OISD STD 236 Refrigerated Storage1

Page No.
Draft Document OISD-STD-236
FOR RESTRICTED CIRCULATION ONLY
Design, Layout, Operation & Maintenance of Refrigerated LPG Storage Edition 2014
Prepared by: COMMITTEE ON Design, Layout, Operation & Maintenance of Refrigerated LPG Storage
Oil Industry Safety Directorate Government of India Ministry of Petroleum & Natural Gas 8th Floor, OIDB Bhavan, Plot No. 2, Sector 73, Noida, Uttar Pradesh - 201301 Website: www.oisd.gov.in Tele: 0120-2593800, Fax: 0120-2593802
Page No. II
Preamble Indian petroleum industry is the energy lifeline of the nation and its continuous performance is essential for sovereignty and prosperity of the country. As the industry essentially deals with inherently inflammable substances throughout its value chain upstream, midstream and downstream Safety is of paramount importance to this industry as only safe performance at all times can ensure optimum ROI of these national assets and resources including sustainability. While statutory organizations were in place all along to oversee safety aspects of Indian petroleum industry, Oil Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural Gas, Government of India as a knowledge centre for formulation of constantly updated world-scale standards for design, layout and operation of various equipment, facility and activities involved in this industry. Moreover, OISD was also given responsibility of monitoring implementation status of these standards through safety audits. In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and participative process of development of standards starting with research by in-house experts and iterating through seeking & validating inputs from all stake-holders operators, designers, national level knowledge authorities and public at large with a feedback loop of constant updation based on ground level experience obtained through audits, incident analysis and environment scanning. The participative process followed in standard formulation has resulted in excellent level of compliance by the industry culminating in a safer environment in the industry. OISD except in the Upstream Petroleum Sector is still a regulatory (and not a statutory) body but that has not affected implementation of the OISD standards. It also goes to prove the old adage that self- regulation is the best regulation. The quality and relevance of OISD standards had been further endorsed by their adoption in various statutory rules of the land. Petroleum industry in India is significantly globalized at present in terms of technology content requiring its operation to keep pace with the relevant world scale standards & practices. This matches the OISD philosophy of continuous improvement keeping pace with the global developments in its target environment. To this end, OISD keeps track of changes through participation as member in large number of International and national level Knowledge Organizations both in the field of standard development and implementation & monitoring in addition to updation of internal knowledge base through continuous research and application surveillance, thereby ensuring that this OISD Standard, along with all other extant ones, remains relevant, updated and effective on a real time basis in the applicable areas. Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides other issues, calls for total engagement from all levels of the stake holder organizations, which we, at OISD, fervently look forward to.
Jai Hind! Executive Director Oil Industry Safety Directorate
Page No. III

FOREWORD
The Oil Industry in India is over 100 years old. As such, various practices have been in vogue because of collaboration/association with different foreign companies and governments. Standardization in design philosophies, operating and maintenance practices remained a grey area. This coupled with feedback from some serious accidents that occurred in the past in India and abroad, emphasized the need for the industry to review the existing state-of-the-art in designing, operating and maintaining of oil and gas installations. With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a Safety Council, assisted by Oil Industry Safety Directorate (OISD) staffed from within the industry for formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardizing and upgrading existing standards to ensure safer operations. Accordingly, OISD constituted a number of functional committees comprising of experts nominated from industry to draw up standards and guidelines on various subjects. For some time, a need had been felt for a simple yet comprehensive document to provide basic information on Design, Layout, Operation & Maintenance of Refrigerated LPG Storage . This document has been prepared keeping this objective in view. This document will be reviewed periodically for improvement based on the field level experiences, incident analysis and better understanding. Suggestions from all stake holders are fervently solicited.
Page No. IV
NOTE
Oil Industry Safety Directorate (OISD) publications are prepared for use in the Oil and Gas Industry under the Ministry of Petroleum and Natural Gas. These are the property of Ministry of Petroleum and Natural Gas and shall not be reproduced or copied or loaned or exhibited to others without written consent from OISD. Though every effort has been made to assure the accuracy and reliability of the data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use. These documents are intended only to supplement and not to replace the prevailing statutory requirements.
Page No. V
COMMITTEE ON Design, Layout, Operation & Maintenance of Refrigerated LPG Storage
LIST OF FUNCTIONAL COMMITEE (FC) MEMBERS
S. No. 1 2 3 4 6
NAME Shri K Mani Shri S C Gupta Shri Rakesh Gupta Shri Kannan Srinivasan Shri Rakesh Agrawal
ORGANISATION Indian Oil Corporation Ltd Bharat Petroleum Corporation Ltd. Hindustan Petroleum Corporation Ltd. Reliance Industries Ltd. Oil Industry Safety Directorate
Position in the FC Leader
Member Member Member Member coordinator
In addition to the above, various other experts from the industry contributed in the preparation, review and finalization of this document.
Page No. VI
CONTENTS Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 Description INTRODUCTION SCOPE DEFINITIONS REFRIGERATED LPG STOARGE AND HANDLING FACILITIES PROCESS TERMINAL LAYOUT DESIGN CONSIDERATIONS REFRIGERATED STORAGE TANKS FIRE PROTECTION, SAFETY AND EMERGENCY SYSTEMS OPERATIONS OF REFRIGERATED LPG STORAGE INSTALLATION INSPECTION & MAINTENANCE OF REFRIGERATED LPG STORAGE INSTALLATION COMMISSIONING AND DECOMMISSIONING : ANNEXURES REFERENCES Page No.
Draft OISDSTD236
Design, Layout, Operation & Maintenance of Refrigerated LPG Storage
Page No. 1
Design, Layout, Operation & Maintenance of Refrigerated LPG Storage 1.0 INTRODUCTION Safety in Refrigerated LPG Storage facilities need specific attention considering the fact that large volumes of LPG are stored at near atmospheric pressure well below the ambient atmospheric temperatures. Any change in the ambient conditions of the product would result in boiling of large volume of liquid at a very high rate which may lead to rise in tank pressure and failure of storage tanks. These tanks are prone to collapse under vacuum in case of high rate of evacuation of product. The product stored in the tanks is without any odour. At present, there is no specific standard in the country for standardizing the design, Layout, Operation and Maintenance of the refrigerated LPG Storage Facilities. This standard is intended to serve as a guide to the Design, Layout, Operation & Maintenance of Refrigerated LPG Storage facilities. The primary objective of preparing this standard is to ensure safety in Refrigerated LPG Storage facilities by following the basic safety requirements and practices in the design, construction and Operation of Refrigerated Storage Facilities . 2.0 SCOPE This standard lays down the minimum safety requirements for Design, Layout, Operation & Maintenance of Refrigerated LPG Storage facilities. The facilities at port and the associated cross country pipelines are not part of the scope of the present standard. This standard does not cover the buried / semi buried refrigerated LPG storage facilities. The requirements of OISD-STD-144 / 150 / 214 shall be applicable after the point LPG is no longer in Refrigerated State.
3.0
DEFINITIONS: (1) Aboveground Tank or Aboveground Vessel: a tank or vessel all or part of which is exposed above grade. Auto-refrigeration: The chilling effect of vaporization of LPG when it is released or vented to a lower pressure. Annular Space: The space between the primary cylindrical liquid container and the primary cylindrical product vapor container or cylindrical purge gas container of a double wall tank. Base Heating System: A heating system provided in the base slab or soil below the tank system to prevent freezing of the soil and frost heave. Base Slab: A continuous concrete base supporting the tank system. This base may be either at grade or elevated and may be either supported by soil or piles. Deriming: Synonymous with defrosting or de-icing refers to the removal, by heating and evaporation, sublimation, or solution, of accumulated constituents that form solids, such as water, carbon dioxide, etc. from the low-temperature process equipment. Dyke: A structure remote from the tank system used to establish an impounding area for the purpose of containing any accidental spill of stored liquid. Sometimes this structure is referred to as a bund wall.
(2)
(3)
(4)
(5)
(6)
(7)
OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from the use of OISD Standards/Guidelines.
Draft OISDSTD236
Page No. 2
(8)
Elevated Foundation: A foundation with base slab, supported by either piles or piers located at an elevation above grade, leaving an air gap between the grade and the bottom of the base slab. Flameproof Enclosure: Type of protection in which the parts which can ignite an explosive atmosphere are placed in an enclosure which can withstand the pressure developed during an internal explosion of an explosive mixture and which prevents the transmission of the explosion to the explosive atmosphere surrounding the enclosure.
(9)
(10) Frostbite: Frostbite is the medical condition where localized damage is caused to skin and other tissues due to freezing temperatures. Frostbite is likely to happen when human body comes in accidental contact with refrigerated LPG at subzero temperatures. (11) Hazardous area: An area shall be deemed to be a hazardous area, where (i) Petroleum having flash point below 65C or any flammable gas or vapour in a concentration capable of ignition is likely to be present. (ii) Petroleum or any flammable liquid having flash point above 65C is likely to be refined, blended, handled or stored at or above its flash point. (12) Hazardous Atmosphere: An atmosphere containing any flammable gas or vapour in a concentration capable of ignition. (13) Levels and Volumes Design Liquid Level: Maximum liquid level that will be experienced during operation of the tank. This is used for the static shell thickness determination. Maximum Liquid Capacity: The total volume between the design liquid level and the tank bottom. (This is also referred to as total liquid capacity in API 620.) Maximum Normal Operating Level: Maximum liquid level that will be experienced during normal operation of the tank. Minimum Normal Operating Level: Minimum liquid level that will be maintained during normal operation of the tank. The unusable volume of liquid below the minimum normal operating level is known as Heel. Net Working Capacity: The volume between the maximum normal operating level and minimum normal operating level. Overfill Protection Margin: Capacity (tank height or volume) between the maximum normal operating level and the design liquid level Seismic Freeboard: The design height above the maximum normal operating level to minimize or prevent overflow or damage to the roof due to sloshing of the liquid contents during a seismic event. Refer figure in Annexure A1 for details of Level and Volumes (14) Liquefied Petroleum Gas (LPG or LP-Gas): The term applies to a mixture of certain light hydrocarbon predominately C3 & C4, derived from petroleum & natural gas which are gaseous at ambient temperature and pressure, may be condensed to a liquid state at normal ambient temperature by the application of moderate pressure and conforming to IS : 4576 or IS: 14861.
Draft OISDSTD236
Page No. 3
(15) Load Bearing Insulation: Insulation with special compressive strength properties used for thermal insulation and for transferring the load to the load bearing structure. (16) Primary Liquid Container: Parts of a tank system that contain the liquid during normal operation. (17) Primary Vapour Container: Parts of a tank system that contain the product vapour during normal operation. (18) Pump Column: A pipe column to house a combined vertical pump and close coupled electric motor. The column itself protrudes through the outer tank roof. (19) Secondary Liquid Container: Parts of a tank system that contain the liquid in the event of leakage from the primary liquid container. (20) Process Boil-Off: The process of vaporization of refrigerated product by heat conducted through the insulation surrounding the tank. Design Pressure: The maximum gauge pressure permissible in the vapour space above the product of a tank system in its design condition. Rollover: The spontaneous and sudden uncontrolled movement of a large mass of liquid from the bottom to the top surface of a refrigerated storage vessel due to an instability caused by an adverse density gradient due to presence of stratified liquids of different densities. Rollover can cause a sudden pressure increase and can affect vessel integrity. Set Pressure: The gauge pressure at which the pressure relief device first opens. Set Vacuum: The gauge pressure at which the vacuum relief device first opens. Sweetening : Introduction of LPG vapour into the tank (21) Purging: The replacement of one gas/vapour by another in an enclosed tank system by displacement, by dilution, by diffusion or by combinations of these actions. (22) Shall: Indicates provisions that are mandatory; (23) Should: Indicates provisions that are recommended but not mandatory; (24) Storage Concepts Double Containment (double integrity) Tank System A double containment system is one having a double tank designed so that both the inner tank and the outer tank are capable of independently containing the refrigerated liquid stored. The inner tank contains the refrigerated liquid under normal operating conditions. The outer tank is intended to contain the refrigerated liquid product leakage from the inner tank. The outer tank is not designed to contain product vapour in the event of liquid leakage from the inner tank. Full Containment Tank System A full containment storage tank is one meeting all the requirements of double containment storage plus the additional requirement of that it shall avoid the uncontrolled release of
Draft OISDSTD236
Page No. 4
product vapour in the event of liquid leakage from the inner tank. The outer tank shall always contain the vapour during normal operation. Refrigerated Tank System Storage in a vessel or tank artificially maintained at a temperature below the nominal ambient temperature. This includes the combination of a primary liquid container, together with secondary liquid container (if any), insulation, vapor container, appurtenances, instrumentation and all other associated elements. The product is stored at their respective boiling point depending upon the constitution at near atmospheric pressure. Single containment A single containment system is one having either a single tank or a tank comprising an inner tank and an outer container designed and constructed so that only the inner tank is required to meet the low temperature ductility requirements for storage of that product. The outer container of a single containment storage tank would primarily be for retention and protection of insulating material and to contain the vapour gas pressure, and would not be designed to contain liquid in the event of leakage from the inner tank. (25) Stratification: When liquids of different densities are received in the same tank, there is a possibility that layers are created with a less dense liquid overlaying a heavier one. This is called stratification. Unstable stratification may also occur when the liquid in the lower layer becomes less dense due to heat input, while the liquid in the upper layer becomes heavier due to the evaporation at the surface. This unstable situation can relieve itself with a sudden /spontaneous rapid mixing process (Roll over) which occurs in tanks as a result of a density inversion.
Draft OISDSTD236
Page No. 5
4.0
REFRIGERATED LPG STORAGE AND HANDLING FACILITIES - PROCESS
Refrigerated LPG: The product stored either in pure propane & pure butane form or in premixed LPG (i.e. mix of propane & butane conforming to IS: 4576) at their respective boiling point at near atmospheric pressure. Receipt of refrigerated LPG, butane or propane. The refrigerated propane, butane or LPG is discharged by the pumps of the ocean tanker through the unloading arms at the port to the cross country pipelines and is transferred to the designated storage vessels at the terminal through insulated pipelines. Storage of Refrigerated LPG: The primary function of storage vessel is to receive, hold and stock refrigerated product. Above ground dome roof tanks are used to store the liquefied gas at or below its boiling point. The tank is designed to ensure the following functions: Liquid Retention The storage tank shall be capable of withstanding the hydrostatic load of the liquid and low temperature of the propane, Butane and /or LPG. Gas Tightness Tanks should be tight enough to prevent any evaporation losses and also to avoid ingress of air and moisture. Thermal Insulation Thermal insulation shall be provided to: Limit boil-off rates Avoid cold spots on the outer shell. Thermal Stresses Under normal operating conditions, the tank is subjected to variation in the temperatures. Also during start up, tank temperature is required to be brought down from ambient to refrigerated temperatures. Sometimes the tank may require deriming for various reasons like repair of internals, modifications etc. Hence, the tanks shall be capable of withstanding the heat variation. The detailed requirements of Refrigerated Storage Tanks has been detailed in section 5 REFRIGERATION SYSTEM: BOIL OF COMPRESSORS, FLASH COMPRESSORS, CHILLERS/ CONDENSERS: An auto-refrigeration system comprising of positive displacement compressors, LPG condenser and liquid receiver is provided to maintain refrigerated LPG tank pressure. The auto-refrigeration system compensates for heat gain in the tank, headers and in-tank pump heat. Large capacity refrigeration compressors called Flash Compressors are operated to handle large-scale refrigeration requirement during ocean tanker receipts and smaller capacity refrigeration compressors called Boil-Off Compressors are used during normal course of operations to maintain tank temperatures at required levels.
Draft OISDSTD236
Page No. 6
The vapor thus extracted is compressed and then re-liquefied by condensing in condensers / chillers. The condensate, intermediately stored in condensate receivers, is then pumped to separate buffer storage tanks thereby completing an open-cycle auto-refrigeration process. The liquid returned to the either refrigerated storage tank or above ground tank as per the designed process flow. Refrigerated storage tanks and refrigeration systems are designed to maintain normal process operations during routine maintenance of equipment, and to assure plant safety under emergency conditions. Sufficient sparing of equipment is provided so that any single piece of equipment can be removed from service while maintaining normal operations. The terminal shall be provided with flare system to enhance the plant safety. The flaring is done only as a final solution when the normal Boil / Flash compressor are not available able to meet the requirement. Flare is connected to the tank pressure vent valve to provide sufficient time for operator intervention in case of pressure rise. Product withdrawal The product stored in the tanks is pumped out using In tank Pumps (duty and standby) installed inside each tank. Heating / Blending: The refrigerated product (LPG/propane/ butane) is brought to ambient condition from its sub-zero temperature by various method of heating the product by either through steam / heat exchangers / air preheaters etc. It is very important to ensure that the product LPG / propane / butane at downstream of heating arrangement shall be at temperature above 15C. The failure of the heating arrangement to increase the temperature of the product upto 15C should immediately trip the intank pump and prevent flow of refrigerated product from heating arrangement. The product (propane & butane) at normal temperature above 15C is blended in a blending unit in the correct ratio to make commercial LPG. The final product is dozed with ethyl mercaptan from the dozing facilities for odorizing LPG in the correct proportion. Beyond this point provision of OISD-144/150 shall be applicable. The pipings/equipments at the downstream of the heating arrangement upto the next storage vessel or despatch / loading end shall be of LTCS material only.
Draft OISDSTD236
Page No. 7
5.0
Terminal Layout:
Philosophy: Terminal lay out philosophy shall consider location of the facilities at a site of suitable size, topography and configuration with a view to minimise the hazards to persons and property due to leaks and spills of LPG. Before selecting a site, all site related characteristics which could affect the integrity and security of the facility shall be determined. A site shall provide ease of access so that personnel, equipment, materials from offsite locations can reach the site for fire fighting or controlling spill associated hazards or for the evacuation of the personnel. OISDSTD-118 covers the layout consideration for the Oil and Gas Installations. The above standard is generally applicable for consideration of layout of Refrigerated LPG Terminal. The Control Room shall be constructed as per OISD-STD-163.The minimum distance of 60 m shall be maintained between LPG Storage Tank and Substation. Specific points related to Refrigerated LPG are brought out here. Basic Information Information on following items should be collected before proceeding with the development of overall plot plan. A: Site location map Site Geotechnical and Seismic data. Soil characteristics Prevailing wind speed and direction over a period Meteorological data including corrosive characteristics of the air and frequency of lightening Area topography contour map High flood level in the area and worst flood occurrence. Storm water disposal point and effluent disposal point Source of water supply and likely entry / exit point Electric supply source and direction of entry point LPG entry point/ Gas exit point Approach roads to main Terminal areas Surrounding risks Air routes and the proximity of the Airports. Fire station The Proximity to the unloading jetty. B: Terminal capacityProcess flow diagram indicating flow sequence Process units and capacities Refrigerated LPG storage tanks, sizes and type of storage tanks Other LPG storage tanks LPG transfer No. of flares Provision for spill containment and leak control Minimum inter distances between facilities as well as between facilities & boundaries Operating and maintenance philosophy for grouping of utilities Plant and non-plant buildings Space for future Expansion Chemical storage Ware house and open storage areas.
Draft OISDSTD236
Page No. 8
Grouping: The Refrigerated LPG Terminal may consist of the following basic facilities. Refrigerated LPG receipt line to shore terminal. Refrigerated LPG Storage Pressurized LPG storage facilities. Boil Off / Flash Compressor, condensers, chillers, Process Area Heating / Blending / dozing facilities. Flare system Utility Block (Air Compressors, De-mineralization plant, Boiler Room etc.) Fire water Storage and fire water Pump House. LPG loading/ transfer facilities Road / Rail / Pipeline Control Room Administrative Block Workshop Warehouse Electrical Substation. Laboratory
General Considerations Future expansion requirement shall be assessed and provision of space for the same should be made. The Erection and Maintenance requirements shall be considered. The layout of the facilities including the arrangement and location of plant roads, walkways, doors and operating equipment shall be designed to permit personnel and equipment to reach any area effected by fire rapidly and effectively. The layout shall permit access from at least two directions. Each group shall be separated by roads on all four sides for easy access and emergency handling. Classification of areas for Electrical Installations in LPG Terminal shall be as per OISD-STD-113 as applicable.
Processing Equipment Spacing: The table II of OISD-STD-118 shall be applicable for process equipment. Aboveground Refrigerated LP-Gas Containers The minimum horizontal distance between the shell of a refrigerated LPG tank and the line of adjoining property that may be developed shall be 60 m. Where residences, public buildings, places of assembly, or industrial sites are located on adjacent property, greater distances or other supplemental protection shall be evaluated. Non refrigerated LP-Gas containers or flammable liquid tanks shall not be located within dykes or impoundments enclosing refrigerated LP-Gas containers. Refrigerated LP-Gas containers shall not be installed one above the other. The minimum distance between aboveground refrigerated LP-Gas containers shall be one-half the diameter of the larger container. The minimum horizontal distance between the shell of a refrigerated LPG tank and the shell of another non-refrigerated hydrocarbon storage facility shall be the largest of the following distances subject to a max of 60 m.
Draft OISDSTD236
Page No. 9
i. ii. iii.
If the other storage is pressurized, three quarters of the larger tank diameter. or 30 m whichever is more. If the other storage is in atmospheric tanks and is designed to contain material with a flash point of 55 or less, one diameter of the larger tank or 30 m whichever is more If the other storage is in atmospheric tanks and is designed to-contain material with a flash-point greater than 55 C, half the diameter of the larger tank or 30 m whichever is more.
Refrigerated LPG tanks shall not be located within buildings, within the spill containment areas of other flammable or combustible liquid storage tanks or within the spill containment areas of pressurized storage tanks. The inter-distance requirements among various process facilities such as flash / boil off compressor area heat exchanger / condensors / blending / dosing facilities shall be governed by process / design / hazop considerations. There shall not be any process facility such as condenser / compressor house / dosing / blenders within 30 m of tank shell. The inter-distance for the facilities handling non refrigerated LPG shall be as per OISD144/150/214 for respective facilities.
Spill Containment a. Single containment Refrigerated LPG tanks shall be provided with spill containment facilities. Spill containment shall be provided by the dyking of the area surrounding the vessel. For double and full containment tanks, only kerb wall of atleast 0.6 m height shall be provided. The distance of kerb wall from tank shell shall not be less 15 m. In this case, double wall tanks shall be designed to hold the entire quantity in the outer shell as well as suitable to handle hydrostatic pressure and low temperature requirements. To prevent the accumulation of flammable material under or near a refrigerated LPG tank, the ground under and surrounding the tank shall be graded to drain any spills to a safe area away from the tank. Diking: (i) If diking around the vessel is to be used for spill containment, the dyked area shall be designed to meet the capacity of single largest tank in the dyke. Effective containment capacity shall be after considering 0.2 m of free board. (ii) The grading of the area under and surrounding the vessel shall direct any leaks or spills to the edge of the dyked area. The grading shall be a minimum of 1% slope. Within the dyked area, the grading shall cause spills to accumulate away from the vessel and any piping located within the dyked area. (iii) Each refrigerated LPG tank shall be provided with its own dyked area. The holdup of the dyked area shall be at least 100% of the volume of the tank. (iv) More than one tank may be enclosed within the same dyked area provided provisions are made to prevent low temperature exposure resulting from leakage from any one tank from causing subsequent leakage from any other tank. When dykes are used as part of the spill containment system, the minimum height shall be 0.5 m, measured from the inside of the dyked area. Where dykes are higher than 1.8 m, provisions shall be made for normal and emergency access into and out of the dyked enclosure. The height of dyke shall not exceed
b.
c.
d.
