors onany floor. It is recommended to have a minimum floor area of 5m2 for such aninstallation.

4.1.2 Stationary installations each not exceeding 50 kg of LPG may be installedindoors on any floor and within the same workspace provided the minimum distance

between two such installations is 3 m, the proportion of such installations to floorarea is one installation per 5m2 and the aggregate quantity of gas of all suchinstallations does not exceed 200 kg.

4.1.3 Stationary installation not exceeding 100 kg of LPG maybe installed indoors onany floor provided the floor area for such an installation is not less than 12m2.

4.1.4 Stationary installations each not exceeding 100 kg of LPG may be installedindoors on any floor and within the same workspace provided the minimum distance

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between two such installations is 3 m, the proportion of such installations to floorarea is one installation per 12m2 and the aggregate quantity of gas of all suchinstallations does not exceed 200 kg.

4.1.5 Stationary installation not exceeding 400 kg of LPG maybe installed indoors inan enclosed section of a building or a room reserved exclusively for this purpose andventilated at low level directly to the outside air.

4.1.6 Stationary installations above 400 kg (200 kg in case provision as in 4.1.5 is not(possible) but not exceeding 1 000 kg shall be installed outdoors on ground levelonly. A minimum distance of 3 m shall be maintained between an installation and anybuilding, public place, roadways, and other surroundings. The installation shall beprotected from excessive weathering by sun, rain, etc, and from tampering byunauthorized persons. A lean-to roof with expanded metal on angle-iron frameworkon the sides is considered suitable for this purpose. In any case, adequate ventilationat ground level to the outside air shall be provided.

4.1.7. If the storage through manifold is more than 1000 kg , installations in multiplesof 1000 kg with manifold, safety devices, change over mechanism, not exceeding 4such installations ( including stand by ) may be provided with minimum inter distanceof 3 m from all sides. If more than two installations are used, then no. of cylinders per

installations should not exceed 20.

4.1.8 The position of the cylinders shall facilitate:

a) changing and quick removal of any cylinder in case of necessity, andb) access to cylinder valve connections and regulating devices.

4.1.9 Cylinders shall be installed upright with the valves uppermost.

4.1.10 Cylinders containing more than 20 kg of gas shall not be located on floorsabove ground level.

4.1.11 Cylinders shall be located on a concrete or brick floor, preferably raised in

case of outdoor installations.

4.1.12 In order to prevent the hazardous collection of gas, cylinders shall be placedat least 1 m away from culverts, depressions, or openings leading to below groundlevel compartment and drains.

4.1.13 Cylinders which have safety relief valves or similar devices incorporated inthem shall be so positioned that if the relief device operates, escaping gas is nothazardous.

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4.1.14 Cylinder installation for Commercial/Industrial/ domestic / residentialcomplexes etc. or at any public place shall meet the following requirements:

a) For commercial and industrial cylinder installation for any publicplaces likeMall, Buildings, Industries, Hotels etc. the sum total of all stationeryInstallations inside the building shall not exceed 400 kg in any case.

In casesum total of net weight of all the cylinders installed indoors exceed400 kg

provision for outdoor installations shall be made. For installationswhere the

sum total is less than 400 kg, provisions of 4.1.2 to 4.1.5 shall apply.

b) For commercial and industrial cylinder installation for any public place,industry etc. if the net weight of all the cylinders installed is more than400 kg but less than 1000 kg, than the installation shall be providedoutdoors in line with 4.1.6. The Cylinder installation shall be providedin a covered industrial shed but open form all sides for properventilation. In case the installed capacity increases more than 1000

kg, than the installation shall be provided in line with 4.1.7. Twoseparate installations shall be provided and distance between each ofthe installations shall be minimum 5 m.( this distance shall be betweenthe outer edge of the two sheds ) .

c) For Multi storied buildings, flats housing society the reticulatedinstallation of any capacity shall be provided at a safe place especiallyearmarked for this purpose. The installation shall not be provided bythe side of road where there is continuous movement of vehicles or isapproachable to residents especially children. The Installation shouldbe secured and should be provided in a covered shed open from allsides for ventilation. The area shall be demarcated by 1.5 m highchain link fencing having one gate. There should be minimum 3 m

clear space all around the fencing and the space between the fencingthe edge of the shed should be minimum 2 m all around.

d) If the storage through manifold is more than 1000 kg, installations inmultiples of 1000 kg with manifold, safety devices, change overmechanism, not exceeding 4 such installations ( including stand by )may be provided with minimum inter distance of 3 m from all sides. Ifmore than two installations are used, then number of cylinders perinstallations should not exceed 20.

e) Location of Cylinder bank:

i) The site for LPG cylinder manifold shall be located away from

thekitchen / LPG Utility Area/Residential Building. Installation

shall beslightly raised minimum 100 mm from surrounding ground

level.

ii) Cylinders installation should not be located in inaccessiblelocation, under a stairway, basements, cellars, where airmovement across cylinders is very low/not present, to preventthe cylinders from getting inadequate latent heat and un-approachable during emergency.