Draft OISDSTD236
Page No. 10
2.0 m excluding free board of 0.2 m e. The edge of a dyke/ kerb wall , impoundment, or drainage system that is intended for a refrigerated LP-Gas container shall be 30 m or more from a property line that can be built upon, a public way, or a navigable waterway. The ground within 7.5 m of any aboveground refrigerated LP-Gas container and all ground within a dyke, impoundment, or drainage area shall be kept clear of readily ignitable materials such as weeds and long, dry grass. Marking of Tanks Each refrigerated storage system shall be identified by the attachment of name plates readily visible and accessible which shall give the following details: Manufacturers name and serial number Design standard Maximum LPG filling level Liquid volume of the tank when filled with LPG to the maximum safe level Maximum and minimum design pressure Maximum and minimum design temperature Density of the LPG for which the tank is designed Year of construction and test
f.
Piping, Valves and Equipment: a. Piping, valves and equipment for handling refrigerated LPG shall confirm to the low temperature requirements and to be suitable for use at the temperature of the application and shall be designed for not less than the maximum pressure and for minimum temperature to which they may be subjected. b. Cast iron shall not be used for piping systems handling refrigerated LPG c. Screwed joints and compression fittings shall not be used in piping for low temperature Propane, Butane or LPG service , except for the instrument lines downstream of an isolation valve. d. All the welds of Propane, Butane or LPG service line shall be 100% radiographed and retained for future references. e. Piping systems and their supports shall be suitably insulated / protected for fire exposure conditions.
Draft OISDSTD236
Page No. 11
6.0
DESIGN CONSIDERATIONS REFRIGERATED STORAGE TANKS
Design Information: Following information shall be collected at the design stage: Natural environmental loads (such as earthquake, wind), Spillage handling requirements, Corrosion allowances, Hazard Protection System requirements (such as water spray, gas detection, if any); Accidental loads determined by assessment of risk (such as fire, pressure wave, projectile impact, if any); Settlement prediction and inspection method; Ambient temperature Properties of the stored product, including density at the design temperature, Minimum design temperature of primary containment, Tank maximum liquid capacity; Design liquid level; Internal diameter and height of inner tank Normal maximum/minimum operating liquid level; Design pressure/vacuum, maximum/minimum operating pressure, Pressure relief and vacuum set points.(High/low pressure alarm set point,) High/low level alarm. Minimum normal operating level basis, Overfill protection margin, Capacity to receive the interface turbulance of two products at different temperature and density. Product filling/emptying rates, Rollover applicability and rollover prevention provisions, Design boil-off rate, Condensation of vapours in annular space. Risk assessment, Applicable codes and standards; Materials of tank construction; Emergency relief valve discharge flow rate Piping and instrumentation requirements, NDE applied to non-hydrostatically tested components; Tank type, Networking capacity, Tank location on plot plan, Process flow diagrams, piping & instrumentation diagrams (P&IDS) Pre-commissioning and commissioning procedures, including purging, drying, and cool down;
DESIGN REQUIREMENTS Tank Systems for Refrigerated Storage This section covers low pressure, aboveground, vertical, and cylindrical tank systems storing liquefied gases requiring refrigeration. These are general requirements on selection of storage concept, performance criteria, accessories/appurtenances, quality assurance, insulation, and commissioning of tank systems. The Refrigerated storage tank system consist of a primary liquid and vapor containment constructed of metal, concrete, or a metal/concrete combination and, when required, a secondary liquid containment.
Draft OISDSTD236
Page No. 12
Metallic Containers Metallic container materials, design, fabrication, inspection, examination, and testing shall be in accordance with API 620 including Appendix R. Concrete Containers Concrete container materials, design, construction, inspection, examination, and testing shall be in accordance with ACI 376. General Requirements: For all containment systems, liquid-tightness of the primary liquid container is required. Liquid is not permitted to accumulate outside the primary liquid container during normal operation. Tank systems where this is not assured would require consideration of issues such as liquid collection and disposal, potential cold spots, effect on tank venting, etc. Type: Three main different storage concepts are : Single containment Double Containment Tank System Full Containment Tank System Single containment A single containment system is one having either a single tank or a tank comprising an inner tank and an outer container designed and constructed so that only the inner tank is required to meet the low temperature ductility requirements for storage of that product. The outer container of a single containment storage tank would primarily be for retention and protection of insulating material and to contain the vapour gas pressure, and would not be designed to contain liquid in the event of leakage from the inner tank. Double Containment (double integrity) Tank System A double containment system is one having a double tank designed so that both the inner tank and the outer tank are capable of independently containing the refrigerated liquid stored. The inner tank contains the refrigerated liquid under normal operating conditions. The outer tank is intended to contain the refrigerated liquid product leakage from the inner tank. The outer tank is not designed to contain product vapour in the event of liquid leakage from the inner tank. Full Containment Tank System A full containment storage tank is one meeting all the requirements of double containment storage plus the additional requirement of that it shall avoid the uncontrolled release of product vapour in the event of liquid leakage from the inner tank. The full containment concept evolved from double containment and has the following advantages: Controls or prevents the release of product vapors following primary liquid container leakage or failure; Greater ability to resist external threats such as blast, fire and impact compared to single and double containment tanks.
Draft OISDSTD236
Page No. 13
Guidance on selection of storage concept: The selection is to be based on a risk assessment. The risk is a function of not only the storage concept itself but also the way the tank system relates to many other aspects of the overall facility. Therefore other aspects of the facility and its surroundings shall be considered. Plans for the proposed facility should specifically address the impact of vapour clouds and radiant heat flux on plant facilities and adjacent properties. Intrinsic within this approach is the selection of storage concept; separation distances and proximity to property lines; site topography; soil conditions; and ground water conditions. A review of the site may identify constraints or provide opportunities to utilize specific features of site to the benefit of the facility. The rate of heat generation from a large pool of burning liquefied gas is significantly higher than that of a similar pool of another oil product. In order to limit the radiant heat flux on the surroundings to acceptable levels it may be necessary to reduce as much as possible the area of the pool of spilled liquefied gas though the selection of containment concept. External hazards include the following: Environmental hazards including earthquake, lightning, wind loading including hurricane/typhoons, flooding, Snow and ice loading, tsunamis; Ground conditions, weak strata, liquefiable layers, lateral spreading, and presence of caverns, voids and defects; Flying objects, and equipment following a process incident; Pressure waves due to vapor cloud ignitions from the process plant, adjacent plant, process equipment, and Carriers including facilities located outside the boundary limits; Operational and upset conditions including spillage and leakage of product; Maintenance hazards; Fire hazards from adjacent tanks, dykes, relief valves, sumps, jet fires, and plant areas; Proximity of tanks to external uncontrolled sources of ignition such as ground flares, flares.
Internal hazards include the following: Leakage of product from the inner tank; Overfilling of the tank; Over/under pressurization of the tank due to process upset; Rollover leading to over pressurization of the tank; Major leak (i.e. The complete failure of the inner tank); Minor leak (i.e. Partial leakage from the inner tank due to a postulated defect); Fatigue and cyclic loading of key components (e.g., annular plates); Corrosion; Failure of pipe work attached to the tank bottom/sides; Instrumentation failures.
Safety Improvement If the assessment of risk identifies risks that exceed acceptable limits, then positive measures (action) should be taken to reduce the level of risk to an acceptable level. Typical mitigation measures may be as follows:
Draft OISDSTD236
Page No. 14
Selection of alternative containment concepts (i.e. Migration from single containment to double or full containment); Improvements to process equipment selection; Substitution of a metal roof on a full containment tank with a concrete roof; Increase in safety distances (separation distances) to limit impact in respect of vapor dispersion and radiant heat flux; Elimination of ignition sources; Selection of alternate layouts and site locations; Inclusion of protection systems to shield/protect critical equipment from hazard.
General Design Considerations: All pipe connections shall be through the top of the tank to avoid siphoning effect. All isolation valves shall be pneumatically operated and interlocked to prevent accidental movement of tank contents from one tank to another. Each tank shall be provided with at least two independent means of determining the liquid level. The same shall be provided with isolation arrangement so that they can be replaced/ repaired without taking the tank out of service Additionally each tank shall be provided with high level alarm and a high level trip system which shall be designed to stop all liquid flows into the tank to prevent over-filling. The high level trip system shall be independent of both high level alarm and of liquid level gauges. Double and full containment system shall be provided with means for detecting and removing the liquid leakage / buildup of condensation in the annular space. The provision made for injecting nitrogen for purging is considered meeting the requirement. Vapor at higher temperatures may be pushed for vaporizing the condensate thru this provision. All the primary containers shall be tested to the maximum filling level with water. Outer tanks of double and full containment system shall be tested as above. To prevent damage to the inner shell the level in the inner tank shall be maintained above the level in the outer shell during the hydrostatic test. The tank has a spray-ring for cool-down with product and skin mounted temperature elements at Tank Shell to monitor the cool-down during commissioning. Temperature element is also required to be provided at Tank bottom at different radii in uniformly distributed manner to avoid temperature stratification during commissioning. If the tank is resting for a longer period, a potential for temperature stratification could exist. Warmer liquid from the tank bottom is moved upwards during restarting which could lead to excessive evaporation and higher tank pressure. Mean, such as the recirculation should be provided to break the stratification. Tank shall be provided with pressure/vacuum relief valves as per API standard 2000 independent of the pressure/vacuum control and trip systems. Sections of LPG pipe-work that could be blocked are provided with thermal relief valves. 100% capacity In-tank pumps (duty and standby) shall be provided for delivery of product from the refrigerated storage tank. An additional separate pump well and foot valve shall be provided in each refrigerated tank.
Draft OISDSTD236
Page No. 15
Design Pressure The design pressure of a refrigerated LPG tank is determined by the product's vapor pressure at the storage temperature. The set pressure of the pressure-relieving device shall be at least 5% greater than the design operating pressure. The tank section above the maximum liquid level shall be designed for a pressure of at least that at which the pressure relief valves are to be set and for the maximum partial vacuum that can be developed. All portions of the tank below the maximum liquid level shall be designed for at least the most severe combination of gas pressure (or partial vacuum) and static liquid head affecting each element of the tank. Design Temperature The design temperature for a refrigerated-LPG tank shall be the lowest of the following: - The lowest temperature to which the tank contents will be refrigerated. - The lowest shell temperature resulting from cold ambient conditions, if that temperature is below the refrigerated product temperature. - The auto refrigeration temperature of the contents. Pressure / Vacuum Control and Relief Systems: The purpose of the pressure relief system is to prevent the Tanks from excess pressure beyond design by way of controlled release of hydrocarbon vapour to the atmosphere. The purpose of the vacuum control system is to prevent the Tanks from implosion under vacuum beyond design by way of controlled breathing of air from atmosphere into the tank.
All the tanks shall be provided with a pressure / vacuum control and relief system to maintain the Tank pressure within the design pressure range in all conditions.
Vapour are generated by: Liquid entering the tank. System heat inleak Energy input from Intank Pumps. Decrease in atmospheric pressure. Mixing of Product of different constituents.
In normal operation such vapours shall be collected by the Boil Off / Flash compressors and the same is re-liquefied thus preventing their loss to the atmosphere. The terminal shall be provided with flare system to relieve the excess pressure, when the normal Boil / Flash compressor are not available / able to meet the requirement. Flare is connected to the tank pressure vent valve to provide sufficient time for operator intervention in case of pressure rise. Low pressures shall be limited by the use of following systems: Tripping of Boil off / Flash compressors and product transfer pumps. The supply of hot gas or liquid or inert gas into the tank. The relief system shall be such that it is able to function even at time when the control system is failed.
The mixing of air with flammable LPG vapours is undesirable and only acceptable when an alternate (implosion leading to potential tank failure) would constitute a greater hazard. Pressure / Vacuum-Relieving Devices
Draft OISDSTD236
Page No. 16
Relief Valves shall be provided for tanks designed to conform to API Std 620 R in accordance with API Std 2000. The pressure relief valves should be adequate to relieve the worst case emergency flow, assuming all other outlets from the tanks including that of flare are closed. When a closed inner-tank design is used with an outer vapor-tight shell, the outer shell shall be equipped with one or more pressure/vacuum-relieving devices. Each refrigerated LPG tank shall be provided with at least one pressure-relieving device set to discharge at no more than the maximum allowable working pressure of the tank. Tanks that may be damaged by internal vacuum shall be provided with at least one vacuum-relieving device set to open at not less than the partial vacuum design pressure.
Factors for consideration for sizing of pressure relief valves: Liquid entering the tank at maximum rate. Maximum possible boil off assuming failure of boil off compressor. Effect of radiation from an adjacent fire (tank) Effect of possible hot product intake in the tank. Flow of hot liquid / vapour in the tank assuming failure of vacuum protection system. Effect of possible mixing of products Product Mixing Loading LPG into a partially full refrigerated LPG tank where LPG being loaded has a different composition than the existing tank content can cause generation of huge quantities of vapor. If this condition can exist, the vaporization rate can be calculated and included in the sizing of the tank pressure relief valves. As a minimum, the pressure relief valves shall be sized to discharge vapor in case of refrigeration system failure to maintain the refrigerated storage tank pressure within the design limits for at least 24 hrs. Factor for consideration for sizing of vacuum relief valves: Maximum possible liquid withdrawal rate. Maximum possible vapour withdrawal rate (assuming the compressors fail to trip)
The pressure and vacuum relief valves must be provided with block valves with spare positions and interlocks so that inspection / maintenance can be done without opening the tank to atmosphere and without reducing the relief capacity below the design requirements. Emergency relief valves shall discharge directly to the atmosphere. Precautions must be taken to prevent icing on relief valves. Care must be taken to ensure prevention of possibility of freezing up of vent / flare system. Care must be taken to ensure prevention of possibility of blockage due to liquid in lines of vent / flare system. Therefore such lines should be free of pockets and slope towards a knock out drum. THERMAL CONSIDERATIONS The tank foundation shall be designed to prevent 0C (32F) or lower temperatures from penetrating the pad and soil. This limitation shall be accomplished by ventilation, insulation, heating systems, or a combination of these. Heating elements, controls, and temperature sensors shall be designed for easy access and replacement while the tank is in service. Foundation heating systems shall be provided with
Draft OISDSTD236
Page No. 17
temperature monitoring and controls. The design of the supporting structure shall consider loads resulting from (a) the thermal gradient across the supporting structure, foundation, and piling due to the temperature of the contents of the vessel and (b) the thermal shock from accidental spills. Insulation The tanks external insulation and cladding shall: Be weatherproof and capable of withstanding direct impingement of the cooling water from any fixed deluge system. Be impervious to the ingress of moisture. The insulation shall comprise or contain a vapor barrier shall be weatherproofed. Insulation and weatherproofing to be fire retardant. Steel surfaces covered by insulation to be properly coated to prevent corrosion.
TANK ACCESSORIES Temperature Indicators/ Level Indicators / Pressure Indicators Each tank shall be fitted with thermocouples or equivalent temperature indicating devices for use during cooldown and operations. Temperature Element shall be provided in skin at uniform interval of the tank shell at different heights for correct representation of temperature of product inside. Temperature element is also required to be provided at Tank bottom at different radii in uniformly distributed manner to avoid temperature stratification during commissioning. Level Indicators Each tank shall be provided with at least two independent means of determining the liquid level. The same shall be provided with isolation arrangement so that they can be replaced/ repaired without taking the tank out of service Additionally each tank shall be provided with high level alarm and a high level trip system which shall be designed to stop all liquid flows into the tank to prevent over-filling. The high level trip system shall be independent of both high level alarm and of liquid level gauges. Double containment and full containment system shall be provided with means for detecting and removing the liquid leakage in the annular space
Pressure Indicators Each tank shall be provided with at least two Pressure Gauges/Transmitters. The same shall be provided with isolation arrangement so that they can be replaced/ repaired without taking the tank out of service. Pressure indicators shall also be provided with local display. Sampling Connections If sampling connections are required, they shall be installed on the tank piping rather than on the tank. Tank Accessory Materials All materials including non-metallic parts of valves, seals, gaskets, etc shall be resistant to LPG under the service conditions of pressure and temperature to which they will be subjected. Low-ductility materials such as cast iron shall not be used.
Draft OISDSTD236
Page No. 18
Except for instrument lines downstream of an isolation valve, screwed joints and compression fittings shall not be used in piping for low temperature service.
PIPING REQUIREMENTS Piping for refrigerated product shall conform to the low temperature requirements of ASME B31.3 or equivalent. All the piping welds shall be 100 % radiographed. The same shall be preserved for future reference. Location: When cold piping is routed below grade, trenches, casing, other means shall be used to permit expansion and contract of the piping. Multiple Product Types: When a storage facility handles more than one type of product, dedicated loading and unloading lines between tanks and racks shall be considered for each type of product.
Thermal pressure relief: Any sections of pipelines in which LPG may get trapped e.g. between shut off valves, shall be protected against excessive pressure caused by thermal expansion of the liquid contents by thermal pressure relief valves. The settings shall of thermal pressure relief valves shall not be less than the maximum working pressure of the line and shall not be more than the design pressure of the pipe line. If the relief valves discharge to atmosphere the discharge must be arranged in a safe manner.
Valves Shutoff valves and accessory equipment shall be of material suitable for the operating pressure and temperature extremes to which they may be subjected. REFRIGERATION SYSTEM LPG Temperature The refrigeration system shall maintain the product (Commercial Propane, butane and /or LPG) at a temperature at which the LPG's vapor pressure does not exceed the tank's design pressure. Sizing The sizing of the refrigeration system shall consider the following factors: Heat flow from the following sources: The difference between the design ambient temperature and the design storage temperature. Maximum solar radiation. Receipt of product that is warmer than the design temperature, if such an operation is expected. Foundation heaters, connected piping. Vapor displacement during filling and vapor return during product transfer.
Pressure-Relieving Devices
Draft OISDSTD236
Page No. 19
The system shall be in line with the design code of the refrigerated storage. Refer to API 2000 & API RP 520, Parts I and II, for the proper design of pressure-relieving devices and systems for process equipment used in liquefaction and vaporization facilities.
Draft OISDSTD236
Page No. 20
7.0
FIRE PROTECTION, SAFETY AND EMERGENCY SYSTEMS GENERAL
The concept of loss control shall be based on the philosophy that an incident of loss of containment of LPG should not escalate to the extent that facilities are endangered and the public at large is subjected to an unacceptable risk. Reasonable and reliable safeguards for the protection of properties, personnel and surroundings from damages resulting from fires, explosions and other unsafe conditions in a Refrigerated LPG Storage Facility shall be provided so as to accomplish the following objectives considering both normal and abnormal conditions: Limit or prevent escalation of a fire by providing spacing that adequately separates the Storage, transfer, loading and unloading equipment, buildings, utility etc. Minimize or avoid serious injury to personnel by providing adequate means of escape to evacuate safely, access for emergency responders and safe access for personnel to isolate plant and equipment. Contain and prevent the spread of fire by having early detection and warning devices that enable emergency isolation, shutdown and depressurization of vessels/equipment remotely to limit the volume of flammable material released in the event of a fire.
Refrigerated tanks and their associated dykes and impounding basin should be such that in the event of either a tank fire or a spill fire, thermal radiation levels do not exceed the maximum limits in the table below (IP 1987): In any case minimum Inter-distance spacing as per table 2 of OISD Std. 118 & chapter 5.0 of the present standard shall be observed. Sl Nos 1 Site Outer surfaces of adjacent refrigerated tanks - Thermally protected(1) - Unprotected(2) Outer surfaces of adjacent tanks having flammable products -Thermally protected(1) -Unprotected(2) Outer surfaces of adjacent LPG pressure vessels/ process equipment(3) Personnel inside boundary -Process Area (4) -Protected work area(5) -Work area (6) Plant Boundary Maximum Thermal Flux ( kW/m2) 32 8 32 8 8
3 4
8 8 5 1.5 5 13
-Critical area(7) -Urban Area(8) -Remote area ( 9) Notes (1) Protection by water sprays, insulation , radiation screens (2) Protection by spacing alone (3) Allowable radiation flux restricted due to longer duration of exposure resulting from a refrigerated tank /bund fire. (4) Trained plant personnel familiar with escape routes and temporary shelter locations in plant (5) Permanent building where personnel are shielded (6) Temporary building without shielded means of escape (7) Unshielded area with people present during emergencies (8) Neither a remote or critical area (9) Infrequently occupied by people
Draft OISDSTD236
Page No. 21
The extent of Fire Protection shall be determined by an evaluation based upon sound fire protection engineering principles, analysis of local conditions, hazards within the facility and exposure to or from other property and include, as a minimum: a. The type, quantity and location of equipment necessary for the detection and control of fires, leaks and spills of LPG, flammable refrigerants or flammable gases all potential fires non process and electrical fires. b.The methods necessary for protection of the equipment and structures from the effects of the fire exposure. c. Fire protection water system d. Fire extinguishing and other fire control equipment's
e. The equipment's and process systems to be operated with the emergency shutdown (ESD) system. f. The type and location of sensors necessary for automatic operation of the emergency shutdown (ESD) systems or its subsystems g. The availability and duties of individual plant personnel and the availability personnel operating an emergency. of external response
h. The protective equipment and special training necessary by the individual plant personnel for their respective emergency duties. Procedures developed for handling emergencies shall include: a) Shutdown or isolation of various equipment in full or partial and other applicable steps to ensure that the escape of gas or liquid is promptly cut off or reduced as much as possible. b) Use of fire protection facilities. c) Notification of public authorities. d) First aid e) Duties of personnel. f) Communication procedure in case of emergency Pre incident planning which forms part of site emergency plans should be prepared addressing likely and realistic scenarios to define personnel responsible for addressing an emergency ,communication, determine operational actions required for isolating plant and equipment ,quantify the fire or vapour cloud dispersion, set priorities for fire fighting and quantify extent of fire fighting capacity required ( equipment and resources) to control the incident effectively. The updated emergency response plan shall be available in the operating control room. All personnel shall be trained in handling flammable products, use of portable, mobile and fixed fire protection equipment, first aid and breathing apparatus. Training should expand to cover Emergency response the use of fire protection equipment. Refresher training of personnel shall be conducted periodically. The planning of effective fire control measures shall be co-ordinated with the authority having jurisdiction and emergency handling agencies such as Fire and Mutual Aid arrangements that are expected to respond to such emergencies. IGNITION SOURCE CONTROL
Draft OISDSTD236
Page No. 22
Sources of ignition should be effectively controlled in all hazardous areas by a combination of design measures, and systems of work: Using electrical equipment and instrumentation classified for the zone in which it is located. Continuity of Earthing /Bonding of all plant/ equipment to avoid static electrical charges build up Elimination of surfaces above auto-ignition temperatures of flammable materials being handled/stored Provision of lightning protection involves installation of a surge protection device between each non-earth bonded core of the cable and the local structure. Control and restricted entry of vehicles/ in the zoned areas. Site rules should be clear where normal road vehicles may be taken and areas where they must be excluded. Prohibition of smoking/use of matches/lighters. Controls will be needed to prevent or minimize the release of gas or vapor during the transfer operation. Control of maintenance activities that may cause sparks/hot surfaces/naked flames through a Permit to Work System. Furnaces /Heaters with open flames shall be located upwind of the LPG storage or sources of potential leaks Precautions to control the risk from pyrophoric scale, in process equipment. Flare shall be located in predominant upwind area at a safe distance arrived as per consequences modeling. Cold flaring/venting should be avoided. Road and Rail rakes permitted to enter hazardous areas shall have their engines switched off and locomotives removed prior to commencement of loading /unloading operations. No vehicles shall be permitted within impounding areas or within 15 m of containers or equipment containing LPG, flammable liquids or flammable refrigerants except when specifically authorised and under constant supervision. EMERGENCY SHUTDOWN SYSTEMS The emergency shutdown system shall consider process safety as well as leakage of gas, fire, smoke detection. Depending on seriousness, the level of shut down is required to be graded and considered. This could be by way of section isolation or total complex shut down. The emergency shutdown system (ESD) or systems shall be of failsafe design. It should be installed, located or protected so as it is easily operate in the event of an emergency or failure of the normal control system. Emergency shutdown systems that are not of failsafe design shall have all components that are located within 15 m of the equipment to be controlled either: i) Installed or located where they will not be exposed to a fire or ii) Be protected against failure due to fire exposure of at least 15 minutes duration. Emergency shutdown (ESD) system that when operated: a. Isolates or shutoff a source of LPG, flammable refrigerant or flammable gases. b. Shuts down equipment which on continued operation may add to an emergency. c. Audio-visual alarm at control room with identification of the risk area When equipment shutdown result in an additional hazard or substantial mechanical damage to the equipment , the shutdown of such equipment or its auxiliaries shall be omitted from the ESD system , provided that continuous release of flammable or combustible fluid are controlled. Vessel containing liquids that are subjected to metal overheating and catastrophic failure from fire exposure and not otherwise protected shall be depressurized by the ESD system.
Draft OISDSTD236
Page No. 23
Initiation of ESD system shall be either manual, automatic, or both manual and automatic, depending upon result of evaluation performed in accordance with fire protection facilities. Manual actuator shall be located in an area accessible in an emergency and shall be located at least 15 meters away from the equipment and marked distinctly and conspicuously with their design function. Communication shall be provided between ship and terminal control room. Interlock shall be provided between the ship and the Jetty control Room. Provision shall be given in the jetty for the above facility. During unloading operation, the terminal operator shall take control of the unloading. In addition to automatic shutdown system (ESD) the terminal operator shall be in a position to initiate shut down of unloading. FIRE AND HYDROCARBON LEAK DETECTION SYSTEM Hydrocarbon detectors shall be installed near all potential leak source of LPG vapors e.g. On the top of the vessel, tank dykes, manifolds, pump house manifold etc. Hydrocarbon detector of proper type shall be selected and also shall be proof tested and shall be maintained in good condition. The Hydro Carbon Detection System shall provide early warning on build up of Vapour concentration below the LEL limits. These detectors shall be placed in a way that entire possible source of leaks and collection of products is continuously detected and alarm is set at 20% of lower explosive limit. Those areas including enclosed buildings that have a potential for flammable gas concentrations of LPG or spill of flammable refrigerant and fire shall be monitored. Continuously monitored low temperature sensors or flammable gas detection systems shall sound an alarm at the plant site and at a constantly attended location. Flammable gas detection systems shall initiate this alarm at 20 % LEL of the gas or vapour being monitored. The Fire detectors shall initiate an audio and visual alarm at the plant site and at a constantly attended location.
Power Supply: The supply to the system (control system such as DCS , PLC , control valves , Txs) shall be through a reliable on line uninterrupted power supply. (online UPS). Architecture Components The main components shall be: 1. 2. 3. 4. 5. 6. Hydro Carbon Detectors Field Transmission units / Signal scanners. Control system / PC with printing option for alarms Display Annunciation System etc Cables, hooters, repeater, Power Supplies etc.
All the components installed in the hazardous area shall confirm to the Hazard Area Classification applicable and shall be certified by PESO / Authorized lab by the country of the origin. i) Annunciation System
Appropriate annunciation system shall be available to ensure that all the alarms generated, both, audio and visual are reported to the installation personnel at local and remote control panel. The alarms both, audio and visual can be repeated at additional location to ensure corrective action is taken. ii) Hydro Carbon Detectors:
Draft OISDSTD236
Page No. 24
The detectors shall be able to detect the presence of Hydro Carbon Vapours well below the LEL level. Any one or more in combination from the following types can be provided. i) Catalytic detectors ii) Infra-red detectors iii) Line / Path detectors. The system shall be available at all times. The control equipment should have data logging facilities to provide print outs of the history of the events with date and time of leakages. The control equipment should be able to generate at least two alarms at different levels of LEL concentration of Hydro Carbons. iii) 1. Inspection and Testing: The system health status shall be checked by the safety officer on a daily basis.
The system shall be thoroughly inspected once in each quarter by releasing Hydro Carbon Mixture at each detector. 2. Calibration of the detectors shall be done every three months by releasing known concentration of Hydro Carbon mixture and the records maintained. The drift in the sensitivity of the individual detectors shall be recorded in maintenance history log book during calibration and the detectors with abnormal or wide drift in sensitivity shall be rectified / replaced. FIRE PROTECTION SYSTEM FOR LPG TERMINAL The primary source of fire and explosion hazard is from a leak or spill from the LPG storage or transfer systems. FIRE WATER SYSTEM The main components of the fire water system are: Fire Water Storage Fire Water Pumps Fire Hydrant/ Monitor distribution piping network. Water Sprinkler/ Deluge system.
(i) The fire protection scheme shall be designed on the assumption that only one major fire shall occur at a time in the terminal. (ii) For the storage tanks, water sprays shall be provided on the tank shell including the roof and the appurtenances on the tank. a. W ater application rate for the tank roof and walls shall be minimum 3 lpm/m2 2 b. The water application rate on the appurtenances shall be 10.2 lpm / m as per this code. c. Water spray is not applicable for the concrete outer tank. d. The water densities applicable to other equipment shall be as follows: 2 Vessels, structural members Piping & valves manifolds : 10.2 lpm / m 2 Pumps and Compressors : 20.4 lpm/ m (iii) ) The roof section shall be provided with duplicate 100% risers. (iv) The deluge valves on the water spray systems on the tanks as well as the pumps, compressors, vessels etc. shall be actuated automatically through a fire detection system installed around the facilities with provisions of manual actuation from Control Room or locally at site.
Draft OISDSTD236
Page No. 25
(v) For single containment tanks having metallic outer tank which are having a dyke, high expansion foam systems shall be provided as per NFPA 11. High expansion foam generators shall be located on the impounding area around the storage tanks. Foam units comprising storage facilities and pumps shall be provided in a safe area removed from the protected risk and shall be accessible in an emergency. (vi) Portable high expansion foam generators may also be provided, suitable for coupling to hydrant hose lines for isolated LPG spills. Fixed dry chemical powder or nitrogen snuffing systems shall be provided for each relief valve outlet of the LPG storage tanks. Each set shall provide two shots of dry chemicals in the event of ignition during venting.
(vii)
(viii) Fire hydrants shall be provided along the main fire header at suitable intervals in the process and storage areas. Fixed foam/water monitors may be provided around the process areas based on requirement. (ix) Water Spray System shall be provided for process area housing condensors heat exchangers, evaporators, blender with spray density @ 10.2 lpm / Sq. M. Refer Annexure A2 for typical water Calculations in Refrigerated LPG terminal FIRE EXTINGUISHING AND OTHER FIRE CONTROL EQUIPMENT Portable wheeled fire extinguishers suitable for gas fires, preferably of the dry chemical type shall be made available at strategic locations. Fixed fire extinguishing and other fire control systems that may be appropriate for the protection of specific hazards, are to be provided. Vessels, equipment, structures, cables, safety critical instruments etc., that are likely to be exposed to LPG fire radiation shall be provided with a passive fire protection in the form of fire proofing insulation or/and water deluge for the duration of the hazard . Fire proofing shall be executed as per appropriate standards. The extent & duration of passive Fire protection shall be based on the HAZOP study. Embrittlement Protection. Equipment and structures shall be protected by insulation or appropriate metallurgy selection against cold shock and failure due to a spill of LPG. CCTV cameras shall be provided at the critical points such as Flash & Boil off Compressor house, heaters, condenser, refrigerated tank dyke, Top of refrigerated tanks, LPG storage Vessels, LPG pump house and blender area, Flare, process area, cross country pipeline transfer area etc. PERSONNEL SAFETY Personnel shall be advised of the serious danger from frostbite that can result upon contact with LPG or cold refrigerant. Suitable protective clothing and equipment shall be made available. Low temperature suits / hand gloves shall be worn when carrying out emergency repairs / maintenance. This is also suitable in case of exposure to flash fires as well. Those employees who will be involved in emergency activities shall be equipped with the necessary clothing and equipment. Self-contained breathing apparatus shall be provided for those employees who may be required to enter an atmosphere that could be injurious to health during an emergency. A portable flammable gas indicator shall be readily available because LPG and hydrocarbon refrigerants within the process equipment are usually not odorized and the sense of smell cannot be
Draft OISDSTD236
Page No. 26
relied upon to detect their presence.
Draft OISDSTD236
Page No. 27
8.0
OPERATIONS OF REFRIGERATED LPG STORAGE INSTALLATION:
In refrigerated LPG installation the product is stored either in pure propane & pure butane form or in premixed LPG (i.e. mix of propane & butane conforming to IS: 4576) at their respective boiling point (i.e. 42 deg C for Pure Propane, - 5 deg C for Pure Butane and 25 to 28 deg C for LPG depending upon the constitution) at ambient pressure. The area wise operations are as followings: Storage Tank Operation: Receipt & Storage: Before receipt of any parcel in the refrigerated storage tanks, it is required to be ensured that the receipt lines to be maintained at the temperature of the receiving product. This is normally done by re-circulating the product of the same specification already available in the storage tank. Receipt operation should be carried out in a way so that storage tank pressure & temperature can be maintained within the limit. The same may be accomplished by operating the refrigeration compressors. The storage tank pressure & temperature are the key parameters for this kind of installation, which should be religiously monitored by operational personnel to avert product loss due to auto-flaring or pop-up of SRVs on excess pressure. After completion of receipt the receipt lines need to be evacuated by pushing compressed vapor from the refrigeration compressor discharge. Dispatch: Specially designed submersible In-tank pumps are used for dispatching of product because of very low NPSH availability. The levels of product to be monitored while starting & during the dispatch operation. The Tank pressure & temperature to be continuously monitored during the dispatch operation as there may be pressure rise due to re-circulation of product or pressure decrease due to faster evacuation of product. Before start-up of pumps, it is to be ensured that all the discharge valves are in closed condition. The recirculation valve to be put mandatorily on auto mode. Compressor House Operation: The refrigeration compressors plays very important role in keeping the pressure & temperature in the refrigerated storage tanks under control. The compressors to be run on need basis as per the requirement during receipt, dispatch and even when there is no operation to maintain the pressure. These compressors are very big compressors normally run by HT motors with lot of safety interlocks. Normally the capacity of the compressors may also be varied seamlessly as per the requirement. These compressors are positive displacement types hence the discharge valves should mandatorily be in open condition while starting the compressors. The cooling water supply & control air supply as per the specification must be ensured. The lubricant supply should be ensured before starting. Process Unit Operation: The process unit consists of following operations: a) b) c) d) e) f) g) Condensation of the Refrigeration Compressor Discharge LPG Condensate Transfer unit Heating Section for heating the refrigerated product to ambient temperature Steam Condensate Transfer Unit Blending of Pure Propane & Pure Butane for manufacturing LPG Odourisation Vapour Pressure Analyser
Condensation of the refrigeration compressor discharge:
Draft OISDSTD236
Page No. 28
Compressed gas from the discharge of the refrigeration compressor is being fed to the condensation unit where the liquefaction process is taking place through heat exchangers using Cooling Water as the cooling medium and the condensate is received in transit tanks (known as product condensate receiver). Subsequently the condensate is pumped to buffer storage bullets where the product is stored under pressurized conditions. The whole system of condensation and condensate pumping is being associated with safety interlocks and alarms for safe operation. Heating Section for heating the refrigerated product to ambient temperature: The refrigerated product pumped from the storage tanks is heated through Heat exchangers using LP Steam as the heating medium or by any suitable alternate heating mechanism such as hot air, ambient air, water etc. The steam / air / water heating process is normally a multistage process where product is passed thru more than one heat exchanger. The hot product is routed to blending section for further processing and the steam condensate in case of steam heating arrangement (i.e. LP Steam converts into water by releasing latent heat to the refrigerated product) is collected in a Steam Condensate receiver. The Steam condensate is subsequently pumped from the receiver to the Demineralised Water plant polishing unit for further processing. The whole system of heating of product is associated with safety interlocks and alarms to ensure desired temperature of product at the heating section outlet for safe operation. Air Preheater System: Tube bundle is provided for increasing the surface area of the product during travel. All tubes are covered with fins and subjected to forced draft air from the fans operating at fixed / variable RPM to maintain the required temperature at the outlet. Steam Condensate Transfer Unit The unit consists of a Steam Condensate receiver & Condensate transfer pumps. The steam condensate is transferred by the pumps at regular interval preferably in auto mode interlocked with the level of receiver to DM plant condensate receiver tank for further processing. Blending of Pure Propane & Pure Butane for manufacturing LPG: The heated product (i.e. Pure Propane & Pure Butane) is blended at specified ratio in blender with the help of automatic flow control valves for making LPG conforming to IS:4576. The property of the blended product is checked thru online analyzer for meeting IS: 4576 and subsequent feedback control mechanism. Blending conforming to IS: 4576 is compulsory & hence necessary measure should be always in place to check the composition meeting IS: 4576. Odourisation Unit: The LPG is extremely inflammable and it has no odour, so that detection of any leakage of LPG is very difficult. Hence the LPG is subsequently passed thru odourisation section where Ethyl Mercaptan is dosed @ 15 to 20 PPM immediately after blending for identification of any leakage at the downstream in line with IS: 4576. Proper deodorizing agent i.e. Sodium hypo chloride / sand / mask/ etc to be provided at Dozing unit.
Buffer Storage Operation: The product transferred from Product condensate receiver is stored at buffer storage in pressurized condition at ambient temperature. Subsequently the product is evacuated by pumps and sent to blending area for further processing. Flaring Operation:
Draft OISDSTD236
Page No. 29
Normally these types of installations are equipped with hot flaring facility. Flaring is usually avoided as it leads to loss of product however whenever required flaring resorted to control the pressure inside the refrigerated tanks. Flaring can be done thru flow control valves by operator or it may be done in automode as per the system presets. The flaring either hot or cold is of extreme importance as this is the last resort to maintain the pressure inside the tank & avoid any untoward even due to pressure rise. Control Room Operation: There is lot of operations to be handled simultaneously for running these types of installations. Hence a central control room is provided to facilitate all the operation from remote from a single location. Control Room houses DCS based or equivalent automation system where from all the commands can be initiated, controlled & all the parameters can be monitored thru single window system. The system is backed-up with UPS of suitable capacity. Utility Section: The utility section mainly consists of following facilities: a) Boiler b) Instrument Air c) Cooling Tower d) Electrical Sub-station Boiler: If Low Pressure Steam heating is envisaged, Boiler of suitable capacity is used to produce LP Steam for using in heating of refrigerated product. Boiler system houses DM Water Generation Plant, Effluent Treatment Plant & Boilers. Instrument Air: Instrument Air is used for operating ROVs and other control systems of the entire plant. Cooling Tower: Cooling Tower is used for supplying Cooling Water for mainly using in condensation of refrigeration compressor discharge, for cooling of refrigeration compressors and other cooling requirements. Maintaining schedule for chemical treatment of cooling water / cooling tower Electrical Sub-station: For catering the electrical requirement of all HT & LT Motors and other electrical loads. DG sets for HT supply and LT supply RAW WATER TANK RAW WATER TANK and associated pumping system on auto mode to top up cooling water reservoir shall be considered.
Draft OISDSTD236
Page No. 30
9.0
INSPECTION & MAINTENANCE OF REFRIGERATED LPG STORAGE INSTALLATION:
INSPECTION -TANK Routine internal inspection of RLPG tanks are not required to be carried out since RLPG tanks are not subjected to corrosion under service condition because of the low temperature involved. However, RLPG tanks can be taken up for internal inspection when the tanks are taken out of service for other operational / repair reasons. - Tank Settlement Tanks levels and settlements shall be checked at intervals and records shall be maintained. - Roof Outer roofs shall be checked visually for external corrosion at intervals of every Qtr. - Regular monitoring of LPG leakage in between area of tank & dyke wall using GMS sensors - Check for leakage of liquid LPG from inner tank to outer tank in case of double containment & full containment tanks on continuous basis. - Visual check to ascertain the condition of external insulation cladding, insulating material & load bearing insulation every year. - Check foundation bolts and anchor straps for deterioration & tightness every year - Check filling and off take pipes, supports for movements yearly - Inspections to be carried out under the supervision of competent person - Pressure & Vacuum Relief Valves Shall be inspected for corrosion, blockage etc and tested annually and records maintained. In-situ tests shall be permissible. - Refrigerated LPG lines inside the terminal NDT shall be carried out once in three years at selected windows and records maintained. Hydro test of the concerned section shall be done after any hot work. - Process Unit Equipment / fittings shall be inspected & tested as per the relevant OISD / OEM Stds. Storage Tank: This atmospheric above ground double walled, double roof integrity tanks are designed for life time without any appreciable maintenance. However regular maintenance is required regarding external painting, insulation, external cladding, calibration of valves, transmitters, gauges etc.. For any other maintenance in this type of tank requires complete de-commissioning of the tank. Compressor House: The regular maintenance requirement of the compressors is as following: Checking of lubricant level in the gear box Checking of lubricant level in the oil separator drum Checking & cleaning of the vapour suction filter Checking & cleaning of the Oil Filters Cleaning of Intercooler, After-cooler heat exchangers Calibration of Safety Valves Insulation Resistance Checking of Motors Greasing of Motor Bearings Checking of Alignment between Motor, Gear Box, Compressor as applicable Checking functioning of solenoid valves & control valves Maintenance Painting of the equipment
Draft OISDSTD236
Page No. 31
Major overhauling of the compressor as per the period specified by OEM
Process Unit: Periodical cleaning of Condensers Periodical cleaning of Pump Filters Periodical cleaning of Heat Exchangers & Vaporisers Periodical testing & calibration of safety valves Periodical maintenance / overhauling of mechanical valves Periodical calibration of gauges, transmitters Statutory testing of Heat Exchangers, Condensate Receiver Vessels Periodical Calibration of Vapor Analysers Maintenance Painting of Structures & equipments Periodical calibration of metering pump of odourisation unit. Periodic testing of redundancy of the DCS and PLC system. Periodic checking of various parameters of software programs. Periodic checking of all interlocks and logic for effective functionality.
Buffer Storage: Periodic Testing of Buffer Vessels Periodic cleaning of Pump Filters Periodic maintenance / overhauling of pumps Periodical testing & calibration of safety valves Periodical maintenance / overhauling of mechanical valves Periodical calibration of gauges, transmitters Daily monitoring of CP system & rectification if required Statutory testing
Utility Section: Periodical testing of DM water quality Health Checking of the Refractory of Boiler Statutory inspection by IBR Periodical testing & calibration of safety valves Periodical maintenance / overhauling of mechanical valves Periodical calibration of gauges, transmitters Maintenance Painting of Structures & equipments Periodical maintenance of IA Compressor Periodical cleaning of Cooling Tower Periodic chemical treatment of cooling water. Periodical testing of CW Water quality Periodical checking & filling of lubricant in CW Fan Gear Box Periodical health checking of CW Fan Motors
Electrical Sub-station: Carrying out all electrical maintenance periodically as per requirements Inspection of Refrigerated LPG Storage Installation:
Draft OISDSTD236
Page No. 32
Besides routine and statutory inspections like other plants following specific inspection may be undertaken: Checking the condition of Insulation of the storage tanks Checking the condition of Insulation of receipt lines Checking the health of Refractory Lining of Boilers SQC of DM Water SQC of Cooling Water Periodical Checking the quality of all lubricants
Ethyl Mercaptan Dosing unit : Periodic testing of ethyl mercaptan storage tank, Periodic testing of ethyl mercaptan pumps Periodic testing of SRV on mercaptan tank.
EQUIPMENTS MAINT & INSPECTION: Relevant OISD stds and OEM recommendations shall be followed. EMERGENCY MANAGEMENT PLAN: Emergency Management Plan as per PNGRB act shall be made. SAFETY AUDIT Indicative check list are in annexure.
Draft OISDSTD236
Page No. 33
10.0
COMMISSIONING AND DECOMMISSIONING :
COMMISSIONING After hydro testing Tanks to be dried to desired level considering storage of the refrigerated product. Purging of the Tank to be done by inert gas to drive away ambient air & moistures Cool down shall be performed after the tank purge has been completed. A cool down procedure shall be developed to provide a controlled process. During the initial introduction of liquid product, it is important to ensure that the storage tank cools as uniformly as possible. Sharp thermal gradients can cause permanent local distortions and potential crack growth. The cool down rate for a steel primary liquid container shall be as per the design in line with the standard used for design. Sweetening of Tanks to be done very slowly by taking refrigerated product vapor thru bottom ring so that temperature stratification at the tank bottom & tank wall can be avoided. The temperature gradient to be closely monitored. The pressure inside the tank is also to be closely monitored so that it lies within the designed pressure range of the Tank. For controlling pressure inside the tank controlled flaring to be resorted till the Tank is completely filled up with the refrigerated product vapour. For sweetening of tank & maintaining uniform temperature gradient the bottom sprayer rings installed inside the tanks to be used. On achieving the final temperature inside tank using refrigerated product vapour, refrigerated liquid product to be introduced very slowly thru bottom sprayer rings for avoiding any cold spot & to be filled up to minimum 6 inches, thereafter the rate may be slowly increased up to designed level. The Compressors, Process Unit Equipment, product pipings & Buffer Storage to be purged & sweetened before commissioning of Tank. After sweetening of the Tanks is completed, immediately compressor to be used for maintaining pressure & temperature inside tanks for avoiding flaring loss. DECOMMISSIONING: Refrigerated LPG tanks are constructed for life time and not envisaged for decommissioning. Maintenance of the tank internals should not be attempted on routine basis. However if any operational reasons or any tank internal failure is envisaged decommissioning may be planned. Following minimum procedures to be adopted Removal of pumpable liquid using In-tank pumps Removal of liquid dead-stock using Compressors by means of vaporization as advised by the licenser. Close monitoring to be done to maintain the Tank Pressure within design pressure range & maintaining a slow temperature gradient suitable as per design. Degassing the Tanks using dry inert-gas introducing from the top & evacuating the hydrocarbon from bottom dip-pipe. The procedure to be continued till the entire tanks become gas free which may be ascertained by sampling.
Draft OISDSTD236
Page No. 34
11.0
Annexures
S. No A1 A2 Item Details of Level and Volumes Fire Water Calculations details Illustrative figure Illustrative example
S. No A3 A4 A5 A6 A7
Checks Typical Daily Safety Check list. Typical Monthly Check list Typical Electrical Safety Audit Check list Typical Maintenance & Inspection Audits Check List Typical Safety Index Assessment.