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iii) Cylinders installation should not be close to steam pipes,boilers, Transformers, DG sets, etc. to prevent cylinders fromgetting affected due to radiant heat.

iv) Cylinders shall not be installed at a place where they are likelyto cause obstruction, suffer damage or be exposed toconditions likely to affect safety.

v) Cylinders installation should not be located along the driveway. Under unavoidable conditions, minimum distance of 3 mfrom drive way should be maintained. Brick masonry (min. 230mm thick)/concrete (min. 100 mm thick) walls or metallicShields/barriers (min. 16 SWG sheet) and of minimum 2 mheight should be erected between drive way and cylinderinstallation for the safety and security of the installation.

vi) Cylinders shall be located on a concrete or brick floor that isfirm,

at level, smooth, drained in case of outdoor installation.vii) The cylinder shall be installed in upright position with the valve

pointing upwards and minimum 1 m away from anycombustible materials.

4.1.15Cylinder Storage Room

a) The cylinder storage room shall be made out of non flammablematerial that is concrete (min. 100 mm thick) or brick masonry walls (min.230 mm thick) or steel structures made out of minimum 5 mm thick MSangle iron structure and 16 SWG MS wire mesh of size minimum 11.

b) Since LPG is heavier than air, ventilation shall be provided at floor

level that is 100 mm above inside cylinder bank room, open toatmosphere. The

ventilators shall be provided with 2 layers copper or non - corrodingmetal

wire mesh not less than 11 to the linear centimeter. The size of theventilators should be minimum 500 mm long x 300 mm height.

c) The storage room shall be well ventilated that is openings/ventilatorsshall be provided in the walls of cylinder storage covering min 25percent of wall area. It should also have adequate lighting. Bothexteriors and interiors should be painted with weather proofpaints.

d) The doors of the room where cylinders are installed shall openoutwards and shall have louvers / wire mesh to ensure visibility andventilation.

e) Flammable materials like wood and plastic shall not be used. Thecylinder bank storage room should not used for storing any othermaterials.

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4.2 Portable Installations

When portability of cylinders is necessary, the following requirements shall befulfilled:

a) The sum total of capacity of the cylinders connected to each manifoldshall

not exceed 100 kg of LPG. The total quantity of gas thus installed in a

workspace shall not exceed 200 kg.

b) If cylinders are mounted on a trolley, the trolley shall be stable. Wherenecessary, the cylinders shall be secured to prevent them from

falling.

c) The regulator shall be connected directed to the cylinder valve or to amanifold which shall be connected to the cylinder valves by means ofrigid connections to give adequate support to the regulator. The onlyexception to this requirement is where cylinders are mounted on atrolley and the manifold is rigidly supported on the trolley. In such acase flexible or semi flexible connections may be used between thecylinder valves and the manifold but not between the manifold and the

regulator.

d) Anytime the total quantity of gas at portable installations shall be inproportion to the floor area as specified in 4.1.1 to 4.1.7.

e) At any time the provision at 4.1.1 to 4.1.15 to be ensured for allinstallations.

4.3 Point of Delivery

Location of Cylinder bank and point of delivery of LPG cylinders shall be acceptableto the Gas supplying company. Proper motorable approach to the point of delivery /Bulk LPG storage installation shall be provided for ease in delivery/receipt of

filled/empty cylinders or Bulk LPG through vehicles. The approach is also required toprovide free access to fire tender and fire fighting personnel in case of anyemergency.

The access route to point of delivery must be firm and compact even in wetconditions and adequate space must be provided for parking of cylinder truck formaking delivery of cylinders.

The distance from point of delivery to cylinder bank should not be more than 75 mand the path should firm and compact even in wet condition and min 600 mm widefor easy movement of cylinder trolley,

5 CYLINDER MANIFOLDS

5.1 Allmaterials, fittings, etc, used in cylinder manifold systems shall comply with thestatutory provisions or relevant Indian standards. In absence of any such provisionsor Indian standards, equivalent international norms shall be followed.

5.2 The individual component parts of manifolds, that is, piping, fittings, pigtails, etc,which are subject to cylinder pressure shall be capable of withstanding a testpressure without bursting of 25 kgf/cm2 or one and a half times the maximumpressure corresponding to the maximum assessed temperature of the cylinders,whichever is more.

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5.3 Where cylinder installations are made up with service and reserve batteries ofcylinders, suitable change-over devices or valves shall be incorporated in themanifold header to prevent undue escape of the gas when cylinders are changed.

5.4 In case pressure regulators, manifold headers and automatic change-overdevices are connected to cylinder by semi-flexible connectors, these shall be rigidlysupported. Copper tube pigtails are considered to be semi-flexible for this purpose.

5.5 It is recommended that joints in manifold headers which do not have to be brokenin normal use should be welded or brazed using a material which shall have amelting point of at least 540oC.

5.6 All joints between manifold headers and cylinder connectors shall be readilyaccessible.

5.7 All joints in the manifold should be welded (except for valve fixation) and beeasily accessible for inspection / repairs etc.

5.8 Each manifold arm shall be fabricated in such a way that minimum joints areprovided. Only seamless pipes are recommended for use in manifolds. There shouldbe a minimum gap of 300 mm between the manifold and valve protection ring of the

LPG cylinders.

6 PRESSURE REGULATORS

6.1 Pressure regulators and other devices used to control the gas shall comply withthe statutory provisions or relevant Indian standards. In absence of any suchprovisions or Indian standards, equivalent international norms shall be followed.

6.2 If the regulator is fitted with a relief valve, care should be taken in positioning theregulator to avoid unnecessary hazards if the relief valve functions.

6.3 Pressure regulators and other control devices shall be adequately supported.

6.4 The pressure regulators installed shall be accessible for servicing and they shallbe protected against any physical damage. The minimum height of first stageregulators above cylinder valve protection ring should be 300 mm.

6.5 Venting

An independent vent to the outside of the building sized in accordance with themanufacturers instructions/ oil companys guidelines shall be provided where thelocation of a regulator is such that a ruptured diaphragm will cause a hazard. Wheremore than one regulator is installed, then each regulator shall have separate vent tothe outside. The vent shall be designed to prevent the entry of water, insects, orother foreign material that could block the passage.

The regulator shall not be vented to the gas equipment flue or exhaust system.

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6.6 Parallel Regulators

Where uninterrupted supply is required two pressure regulator in parallel along withNon return valves, double isolation valves may be installed. Both regulators may beset at slightly different pressures so that one of the regulators shall act as a stand by,

6.7 Identification

When multiple regulators are installed in a building/system, then they shall bemarked by a metal tag or other permanent means designating the building or part ofthe building / gas utilizing equipment being supplied.

6.8 Over Protection Devices

Over pressure shut-off (OPSO) protection required to protect the downstreamappliances from hazardous pressure or the failure of the regulator shall be provided.

6.9 Under Protection Devices

Under pressure shut-off (UPSO) protection shall be provided in regulator near gas

utilizing appliances. This shall shut off gas flow in case of low pressure in the downstream gas supply.

7 PIPING, TUBING AND FITTINGS (EXCLUDING MANIFOLDS)

7.1 All piping, tubing and fittings shall comply with the statutory provisions or relevantIndian standards. In absence of any such provisions or Indian standards, equivalentinternational norms shall be followed.

7.2 Copper Tube

Solid drawn copper tribes of outside diameter 10, 12 or 20 mm, as suitable,conforming to IS 2501 shall be used. The minimum wall thickness of the tubes

shall be 1mm.

7.3 Steel Tubes

Cold drawn seamless, electric welded, cold drawn electric resistance welded (ERW),or oxyacetylene welded tubes of suitable sizes conforming to IS 3601 shall be used.

7.4 Mild Steel Tubes

Hot finished seamless, or electric resistance welded (ERW) mild steel tubes ofsuitable size, conforming to medium or heavy class of IS 1239 (Part 1) or any otherinstallations approved by statutory authority shall be used.

7.5 The material used for flexible tubing and hose which are not subjected to fullcylinder pressure shall be such that the tubing may withstand a test pressure withoutbursting of 3.5 kgf/cm2 to 7 kgf/cm2 or five times the maximum operatingpressure to which it may be subjected in normal use, whichever is more.

7.6 The material used for shut-off valves and similar equipment which are notsubjected to fill cylinder pressure shall be such that they may withstand a testpressure of 14 kgf/cm2 or one and a half times the maximum operating pressure towhich they may be subjected in normal use, whichever is more.

7.7 Cast iron and aluminum fittings shall not be used.

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7.8 In the case of flange connections, the flanges shall be machined and shouldpreferably have raised face. Metallic with gasket of min thickness or 1.5 mm ispreferable to be used.

7.9 For any kind of movable appliance or burner, flexible connectors shall be usedand they shall be of a type that resists abrasion.

7.9.1 Where the operating pressure of the appliance or burner exceeds 100 kgf/cm

2

,both ends of the connectors shall be positively attached (for example, by suitableclips) to prevent them from coming off the hose nipples because of pressure ortension in the hoses.

7.10 Emergency Shut Off Valve

A quarter turn emergency shut off valve (ESOV) designed to work on LPG, shall onlybe used for mainline for shut-off operations. They should be installed as close aspracticable to the point where gas enters the premises to which adequate accessshall be provided. If it is installed inside the building it should be close to the entrypoint.

In open position, the lever/key of the ESOV shall be in parallel to the axis of thepipeline in which it is installed. An emergency operating procedure is distinctlydisplayed near the ESOV.