Frequency Daily Monthly Yearly Six Monthly Yearly
By Safety Officer Location In-charge Competent Electrical engineer Multi-Disciplinary Team Multi-Disciplinary Team
Draft OISDSTD236
Page No. 35
12.0
REFERENCES
The following codes, standards and publications have either been referred to or used in the preparation of this document and the same shall be read in conjunction with this document: S.No. 1 2 3 4 5 6 7 8 9 10 11 12 13 Ref Code No EEMUA: Pub 147 IP 9 API 2510 API 620 API 2350 API 2000 NFPA 58 NFPA 59 NFPA 59A, API 625 ACI 376 AGA XK 0101 EN 14620:1-4 Title Recommendations for the Design and Construction of Refrigerated Liquefied Gas Storage Tanks Institute of Petroleum Liquefied Petroleum Gas Volume 1 Large Bulk Pressure Storage and Refrigerated LPG Design and Construction of LPG Installations Design and Construction of Large, Welded, Low-pressure Storage Tanks Overfill Protection for Storage Tanks in Petroleum Facilities, Third Edition Venting Atmospheric and Low-pressure Storage Tanks Liquefied Petroleum gas Code Utility LP-Gas Plant Code Standard for the Production, Storage, and Handling of Liquefied Natural Gas (LNG) Tank Systems for Refrigerated Liquefied Gas Storage Code Requirements for Design and Construction of Concrete Structures for the Containment of Refrigerated Liquefied Gases and Commentary Purging Principles and Practice Design and manufacture of site built, vertical, cylindrical, flatbottomed steel tanks for the storage of refrigerated, liquefied gasses with operating temperatures between 0 C and 165 C Part 1 to Part 4. Standard Test Method for Measuring Compressive Properties of Thermal Insulations Standard Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the GuardedHot-Plate Apparatus Standard Test Methods of Testing Cellular Glass Insulation Block Standard Specification for Cellular Glass Insulation Standard Specification for Perlite Loose Fill Insulation Standard Specification for Mineral Fiber Loose-Fill Thermal Insulation Process Piping Work Permit System Code of Practice for Design loads (Other than Earthquakes) for buildings and other structures. IS 1893 (Part 1) (2002, Reaffirmed 2007): Criteria for Earthquake Resistant Design of Structures, Liquefied Petroleum Gas Installations Guide for selection of electrical equipment for hazardous areas. Classification of Hazardous area having flammable gases and vapours for electrical installation. Code of Practice for Earthing. Insulating mats for electrical purposes Personal Protective Equipment to be referred for details on selection, use and maintenance of electrical PPEs.
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
ASTM C165 ASTM C177 ASTM C240 ASTM C552 ASTM C549 ASTM C764 ASME B31.3 OISD-STD-105 IS:875 IS:1893 (Part 1)2002 OISD-STD-144 IS 5571 IS 5572 IS 3043 IS 15652 OISD-STD-155
Annexure A2 Fire Water / Pump Requirement Calculation A. Sl. No. 1 2 Medium Velocity Water Spray System (MVWSS): Location Tank Truck Loading / Unloading Facility a. Refrigerated Tank Surafce area b. Refrigerated Tank Roof area c. Refrigerated Tank Total area LPG Pump House Compressor House Rail Loadinf Facility Process Area Horton Sphere Shed Water Req / Area of Single Area of Spray Density Hour Cu Mtr per (LPM) hr Area / size Area / size largest zone adjacent zones 30 15 450 0 10.2 275 35 20 2198 2198 3 791 35 961.6 961.63 3 346 1137 20 10 200 0 20.4 245 30 20 600 0 20.4 734 30 15 450 900 10.2 826 20 15 300 0 10.2 184 18 1017.4 2034.7 10.2 1868 40 12 480 960 10.2 881 1868 288 2156 5.3 Say 6 2 8 Cum/Hr
3 4 5 6 7 8 B. C. D. E. F G H I J
Single largest area covered by Medium velocity Water Sprinkler System is Horton Sphere: Water Requirement for operating 2 nos. Monitors @ 144 Cum/Hr: Total Water requirement ( B+C ): No. of Fire Water Pumps Required ( 410 Cum/Hr capacity): 2156/410= No. of standby pumps required ( minimum 50% of main pump): 2 Total number of Fire Water Pumps Required ( 6 + 2)= 8 Total No. of main Fire Water Pumps Available : 6 Fire water storage tanks capacity requied for 4 Hrs fire fighting (6 x 4 x 410): Minimum two nos of tanks shall be provided.
9840
Kl
Annexure-A3
DAILY SAFETY AUDIT - TYPICAL CHECKLIST FOR REFRIGERATED LPG IMPORT TERMINAL
Date: LOCATION -
dit / Inspection by Target Date 5
Sr No 1 2
Item
Observation
Action Plan 4
Review Date 6 (Status)
A. MAIN GATE / TRUCK PARKING AREA A-01 Door Frame Metal Detector in working condition Acess to the Terminal is controlled and records for entry of all persons A-02 available A-03 Persons entering the plant premisies properly frisked by security. Persons entering the plant premisies breifed about safety prequations, A-04 Do/Donts by security. A-05 Mobile are not allowed in the operating areas in side the battery limit. Material In-Out documents maintained and entries made in the A-06 registers A-07 Vehicles entering the plant premises properly checked. Proper gates passes issued to contract workmen while entering the A-08 plant premises. A-09 CCTV cameras are being monitored by security supervisor. A-10 Vehicles parked properly in the alloted parking area Entry exit gates in TT parking area in locked condiition during non A-11 operating hours. A-12 Driver rest room clean and hygenic A-13 No driver found cooking in the parking area/outside the rest room. A-14 Speed limit board visible at TT entry. B. SAFETY / FIRE PROTECTION SYSTEM B-01 Water Level in static water tank is satisfactory B-02 Hydrant pressure maintaied with jockey pump. Record Pressure B-03 Fire Water Pumps / Engines B-04 Are the batteries in good condition B-05 Are the diesel tanks full B-06 Start one pump, record pressure developed B-07 Whether auto start system working B-08 Fire alarm / communication system in working order B-09 Automatic Gas Detection system operating B-10 Any unsafe condition of S&EP system observed (specify in brief under remarks column) B-11 Regular surprise checks / testing being done at gate / at the plant B-12 Checking for presence of security personell in designated areas. B-13 Checking of duty roster, attendance of security. B-14 Direction of wind (specify in remarks column by observing wind stock) B-15 Caution signs displayed at appropirate places B-16 Security air compressor in working condition in auto-mode B-17 Last fire drill in this area done on B-18 Jockey pumps in working condition in auto-mode B-19 Housekeeping properly maintained and in order. C- SUBSTATION C-01 Adequate CO2 FE's in the designated places. C-02 ALL panels in lock-close condition Page 1 of 5
Item Sr No C-03 Adequate lighting in the substation C-04 Panel indication lamps working. C-05 Housekeeping properly maintained and in order. D. BUFFER TANK AREA D-01 Whether water draining sampling done under constant supervision D-02 Earthing connection apparently sound D-03 Cathodic Protection healthy D-04 Whether level instruments are working D-05 High level alarm in working condition (test check) D-06 Portable fire extinguishers in postion D-07 Water spray / sprinkler system apparently OK D-08 Housekeeping is in order D-09 Gas Detection system working D-10 Any sign of LPG leakage D-11 Any settlement of vessel observed D-12 Condition of Water Seal D-13 ROVs on remote mode D-14 Bonding across flanges visible D-15 API 52 pump tripping in Buffer tank in working condition. D-16 Last fire drill in this area done on E. PROPANE/BUTANE TANK AREA E-01 Earthing connection apparently sound E-02 Whether level instruments are working E-03 High level alarm in working condition (test check) E-04 Portable fire extinguishers in postion E-05 Water spray / sprinkler system apparently OK E-06 Housekeeping is in order E-07 Gas Detection system working E-08 Any sign of LPG leakage E-09 Any settlement of tank observed E-10 Condition of Water Seal in dyke area E-11 ROVs on remote mode E-12 Bonding across flanges visible E-13 High Pressure tripping-interlock with import valves. E-14 Auto Flare of tanks in working condition. E-15 Portable fire extinguishers in postion E-16 The insulation cover and cladding of cryogenic tanks is in good condition E-17 Last fire drill in this area done on E-18 vapour trap is provided as per design. E-19 The upstream and down stream valves of TSV on intank pump discharge line are in open and locked position E-20 The pressure gauges on intank pump discharge line on tank top are in working condition E-21 The updtream valve of SRV and VRV should be in open locked position F. TANK WAGON LOADING AREA F-01 Any visible sign of LPG leakage F-02 Earthing connection apparently sound F-03 Whether hose condition / connections are proper F-04 Are these properly plugged if not in use F-05 House Keeping in order F-06 Portable fire extinguishers in postion F-07 Water spray / sprinkler system apparently OK F-08 No open wire / improper glanding visible.
Observation
Action Plan
Target Date
Review Date
Page 2 of 5
Sr No F-09 F-10 F-11 F-12 F-13 F-14
Item
Observation
Action Plan
Target Date
Review Date
House Keeping in order Condition of Water Seal Gas Monitoring System Functional ROVs on remote mode Bonding across flanges visible Winch system in working condition with trippings to avoid De-railment of wagons. F-15 Last fire drill in this area done on
G. TANK TRUCK LOADING AREA G-01 Are all vehicles allowed in licensed are permanently fitted with CCE approved spart arrestors on exhaust pipe (Random check) G-02 Is the vehicle engine and master switch being shut off during unloading bulk LPG (site check) G-03 All the drivers and cleaners wearing PPE. G-04 All the keys kept in designated key box at TLF G-05 Are the earthing connection properly made before connecting hoses to tank trucks G-06 Rotogauge, Fixed leevl instrument in working order (Random check Record TT No) G-07 Any visible sign of LPG leakage G-08 Random safety check of tank truck No. G-09 a) CCE licence available / valid G-10 b) Fittings as per CCE G-11 c) 2 Nos of Fire extinguishers available in good condition / easily accessible (physical check) G-12 d) Safety instruction booklet TREMCARD available. Record any abnormality / discrepancies observed G-13 e) Wheel choke used G-14 a) Portable extinguisher available in nominated places G-15 b) Sprinkle system in working condition G-16 Any LPG leakage observed. G-17 House Keeping in order G-18 Bonding of flange connection given G-19 Hose test date G-20 Last fire drill in this area done on H. H-01 H-02 H-03 H-04 H-05 H-06 H-07 H-08 LPG COMPRESSOR HOUSE Electrical connections apparently sound Earthing apparently proper Gauges on compressor in working condition, record pressure Drain / vent connection cap in position Safety guards in position Abnormal vibration / excessive noise Portable fire extinguishers in postion Any visible sign of LPG leak or any unsafe conditions observed (record under remarks column). H-09 House Keeping in order H-10 Gas Detection system working H-11 No leakage/smell of mercaptan observed at Vapou analyser unit
H-12 Last fire drill in this area done on I. BOILER HOUSE I-01 No leakags observed in the Deisel/HSD lines. I-02 No leakages observed in LPG lines. I-03 No leakages observed in LPG cylinder. I-04 No flue gas leakage observed from the Chimney.
Page 3 of 5
Item Sr No I-05 No flue gas leakage observed from the combustion chamber/ I-06 No steam leakage from valve glands. I-07 Explosion door properly placed. I-08 No lagging damage found in steam lines I-09 Portable fire extinguishers in postion I-10 Abnormal sound / vibration I-11 Electrical connections apparently sound I-12 Earthing apparently proper I-13 House Keeping in order J. PRE HEATER SYSTEM J-01 No leakages observed from the preheater tubes J-02 All tempearture gauges and transmitters at inlet and outlet are in working condition J-03 All pressure gauges and transmitters at inlet and outlet are in working condition J-04 Fan belt are aligned and are in good condition. J-05 Earthing is provided and effective J-06 ROV at inlet is working on OK mode J-07 Pre heater fan motor alignment is OK K. DM WATER PLANT K-01 No leakages observed in the Acid and Alkali pipelines. K-02 No leakages observed in the Acid and Alkali over head tanks. K-03 All motor coupling guards in position. K-04 Emergency Water Shower in working condition. K-05 DM water tank level more than 3 mts. K-06 Deareation of efluent treatement plant in working condition. K-07 No leakage in primary effluent tanks K-08 No air leakage observed, K-09 Electrical connections apparently sound K-10 Earthing apparently proper K-11 House Keeping in order K-12 Acid Corrosion / Rusting visible L - AIR COMPRESSOR HOUSE L-01 No air / water leakage observed, L-02 House Keeping in order L-03 Equipment properly painted. L-04 No abnormal vibration observed. L-05 Electrical connections apparently sound L-06 Earthing apparently proper L-07 Portable fire extinguishers in postion L-08 All the V-Belts available and properly tightened. M - DIESEL YARD M-01 House Keeping in order M-02 Equipment properly painted. M-03 Electrical connections apparently sound M-04 Earthing apparently proper M-05 Portable fire extinguishers in postion M-06 Sand buckets filled with dry sand and in position. M-07 No HSD leakage / accumulation observed. M-08 No open electrical wire / connection available. N - SCRAP YARD N-01 Designated scrap yard available. N-02 No scrap material kept outside designated area. N-03 Scrap yard seperated by barbed wire fencing and gate kept closed.
Page 4 of 5
Observation
Action Plan
Target Date
Review Date
Item Sr No O - ADMINISTRATIVE BUILDING O-01 House Keeping in order O-02 No temporary electrical connections visible. O-03 Electrical connections apparently sound O-04 Portable fire extinguishers in postion ELCB for Water Cooler and Refrigerator in working condition. (Admin O-05 building) O-06 Earthing system proper. P - AMINITIES BLOCK P-01 House Keeping in order P-02 No temporary electrical connections visible. P-03 Electrical connections apparently sound P-04 ELCB for Water Cooler and Refrigerator in working condition. P-05 Fly catcher in working condition. LPG storage having double wire mesh enclosure with DCP placed. P-06 P-07 Quick shut off valve available both inside and outside. P-08 Earthing system proper. P-09 Portable fire extinguishers in postion Q - JETTY FACILITIES Q-01 Any visible sign of LPG leakage/icing in dockline Q-02 Gas Detection Functional Q-03 ROVs on remote mode Q-04 Bonding across flanges visible Q-05 High Pressure tripping-interlock with import valves. R - ADDITIONAL POINTS R-01 Emergency shut down system is working and effective R-02 Cooling Tower in working condition R-03 CCTV OPERATIONAL
Observation
Action Plan
Target Date
Review Date
Signature of inspecting officer
Signature of Location I/C
Page 5 of 5
Annexure-A4
Monthly Checks
Typical Monthly Check list
Name of the location

Sl No Description 1 1.1 1.12 1.13 1.14 1.2 1.22 1.23 1.25 1.26 1.3 1.31 1.32 1.4 1.41 1.42 1.5 1.51 1.52 1.53 All statutory records available and updated License / Test Certificate No.
Date
Remarks/ Renewal Application Date
Validity
PESO Licenses License to Store Compressed Gas in Pressure Vessels Storage of HSD inside premises for Own Use Updated Plant & equipment Layout duly approved. Weights & Measures Stamping of Weigh Bridge (TLF IN & OUT) Stamping of Weigh Bridge (RLF) Stamping of Standard Weights Stamping of MFM (RLF/TLF) Factory Related Factory License Copy of Notification of Occupier issued by MOPNG available Pollution Control Consent under Air (Prevention and Control of Pollution) Act, 1981 Consent under Water (Prevention and Control of Pollution) Act, 1974 Labour Related PF no. & ESI Registration no. of Location, if applicable Registration under Contract labour ( Regulation and & Abolition )Act 1970 License details of Contractors under Contract Labour (Reg. & Abo.) Act. All statutory records available and updated License / Test Certificate No.
Validity
Remarks/ Renewal Application Date
2 2.1 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26
Test Certificates Valid test certificates available for Hydrotest of LPG STORAGE VESSELS NDT and Hydrotest records for Underground / aboveground LPG pipelines NDT and Hydrotest records for Jetty LPG pipelines NDT & Hydrotest for other Pressure vessels as per Factory Act SRVs & TSVs Lifting tools & Tackles, chain pulley block Fire Water Line NDT Fire Water Tanks cleaning details LPG Hose Testing Pr gauge / Temp gauge testing records Relay Test record Earth Pit Testing Motor & LT / HT Cable IR testing Electrical Hand Gloves Insulating mats/Rubber Mats for Electrical purpose Transformer Oil Test
3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2 3.3 3.4 3.5 3.6 3.7 3.8
SAFETY
Audit Compliance Status Name of Audit OISD- ESA OISD- surprise MDT Audit Electrical Audit Security Audit Internal Audit Emergency lighting system provided in strategic locations & system working satisfactorily Records of `Daily Safety Audit' reviewed by Loc.In-Charge Work Permit system viz Hot, Cold, Electrical and Working at height (issue and closure) checked First-Aid facilities maintained Safety Circle / Committee meeting are conducted . Record last meeting dates Fire alarm (electrical & hand sirens) working satisfactorily Total Points Complied Remarks
Remarks
Status
Communication system (PA Paging / VHF) working satisfactorily 3.9 Flame proof Torches in working condition 3.10 Automatic Gas Detection system : Working & Calibration records available 3.11 Record Pressure at farthest end of hydrant network 3.12 Interlock shutdown system as per OISD 11.11 (iv) checked and found ok Remarks 3.13 Fire Protection System on auto. Test check atleast one DV through QB. 3.14 Fire engine - Sequence logic tested and found OK. 3.15 Fuel gauge of HSD tanks ( DG & fire engines) working and levels OK 3.16 Fire Water storage tank : Indicate Requirement in KL and availabilty in KL 3.17 Fire Extinguishers / Fire Hoses kept at nominated places 3.18 No temporary electrical connection existing Safety Equipment inventory reviewed for shortfall and 3.19 action taken 3.20 Any unsafe conditions observed in TTs Parking area 3.21 Important DO's & Dont's , Operating Instructions, displayed prominently in respective places 3.22 SOP displayed at operating locations Trainings being conducted and records available as per 3.23 OISD 154 4 SECURITY 4.1 Fencing around plant is in proper condition 4.2 Tower lights illumination checked and found ok. 4.3 All records at the gates are maintained and reviewed as per norms 4.4 Material In-Out Register (Corporation / Contractor) 4.5 Returnable material register 4.6 Visitor's register 4.7 Gatepass systems 4.8 CCTV functional Status
4.9 4.10 4.11 4.12 5 5.1 a b c 5.2 5.21 5.22 5.23 5.24 5.25 5.26 5.27 5.28 5.29 5.3 5.31 5.32 5.33 5.34
5.35 6 6.1 6.2 6.3 6.4 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15
ACS functional DFMD & HHMD in use Under vehicle search mirror in use Updated list of authorised signatory available. Operations One panel in PMCC checked for following Cleanliness Fuse/rating Relay setting ROVs working Satisfactorily Cooling water flow adequate and cooling fans in working condition. Whether on line analyser working satisfactorily. DM water level in DM tank above 3 mtrs. No acid / alkali leak visible No HSD / LPG leak at boiler. No Flue / Steam leak observed. Whether logsheets/records are maintained for daily activities at PPH/PMCC/FPH/CCR Loading hoses of Tank wagon Gantry when not in use positioned correctly, ends blinded. Open ends of Unloading arms/hoses capped when not in use at TLD Eight studs used for connection of flanges at TLD Wheel chokes available & chained at TLD No portion of pipe length found buried with soil or undergrowth SRVs are locked in open position Vent pipes of Safety Relief valves on LPG storage vessels are provided with rain caps & weep holes (connected with drain pipe and isolation valve). No LPG leakages observed in operating areas. MAINTENANCE Double independent earthing connection for all motors /structures/vessels/ pipelines provided FLP condition of electrical equipments intact Push button earthed properly All LPG Vent lines provided with double mesh and properly earthed No leakage from mechanical seals of LPG pumps Pipeline colour code system maintained Bonding connections maintained for pipelines, Vessels, conveyors, gantry. Two independent level instruments provided in storage vessels & are in working condition HLA interlock with ROV on storage vessels working Stores Module (SAP-MM module ) implemented for equipment and consumable stores Whether functional locations in PM module created and tasklists for these implemented Whether all continuous monitoring devices are periodically checked & calibrated Cathodic Protection System of Mounded storage system checked and found ok Condition of the mound checked / No settlement observed.
BI monthly M&I indexing being carried out and corrective 6.16 action taken
6.17 Stocks of critical spares maintained 7 GENERAL 7.1 System for monitoring work done by the handling contractor, exists. 7.2 Canteen cleanliness adequate 7.3 Cylinder bank for canteen kitchen properly constructed/maintained 7.4 General Housekeeping standards 7.5 Maintenance of Buffer Zone, Peripheral Road motorable. 7.6 Condition of Painting of buildings, structures and facility Monitoring of turn around time of packed and Bulk trucks 7.7 ensured 8 FINANCE 8.1 Physical Inventory of LPG bulk and HSD tallying with Book Balance as per SAP
Signature of Location Incharge

Notes: The above audit is to be carried out by Location In-Charges on monthly basis within the 1st week of the 1 Audit month In case of expiry of validity of statutory certificates/licenses, application date for renewal is to be 2 mentioned in remarks Column 3 Sample test checks carried out should be different from the previous sample tests carried out 4 Self M&I Indexing to be carried out by Plant Maintenance Officer on bi-monthly basis Compliance to terms and conditions of various statutory licenses and certificates to be ensured. 5
Annexure-A5 REFRIGERTAED LPG IMPORT TERMINAL Typical Electrical Audit Format Sr. No. A a
Observation Recommendation
Item SWITCHYARD AND OUTDOOR EQUIPMENT: Are the following components individually earthed with two separate earth leads (No. 8 SWG copper or equivalent)? 1) Metal Frameworks 2) A.B.Switches and circuit breakers 3) D/O and H/G Fuses 4) Poles/switches/insulator pins/stay clamps 5) Operating handles of the A.B.swithes Whether the vertial and horizontal clearance from O.H. ondutors are maintained as per I.E. Rule-79 Are the earth eletrodes provided in sufficient numbers Whether the earth pits are properly maintained and tests carried out as per schedule? Whether the lighting arrestors are connected after the A.B.switch for the protections of transformer/circuit breaker? Whether a separate earth electrodes of proper size is provided properly for the lighting arrestors? Is there O.H. shielding for lightning protection and whether it is properly maintained? whether there is locking arrangemant for the Transformer bay to prevent entry to the yard by unauthorised persons?If so, whether it is being followed? Whether the doors of the gate are rusted and need to be painted? Whether transformer is providedwith oil level indicator explosion vent and buchholz relays and are in working condition? Is the buried underground earth conductors getting exposed at any location ? Whetherthe High Voltage breaker is overhauled and relay tested periodicaly? HV Transformer Where a sub-station or a switch station with apparatus having more than 2000 litres of oil is installed, whether indoor or out-doors, the following measures are taken, namely: State in case of transformers or switches or static condensers involving the use of more than 2,275 litres of oil in one chamber, if suitable oil soak pits are provided.
b c d e f g h i j k l A1
d e f g h i j k
The transformer shall be protected by an automatic high velocity water spray system or by carbon dioxide or BCF (Bromochlorodifeuromethane) or BTM (Bromotrifluromethane) fixed installation system. The baffle walls [of 4 hour fire rating] shall be provided between the apparatus in the following cases: (A) Single phase banks in the switch-yards of generating stations and substations; (B) On the consumer premises; (C) Where adequate clearance between the units is not available. Whether the transformer oil samples are being tested periodically and results recorded in a register? Whether suitable lightning arrestors have been provided near the transformers for protection against lightning? No Oil leak / sweating observed. Silica gel OK. Oil / winding Temperature OK Terminal Box earthing OK Oil level in transformer(s) and circuit breakers(s) found in topped up condition. Periodic / scheduled oil quality test / oil change conducted and dielectric strength test results are found acceptable. Whether general condition of transformer yard / shed, flooring surface, painting of the transformer / shed / fencing / gates, and over all cleanliness / house keeping etc. is OK? Whether dry vegetation / grass found in the yard? Whether there is locking arrangement for the Transformer yard to prevent entry by the unauthorized persons? If so, is it being followed? Substation Is the substation equipment freely aessible for Operation,Inspection and Maintenance? Are the minimum clearances around the equipments maintained as per I.E. Rule 51 ? Are the substation equipments provided with double earthing connetions? Are the live parts of equipments made inaccessible from inadvertent contacts (by barrier / shrouds)? Whether the rubber gloves and mats with voltage test seals are provided in front of the switch boards and are in good conditions? Whether the switchboards are dust / vermin proof ? Is pest control treatment given for substations? Are any unused cable entries left open? Have the protective relays been set at the recommended values (as per the design )? Whether the fuses are HRC Type and of ratings specified in single line diagrams? Whether each outgoing distinct circuit from the switchboard is separately controlled by a suitable linked switchfuse or circuit breaker of required capacity?
m B a b c d e f g h i j
k l m n o p q r s t u v w x y z aa ab ac ad ae af ag ah B1 a b c d e f g
Whether circuit identification marks / tags are provided? Are the relays and meters tested for proper functioning/ calibration as per approved shedule ? Whether the bus are provided with distint colour identification(Red,Yellow,Blue& Black) Whether the conduits used for cable entry are sealed and earthed? Are the energised eletrical equipment provided with caution notices? Is the substation building made water tight and all the openings in walls (such as cable trench entry /bus duct entry) sealed? Whether any water stagnation is there inside the cable trenches? Are all the power (H.T/L.T.) and control cables in the trenches properly segregated? Are the cables near the terminations clamped? Is there any combustible material used for construction of substation building? Whether the cable trenches are provided with concrete slabs/ chequered plates? Are the earth electrodes periodically tested and maintained properly? Are the earth resistance of the grid measured checked and recorded periodically? Is the substation provided with Emergency Lighting? Is the substation provided with telephone? Is the trench such sump (for dewatering) in working condition (wherever provided)? Are floors kept clean, free of tripping hazards? Whether the switchgear rooms located in the hazardous area are pressurised? (if not,are these provided with flameproof equipments) ? Whether all panel doors are kept closed ? whether all the indicating lamps in the panel are in operating condition (i.e. not fused)? Whether live parts of equipments made inaccessible by barriers / shrouds? Are the oil immeresed starters filled with oil to the required level and of required dielectric strength? whether shock restoration hart & first aid box provided? Whether Emergency Light is provided and is in working condition or not ? DC Battery Charger What is type of battery used ? Whether the battery Room is clean and well ventilated Are the floors acid proof ? Whether exhaust fans provided ? Are the cell voltage of cell being checked and recorded as per approved schedules ? Is there any corrosion on terminals / connectors ? Whether all the safety equipment ( rubber apron,googles, acid proof handgloves etc. ) are available ?
h i B2 a
Is the operation of Battery Charger satisfactory ? ( Test for critical service ) ? Whether tricle charger working and checked properly ? Points for Medium/High Voltage Installation at Substation Providing Circuit Breaker for positive power isolation. Whether a suitable linked switch/circuit breaker is placed near the point of commencement of supply so as to be readily accessible and capable of being easily operated to completely isolate the supply? Is there a suitable linked switch or a circuit breaker to carry and break the full load current on the secondary side of a transformer? Whether every distinct circuit is protected against excess energy by means of a suitable circuit breaker or cut-outs? State if a suitable linked switch or circuit breaker is provided near the High Voltage motor or other apparatus for controlling supply to the motor or apparatus. State if adequate precautions are taken to ensure that no live parts are so exposed as to cause danger. Clearance of swith board in case of HT/Medium Voltage at Substation State the condition of metallic coverings provided for various conductors. State whether clear space of 90 cm is provided in front of the main switchboard. State whether the space behind the switch-board exceeds 75 cm.in width or is less than 23 cm. In case the clear space behind the switch-board exceeds 75 cm state whether a passage way from either end of the switch board to a height of 1.80 meters is provided. Additional provisions for use of energy at high and extra-high voltageThe following additional provisions shall be observed where energy at high or extrahigh voltage is supplied, converted, transferred or used, namely: Suitable inter-locks shall be provided in the following cases: Where two or more supplies are not intended to be operated in parallel, the respective circuit breakers or linked switches controlling the supplies shall be interlocked to prevent possibility of any inadvertent paralleling or feedback; All gates or doors of the panel which give access to live parts of an installation shall be inter-locked in such a way that these cannot be opened unless the live parts are made dead. Proper discharging and earthing of these parts should be ensured before any person comes in close proximity of such parts; Electrical Caution Notice/First Aid Training in case of HT installaions. Every medium, high voltage installation shall affix permanently in conspicuous position a caution notice in Hindi and the local language of the district, and of a type approved by the Inspector on
b c d e B3 a
b c
B4
B5
Every motor, generator, transformer and other electrical plant and equipment a together with apparatus used for controlling or regulating the same. All supports of high, and extra-high voltage overhead lines Provided that where it is not possible to affix such notices on any generator, motor, transformer or other apparatus, they shall be affixed as near as b possible thereto: Provided further that where the generator, motor, transformer or other apparatus is within an enclosure, one notice affixed to the said enclosure shall be sufficient for the purpose of this rule. c In the case of generating and enclosed stations have fire-buckets, filled with clean dry sand, been conspicuously marked and kept in convenient situations in addition to fire-extinguishers suitable for dealing with electric fires? State if First Aid Boxes or Cupboards conspicuously marked and properly equipped are provided and maintained. Is some staff trained in First Aid Treatment? In every manned high voltage or extra-high voltage generating station, substation or switch station, an artificial respirator shall be provided and kept in goodworking condition LV Transformer / Lighting Transformer Cable terminations / horn gap / CTPT / main circuit breakers etc. is OK. Foundation OK. Transformer positioned properly. No Oil leak / sweating observed. Silica gel OK. Oil / winding Temperature OK Terminal Box earthing OK Oil level in transformer(s) and circuit breakers(s) found in topped up condition. Periodic / scheduled oil quality test / oil change conducted and dielectric strength test results are found acceptable. Whether general condition of transformer yard / shed, flooring surface, i painting of the transformer / shed / fencing / gates, and over all cleanliness / house keeping etc. is OK? Whether dry vegetation / grass found in the yard? Whether there is locking arrangement for the Transformer yard to prevent entry by the unauthorized persons? If so, is it being followed? Is the buried underground earth conductors getting exposed at any location ? DG Room Is the neutral of the generator provided with an isolator? Whether DGs is provided with two independent body earthing? Whether the neutral of the generator is earthed by minimum two separate earth connections and whether the earthing is after the isolator?
d e f B6 a b c d e f g h
j k C a b c
d e f g h i j k
Whether the wires / cables near the Generator / Generator to switch board are housed in metallic conduit and the conduit is earthed? Whether the control panel for the generator is earthed with two separate and distinct connections with earth? Whether the generator panels are made vermin proof? Wherever more than one generator is provided, whether provision of individual breakers is kept for paralleling arrangement? Whether danger notices are provided on equipments / panels in the generator room? Whether the DG Room (where generator is installed) is dry and dust free? Whether generator room is having adequate ventilation? Whether control panel provided is with all protection devices like short circuit, over current, earth fault relays? Whether calibration of these devices carried out annually? Are the following tripping are working in HT DG Main Alternator Fault, Very High Bearing Temp, Low Air Pressure, Speed Sensing Failure and other tripping as recommedded and provided by OEM Emergency lighting is provided in DG room and is in working condition Is the buried underground earth conductors getting exposed at any location ? Boiler/DM Plant Check for working of the following tripping High Steam Outlet Pressure Low Drum Water Level Fuel Oil Level low F/D Fan is in Off condition Inlet Fuel Pressure is low Scanner Cooling air pressure low Deaerator Level Low Automising Air pressure low Whether motors in boiler are provided with double earthing ? Whether the glanding are done poperly for motor in boiler area ? Whether the boiler control panels are provided with double earthing ? Whether Emergency lighting is provided in the boiler area and panel room and is in working condition ? Whether CO2 is provided for electrical fire fighting in control room ? Whether the boiler control panels are made vermin proof? Is the Lumen value is as per standard for proper lighting in boiler area and control room ? Whether DM plant tank is provided with double earhting or not ? All the electrical JB in DM plant area are provided with double earhting or not ? Wheter the coupling guard and fan guard is provided for all the motors at boiler? Instrument Air Compresssor Is the motor provided with double earthing? Is the motor provided with fan guard and coupling guard?
l m n D a (i) (ii) (III) (iv) (v) (vi) (vii) (viii) b c d e f g h i j k E a b
c e f F a b c d e f g h i j k G a b c d e f H a b c d e f g h
Is the junction boxes/push button/lighting fixtures provided with the double earthing? Are all the tripping of the air compressor are working? Is the visual indication and annunciation provided for respective tripping for air compresor and is in working condition? Fire Pump House Is Fire Pump / Engine base frame connected to earthing pits / grid at two independent points. Whether visual indication and alarms of tripping are working in fire panels for all the engines ? Is double body earthing provided for all the fire water pump (Jocky pump and well / sump pump) motors. Is the Lumens value is as per standard for proper lighting in fire pump house area ? Are the cell voltage, specific gravity of cell, and level of the electrolyte being checked and recorded as per approved schedules ? Is there any corrosion battery on terminals / connectors ? Whether all the safety equipment ( rubber apron,googles, acid proof handgloves etc. ) are available ? Whether tricle charger working and checked properly ? All the electrical panels are provided with double earthing with proper glanding ? Whether Emerency Lights are provided and is in working condition ? Wheter the coupling guard and fan guard is provided for all the jockey pump motors? Cooling Tower Are all the motor at cooling tower is provided with double earthing? Are all the motor provided at cooling tower is flame proof in nature? Whether the push button provided are flame proof in nature and provided with double earthing? Is the panel for cooling tower provided with double earthing as per standard? Is the fan motor provided with double earthing? Wheter the coupling guard and fan guard is provided for all the motors? Administrative Building Is 30 mAmp ELCB is provided in admin building and is in working condition ? Whether the Air Conditioner are provided with double earthing ? Whether the water cooler is provided with double earthing? Is UPS provided in admin building for giving backup to PC ? Whether the UPS in the admin building is provided with double earthing ? Is emergency lighting provided in admin building ? Is the Lumens is as per standard for proper lighting in the admin buliding? Whether C02 is provided in admin building for electrical fire fighting ?
i I a b c d e f J a b c K a b c d e f g h i j k l m n o L a b c
Is the buried underground earth conductors getting exposed at any location ? Canteen Area Is 30 mAmp ELCB is provided in canteen and is in working condition ? Is appropriate Nos. of Fly Catcher Is provided in Canteen and is in working Condition? Is Water Cooler is provided with double earthing at canteen? Are all the fans/lighting provided is in working condition? Is the double mess provided in cylinder bank provided with earthing? Is Cylinder bank product pipeline is properly earhted? Store/Amenity Area Is 30 mAmp ELCB is provided in store and is in working condition ? Are all the fans/lighting provided is in working condition? Is the lumen value as per standard for proper lighting in store and amentiy area? Central Control Room (CCR) Is 30 mAmp ELCB is provided in and is in working condition ? Are all the air conditoner provided with earthing? Are all the electronic equipments that stores energy In CCR is provided with earthing? Is the UPS provided with double earthing and is as per standard? What is type of battery used for UPS ? Whether the battery Room is clean and well ventilated? Are the floors acid proof ? Whether exhaust fans provided for battery room ? Are the cell voltage of cell being checked and recorded as per approved schedules ? Is there any corrosion on terminals / connectors? Whether all the safety equipment ( rubber apron,googles, acid proof handgloves etc. ) are available ? Is the operation of UPS satisfactory ? ( Test for critical service ) ? Whether tricle charger working and checked properly ? Is the lumen value as per standard for proper lighting in CCR? Is CO2 fire extinguisher provided for electrical fire fighting? Weigh Bridge Whether Weigh Bridge plateform is connected with earthing pits / grid at two independent points? Whether load cells of Weigh Bridge are earthed? Whether the JBs is flame proof in nature and is provided with double earthing or not? Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel.
e f g M a
Whether electrical light fittings are flame proof, cable connections are with flame proof double compression glands and no armour is exposed any where? The Electronic Indicator of weigh bridge is provided with earthing or not ? Whether all electronic equipment which stores electrical energy are properly earthed ? Tank Lorry Filling (TLF) Whether electrical light fittings are flame proof, cable connections are with flame proof double compression glands and no armor is exposed any where?
c d e f g h i j k l N a b c d e f g h i
Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. Whether earthing connections, fixing and continuity of conductor with body and junction box in the pits is OK? Whether bonding arrangement for Tank trucks with crocodile clips provided? Whether crocodile clips have lost the springing action causing improper grip with the surface, clips are rusted? Whether Emerency Lights are provided and is in working condition ? Are all the loading arms earthed? Whether the flexible wire used for tankers body earthing (TTL Gantry) is soldered to crocodile clips ? Whether earth jumpers across the pipe flanges (of gantry piping ) are provided ? Whether all electronic equipment which stores electrical energy are properly earthed ? Is the buried underground earth conductors getting exposed at any location ? Whether all GMS Sensors provided are properly earthed ? Mounded bullet/LPG pump House Is Cathodic Protection Log Book maintained on daily basis ? Is Mounded Bullet properly isolated from oulet and inlet pipelines for effective protection Is reference voltage of reference cell within the limits Is over and under protection alarm & indicator for cahtodic protection is provided and is working Are the Junction boxes of cathodic protection are flame proof and provided with double earthing. Is healty and unhealthy condition status of cathodic protection is being displayed in DCS. Anode current value is within the range as per OEM recommendation. Is lighting arrestor provided for cathodic lighting prtotection. Whether the motor of LPG Pump is provided with double earthing
Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination) and no armour is exposed? Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. Panels of LPG pump is flame proof and is provided with double earthing. Whether push button for the motor is installed near the motor? Emergecny Lighting is provided at LPG Pump House and is in working condition ? Whether tripping of LPG pump such as high discharge, Low suction etc is working ? Whether daily / monthly / quarterly / yearly inspection of motors being done and records maintained? Are the nameplates of Motors worn out? Whether the inscriptions are visible? In case of worn out / non legible name plates, whether records are available? Whether motor winding insulation resistance tested annually (review test records)? Is the buried underground earth conductors getting exposed at any location ? Whether all GMS Sensors provided are properly earthed ? Railway Gantry Are the Rail Tracks within the gantry / siding premises earthed and bonded with piping? Are all the loading arm earthed ? Are all the swivel joint of loading arm bonded. Whether crocodile clips user for earthing Railway wagon have lost the springing action causing improper grip with the surface? Whether crocodile clips are rusted? Whether earth jumpers (strip / wire) across the pipe flange joints (of Railway gantry piping) are provided? Are the Control panels/motors of Winch system at RLF is properly earthed at two different point. Are all the electrical tripping of Winch systems are workin such as overload tripping etc. Whether electrical light fittings/junction box are flame proof, cable connections are with flame proof glands? Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination) and no armour is exposed? Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. Whether Emerency Lights are provided and is in working condition ?
l m n o p q r s t O a b c d e f g h i
j k
l m n P a b c d e f g h i j Q a b c d
Whether all electronic equipment which stores electrical energy are properly earthed ? Is the buried underground earth conductors getting exposed at any location ? Whether all GMS Sensors provided are properly earthed ? Degassing Unit Whether the motor is provided with double earthing and is flameproof in nature? Whether the coupling guard and fan guard is provided for motor? Wheter the push buttons/junction boxes is provided with double earthing and is flame proof in nature? Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination) and no armour is exposed? Whether the screw compessor is provided with double body earthing? Whether the screw air compressor tripping are working? Whether the visual indication and annunciation is provided for respective trippings of compressor and is in working condition? Whether it is provided with flame proof lighting fixtures and is provided with earthing? Is the lumen value as per standard for proper lighting in degassing unit area?
Is the buried underground earth conductors getting exposed at any location ? Mother Tanks Whether the Mother Tanks are provided with double body earthing from two different earth pits ? Whetther the electrical Junction boxes are flame proof in nature and provided with double earthing ? Whether the Lighting Fixtures provided is Flame proof and provided with double earthing ? Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination) and no armour is exposed? Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. Whether the flanges of liquid line and vapour line are bonded with GI strip for proper electrical continuity? Are the steelcolum/mettalic structure/stair case properly earthed. Is the Lumen value is as per standard for proper lighting in boiler area and control room ? Whether all electronic equipment which stores electrical energy are properly earthed ? Whether all GMS Sensors provided are properly earthed ? Is the buried underground earth conductors getting exposed at any location ?
f g h i j k
R a b c d e f g
Vapor Compressor House Is dust or dirt accumulated on motor Whether the motor is properly protected from dust dirt water chemical fumes etc Is motor Vibration level is within permissible value Is there any abnormal sound in motor Whether the motor has been earthed properly by two separate earth connections? Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination) and no armour is exposed? Are all the Junction Boxes are of flame proof type and provided with double earthing Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. For oil filled bearings, whether sufficient oil is there in bearing and check for oil circulation. Is the lumen value as per standard for proper lighting? Vapor Compressor Tripping such as Low Suction Pressure ,High Suction Pressure, High Fine Oil Seprator Pressure, High discharge temperature and others as per OEM recommendation are working Is the IR value of HT motor measured with 2.5 KV Megger and IR value is equal to or above 50 M Ohms for 6.6. KV motors Whether electrical light fittings are flame proof, cable connections are with flame proof glands? Whether Emerency Lights are provided and is in working condition ? Whether daily / monthly / quarterly / yearly inspection of motors being done and records maintained? Are the nameplates of Motors worn out? Whether the inscriptions are visible? In case of worn out / non legible name plates, whether records are available? Are the steelcolum/mettalic structure/stair case properly earhted? Whether there is any discontinuity of earthing connection ? Whether earth jumpers across the pipe flanges (of gantry piping ) are provided ? Is the buried underground earth conductors getting exposed at any location ? Whether earth jumpers across the pipe flanges (of gantry piping ) are provided ? Whether all GMS Sensors provided are properly earthed ? Appartus Field System (AFS) Whether the receiver tank/condenser/vaporiser/heater is provided with double body earthing as per standard? Are the steel colum/mettalic structure/stair case properly earhted? Whether the lighting fixtures is flame proof in nature and provided with earthing?
i j k l m n o p q r s t u v S a b c
Are all the Junction box are flame proof in nature and provided with double body earthing? Whether all the flame proof equipments are provided with additional internal earthing inside the terminal box through additional core of cable and the other end of the core is terminated to earth bus in the panel. Are the cable entries in termination / Junction Boxes through Double Compression FLP glands in the classified areas (No direct cables termination)? Are all the cable termination is done properly in JBs/motor/lighting fixtures and no cable armour is found exposed? Are the motors at AFS provided with double earthing and in flame proof in nature? Are the steelcolum/mettalic structure/stair case properly earthed? Whether there is any discontinuity of earthing connection ? Whether earth jumpers across the pipe flanges (of gantry piping ) are provided ? Whether all electronic equipment which stores electrical energy are properly earthed ? Is the buried underground earth conductors getting exposed at any location ? Whether all GMS Sensors are properly earthed ? Earth Pits Is the earthing carried out as per IS 3043? Are the earth electrodes being tested periodically? What is the grid resistance (in ohms) ? Is this periodically measured and recorded ? Are the earthing connections to lighting protection and electrical system protection (Neutral earthing and body earthing) provided separately ? Whether the earth pits with chambers are exposed and visible or is embedded inside the loose earth ? Whether the earth strip connections on the earth electrode are loose / sheared off / tight ? Whether the earth strips joints are having an overlapping equivalent to the width of the strip (minimum) and all the four sides are welded ?
f g h i j k l m n T a b c d e f g
Maintenance and Inspection Audit Format TYPICAL CHECKLIST FOR REFRIGERATED LPG IMPORT TERMINAL
Sr. No. 1.0 1.1 1.1.1 AREA UTILITY AREA BOILERS Statutory Yearly inspection of Boilers by Boiler Authority carried out and records maintained. Shortcomings identified during inspection have been rectified before start-up Following trips have been tested by boiler operator and records maintained. Do sample test of two trips during the day. Boiler High Pressure Switch Tripping Drum Level Trippings Low Deisel Pressure Tripping FD Fan Air Flow Tripping Deaerater Level Low Trip Flame Failure Trip Drum Level Trippings No leakage of following Diesel Flue Gas Steam Shift wise blowdown carried out and records maintained Preventive maintenance schedule prepared and carried out and records maintained Following indicators and controllers are healthy and audio visual alarms are working Steam Header Pressure PRDS Pressure PRDS steam temperature Main steam flow Drum Water level Feed water flow LPG Control valve position LPG Flow LPG level controller HSD Tank level alarm high and low HSD Fuel pump pressure indicator FD fan vent openin controller YES / NO MARKS MAX. AWARD REMARKS
WTAGE.