7.11 Flanges

In case of flange connections, the flanges shall be machined and should preferablyhave raised face. For LPG lines subjected to full cylinder pressure of LPG liquid linesthe minimum flange rating shall be 300 lbs.

7.12 Flange Gaskets

The acceptable materials for gaskets are asbestos, metal or metal jacked asbestos

(plain or corrugated), SS spiral wound gaskets. Whenever flange connection isopened, gasket should be replaced. For Liquid lines only spiral wound metallicgaskets shall be used.

7.13 Used Pipes, Fittings

Used pipe, fittings, valves or other materials shall not be used again unless they arefree of foreign materials and have been ascertained to be adequate for the serviceintended.

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8 INSTALLATION OF PIPING AND VALVES

8.1 Flexible Hose

8.1.1 Installations on which flexible hose is used shall satisfy the following conditions:

a) The cylinder and the appliances connected to it shall be in the same

room,

b) The length of hose shall be kept as short as possible and shouldnormally not exceed 2 m, and

c) The appliances connected shall be of portable type and not mountedin a

fixed position.

8.1.2 Flexible hose shall not be extended from one room or verandah or one space toanother and, therefore, shall not be passed through doors, windows, walls, partitions,ceilings, or floors.

8.1.3 Flexible hose shall be accessible for easy inspection and shall not beconnected from view in walls, cupboards, cabinets and other obstructions.

8.1.4 Flexible hose shall not be used in conditions where ambient temperatureexceeds 52oC.

8.1.5 Flexible hose shall be so installed that it is not twisted, looped or kinked and isnot subjected to any external pressure. Periodic inspection to be carried out by thesupplier of the gas.

8.2 Appliances which are rigidly fixed in position shall be connected by means of rigidpiping.

8.3 Appliances which are portable, if connected to rigid piping, shall be connectedthrough flexible or semi flexible connections.

8.4 Cylinder Pigtails

Flexible reinforced synthetic rubber pipes can also be used. The quality of braidedsynthetic rubber tubes shall be such that it is least affected by LPG. Thereinforcement that is braiding should be able to withstand the same pressure as thatof cylinder manifold. The design and test criteria shall be same as that ofcylinder manifold. The hydrostatic test pressure shall not be less than 25.35kgf/cm2. The free nut at the end shall be of non corrosive metal.

8.5 Adaptor

If an adaptor is used to connect the pigtails to the cylinder valves (self-closing) of theLPG cylinders then it shall have non-return device and shall have prior approval ofthe oil industry.

8.6 Pressure Gauge

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A good quality pressure gauge with a range of 0-5 kgf/cm2 (0-75 psi) shall beprovided in the pipeline after the first stage pressure regulator. The joint at whichpressure gauge is fixed shall be thoroughly checked for leakage. Milli barpressuregauges (0- 500 milli bar)shall be provided in the pipelines after II stage regulation.

8.7 Excess Flow Valve

The excess flow check valve shall be provided on each arm of the manifold to ensure

stoppage of LPG supplies in case of heavy leakage / damage to the pipeline in thedownstream facilities. The capacity of the excess flow valve shall be 50 percentmore than the maximum designed flow rate required through the manifold etc.

8.8 Piping

8.8.1 Piping shall be free internally and externally of cutting burrs, loose scales, dirt,dust and other foreign matter before the installation is completed.

8.8.2 It is recommended that, where possible, joints should not be placed beneathground level in inaccessible places, confined places (for example, cellars), air orventilating ducts, space under flooring or lift shafts.

8.8.3 If joints have to be used in piping beneath ground level in inaccessible placesor confined places, they shall be welded or brazed to minimize the risk of leakagewhich may lead to hazardous collection of gas.

8.8.4 Where welded or brazed joints are used, they shall be of adequate mechanicalstrength and, for fire resistance, the material used for welding or brazing shall have aminimum melting point of 540oC.

8.8.5 Joints other than welded or brazed shall be readily accessible.

8.8.6 Piping shall be so located or protected as to avoid extremes of temperaturewhich might give rise to condensation or cracking of the gas.

8.8.7 Provision shall be made to avoid damage to the piping from its expansion,contraction and vibration and by settlement of the building by which it is carried.

8.8.8 Piping shall be protected against corrosive atmospheres and materials.

8.8.9 As far as possible, concealed piping shall be avoided. If concealed piping isused, it shall be protected against inadvertent damage, such as from nails andknocks, by its location, type of material used or sheathing.

8.8.10 Piping shall not be run in or through an air or ventilating duct, chimney, flue orlift shaft.

8.8.11 Piping up to an outside diameter of 12 mm shall be supported at intervals of

about 50 cm by means of pipe saddles or clamps in a way to avoid sagging andshifting. For larger diameter pipes, suitable longer supporting intervals may be used.

8.8.12 It is recommended that if the pipes are run along a surface of a structure, thesupports should be so designed that the joints are sufficiently clear of the surface topermit the use of tools without drainage to the surface.