1.1.2 1.1.3
1.1.3.1 1.1.3.2 1.1.3.3 1.1.3.4 1.1.3.5 1.1.3.6 1.1.3.7 1.1.4 1.1.4.1 1.1.4.2 1.1.4.3 1.1.5 1.1.6
2 2 2 2 2 2 2 3 3 3 2 2
1.1.7 1.1.7.1 1.1.7.2 1.1.7.3 1.1.7.4 1.1.7.5 1.1.7.6 1.1.7.7 1.1.7.8 1.1.7.9 1.1.7.10 1.1.7.11 1.1.7.12
2 2 2 2 2 2 2 2 2 2 2 2
Sr. No. 1.1.7.13 1.1.7.14 1.1.7.15 1.1.7.16 1.1.7.17 1.1.8 1.1.9
AREA Economizer inlet & outlet flue gas temperature indicator De-aerator level controller De-areator steam pressure controller LPG evaporator pressure controller Scanner cooling air pressure General housekeeping in the area satisfactory Economizer condition satisfactory ( mention % of tubes blocked as per Plant feedback ) Condition of all foundations are satisfactoryBoiler/ FD fan/ Feed water pumps. FD Fan condition satisfactory, no abnormal sound,vibration etc. housing condition is OK Condition of blow down pipe and boiler feed water pipe is satisfactory. No corrosion, deep pitter areas etc. Inspection procedure as laid out in OISD 131 has been adhered to and records maintained accordingly. DM Plant Visual condition of tanks satisfactory- PSF, SAC, HCL, WBA, Degasser tank, SBA. Painting OK and no corrosion observed Annual thickness measurement of tanks carried out and records maintained Standard operating procedure and Dos and Dont displayed PH and conductivity meter functional and parametrs are within norms Boiler Feed water quality & Boiler water is tested regularly and parameters are within permissible value as specified in Boiler O&M manual Vol-1 PM jobs are carried out as specified in DM Plant O&M manual- Section-6, records maintained PUMPS
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
2 2 2 2 2 2 3
1.1.10
1.1.11
1.1.12
1.1.13
1.2 1.2.1
1.2.2 1.2.3 1.2.4 1.2.5
3 3 3 2
1.2.6
1.3
Sr. No. 1.3.1 1.3.1.1
AREA Process Water Pump Process water pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of PW pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / PW pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut DM Water pump Cooling water pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of CW pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / CW pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Condensate Water Pump Condensate water pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Boiler Feed Water Pump BFW pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of BFW pumps OK - no oversized bolts used in couplings
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
1.3.1.2 1.3.1.3
2 2
1.3.1.4
1.3.2 1.3.2.1 1.3.2.2 1.3.2.3
2 2 2
1.3.2.4
1.3.3 1.3.3.1
1.3.3.2 1.3.3.3 1.3.3.4
2 2 2
1.3.4 1.3.4.1 1.3.4.2
3 2
Sr. No. 1.3.4.3
AREA No broken/missing footbolts / foundation bolts in compressors / motors / BFW pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Neutralization Pit Pump pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut HSD Pumps HSD pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of HSD pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / HSD pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Appparatus Field Section Condensors and Heaters Flash Gas condensors and boil off condensors are periodically cleaned , (once in 4 years) and records maintained Hydrotest is carried out on shell and tube side every 4 years, records maintained
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
1.3.4.4
1.3.5 1.3.5.1 1.3.5.2 1.3.5.3 1.3.5.4
1 2 2 1
1.3.6 1.3.6.1 1.3.6.2 1.3.6.3
2 2 2
1.3.6.4
2.0 2.1 2.1.1
2.1.2
Sr. No. 2.1.3
AREA Condensate receiver vessel in good condition. Testing not over due. Records of periodic testing and hydrotest maintained. Flash Gas Condensate Receiver is to be tested as per SMPV Rules 1981 ( unfired) Annual test of Boil -off condensate receiver vessel SRV carried out and records maintained Receiver discharge pumps are in helathy condition. No abnormal sound, Vibration. Flow controllers FC70 & 70B for receiver discharge Pumps are in Auto mode and not in manual Four yearly cleaning and hydrotest of LPG heaters carried out and records maintained LPG heaters are in good condition. Painting is OK and no corrosion No leakage of Steam, LPG from exchangers or pipes Piping condition is satisfactory, painting, no corrosion, pipe supports. Structurals are in good condition, painting ok, no corrosion, No loose foundation bolts etc. Pipes are easily identified with proper colour codes Blending Section Control Valves are functional and calibrated. No leakage of Mercaptan from tank or pipes or pumps Dosing pump is operational and dosing is under auto control Flow meters are functional and transmitters are calibrated quarterly Mercaptan is properly stored and no spillage is observed Pressure and temperature gauges are working and claibrations are done
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
2.1.4
2.1.5 2.1.6
2 2
2.1.7
2.1.8 2.1.9 2.1.10 2.1.11
3 2 3 3
2.1.12 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6
2 2 3 2 2 2
Sr. No. 2.2.7 2.2.8 2.2.9 3.0 3.0.1
AREA Vapour Pressure Analyser is functional and online Housekeeping in the area is satisfactory Pipeline condition is satisfactory- Painting, no corrosion TLF / WEIGHBRIDGE Hoses used are of approved quality standards (IS 9573) OR Unloading arms are free & easy to operate, quick couplings in good working condition Loading hoses when not in use are stored properly & open end kept blinded [O] / Female coupling kept covered with plastic/rubber caps. No loading / unloading hoses having kinks / cracks Hoses periodically tested and test records available Studs & gaskets used for connecting with tankers are of acceptable quality All quick shutoff valves / ROVs of TLD functioning properly Unloading arms PM schedules followed & records maintained Interlocking system of female coupling with male coupling is OK in all unloading arms not tied with ropes/wires Foundation bolts & other bolts of unloading arms are properly tightened Earthing wires of swivel joints / unloading arms are OK & not broken All Balancing devices are operational Swivel joints are operational without any leaks No visible external damages on unloading arms Unloading arms central column and brackets not damaged / corroded Gantry structurals in good condition painting in good condition
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
4 2 2
3.0.2
3.0.3 3.0.4 3.0.5 3.0.6 3.0.7 3.0.8
2 2 2 2 2 2
3.0.9 3.0.10 3.0.11 3.0.12 3.0.13 3.0.14 3.0.15
2 2 2 2 2 2 2
Sr. No. 3.0.16 3.0.17 3.0.18 3.0.19 3.0.20 3.0.21 4.0 4.0.1 4.0.2
AREA
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
No leakages from valves/flanges Earthing / bonding / lightning protection done as per requirement Sprinkler system in good working order no leaks / nozzles choked Weigh Bridge in working order / calibration not overdue Entry / exit ramps at level with WB platform condition OK Double earthing of WB done RLF ( Railway Loading farm) Hoses used are of approved quality standards (IS 9573) Loading hoses/ Unloading arms when not in use: a> are stored properly b> open ends kept blinded/Female coupling kept covered with plastic/rubber caps. Unloading arms PM schedules followed & records maintained Interlocking system of female coupling with male coupling is OK in all unloading arms not tied with ropes/wires Foundation bolts & other bolts of unloading arms are properly tightened Earthing wires of swivel joints / unloading arms are OK & not broken All Balancing devices are operational Swivel joints are operational without any leaks No visible external damages on unloading arms Unloading arms central column and brackets not damaged / corroded Studs & gaskets used for connecting with wagons are of acceptable quality All quick shutoff valves / ROVs of TWD functioning properly Gantry structurals in good condition painting in good condition No leakages from valves/flanges
2 2 3 3 2 2 2
2 2
4.0.3 4.0.4
2 2
4.0.5 4.0.6 4.0.7 4.0.8 4.0.9 4.0.10 4.0.11 4.0.12 4.0.13 4.0.14
2 2 2 2 2 2 2 2 2 2
Sr. No. 4.0.15 4.0.16 4.0.17
AREA Earthing / bonding / lightning protection done as per requirement Winch for wagons are tested and records available Mass flow meters are functional and calibrated. Calibration certificates are valid
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
2 2 2
4.0.18 4.0.19 4.0.20 5.0 5.1 5.1.1
5.1.2 5.1.3 5.1.4 5.1.5
5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 5.1.12 5.1.13
Sprinkler system in good working order no leaks / nozzles choked In-motion Weigh Bridge in working order / calibration not overdue Double earthing of WB done BULK STORAGE AREA ATMOSPHERIC REFRIGERATED BUTANE/PROPANE TANKS Following records were available and found valid: a> Whether inspection / test certificates at the time of original fabrication available (including drawing and certificates mentioning NDT inspection) [O] All SRVs are tested annually / tests are not overdue [O] SRVs are provided with vent pipes SRVs are provided with isolation valves & locked [O] insulation periodically checked for damage/, bulging & suspect areas are further inspected for presence of corrosion, etc., & corrective steps taken Auto Flare valve opening at 1000mm WC is functional and tested Earthing connections properly maintained [O] Condition of grounding electrodes OK [O] Pipeline insulation condition is OK. No portion exposed No portion of pipe length found buried with soil or undergrowth Bolts on flanges are properly sized / no bolts missing No leakages from valves glands Caps provided over Pop action valves
2 3 2
2 2 2 4
2 3 3 2 3 2 3 5
Sr. No. 5.1.14
AREA
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
5.1.15 5.1.16 5.1.17
5.1.18 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6 5.2.6.1 5.2.6.2 5.2.6.3 5.3 5.3.1 5.3.2
5.3.3
5.3.4 5.3.5 5.3.6 5.3.7
Condition of paint of Vessel cladding and roof acceptable for 1 more year - no large corroded areas Condition of structurals, ladders, railings, platforms OK Pressure / Temperature gauges and transmitters OK Both the level gauges are functional and there is no abnormal variation in their readings Sprinkler system OK no leaks / choked nozzles Intank LPG Pumps Following operating parameters within permissible Vibration Readings. Discharge Flow rate Motor Current drawn Discharge pressure Following trips are functional Interlock tripping for : Pressure Interlock tripping for : Flow rate Interlock tripping for : motor current MOUNDED LPG TANKS ( BUFFER TANKS) Condition of mound OK. No cracks / seepage Overall condition of Cathodic Protection system (cabling / JBs / surge protectors, etc.) OK Six monthly settlment reading is being taken and recorded. Reference level is identified and marked. CP panel and meters in proper working condition All CP voltages are as per requirement (records to be checked) Sprinkler system OK no leaks / choked nozzles ROVs of bulk storage areas operate within acceptable response time (max. 30 secs.)
3 2 2
4 4 4 4 4 4 4
3 2
2 3 2 2
Sr. No. 6.0 6.1 6.1.1
AREA PIPELINES / VALVES PIPELINES A/G & U/G Inspection records of annual / 5-year testing of underground / aboveground LPG lines [O] Pipe supports are not damaged point contact & properly spaced No vegetation growth below pipelines or concreting / brick pitching done below pipelines Pipelines crossing roads/ dykes are wrapped & coated - visible portions are OK Piping culverts are clean & pipe painting OK Pipe surfaces are free from deep pitting corrosion & large pitted areas Pipeline painting/Insulation is free from defects and corrosion spots No voids / peeling in wrapping-coating on portions of lines emerging from ground at road crossings NDT of pipelines carried out as per HO LPG (M&I) guidelines in the last 3 years & reports available Continuity of Earthing / Bonding in LPG pipelines maintained All pop-action valves are OK (properly set & not passing) & their isolation valves are kept open Flange joints have proper studs/nuts & are leak free Re-circulation line provided from farthest points in the FW network back to the FW tanks OR schedule for flushing of FW lines being followed F/W monitors / hydrants brick pitched & provided with platforms VALVES Valve gland / gasket leaks attended regularly no leaks observed
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
6.1.2 6.1.3
2 2
6.1.4
6.1.5 6.1.6 6.1.7 6.1.8
2 3 4 3
6.1.9
6.1.10 6.1.11
2 2
6.1.12 6.1.13
2 2
6.1.14 6.2 6.2.1
Sr. No. 6.2.2 6.2.3 6.2.4
AREA Isolation valves with drains for pressure gauges / switches provided Valve bodies are properly painted no excessive corrosion Preventive maintenance followed - Greasing of valve stems and wheel bushes done
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 3 2
6.2.5 6.2.6 6.3 6.3.1 6.3.2 6.3.3 7.0 7.0.1 7.0.2 7.0.3 7.0.4 7.0.5 7.0.6 7.0.7 7.0.8 7.0.9 7.0.10 7.0.11 7.0.12
No bent / damaged valve stems, missing wheels found Drain valves & vent valves are not passing & are capped SERVICE / SECURITY AIR , WATER & STEAM LINES Condition of pipelines are good and properly painted no excessive corrosion Pipe supports are OK (no pipe sagging) & in good condition No leaks observed COMPRESSORS - LPG No lekage from Mechanical seal Oil level in gear box is OK Noise / vibration levels of compressors / motors.gear box are satisfactory Condition of coupling & alignment OK Coupling guards in position - rigid Earthing connections properly maintained not connected to footbolts Painting / cleaning of body OK / no oil spillage Oil level in Oil drum is sufficient & quality OK ( to be checked in Off- condition ) discharg gas temperatures within limits Differential pressure between lubeoil and LPG vapour is within acceptable limits Preventive maintenance schedules followed & records maintained All tripping devices are healthy ( discharge pressure , low suction pressure, low lubevapour differential, low lube level, high gas dischage temp, low lube temperature,) 32 deg C ), High Lube temp ( 60 deg C )
3 3
2 2 3 2 3 2 2 2 1 2 2 2 3 3 3
Sr. No. 7.0.13 7.0.14 7.0.15 7.0.16 8.0 8.0.1 8.0.2 8.0.3
AREA All pressure / temperature gauges are in working order Inter cooler is functional ( check temp at both ends ) All SRVs are tested & sealed Suction / discharge bottles are in good condition & tested COOLING TOWERS Cooling water pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of CW pumps OK - no oversized bolts used in couplings. No broken/missing footbolts / foundation bolts in compressors / motors / CW pumps
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 3 3 2
2 2 2
8.0.4
8.0.5 8.0.6 9.0 9.0.1
9.0.2 9.0.3 9.0.4
9.0.5 9.0.6 9.0.7 9.0.8 9.0.9
All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings used under main nut Cooling towers are well maintained & effective cooling achieved FD fan is operational , no abnormal sound, vibration PUMPS / MOTORS - LPG- Flash/Boil-Off Condensate and Buffer Tank pumps No leaks from Mech. Seals. API Plan 52 (buffer fluid) systems / gland packings in good working condition Vibration / noise levels / cleanliness of pumps / motors within acceptable limits Coupling guards in position Coupling hubs are locked on shafts with Allen / grub screws only (including CW pumps). No oversized bolts used Constant level oilers / grease nipples are in working order Regular schedule for oil change / greasing followed Suction strainers cleaned as per schedule Pressure gauges on suction / discharge sides are in working order No broken/missing footbolts / foundation bolts in motors / LPG/CW pumps
3 3
2 2 2
2 2 2 2 2
Sr. No. 9.0.10
AREA All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nuts Shims / packings used for alignment are of Brass / SS only & of proper shape & size Breathers / Vents of bearing housings are as per requirement & kept clean No oil/water spillage on base frames Bearing / lube oil temperatures within limits Condition of base frames OK (painting pitting / corrosion, etc.) - no water logging Preventive maintenance schedule of pumps implemented, followed & recorded Preventive maintenance schedule of motors implemented, followed & recorded Pipe manifolds / valves (no leaks) / fittings well maintained and painted Servo gauges / Level gauges / alarms in working order FPH / ACH COMPRESSORS - AIR Stuffing box leakage not excessive Noise / vibration levels of compressors / motors are satisfactory Condition of belts / pulleys & alignment OK Coupling guards in position - rigid Painting / cleaning of body OK / no oil spillage Oil level in sump is sufficient & quality OK (no frothing) Discharge air temperatures within limits Lubricating oil pressure is proper Preventive maintenance schedules followed & records maintained All tripping devices are healthy
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
9.0.11
9.0.12 9.0.13 9.0.14 9.0.15 9.0.16
2 4 3 2 3
9.0.17
9.0.18 9.0.19 10.0 10.1 10.1.1 10.1.2 10.1.3 10.1.4 10.1.5 10.1.6 10.1.7 10.1.8 10.1.9 10.1.10
2 2
3 3 2 3 2 3 2 3 3 2
Sr. No. 10.1.11 10.1.12 10.1.13 10.1.14 10.1.15 10.1.16
AREA All pr./temp. gauges are in working order. Calibration not overdue All SRVs are tested & sealed All Cooling water passages including gland cooling are clear with proper flow Cooling water pumps maintained properly no abnormal noise/vibration/corrosion Coupling / alignment of CW pumps OK - no oversized bolts used in couplings No broken/missing footbolts / foundation bolts in compressors / motors / CW pumps All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Aftercoolers are in good condition - no overheating of shell Air receiver vessels are in good condition no corrosion / proper paint & supports / testing not overdue Cooling towers are well maintained & effective cooling achieved Frequency of starting of Security Air Compressor is more than 30 minutes AIR DRIER Air dryer in proper working condition. PM schedules followed & recorded - all filters cleaned / valves serviced Dew point test done in last 6 months & record available Air pressure at inlet / outlet OK All SRVs are tested & sealed Buffer vessels drained of condensate PUMPS / ENGINES / MOTORS - WATER No excessive leaks from glands - packings in good working condition Gland plates are not overtightened - no smoke from glands during pump running All bearing housing bolts are tight - no bolts missing
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 2 3 2 2 2
10.1.17
10.1.18 10.1.19
2 2
10.1.20 10.1.21 10.2 10.2.1 10.2.2 10.2.3 10.2.4 10.2.5 10.2.6 10.3 10.3.1 10.3.2 10.3.3
2 2
2 2 2 1 2 2 2 2 2
Sr. No. 10.3.4
AREA Vibration / noise levels / cleanliness of pumps / motors / engines are satisfactory Coupling guards in position Constant level oilers / grease nipples are in working order Regular schedule for oil change / greasing followed Pump suction strainers / engine air filters cleaned as per schedule Pressure gauges on suction / discharge sides are in working order. All gauges in engines are working accurately All audio-visual alarms of fire engines are operating All foundation bolts have proper washers/nuts & are fully tightened. No spacers / packings / earth connections used under main nut Shims / packings used for alignment are of Brass / SS only & are of proper shape & size Breathers / Vents of bearing housings are as per requirement & kept clean All drive belts are in good condition - proper tension / no cracks / not worn out Coupling hubs are locked on shafts with Allen / grub screws (CW / Jockey pumps). No oversized bolts used No oil/water spillage on base frames Bearing / lube oil temperatures are within limits. Condition of base frames OK (painting / pitting / corrosion, etc.) - no water logging takes place Preventive maintenance schedule of pumps are implemented, followed and recorded Preventive maintenance schedule of motors / diesel engines implemented, followed & recorded
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
10.3.5 10.3.6 10.3.7 10.3.8 10.3.9 10.3.10 10.3.11 10.3.12
2 2 2 5 3 2 2 1
10.3.13
10.3.14 10.3.15 10.3.16
1 3 3
10.3.17 10.3.18 10.3.19
2 2 3
10.3.20
10.3.21
Sr. No. 10.3.22 10.3.23 10.3.24 10.3.25 10.3.26 10.3.27 10.3.28 10.4 10.4.1 10.4.2
AREA
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
Fire Engine exhaust lines are properly supported. Fire engines batteries and charger in good working condition Diesel tanks OK (breather, LG, covers, etc.), piping & hoses OK Cooling water / coolant flow in engines OK & temperatures normal Pipe manifolds / valves (no leaks) / fittings well maintained and painted Coolant quality is checked regularly sufficient kits are available. Frequency of starting of Jockey pump is more than 30 minutes WATER TANKS- Fire Water, DM Water, Steam Condensate Foundation-tank pad: No cracks, no excessive settlement; proper slope No voids between tank pad & annular plates no grass growth from below the plates Annular plate is exposed & painted and not covered by debris / vegetation Inlet and outlet lines properly supported No excessive undulations / buckling on the shell / roof Roof & shell properly painted condition acceptable for 1 more year No leaky conditions in shell courses Ladders / platforms are in good condition, safe & not corroded (painted) Wind girders / roof hand rails are painted Level gauges in working condition Tank outlet valve in good working condition preventive maintenance done Piping manifold supports are in good condition no damages / cracks Common strainers, if provided, is cleaned as per schedule Roof vents (goosenecks) are adequate and covered with wire mesh Tanks are not over-filled no overflow water marks on roofs
2 2 2 2 2 2 2
2 2
10.4.3 10.4.4 10.4.5 10.4.6 10.4.7 10.4.8 10.4.9 10.4.10 10.4.11 10.4.12 10.4.13 10.4.14 10.4.15
2 2 2 2 3 2 2 2 3 2 2 2 3
Sr. No. 10.4.16 10.4.17
AREA Tank cleaning & internal inspection done in last 5 years Thickness survey carried out in last 3 years as per HO LPG-M&I guidelines. Report available DG ROOM / PMCC DG SETS All trips / alarms (high water temp, low lube oil pressure, over speed) are healthy No Oil spillage on base frame of DG sets Vibration / noise levels / cleanliness of generators / engines are satisfactory Coupling guards in position Insulation provided upto silencer Condition of radiators / heat exchangers no excessive fin damage / leakages / scaling
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 2
11.0 11.1 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.1.6
2 2 2 2 2 2
11.1.7 11.1.8 11.1.9 11.1.10 11.1.11 11.1.12 11.1.13 11.1.14 11.1.15 11.1.16
11.1.17 11.2 11.2.1
Diesel tanks OK (breather, LG, covers, etc.), piping & hoses OK Coolant in engines OK & temperatures normal Coolant quality is checked regularly sufficient kits are available. Condition of diesel & coolant hoses good All drive belts are in good condition - proper tension / no cracks / not worn out No excessive smoke in exhaust Exhaust lines are properly supported Baseframes & vibration dampers / foot bolts in good condition Engines batteries and charger in good working condition Panels are well maintained all meters / audio/visual alarms / trips annunciations are functional Preventive maintenance schedule of generators / engines followed & recorded ELECTRICALS PMCC / LIGHTING / MOTORS Earth strips connected to electrodes by electro-galvanized bolts / bolts not rusted. Earthing pits' condition OK & as per HO LPGENGG guidelines [O]
1 1 2 3 2 3 3 2 3 3
Sr. No. 11.2.2
AREA MCC Panel condition [O]: a> Doors okay & closed b> Dust / soot / cobwebs not existing c> Visual condition of switch contact, fuse, etc., OK d> Control wiring condition satisfactory e> Grounding okay Condition of cable/duct [O]: a> Cables are on rack b> Cable ducts are clean c> Sealing of ducts / panels OK d> Cable identification tags are fixed Condition of transformer [O] a> Grounding OK b> No oil leaks c> Silica Gel OK d> Oil level OK e> Terminal box earthing OK f> Oil / winding temperatures OK g> Periodic oil quality test conducted a> Earthing of fixtures proper [O] b> Condition of wiring good [O] c> Water does not enter & accumulate in fixtures / distribution boxes etc. [O] FLP property of fixtures: a> No Allen bolts missing & all are tight b> Cable gland proper c> No unplugged openings observed Lighting DBs, switches, MCBs, etc., well maintained [O] Tower / Mast Lights (Area Lighting) [O] a> Grounding of mast OK b> Condition of JBs, switch boards, fuses, etc., OK c> Approach to electrical installation & ladders good & safe Ground resistance at motor / push buttons measured & found OK. [O] a> Terminal boxes/glands/push buttons, etc.,& their FLP properties OK. [O]
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 3 2 2 3 2 2 2 2 2 2 2 2 2 2 2 2 2 2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7 11.2.8
2 1 2 3
2 2 2 1 1
11.2.9 11.2.10
Sr. No. 11.2.11 11.2.12 11.2.13 11.2.14
AREA b> Existing cable terminations are proper [O] All fuses are of proper type & rating as specified in single line diagram. [O] Emergency lighting system in order [O] Transformer maintenance carried out as per schedule (oil change / oil filtering / check dielectric strength) Condition of flameproof / Ex equipment in licensed area is good Cable insulation resistance between phases and phase to earth checked (at least once in 2 years) Servicing of motors done as per schedule (megger test / PM jobs) Calibration of protective relays done as per schedule Sub station wiring & terminations are neatly done. No loose wires. Panels sealed. Cable glands & tags OK All light points are in working condition; glass covers are clean Ammeters & Voltmeters provided in motor starters are in working condition All telephones & intercom systems are in working order PM schedules for all electrical eqpt exists and are strictly followed records available. Lighting towers / poles are painted properly
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
1 2 3 2
11.2.15 11.2.16
2 2
11.2.17 11.2.18 11.2.19
2 2 2
11.2.20 11.2.21 11.2.22 11.2.23
3 2 2 2
11.2.24 11.2.25 11.2.26 12.0 12.0.1
2 2 2
12.0.2
Condition of capacitor bank and power factor controller OK UPS / batteries / chargers in working condition GMS / ILSD / SPRINKLER SYSTEM / PA PAGING / WIRELESS COMMUNICATIONS Sprinkler system working satisfactorily in: a> All sheds (empty / filling / filled / CR) b> LPG pumphouse GMS sensors are quarterly calibrated & in working condition
2 2 2
Sr. No. 12.0.3 12.0.4 12.0.5 12.0.6 12.0.7
AREA
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
12.0.8
13.0 13.1 13.2 13.3
13.4 13.5 13.6 13.7
13.8 13.9 13.10 13.11
All GMS sensors are healthy & in good condition provided with canopies. GMS panel / mimic panels in good working condition GMS PC - printer interface OK; logs being maintained ILSD system logic OK (as per OISD 144 Cl.11.11) Fire fighting / MCP panels / push buttons / siren are operating satisfactorily all audiovisual alarms are healthy PA / wireless communication systems in good working order-all stations can be contacted BUILDINGS / SHEDS / ROADS / DRAINS / HOUSEKEEPING BUILDINGS / SHEDS Periodic painting / distempering of buildings done General maint. & cleanliness of buildings / structurals / sheds / DV chambers etc., is good Canteen building maintenance and facilities are satisfactory No excessive cracks / water seepage in any of the buildings Shed structurals are in good condition Spaceframe structures in sheds in good condition no sagging / bending / broken structures/bolts Sheds roofing sheets are in good condition no damages / leaks Mastic flooring in sheds /columns OK no gaps / discontinuities Trench drains in sheds are clean no choking / accumulation of water General maint. of fans / lights / electricals in buildings MCBs / ELCBs as per norms Exhaust fans working in battery room / urinals / lavatories / bathrooms Flush system / plumbing in lavatory are working properly
3 3 3 3 3
3 3
3 3 3 3
3 3 3 3
13.12 13.13
2 3
Sr. No. 13.14 13.15
AREA Bath / lavatory / wash basin routine maintenance done. Hygiene satisfactory General cleanliness in pump houses, filling / other sheds and other buildings satisfactory Stores material properly stacked / stored; neatness maintained. Office PCs / UPS in good working order Office ACs in good working order - servicing done regularly ROADS / DRAINS Roads / hard-surfaced areas are free from pot holes and maintained well Pavements / footpaths are in good condition Emergency exit route is clear of vegetation / debris Entry / Exit barriers & gates are maintained well & in operating condition All DFMDs are in good working order Surface / storm water drains are clean and free from any debris Motorable road available in buffer area / green belt. HOUSEKEEPING Grass cutting done regularly & licensed area maintained well no excessive wild growth
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
3 3
13.16 13.17 13.18 14.0 14.0.1 14.0.2 14.0.3 14.0.4 14.0.5 14.0.6 14.0.7 15.0 15.0.1
2 2 1
1 2 2 2 2 2 2
15.0.2 15.0.3 15.0.4 16.0 16.0.1 16.0.2 16.0.3
Signboards are clear and well maintained No excessive surplus / scrap material lying around in the plant General cleanliness & hygiene maintained at all places in plant DOCUMENTATION / DRAWINGS / EQUIPMENT DATA / HISTORY Layout plan / P&ID incorporating facilities modifications and new additions available Operations manual of the location available Operation & Maintenance manuals including spare parts catalogue available: a> FW pumps & engines
2 2 2
2 2
16.0.3 Sr. No. AREA b> LPG pumps- Intank, Buffer tank,Condensate flash&Boil-off c> LPG compressors- Flash & Boil-Off d> Air compressors e> Security air compressor f> Air dryer g> DG sets h> Jockey pump i> Boilers j> LPG Analyser k> CCR- DCS System l> Electrical eqpt (transformer, breakers, panels, etc.) m> Weighbridge n> GMS system o> ROVs p> Major instruments (Servogauge / DP level gauge / Radar gauge / Transmitters / Rochester gauge / Magnetic gauge, etc.) q> DM Plant Construction / fabrication drawings of FW tanks Fire water network as-built dimensional fabrication drawings exist LPG piping as-built dimensional drawings exist Layout drawings of cabling, lighting, earthing are available Equipment Data Cards (in SAP or as per OISD 127/128) Equipment History Cards (in SAP or as per OISD 127/128) Following manuals / documents available: [O] a> SMPV Rules, 1981 b> Relevant BIS standards c> M&I Painting Manual (recommendations) available YES / NO MARKS MAX. AWARD REMARKS
WTAGE.