8.8.13 It is recommended that when installing pipes along a surface of a structure,the installation is done in such a way that moisture is not trapped between thesurface and the pipeline.

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8.8.14 It is recommended that the piping passing through walls should be protectedby a covering sleeve. If it is necessary to pack the space between the piping and thesleeve, a moisture-proof material which does not corrode the piping shall be used.

8.8.15 The distance between gas piping and electrical wiring system shall be at least60 mm and, where necessary; they shall be securely fixed to prevent contact due tomovement. The gas piping should run below the electrical wiring.

8.8.16 The distance between the gas piping and steam piping, if running parallel,shall be at least 150 mm. The gas piping should preferably run below the steampiping.

8.9 Suitable line shut-off valves shall be fitted for each appliance or burner.

8.10 A main valve shall befitted in the piping as near as possible to its point of entryinto building. It shall be enclosed in a metal box with a glass frontage.

8.11 It is recommended that the number of fittings used in an installation should bekept to a minimum in order to reduce the risk of gas leakage. As far as possible,straight lengths of piping should be used. Where there are bends in the pipeline,these should have a radius of at least five times the diameter of the pipe.

8.12 The open ends of piping and fittings (with the exception of terminal taps or valesin regular use) shall always be made gas-tight by means of either an appropriateterminal fitting or a plug, welded or brazed in position. Welding or brazing materialshall have a melting point of at least 540C.

8.13 The distribution pipe line in residential buildings shall always be laid on wallswith proper cleat supports /hanged from the roofs with adequate clearance from wallsurface so that surface preparation and painting will be easier. The piping shall beanchored to prevent undue strains on connected equipment and shall not besupported by other piping. The spacing of supports in gas piping installations shallnot be greater than 1.8 m for 12/15 mm dia Pipe, 2.4 m for 20 mm/25 mm dia pipe 3m for 40 mm dia pipe.

8.14 The pipeline connecting the storage shed to the main installation shouldpreferably be brought overhead without creating any hazard for the people / vehiclespassing through the same. In case of any foreseen hazard the pipeline can be laidembedded in the ground.

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8.15 The single stage pipeline network (down the range of first stage pressureregulator) from the storage shed onward should work at pressure very close to theworking pressure of the appliances. Under no circumstances, the pressure of thepipelines should exceed 22 psi (1.5 kg/cm2). This should be obtained by doublestage regulation of pressure, if necessary.

9 LEAK TESTING

9.1 Before any system of gas piping is finally put into service, it shall be carefullytested to ensure that it is gas-tight. Where any part of the system is to be enclosed orconcealed, the test shall precede the work of closing in.

9.2 Naked flames shall never be used for checking gas-tightness of the installations.

9.3 It is recommended that the location of leaks should be found by the use of soapsolution or similar materials.

9.4 Defective pipes or fittings shall be replaced and shall not be repaired in-situ.

9.5Electronic Gas leak detectors duly approved by PESO , along with control panel

for giving audio / visual alarms may be used for leak detection especially incommercial/industrial installations and in domestic/ residential housing complexeswhere combined capacity of all installations is exceeding 1000 Kg or wherereticulated system has been provided.

10 MAINTENANCE

10.1 The user shall get the inspection of the cylinder manifold, distribution piping,safety system, equipment, valves fittings, auto change over system etc. regularly asper the periodicity defined by the Distributing company. However, minimumperiodicity of inspection shall be one per year and the records have to be maintained.The inspection shall include checking the health, performance of all equipment likevalves, Regulators, auto change over system for proper operation etc.

10.2 The repair, maintenance of any defective piping, manifold or any otherequipment has to be carried out by agencies approved by the distribution company.

10.3 Pneumatic testing and hydro testing of piping shall be done once in five yearsby agencies approved by Distribution Company.

10.4 All regulators shall be throttled once a year for its accurate throttled pressureand safe operation.

10.5 The Pigtails shall be checked visually every time empty cylinder is replaced.

10.6 Hydro test of pigtails shall be carried out once in two years. The flexible LPG

hose shall also be checked once in two years.

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10.7 The distribution company shall conduct a safety awareness camp once inyear for the consumers particularly for Residential and commercial consumers.

11 INSTRUCTIONS TO CONSUMERS

11.1 Consumers shall be instructed by the distribution company on the following:

a) Operation of the whole system,b) How to recognize gas leaks;c) Action to be taken in case of leakage;d) Action to be taken in case of fire; ande) Action to be taken in case of damage to, or failure of, any part of the

installation.

11.2 Parts or Installation Subjected to Cylinder Pressure

Test pressure of one and a half times the pressure corresponding to the maximumassessed temperature (temperature used for design of cylinder).

11.3 Portions of Installation Downstream of Adjustable Regulators

Test pressure of one and a half times the maximum outlet pressure that may begiven by an adjustable regulator or 2 kgf/cm2, whichever is more.

11.4 Test pressure for portions of installation not subjected to cylinder pressure butcarrying gas at pressure more than 30 gf/cm21.5 times the working pressure.