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
16.0.4 16.0.5 16.0.6 16.0.7 16.0.8 16.0.9
2 2 2 2 2 2 2
16.0.10
2 2 2
Sr. No.
AREA Equipment running hours meters(totalizers) maintained in working order & hours are logged: a> DG sets b> Fire engines (electrical totalizers) c> LPG compressors d> LPG pumps e> Air compressors DCS System AMC exists with OEM for preventive maintenance and is valid Backup of DCS files have been taken during AMC, record date of last data backup.
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
16.0.11
2 2 2 2 2 4 4
17.0 17.0.1 17.0.2
17.0.3 17.0.4 17.0.5 18.0 18.0.1 18.0.2 18.0.3 18.0.4 18.0.5
Earthing system / connections for DCS cabinet properly maintained and values are within permissible limits Cooling / room temperature maintained within limits Fire fighting system provided and is in working condition SAP PLANT MAINTENANCE MODULE IMPLEMENTATION Functional locations are created for all equipment BOM created for all functional locations PM tasklists prepared for all equipment as per HO LPG-M&I guidelines, OEM & OISD requirements PM scheduling being carried out Equipment data maintained in SAP in equipment class & characteristics fields All types of Maintenance orders (breakdown / shutdown / normal etc.) being routed thru SAP PMM (check for last 3 months) VIBRATION MONITORING Safe base vibration limits identified for each rotary equipment (vibration analysis done) Corrective actions taken as per recommendations of vibration analysis
2 4
2 2 2
2 2
18.0.6 19.0
19.0.1 2 19.0.2
Sr. No. 19.0.3
AREA Vibration meter is available at plant and is in working condition Vibration monitoring schedule prepared & adhered to (weekly basis for LPG/FW/Jockey pumps / DG sets / CW pumps / Compressors) BREAKDOWNS No major equipment breakdowns in last 1 year (includes LPG pumps/motors; Air compressors / motors; FW pumps / engines; Jockey pumpsets; DG sets; Carousel; Vapour Extraction Blowers; Checkscales; AVTS; VLD; BLD; O-rLD; Purging unit; Evacuation unit; IWCU; Hot air sealing unit; Transformers; VCB/ACB). Assign (3) marks for each additional breakdown if more than 2 TOTAL
YES / NO
MARKS MAX. AWARD
REMARKS
WTAGE.
2 2
19.0.4 20.0 20.0.1
WEIGHTED MAXIMUM MARKS WEIGHTED AWARDED MARKS
= 0 = 0
M&I INDEX =
#DIV/0!
SIGNATURES OF M.D.T. MEMBERS / LOCATION-IN-CHARGE
SAFETY INDEX LPG PLANT LOCATION: LOCN. I/C: INSPECTED BY: STATE OFFICE: REGION: INSPECTION ON :
Sr. No. A 1
CHECK POINTS LICENSES / APPROVALS / CERTIFICATES / DISPLAY ALL EMPLOYEES ARE AWARE OF S,H&E POLICY (LOCATION & CORPORATE) & BOTH ARE DISPLAYED AT PROMINENT PLACES.
STATUS MARKS-1 YES
2 VALID CCOE LICENSES AVAILABLE / APPLIED FOR RENEWAL IN TIME. 3 UPDATED AND APPROVED LAYOUT OF PLANT BY PESO IS AVAILABLE AND DISPLAYED,. HAZARDOUS AREA CLASSIFICATION DRAWING IF AVAILABLE IS DISPLAYED. VALID FACTORY LICENSE AVAILABLE. / APPLIED FOR RENEWAL IN TIME. POLLUTION CONTROL BOARD CONSENT FOR AIR AND WATER EXIST / APPLIED FOR RENEWAL IN TIME AND ITS CONDITIONS ARE COMPLIED. DAILY STRUCTURED SAFETY CHECK OF LOCATION BEING DONE & REVIEWED BY L-I-C . MONTHLY INSPECTION BY LIC AND QUARTERLY INSPECTION BY SO CARRIED OUT AS PER HO GUIDELINES , RECORDS MAINTAINED AND POINTS COMPLIED AS PER THE TARGET DATES AUTHORISATION FROM STATE POLLUTION CONTROL BOARD FOR HANDLING HAZARDOUS WASTE IS AVAILABLE / APPLIED FOR RENEWAL IN TIME. HYDRANT HOSES ARE TESTED ONCE IN SIX MONTHS AND CERTIFICATE (S) AVAILABLE. TRANSFORMER OIL TESTED ANNUALLY AND RECORDS AVAILABLE AS PER IS:1866. THE CONDITION OF SILICA GEL OF THE TRANSFORMER IS IN ACCEPTABLE CONDITION. ON SHIFT AND OFF SHIFT FIRE ORGANISATION CHART IS DISPLAYED AT PROMINENT PLACE. FIRE HYDRANT LAYOUT AND LOCATION OF FIRE FIGHTING EQUIPMENTS IS DISPLAYED. DISASTER MANAGEMENT PLAN BASED ON RISK ANALYSIS IS AVAILABLE AND SUBMITTED AUTHORITY/RECORD OF SUBMISSION/ DISPATCH AVAILABLE. YES
YES YES YES YES YES YES YES YES YES
4 5 6
7 8 9 10 11 12 13 14
TO
CONCERNED
YES YES NA
MUTUAL AID SCHEME IS AVAILABLE & MEETING IS CONDUCTED FOR EVERY SIX MONTHS & RECORDS AVAILABLE. ANTI LOCK BRAKE SYSTEM (ABS) PROVIDED IN N-3 CATEGORY OF VEHICLES OTHER THAN TRACTOR TRAILOR COMBINATION MANUFACTURED ON AND AFTER 01.10.06 AND N-3 CATEGORY VEHICLES WITH TRACTOR TRAILOR COMIBINATION MANUFACTURED ON AND AFTER 01.10.07. WHETHER THE REQUIRED NO OF FIRST AID TRAINED PERSONNEL AVAILABLE AND THEIR NAMES DISPLAYED AS PER FACTORIES ACTS / RULES. SAFETY AUDIT CHECK LIST AS PER OISD 144 / 145/169 HAS BEEN EVALUATED AND ALL POINTS OBSERVED AS COMPLIED. THE AUDITED CHECK LIST IS ENCLOSED WITH OBSERVATIONS. LAYOUT OF BLOCKS AND FACILITIES MEETS THE DISTANCE REQUIREMENT AS PER OISD 144/169 (PRE OISD LOCATION ARE TO BE EXEMPTED). SAFETY COMMITTEE MEETING IS CONDUCTED ONCE IN TWO MONTHS OR AS PER FACTORY RULES / GUIDELINES ISSUED TIME TO TIME, THE PRESCRIBED FREQUENCY OF WHICHEVER IS MORE.
15 16 17 18
YES YES YES
YES
19
CHAIN PULLEY BLOCKS AND HOISTING EQUIPMENTS ARE TESTED ANNUALLY OR AS PER STATUTORY STIPULATIONS AND OTHER TECHNICAL REQUIREMENTS AND AUTHORIZED TEST CERTIFICATES FOR LOAD BEARING ARE AVAILABLE AND RECORDS MAINTAINED. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED
YES 18 18
B. 1 2
ACCIDENT REPORTING AND INVESTIGATION ALL ACCIDENTS HAVE BEEN REPORTED IN TIME AND INVESTIGATED AS PER LATEST GUIDELINES OF S&EP, HO. LESSONS LEARNT FROM ACCIDENTS OCCURRED AT OTHER LOCATIONS AS CIRCULATED THROUGH SAFETY BULLETINS/S&EP INTRANET SITE ARE IMPLEMENTED AND DISCUSSED DURING SAFETY COMMITTEE MEETINGS AND MONTHLY ATRS SUBMITTED TO S&EP REGION. REPORTABLE ACCIDENTS DURING LAST FINANCIAL YEAR IS NIL. ACCIDENT STATISTICS ARE MAINTAINED IN A REGISTER AS PER FACTORY ACT / RULES. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED BULK STORAGE (MOUNDED BULLET) / BULK LOADING / UNLOADING AREA EXCESS FLOW CHECK VALVE ARE APPROPRIATELY PROVIDED IN ALL INLET & OUTLET OF STORAGE VESSEL/ BULK LPG TANK TRUCKS. ALL GAUGES, VIZ. TWO INDEPENDENT LEVEL GAUGE INDICATORS, PRESSURE & TEMP. GAUGES, HIGH LEVEL ALARM SWITCH ETC ARE PROVIDED ON STORAGE VESSEL AND FOUND IN WORKING CONDITION. ALL SRVS.& TSVS ARE PROVIDED WITH VENT PIPES, RAIN CAPS & TESTED ANNUALLY. VALID TEST CERTIFICATES ARE AVAILABLE. ALL SRVs & TSVs ARE PROVIDED WITH ISOLATION VALVES, KEPT IN OPEN POSITION LOCK / SEALED OR WHEEL REMOVED. KEYS/WHEELS ARE EASILY ACCESSIBLE. PLANT PIPELINES HAVE BEEN INSPECTED & TESTED AS PER CLAUSE NO.9.5.3 OF OISD-144. THE PIPELINES ARE PROPERLY SUPPORTED ON PIPE RACK. DOCK PIPELINES HAVE BEEN INSPECTED & TESTED : -VISUAL INSPECTION, UT MEASUREMENT, DYE PENETRATION TEST OR MAGNETIC PARTICLE TEST. THE DOCKLINE PROPERLY SUPPORTED ON PEDESTALS. THE ROAD CROSSING CULVERTS ARE IN GOOD CONDITION. INTIGRETY OF INSULATION MAINTAINED. LPG HOSES FOR TLD /TW ARE TESTED AS PER OISD STD.135 ONCE IN FOUR MONTHS AND RECORDS MAINTAINED. PHYSICAL CONDITION OF THE HOSES FOUND ACCEPTABLE. LOADING/UNLOADINGS ARMS (INCLUDING RCMA UNLOADING ARM AT JETTY) ARE OF APPROVED TYPE AND MAINTENANCE AND INSPECTIONS ARE CARRIED OUT AS PER OEM RECOMMENDATIONS AS WELL AS LPG OPS CIRCULAR DATED 02.01.03 OR LATEST GUIDELINES/STATUTORY REQUIREMENT ETC.
MARKS -1 YES YES YES YES 4 4 MARKS-1 YES YES YES YES NA YES
3 4 SUB TOTAL:
C. 1
2 3 4 5 6 7
YES
YES
8 9
YES
10 11 12 13 14 15 16 17 18 19
LOADING / UNLOADING OPERATING PROCEDURE (INCLUDING RCMA UNLOADING ARM AT JETTY) DISPLAYED & FOLLOWED AT TLD/TW. LOADING /UNLOADING OPERATION ARE DONE UNDER AUTHORISED SUPERVISION. DRIVING LICENSE OF TT DRIVERS ARE FOUND ENDORSED FOR DRIVING HAZARDOUS GOODS VEHICLE / TRAINING CERTIFICATE AVAILABLE FROM RTO AUTHORIZED NODAL TRAINING CENTRE. EACH BULK/STAKE TRUCK IS EQUIPPED WITH IS MARKED WORKING 2 X 10 KG DCP FE. BULK & STAKE TRUCK ARE HAVING ENCLOSED TYPE BATTERY CUT OFF SWITCH AND THE SAME IS FOUND IN OFF POSITION DURING LOADING / UNLOADING OPERATION. HAZCHEM CHART DISPLAYED ON BODY OF TANK TRUCK AS PER STATUTORY RULES. DRIVER (S) / CLEANERS / HELPERS FOUND TO BE OBSERVING ALL SAFETY NORMS IN THE PLANT AREA. .(TRUCK DRIVERS ARE NOT WEARING SAFETY SHOES,SAFETY HELMETS) VIOLATION OF SAFETY REQUIREMENTS BY TT ARE MONITORED AND PENALTY IMPOSED AS PER TRANSPORT DISCIPLINE GUIDELINES / CONTRACT CONDITIONS. PROPER EARTHING AND BONDING FACILITY PROVIDED AT HSD CONSUMER PUMP/OWN USE HSD PUMP DECANTATION POINT. SEALED DECANTATION OF TT ENSURED. RAIL SLEEPERS IN TANK WAGON SIDINGS ARE OF CONCRETE / METALLIC CONSTRUCTION / OTHER APPROVED MATERIAL. DUMMY WAGONS USED DURING PLACEMENT / WITHDRAWAL OF TANK WAGON AND CAUTION BOARDS ARE PROVIDED AND THE RAKE/ TANK WAGON (S) ARE NOT CONNECTED WITH ANY SHUNTING / HAULAGE DEVICE WHILE LOADING / UNLOADING IS IN PROGRESS. RAIL TRACKS ARE PROVIDED WITH BONDING STRIPS AND CONNNECTED TO WELL-MAINTAINED EARTHING SYSTEM. ALTERNATE HYDRANT AND WATER MONITORS ARE PROVIDED ON BOTH SIDES OF RAILWAY GANTRY / SIDING AS PER OISD / STATUTORY REQUIREMENTS. RAIL TRACKS INSULATION PROVIDED AT 30M FROM FIRST LOADING / UNLOADING POINT, TO INSULATE WAGON SIDING RAIL TRACK FROM ELECTRIC TRACTION SYSTEM OF THE RAILWAYS. OVERHEAD ELECTRIC TRACTION TERMINATES 15M AHEAD OF FIRST LOADING / UNLOADING POINT OF TANK WAGON SIDING.
YES YES YES YES YES YES YES YES YES YES YES YES NA
20 21 22 23
NA YES YES YES YES YES YES YES YES YES YES YES
24 25
IF WORKING BEYOND SUNSET, PROPER LIGHTING ARRANGEMENT IS AVAILABLE IN RAILWAY SIDING. EMERGENCY GATE / ESCAPE ROUTES AVAILABLE. IF NOT AVAILABLE, THEN PLAN FOR TANK TRUCKS EVACUATION WITHIN TWO MINUTES AVAILABLE ALL TTS HAVE VALID EXPLOSIVE LICENSE AND LAYOUT & FITTINGS ARE PROVIDED AS PER PESO APPROVED DRAWING BATTERY TERMINALS HAVE PROTECTIVE RUBBER COVER. ALL ELECTRICAL EQUIPMENTS LIKE GENERATOR SWITCHES, FUSE, CIRCUIT BREAKER AND BATTERY LOCATED INSIDE THE CABIN OR ENGINE COMPARTMENT. HAND BRAKES OF TTs ARE IN WORKING CONDITION.
26 27 28 29
30 31
SELF STARTER OF TTs ARE IN WORKING CONDITION. ALL TTs ARE HAVING VALID FITNESS CERTIFICATE FROM THE CONCERNED COMPETENT AUTHORITY (IES) FOR EXHAUST EMISSION / MECHANICAL FITNESS. ALL TTs ARE FITTED WITH SAFETY RELIEF VALVES AND OTHER FITTINGS COMMENSURATE WITH THE SAFETY REQUIREMENTS PROPER LIGHTING POVIDED IN TANK FARM AREA CONDITION OF EARTHING PROVIDED TO STRAGE TANKS FOUND AS PER GUIDELINES. MINIMUM TWO EARTH PITS PROVIDED AND CONNECTED TO EARTHING GRID. LPG CRYOGENIC STORAGE TANKS ALL GAUGES, VIZ. SERVO GAUGES (2 X 2 No.) , PRESSURE GAUGE & PRESSURE TRANSMETER PROVIDED (2 X 2No.) & IN WORKING CONDITION. RTD -RESISTANCE TEMPERATURE DEPENDENT (15 X 2 NO.) ARE PROVIDED AND IN WORKING CONDITION , HIGH LEVEL ALARM AVAILABLE AND ALARM INDICATION AVAILABLE ON DCS FOUND IN WORKING CONDITION. HIGH LEVEL TRIPPING OF TANK :- INTERLOCK WITH IMPORT VALVES (UV 13A /13B AND 14A / 14 B) AVAILABLE AND IN WORKING CONDITION. HIGH PRESSURE TRIPPING:- INTERLOCK WITH IMPORT VALVES ( 900mm WC FOR BUTANE AND 950mm FOR PROPANE.) AUTO FLARE OF TANKS :-UV 15A A/ B IS IN WORKING CONDITION AT 1000 WC THE INSULATION COVER AND CLADDING OF CRYOGENIC TANKS IS IN GOOD CONDITION NO LPG LEAKAGE OBSERVED FROM FLANGE JOINTS OR PIPELINES OF TANKS. ALL SRV AND VACUUM PROTECTION VALVE ARE IS IN WORKING CONDITION. THE PLATFORM ON THE TANKS IS IN GOOD CONDITION & PROPERLY MAINTAINED. ELECTRIC OPERATED TRAIN (EOT) ON TANK, GIRDER & SS ROPE IS IN IS IN GOOD CONDITION. STOPPERS PROVIDED AT THE END OF GIRDER. BUND WALL IS IN GOOD CONDITION RESCUE LADDER AVAILABLE & IN GOOD CONDITION ALL THE STRUTS / PILLARS OF TANKS ARE IN GOOD CONDITION , NO CRACKS OBSERVED, REBOUND HAMMER TEST TO CHECK COMPRESSIBILITY , ULTRASOUND PULSE VELOCITY, HIGH CELL POTENTO METER -TO CHECK CONDITION OF REINFORCEMENT STEEL RODS CARRIED OUT. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED FILLING SHED / PRODUCT PUMP HOUSE / LPG COMPRESSOR HOUSE AIR VAPOUR EXTRACTION UNIT PROVIDED NEAR ALL CRITICAL UNITS & DULY INTERLOCKED WITH CAROUSAL AND FOUND IN WORKING CONDITION. ONLINE CHECK WEIGH SCALE IS INSTALLED AND FOUND IN WORKING CONDITION AND CALIBRATION CARRIED OUT ON DAILY BASIS WITH STANDARD WEIGHT. DCVT / AVTS ARE WELL MAINTAINED & IN WORKING CONDITION. THE CALIBRATION OF AVTS & DCVT DONE AS PER GUIDELINES. WEIGHT REDUCTION UNIT/ICU ARE WELL MAINTAIED & FOUND IN WORKING CONDITION. INLINE WATER BATH IS WELL MAINTAINED & FOUND IN WORKING CONDITION. ONLINE WASHING UNIT & DRYING UNITS ARE FOUND IN WORKING CONDITION & ARE EFFECTIVE. ONLINE VALVE REMOVAL & VALVE FIXING MACHINES FOUND IN WORKING CONDITION & MACHINES ARE CHECKED WITH TORQUE WRENCH. DEGASSING FACILITIES IS IN WORKING CONDITION & DEGASSED CYLINDER CHECKED WITH EXPLOSIMETER. HANDLING OF MARKET RETURN / WATER FILLED CYLINDER IS DONE AS PER LPG OPERATIONS GUIDELINES. EVACUATION UNIT IS WELL MAINTAINED & FOUND IN WORKING CONDITION. DEFECTIVE LEAKY FILLED CYLINDERS ARE EVACUATED IMMEDIATELY. NO LEAKY CYLINDERS ARE FOUND STORED IN THE SHED. PURGING MACHINE INSTALLED & WORKING EFFECTIVELY. SQC CONDUCTED AND FOUND WITHIN PERMISSIBLE LIMIT. NO DEFECTIVE / MISSING O RINGS FOUND IN CYLINDERS DESPATCHED FROM PLANT ON RANDOM CHECKING.