11.5 Portions of installation subjected to gas pressure of 30 gf/cm2 or less Testpressure of 150 gf/cm2.

11.6 Handling and Use

a) Cylinders shall be adequately supported during handling and shall not

be dropped or should not be allowed to fall upon one another.

b) Trolleys and cradles of adequate strength shall as far as possible beused when moving the cylinders.

c) Use of high powered magnets for lifting the cylinders and chainsfor slinging the cylinders shall not be permitted.

d) No Lubricant should be used on the Valve or any other fitting on thecylinder.

e) Open flames, lights, lighting of fires, welding and smoking shall beprohibited in close proximity.

ANNEX A(Clause 1.2)

Requirements of Liquid off Take Valve Multi Cylinder Installation

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A-1 GENERAL

1. The Liquid off Take (LOT) Valve Multi Cylinder Installation shall meet therequirements given in IS 6044 (Part II) and this standard.

2. Total number of cylinders in a manifold shall be such that the total quantityof LPG in all cylinders is not more than 1000 kg. Two such manifolds can

be provided, provided these are separated by a distance of 5 m.

3. The Liquid off Take Valve installation shall be as provided only forIndustrial -Stationery Installation.

4. The Cylinder and the Valve shall be approved by statutory authority. Thevalve used for liquid off Take shall also be approved by statutory authorityseparately.

5. For any additional cylinders which are to be kept loose, the customercan store them within stipulations as provided for in Gas CylindersRules.

6. The Manifold and the LOT valve installation shall be certified by theOfficer of the distributing company or Third Party Inspection Agencyapproved by Distribution Company prior to commissioning.

A-2 LAYOUT

1. The site for LPG cylinder manifold shall be located away from thefurnace, any source radiating heat like steam pipes and boilers etc toprevent cylinders from getting affected due to radiant heat.

2. The area where this installation is provided shall:

i) Be a segregated area with proper house keeping. Growth ofgrass, etc in this area shall be avoided.

ii) Shall have proper flooring with Shed. The Flooring shall beraised by minimum 150 mm from the natural ground. Thecylinders shall be stored in dry, cool and well ventilated shed.

3. The cylinder storage area and the area where vaporizer is installedshall be a covered shed with sides open for ventilation. Flammablematerials like wood and plastic shall not be stored in this area. Light fixturesprovided in these areas shall be FLP type.

4. The cylinder shall be installed in upright position with the valvepointing upwards.

5. The cylinder installation should be so located so as to facilitate thefollowing :

i) Full and empty cylinders can be easily changed, disconnectedand removed quickly at the time of normal operation or emergency.

ii) It is easy to operate and maintain the valve provided betweenthe manifold and the cylinder.

iii) The manifold maintenance is easier.

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iv) Cylinders shall not be installed below ground level in cellars orbasement or at a place where they are likely to cause

obstruction, suffer damage or be exposed to conditionslikely to affect safety.

6. Since LPG is heavier than air, proper ventilation shall be provided atfloor

level open to atmosphere.

7. Main shut-off valve (Plug or ball-type) on the pipeline emerging outof

cylinder storage shed shall be located in such a manner that it justfalls outside the cylinder storage shed and shall be easilyaccessible at all times. At the point of entry of each work place, theline shall have a quick shut off valve (plug or ball-type).

8. Wherever the pipelines are passing through walls, slacks shall beprovided so that the pipeline does not get abraized.

9. A minimum distance of 1 m shall be maintained between the cylinderinstallation and the surface water drain, if any.

A-3 INSTALLATION

Following provisions, in addition to requirements given in IS 6044 (Part 2) and thisstandard are to be made for LOT valve installation :

1. A Sight Flow Indicator, Safety Valve, Thermal Relief Valve and ExcessFlow Check Valve, Non-Return Valve has to be provided on liquidline as shown.

2. The Safety Relief Valves provided should be of adequate capacity andshall have the approval of statutory authority. The design calculationsof Safety Relief Valve provided should be approved by a statutory

authority

3. The vent of the safety valve shall be at a height of 3 m from the top ofsafety valve. It shall be adequately supported. The safety valve isrequired to be provided between two isolation in the liquid pipeline.

4. For all installations two stage regulation shall be provided. The firststage regulation is provided between LPG Cylinder manifold and theVaporizer for regulating the flow of Liquid LPG as per demand. Thesecond stage regulation shall be provided after the vaporizer asshown in the enclosed drawing.

5. The name plate shall be provided on the piping manifold assemblycontaining the following information:

` i) Name of the owner.ii) Type of installation.iii) Installation date.iv) Date of test and test pressure in Kg/cm2.

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v) Manufacturers identification symbol.

A-4 PIPE AND PIPE FITTINGS FOR PIPING MANIFOLD UPTO STAGE IIREGULATION REGULATOR

1. The pipe fittings used shall be forged fittings of SCH 80, as perspecifications approved by the distributing company/statutoryrequirements.

2. All fittings of less than 50 NB shall also be forged fittings of 3000#rating.

3. The Pipe used for liquid line that is up to vaporizer and from vaporizerto second. Stage regulation regulator shall be seamless steel pipes asper specifications approved by distribution company/statutorybody/local authorities. Pipes of 40NB and below shall be of SCH 80and Pipes of 50 NB and above shall be of SCH 40. Copper tubingmanifolds shall not be allowed.

4. No screwed connection shall be allowed. In case due to any reasonscrewed connection is used, the pipe used shall be of SCH 80 only.

5. The valves, sight flow indicator, thermal relief valve, NRV etc. Usedshall be of 300 # rating. Only cast steel ball valves with firesafe feature shall be used.

6. All flanges used shall be of carbon steel, SA 105, 300# withdimensional standard as per specifications approved by distributioncompany/statutory body/local authorities. No Screwed connectionsshould be provided.

7. All weld joints provided on the line shall be accessible and shall behydro-tested for 25.35 kgf/cm2 pressure. The welding shall be fusionwelding.

8. Only metallic spiral wound gaskets shall be used for liquid line that isup to vaporizer and also down stream of vaporizer.

9. Each arm of the manifold shall have a control valve. To each arm ofthe cylinder manifold, cylinders shall be connected through a pigtail.A Check Valve and a isolation valve shall be provided with eachcylinder pigtail connection to protect the system from back flow of LPGin event of any flexible pigtail rupture. The distance between twopigtail connections on manifold shall be min 500 mm.

10. Cylinder manifold is subjected to full cylinder pressure at all times.The fabrication/ welding of the manifold should be of the bestavailable quality. All such manifolds shall be designed to a pressureequivalent to the maximum possible cylinder pressure (assessed at65oC) of LPG that is at 16.87 kgf/cm2. The test pressure should be 1.5times the maximum pressure (assessed at 65oC) that is 25.35 kgf/cm2.

11. Painting - Piping manifolds and the supporting structure shall bepainted with two coats of red oxide primer and with two coats of firstquality synthetic enamel paint. The LPG liquid line shall be goldenyellow (shade 356 of IS 5) in colour and the vapour line shall beInternational green colour.

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A-5 VAPOURISER

1. The vaporizer used shall be approved by CCOE and shall be as perIS 6044(Part II). Vaporizers may be low pressure steam heated, hotwater heated, electrically heated type. In case electrical vaporizer isused, it shall have FLP connections. However, direct fired vaporizersare not recommended.

2. The minimum safety distance of vaporizer from Cylinder installationshall be as per enclosed drawing.

3. The vaporizers shall be provided with suitable automatic means toprevent liquid LPG passing from the vaporizer to gas discharge piping.

4. Vaporizer shall be marked to include details as per 7.2.2 of IS 6044(Part 2).

5. Vaporizer shall be designed to facilitate testing, inspection andservicing of both LPG and heating units without undue disturbanceof the whole vaporizer.

6. Safety relief valve shall be provided on the vaporizer.

A-6 PIPING, TUBING AND FITTINGS AFTER SECOND REGULATION

1. All pipe fittings after second. Stage regulation shall be in line withIS 6044(Part II) requirements.

2. Steel tubes used shall be as per IS 3601 and shall be cold drawnseamless, electric welded, ERW or oxyacetylene welded type.

3. Mild steel tubes used shall be hot finished seamless or electricresistance welded (ERW) type of medium or Heavy section as per IS1239(Part I).

4. No cast iron or aluminum fittings shall be used.

A-7 FLEXIBLE HOSE

1 The hoses connecting cylinder with manifold shall be in line withIS 6044(Part II) and shall be used for connecting the cylinder tomanifold. The hoses shall be as per IS 9573 Type IV (latest edition) oras approved by statutory authority.

2. The design, material and construction of hoses shall be suitable forgrade of

LPG. Currently, it is envisaged that LPG as per IS 4576 shall besupplied.

3. The flexible hoses should have electrical continuity of 0.75 ohms/m.

4. All flexible hoses used before first stage regulation and after second.Stage regulation shall be tested at 3.5 MPa (35 kg/cm2) during initialmanufacture and should be designed to withstand a minimum burstingpressure of four times the maximum pressure.

5. The flexible hose/pigtail shall be in the same room and its length shallnot exceed 2 M. Flexible hose/ pigtail shall not pass through doors,

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windows, walls, ceiling (or) floors. The pigtails shall be accessible forinspection.

6. In case the ambient temperature exceeds 50oC, flexible hose shall notbe used.

7. The flexible Hose shall not be twisted, looped or kinked. It should notbe subject to any external pressure.

8. The hose shall be tested once every quarter and proper records oftesting etc. shall be maintained.

A-8 SAFETY AND INSPECTION

1. The consumer has to be trained to use the LOT Cylinder installation.A trained personnel who has minimum qualification as Diploma inEngineering shall be responsible for the installation from customersend.

2. Oil companies shall assist the consumer in organizing regular safetyprograms, drills etc. and will also provide regular training on use of

LPG.

3. After empty cylinders shall be placed in a safe place and proper capshall be provided on the valve so as to ensure that no leakage takesplace.

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A-8.1 Maintenance of Cylinder Manifold

Maintenance of the cylinders manifold and the equipments shall be undertakenregularly and the periodicity of the maintenance shall be as under:

A-8.1.1Periodicity of Checks and Maintenance

a) Valves

i) All the valves that is safety valves, TRV shall be checked oncein a year by a Competent Authority approved by statutoryauthority.

ii) All the other valves should be checked for free and full rangeof movement, positive shut off, mechanical damage etc.

b) Piping and manifold

i) It should be checked once a year visually for corrosion, anyphysical damage. All supports of manifold should also be

checked for any corrosion etc.

ii) The manifold should be internally cleaned once a year andshould be free from contaminants such as welding slag,grease, oil etc.

iii) The strainer provided on the manifold should be cleaned atleast once in six months.

iv) Hydro testing of manifold and pneumatic testing of pipe linesshould be done once in 5 years.

c) Vaporizer shall be checked as per maintenance schedule given by themanufacturer and the strainers etc. should be cleaned at least twice ayear.

d) The burners shall be regularly cleaned.

e) Pigtails shall be checked every time empty cylinder is replaced bya filled cylinder and replaced in case of any physical damage.

f) The regulators should be checked once in a year for correct settingsand performance as well as for corrosion and mechanical damage.

g) The pressure gauges should be calibrated once in a year and proper

records should be maintained. The dial of the gauge should be clearlyvisible.

A-8.2 Inspection

1. All the manifold installations shall be checked once in six monthsby the gas supplying company authorized mechanic and recordmaintained at the installation location.

2. The installation shall be checked once in a year by the Sales Officerof the Gas Supplying Company or by their authorized Third PartyInspection Agency.

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3. The area of LOT installation should be free of any uncontrolled weed

growth and accumulation of waste products.

4. Regulator settings should be checked as per norms given in 1 above.

A-8.3 Leak Testing

1. It shall be ensured that the manifold provided has been subjectedto the hydro test pressure of 25.35 kgf/cm2 (360 psi) at least for aminimum period of 1 hour inspected by the Oil Industryapproved contractor/ Inspection agency.

2. It shall be ensured that the fire extinguisher and sand buckets areprovided and installations are adequately protected from weatherconditions.

3. The gas piping system should be carefully tested for ensuring gas tightness.

4. Naked flames shall never be used for checking gas tightness of the

installation.

5. Leak detection should be done using soap solution or similar material.

6. All defective pipes should be replaced and no repair should be carriedout in-situ.

A-8.4 Warning Signals

1. No smoking or naked flames shall be permitted within the SafetyZones of the installation. NO SMOKING, HIGHLY INFLAMMABLEGAS , DANGER, boards shall be provided.

2. Sign Boards, instruction boards for DOs & DONTs shall be provided.

3. Instruction Board with Emergency Telephone Numbers and Importanttelephone numbers shall be provided..

4. Instruction Board prohibiting unauthorized entry shall be provided.

5. It shall be ensured that all signage are in place and are legible.

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A-8.5 Source of Leakages

a) Cylinders:

i) Welded seams,ii) The cylinder/valve connection bung joint, andiii) Cylinder valve.

b) Check leakage from pressure regulator at:

i) Near the joints,ii) In the pressure regulator itself,iii) Check leakage from the piping and manifold regulator and the

appliance inlet nozzle, andiv) Check leakage from cooking appliances at.

a) All threaded connections.b) The appliances itself.

A-8.6Action to be Taken when Leakage is Detected:

a) Leakage of cylinder - Any cylinder which develops a leak should bepromptly removed to an isolated open place away from any source ofignition.

b) In case of leakages of piping, appliances or pressure regulators, closethe valves and isolate the part, disconnect the cylinders and place thesafety cap on the valve of the cylinder. NEVER repair the appliance orany other part of system when in use.

Ic) The matter should be immediately reported to the In-charge and theOfficer of Gas Supply Company.

A-9 EARTHING AND ELECTRICAL PROTECTION

1. The Cylinder manifold installation, the vaporizer installation and thedown stream installation shall be earthed at two places. Twoearth pits as per

IS 3043 latest edition shall be provided and the earthing resistanceshould not exceed one ohm.

2. The system should be tested for electrical continuity and resistance toearth.

3. The earthing resistance shall be checked twice a year once during thesummer season and once during winter and records for same

shall be maintained.

4. Only Flame Proof Electrical fittings as per IS 2148 shall be used in thearea segregated for LOT valve installation. These shall be earthedat two points. The fittings used shall be approved by statutoryauthority.

5. Only flame proof hand torches shall be used.