32 33 34
35
YES
36 37 38 39 40 41 42 43 44 45 46
YES YES YES YES YES YES YES YES YES YES YES 43 43 MARKS - 1 NA NA NA NA NA NA NA NA NA NA NA NA NA NA
SUB TOTAL:
D. 1
2 3 4 5 6 7 8 9 10 11 12 13 14
15 16
ON RANDOM CHECKS NO STATUTORY TEST DUE CYLINDERS ARE FOUND FILLED WITH LPG. ALL CYLINDERS STACKED VERTICALLY; CYLINDERS OF DIFFERENT CAPACITY & TYPE STACKED SEPARATELY AS PER NORMS. ESCAPE ROUTES /EMERGENCY EXIT PROVIDED AND MARKED TOWARDS EXIT POINTS & PLAN FOR EVACUATION AVAILABLE. WATER DRAINS FROM CYLINDER FILLING AREA WHERE THEY ENTER AN OUTSIDE DRAINAGE SYSTEM IS PROVIDED WITH VAPOUR SEAL. DOUBLE MECHANICAL SEAL WITH SEAL FAILURE ALARM/TRIP, LOW COOLANT LEVEL ALARM/TRIP, TRIP FOR LPG PUMPS ARE PROVIDED AND FOUND IN WORKING CONDITION. ALARM AND TRIPS OF LPG VAPOUR COMPRESSOR (BOILOFF & FLASH GAS COMPRESSOR) ARE PROVIDED & FOUND IN WORKING CONDITION. TRIPPING LOW LPG VAPOUR SUCTION PRESSURE TRIP, HIGH LPG VAPOUR SUCTION PRESSURE TRIP, HIGH DISCHARGE PRESSURE TRIP, HIGH LPG VAPOUR TEMPERATURE TRIP, LUBE OIL TEMPERATURE-LOW,LUBE OIL TEMPERATURE-HIGH,DIFFERENTIAL PRESSURE BETWEEN LPG VAPOUR & LUBE OIL , HIGH LEVEL IN SUCTION SEPARATOR. ALARMS ON DCS AT CENTRAL CONTROL ROOM LOW LUBE OIL LEVEL IN LUBE DRUMLUBE OIL PRESSURE ALARM BEFORE LUBE FILTER SAFETY TRIPS LIKE COOLING WATER TEMPERATURE, LOW LUBE OIL ETC OF AIR COMPRESSOR ARE PROVIDED AND IN WORKING CONDITION. AIR RECEIVER VESSELS ARE IN ACCEPTABLE CONDITION AND HYDRAULICALLY TESTED ONCE IN FOUR YEARS OR AS APPLICABLE UNDER STATE FACTORIES RULE. VENTS (1.5 M ABOVE THE EVES OF THE STRUCTURE) PROVIDED FOR VENTING OF LPG AS PER LPG OPS CIRCULAR. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED ELECTRICAL INSTALLATION EARTHING SYSTEM IN LPG BP PROVIDED AS PER CIRCULAR REF.NO.LPG /ENG/117 DATED 06.03.01 & EARTHING PITS ARE AS PER IS 3043. ALL EQUIPMENTS AND APPLIANCES ARE PROVIDED WITH DOUBLE EARTHING AS PER PROVISION OF ELECTRICITY ACT AND OISD. FLAMEPROOF PORTABLE / INTRINSICALLY SAFE TORCHES / EQUIPMENTS ARE IN USE IN HAZARDOUS AREA. EMERGENCY LIGHTS ARE AVAILABLE IN CRITICAL AREA THE LIST OF AUTHORISED PERSONS BEING MAINTAINED AS PER RULE NO. 3 OF INDIAN ELECTRICTY RULES. ALL THE SUB STATION EQUIPMENTS ARE PROVIDED WITH DOUBLE EARTHING. GENERATOR SEPARATELY DOUBLE EARTHED. THE FUSES USED ARE OF HRC TYPE AND OF RATINGS SPECIFIED IN INDIVIDUAL PANEL. CIRCUIT IDENTIFICATION MARKS / TAGS ARE PROVIDED FOR EACH CABLE. NEUTRAL OF TRANSFORMER AND
NA NA NA NA YES
17 18 19 20 20 A 20 B
YES
21 21 A 21 B
YES YES YES YES YES 7 7 MARKS - 1 YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 18 18 MARKS - 1 YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES
22 23 24 SUB TOTAL: E. 1 2 3 4 5 6 7 8 9 10 11 12
CABLE INSULATION TEST CARRIED OUT ANNUALLY OR AS PRESCRIBED AND CERTIFICATES AVAILABLE. ELECTRICAL RELAYS ARE TESTED ANNUALLY & RECORDS AVAILABLE. NO LOOSE WIRE / TEMPORARY ELECTRICAL CONNECTIONS ARE OBSERVED. ELECTRICAL SHOCK TREATMENT CHART / CAUTION BOARD DISPLAYED IN ELECTRICAL SWITCH ROOM/PMCC.
13 14 15 16 17 18
ISI MARK INSULATION MATS ARE PROVIDED IN ELECTRICAL SWITCH ROOM AND THEIR CONDITION IS SATISFACTORY(RUBBER MATS ACCEPTABLE TILL 31/12/2011). RUBBER HAND GLOVES (WITH IS MARK OR CONFORMING TO IS) ARE IN USE. GENERATORS ARE IN WORKING CONDITION AND THEIR FUEL TANKS ARE SECURED AWAY FROM THE EXHAUST OF DG SETS. SAFETY TRIPS WHEREVER PROVIDED LIKE COOLING WATER TEMPERATURE, LOW LUBE OIL ETC OF DG SETS ARE PROVIDED AND IN WORKING CONDITION. UPDATED SINGLE LINE ELECTRICAL LAYOUT DRAWINGS DISPLAYED IN PMCC. WHETHER ELECTRICAL AUDIT IS CONDUCTED AS PRESCRIBED AND AUDIT POINTS ARE COMPLIED AS PER APPROVED TARGET. TOTAL NO. OF TEMS APPLICABLE TOTAL MARKS OBTAINED
F 1 2
FIRE FIGHTING SYSTEM / SAFETY ITEMS SEQUENTIAL OPERATION PROCEDURES OF FIRE PUMP/ENGINES ARE ESTABLISHED / DISPLAYED & FOUND IN WORKING CONDITION DURING CHECKS. DIESEL FUEL TANKS FOR FIRE ENGINES ARE REGULARLY TOPPED UP & PROPER VENT PROVIDED. POSITION OF DIESEL TANKS IS AWAY FROM THE ENGINE EXHAUST. ALL SPRINKLERS ARE WELL MAINTAINED / FOUND IN WORKING CONDITION & TESTED AS PER OISD & RECORDS MAINTAINED. STRAINER PROVIDED IN THE WATER SPRINKLER SYSTEM AND CLEANED ONCE IN A QUARTER AND RECORD MAINTAINED. INSPECTION AND MAINTENANCE OF FIRE EXTINGUISHERS DONE AS PER LAID DOWN / PRESCRIBED SCHEDULES. FIRE DRILLS CONDUCTED MONTHLY & RECORDS MAINTAINED. SAND BUCKETS ARE PROVIDED IN ELECTRICAL SUBSTATION /MCC/DG ROOM / HT ROOM AS PER REQUIREMENTS AND FOUND FILLED WITH DRY SAND. FIRE EXTINGUISHERS ARE PROVIDED AS PER OISD / STATUTORY REQUIREMENTS AND FOUND FUNCTIONING PROPERLY. EFFECTIVE COMMUNICATION SYSTEM LIKE PA PAGING / WALKIE TALKIE PROVIDED AND WORKING SATISFACTORILY. ONLY INTRINSICALLY SAFE / FLAME PROOF EQUIPMENTS ARE USED IN HAZARDOUS AREA. EMERGENCY RESPONSE DRILL CONDUCTED ONCE IN SIX MONTHS & RECORDS MAINTAINED. FIRE FIGHTING PUMPS ARE OPERATED MINIMUM TWICE A WEEK CONTINUOUSLY FOR 30 MINUTES OR AS PRESCRIBED BY OEM WHICHEVER IS MORE AND LOG BOOK MAINTAINED. CONDITION OF BATTERY FOR FIRE ENGINES / DG SETS ETC IS SATISFACTORY. FIRST AID TROLLEY IS AVAILABLE AS PER OISD-144/ HO S&EP CIRCULAR REF.NO. 7/2001 DATED 14.11.2001. AT FARTHEST POINT OF HYDRANT LINE 7 KG / CM2 PRESSURE IS MAINTAINED WITH HELP OF JOCKEY PUMP OPERATING AUTOMATICALLY. HYDRANT/MONITORS ARE PROPERLY DISTRIBUTED IN CRITICAL AREAS. CONSUMPTIONS / RECEPT OF SAFETY EQUIPMENT IS UPDATED ON SAP EVERY MONTH QUANTITY OF CO2 CARTRIDGES AND DCP ARE SUFFICIENT AND KEPT IN A STORE ROOM (AS PER OISD 144/169). HISTORY AND CHECKING OF FIRE EXTINGUISHERS ARE MAINTAINED AND RECORDS AVAILABLE. FIRE HOSES ARE AVAILABLE AS PER OISD-144/169.
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24
EMERGENCY ALARM LIKE HAND OPERATED SIREN/ ELECTRICAL SIREN /MCP/ETB ARE PROVIDED AT STRATEGIC LOCATIONS & FOUND IN WORKING CONDITION. FIRE SIREN CODES ARE DISPLAYED AT PROMINENT PLACE. IN FIRE HYDRANT MAIN ISOLATION VALVE EXIST FOR ISOLATION OF EACH SECTION. ALL VALVES ON THE FIRE WATER RING MAIN/HYDRANT/ MONITOR VALVES CHECKED FOR LEAKS/OPERATION AND LUBRICATED ONCE IN MONTH AND RECORD MAINTAINED & NO LEAKS OBSERVED. EXPLOSIMETER AVAILABLE IN WORKING CONDITION, CALIBRATED YEARLY & OFFICERS ARE CONVERSANT OF ITS OPERATION. RETURN LINE TO TANK IS AVAILABLE IN FIRE WATER TANK FOR FLUSHING THE HYDRANT LINE AS PER M&I GUIDELINES OR SECTIONWISE FLUSHING IS BEING DONE. FIRE HYDRANT SYSTEM IS IN HEALTHY OPERATING CONDITIONS AND KEPT UNDER PRESSURE WITH JOCKEY PUMP. NO LEAKAGE / CORROSION OBSERVED. ALARM INDICATION SYSTEM LIKE LOW LUBE OIL, HIGH WATER TEMPERATURE FOR FIRE FIGHTING ENGINES IS PROVIDED AND WORKING. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED TT PARKING AREA: TRUCK PARKING AREA PROVIDED AT LOCATIONS FOUND ADEQUATELY COVERED BY HYDRANT SYSTEM. NO TT CREW FOUND LOITERING / SLEEPING / COOKING BENEATH THE TANK TRUCK OR IN TT PARKING AREA. TT PARKING AREA IS AS PER APPROVED PLAN / GUIDELINES FROM HO / WITH PARKING SLOTS / SPEED BREAKERS / SPEED LIMIT BOARDS AND ENTRY / EXIT CONTROL. TT CREW REST ROOM FACILITIES ARE MAINTAINED CLEAN & IN HYGIENIC CONDITION. DOS AND DONTS AND SAFE DRIVING PRACTICES HAVE BEEN DISPLAYED IN DRIVERS REST ROOM IN LOCAL LANGUAGE AND HINDI. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED CONSTRUCTION & MAINTENANCE SAFETY DOS AND DONTS DISPLAYED AT CONSTRUCTION SITE IN LOCAL & HINDI / ENGLISH LANGUAGES. INSTALLATION OF ELECTRICAL EQUIPMENTS / SYSTEM AND REPAIRS OR MODIFICATIONS IN EXISTING ELECTRICAL SYSTEM OF THE LOCATION IS CARRIED OUT THROUGH LICENSED ELECTRICAL CONTRACTOR (S). FOR CONSTRUCTION / MAINTENANCE JOB PPE INCLUDING SAFETY SHOES, SAFETY HELMETS, HAND GLOVES, SAFETY GOGGLES ETC. ARE IN USE
YES YES YES YES YES YES YES YES 27 27 MARKS - 1 YES YES YES YES YES 5 5 MARKS - 1 YES YES
25 26 27 SUB TOTAL: G 1 2 3
4 5 SUB TOTAL:
H. 1 2 3
YES
ALL MAINTENANCE WORKS AND CONSTRUCTION WORKS ARE DONE UNDER THE SUPERVISION OF COMPETENT PERSONS OF CONTRACTOR AND / OR REPRESENTATIVE OF IOCL AND WORK PERMIT FOR HOT / COLD / /ELECTRICAL ISOLATION AND ENERGISATION /WORKING AT HEIGHT, ETC IS IN USE. DAILY SAFETY TALK BEFORE START OF WORK AT SITE IS GIVEN BY THE SITE SUPERVISOR AND RECORDS MAINTAINED. NO UNAUTHORISED CONTRACT WORKER IS ALLOWED FREE ACCESS IN OPERATING AREA. POWER CONNECTION PROVIDED TO THE CONTRACTOR IS THROUGH APPROVED TYPE OF ISOLATORS, CABLES, GLANDS AND EARTHING DEVICES. NO LOOSE / TEMPORARY CONNECTIONS OBSERVED. WHILE CARRYING OUT THE WORK ADJACENT TO THE OPERATING AREA ALL REQUISTE SAFETY PRECAUTIONS INCLUDING PROVISION OF FIRE SCREEN, FIRE FIGHTING EQUIPMENTS, RUNNING WATER ETC AS REQUIRED FOR THE JOB ARE COMPLIED. FIRE TENDER IS TO BE PROVIDED IF REQUIRED. PAINTING AND WELDING JOBS NOT CARRIED OUT SIMULTANEOUSLY AT SAME WORK AREA / LOCATION / SYSTEM. WHILE WORKING AT HEIGHT, FULL BODY SAFETY HARNESS WITH LIFE LINE IS IN USE BY WORKERS TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED GENERAL/ HOUSE KEEPING / HYGIENE LICENSE AREA IS FREE OF BURNT MATCH STICK/BIDI/CIGARETTE. FRISKING OF ALL PERSONNEL IS DONE BEFORE THEIR ENTRY INTO HAZARDOUS AREA. NO LPG LEAKAGES OBSERVED IN THE PLANT AREA BEYOND PERMISSIBLE LIMIT. DOS AND DONTS AND OPERATING INSTRUCTIONS DISPLAYED FOR ALL OPERATING EQUIPMENTS INCLUDING TT PARKING AREA. ALL ROTARY EQUIPMENTS HAVE BEEN PROVIDED WITH COUPLING GUARD. SCRAPS / UNSERVICEABLE MATERIALS ARE KEPT IN MARKED SCRAP YARD ONLY AND SAME ARE DISPOSED OFF REGULARLY. ALL EMPLOYEES AND CONTRACTOR LABOURERS / CASUAL LABOURERS / SECURITY / TT CREW ETC ARE TRAINED AS PER OISD 154 MODULES. ALL STRUCTURES, BUILDING, PIPELINES & FACILITIES ARE PAINTED AS PER SCHEDULE & PIPELINE COLOUR CODE SYSTEM MAINTAINED. PAINT CONDITIONS FOUND ACCEPTABLE. ALL STRUCTURED MEETINGS PRECEDE WITH SAFETY RELATED INFORMATION SHARING. SAFETY OBSERVATIONS ARE COMPLIED IN THE INTRANET REGULARLY STANDARD OPERATING PRACTICES DULY APPROVED BY LOCATION CHARGE IS DISPLAYED AT ALL WORK STATIONS HYGIENE MAINTAINED IN CANTEEN i.e. WASH AREA, REFRIGERATOR / FRIDGE, KITCHEN AND DINNING AREA. UTENSILS / CROCKERIES USED IN CANTEEN FOUND CLEAN AND IN ACCEPTABLE HYGIENIC CONDITION. QUALITY OF CANTEEN FOOD FOUND HYGIENICALLY ACCEPTABLE. WATER COOLER MAINTAINED AND FOUND WORKING PROPERLY. POTABILITY TEST FOR DRINKING WATER CARRIED OUT AND TEST RESULTS ARE AVAILABLE. IN CYLINDER BANK 10 KG DCP FE, DOUBLE WIRE MESH MADE OF COPPER OR NON CORRODING METAL OF NOT LESS THAN 11 TO LINEAR CM (11 MESH PER LINEAR CM) AVAILABLE AND ISOLATION VALVE IS OUTSIDE THE CANTEEN / CYLINDER BANK AND CLOSING / OPENING SIGN DISPLAYED. ALL OBSERVATIONS OF LAST MDT INSPECTION ARE COMPLIED AS PER APPROVED TARGET( DEVIATION UTO 20 % ) BUT WITHIN THE GUIDELINES TO THE TIME FRAME IN THIS REGARD. NO ESA POINTS PENDING FOR MORE THAN 2 YEARS. SAFETY AWARENESS OF OFFICER IS MORE THAN 75%. HOUSE KEEPING IN AND AROUND THE PLANT IS FOUND SATISFACTORY. STORM WATER DRAIN, OTHER RUN OFF DRAINS FOUND CLEAN FREE FROM OBSTACLES. THE DRAIN NEAR EMERGENCY EXIT IS COVERED WITH CHEQUERED PLATE OR CONCRETE SLAB. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED CRITICAL PARAMETER HOT/COLD/ELECTRICAL ISOLATION AND ENERGISATION, WORKING AT HEIGHT WORK PERMITS ARE FOUND IN USE AND NO VIOLATIONS FOUND. STATUTORY TESTING OF STORAGE VESSELS DONE AS PER NORMS AND TEST CERTIFICATE (S) AVAILABLE.
YES YES YES NA
5 6 7
NA
9 10 SUB TOTAL:
NA NA 6 6 MARKS -1 YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES NA YES YES NA YES YES YES 20 20 YES YES
I 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
18 19 20 21 22 SUB TOTAL: J 1 2
3 4 5 6 7 8 9 10 11 12 13 14 15
HYDRO TEST OF FIRE EXTINGUISHER DONE ONCE IN THREE YEARS OR AS PRESCRIBED / STATUTORILY REQUIRED AND RECORDS AVAILABLE. SAFETY CHECKS OF TANK TRUCKS ARE CARRIED OUT REGULARLY & RECORDS MAINTAINED. ALL GAUGES, VIZ. TWO INDEPENDENT LEVEL GAUGE INDICATORS, PRESSURE & TEMP. GAUGES, HIGH LEVEL ALARM SWITCH ETC ARE PROVIDED ON STORAGE VESSEL AND FOUND IN WORKING CONDITION. HIGH LEVEL ALARMS PROVIDED IN STORAGE VESSELS INTERLOCKED WITH ROVs. (CHECK FOR AUDIO VISUAL ALARM AT CENTRAL CONTROL ROOM). REMOTE OPERATED VALVE (ROVs) ARE IN WORKING CONDITION AND OPERABLE BOTH FROM LOCAL AS WELL AS REMOTE POSITION. VAPOUR TRAP EXISTS IN THE SUMP OF EACH VESSEL APRON BEFORE DISCHARGING IN THE STORM WATER DRAIN AS PER OISD 144 AND WATER SEAL MAINTAINED PROPERLY. INTERLOCK SHUT DOWN SYSTEM AS PER OISD-144 CLAUSE NO.11.11 (iv) IS AVAILABLE AND IN WORKING CONDITION. BONDING / EARTHING OF BULK TRUCKS DONE PROPERLY. ALL METALLIC STRUCTURES ARE PROPERLY EARTHED. BULK & STAKE TRUCKS ENTERING PLANT OPERATIONAL AREA HAVE CCOE APPROVED SPARK ARRESTOR. NO FLAMMABLE / PROHIBITED SUBSTANCES LIKE BIDDI /CIGARETTE, PETROL/ DIESEL CAN, MATCH BOX ETC ARE FOUND IN BULK/STAKE TRUCK CABIN. NO LOOSE / TEMPORARY WIRING FOUND IN TT. LPG CYLINDERS WITH SAFETY CAP IF INTRODUCED IN CAROUSAL / FILLING M/C, LPG FILLING OPERATION DOES NOT START OR NO LEAKAGE OBSERVED FROM FILLING GUN. EVACUATION VESSELS (BOIL OFF RECEIVERS, ETHYL MERCAPTEN DRUM ) BELOW 1 MT ARE HYDRAULICALLY TESTED ONCE IN FOUR YEARS OR AS APPLICABLE UNDER STATE FACTORIES RULE & EQUIPPED WITH WORKING PRESSURE GAUGE, LEVEL GAUGE, HIGH LEVEL ALARM, PRESSURE SRVS, ETC & PROVIDED WITH SWITCH OVER ARRANGEMENT MASTIC FLOORING IN CYLINDER SHED HAS BEEN PROVIDED & MAINTAINED. LPG HOSES FOR CAROUSAL FILLING GUN/EVACUATION GUN/ICU ARE TESTED ONCE IN FOUR MONTHS AS PER OISD-135 AND RECORDS MAINTAINED. CABLE ENTRY AT JUNCTION BOX IN HAZARDOUS AREA IS THROUGH DOUBLE COMPRESSION GLANDS (PROPER EMBOSSING OF CMRI/CMRI NO. AVAILABLE FOR FLAME PROOF ). GLANDS ARE PROPERLY TIGHTENED AND CABLES IN THE GLANDS ARE NOT LOOSE. EARTHING RESISTANCE FOR INDIVIDUAL EARTH PITS IN ISOLATED CONDITION, FOR GRID AND CONTACT RESISTANCE POINTS IS WITHIN PRESCRIBED LIMITS AND RECORDS PROPERLY MAINTAINED. LIGHTNING PROTECTION ARE PROVIDED IN ALL PRODUCT PUMP HOUSE / TLF / TW GANTRY / LPG COMPRESSOR HOUSE AS PER CIRCULAR REF.NO.LPG /ENG/117 DATED 06.03.01. FLAME PROOF EQUIPMENT ARE PROPERLY TIGHTENED WITH STANDARD FASTENERS AND NO FASTENER IS MISSING HYDRANT SYSTEM / SPRINKLER SYSTEM IS ON AUTO. WATER TANKS FOR FIRE FIGHITNG ARE KEPT FULL ( MINIMUM UPTO OISD NORMS) CLEANED AS PER SCHEDULE AND LEVEL GAUGES ARE IN WORKING CONDITION FIRE ENGINES AVAILABLE AS PER OISD-144. (AS PER OISD 5 NOS X 410 M3/HR. AVAILABLE 3 NOS X 410 M3/ NO X 410 M3/HR AS STAND BY) H R AND 2
YES YES YES YES YES YES NO YES YES YES YES NA
NA NA NA YES YES YES YES YES YES YES YES YES YES YES YES 25 24 YES YES YES YES YES YES YES YES YES YES 10 10 YES 1 1 YES 1 1
16 17 18
19 20 21 22 23 24 25 26 27 28 29 SUB TOTAL: K 1 a b c d 2 3 4 5 6 SUB TOTAL: L 1 SUB TOTAL: M 1 SUB TOTAL: N 1 SUB TOTAL:
WATER STORAGE IS AVAILABLE AS PER OISD-144/169. ( AS PER OISD NORMS 4980 KL. AVAILABLE 7400KL) GAS MONITORING SYSTEM & SENSORS ARE PROVIDED AS PER OISD 144 / WORKING / CALIBRATION DONE & RECORDS MAINTAINED. PERSONAL PROTECTIVE EQUIPMENT SUCH AS HAND GLOVES / SAFETY SHOES / SAFETY HELMETS ETC ARE IN USE. ALL DELUGE VALVES ARE WELL MAINTAINED/ FOUND IN WORKING CONDITION & TESTED ONCE IN A QUARTER & RECORDS MAINTAINED. HYDRANT / MONITORS / DELUGE VALVE ARE EASILY ACCESSIBLE AND OPERABLE TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED BOILER VALID LICENSES AS PER IBR AVAILABLE / APPLIED FOR RENEWAL IN TIME. TRIPPINGS SCANNER COOLING FAN FD FAN FLAME SCANNER 3 ELEMENT BOILER DRUM LEVEL CONTROL NO LPG LEAKAGES OBSERVED IN DIESEL & HSD PIPELINETHE PLANT AREA BEYOND PERMISSIBLE LIMIT. NO LPG LEAKAGES OBSERVED IN ACID & ALKALI PIPELINETHE PLANT AREA BEYOND PERMISSIBLE LIMIT. WATER TREATMENT PLANT IS IN WORKING CONDITION. NDT OF ACID AND ALKALI STORAGE TANKS & PIPELINES CARRIED OUT NO FLUE GAS LEAKAGE OBSERVED FROM THE CHIMNEY. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED HOT FLARE STACK Hot Flare stack is in working condition. The temperature indication available in DCS at Central control room. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED WINCH SYSTEM OF RAIL WAY LOADING FACILITY THE WINCH SYSTEM IS IN WORKING CONDITION AND TRIPPING SYSTEM WORKING TO AVOID DE-RAIL OF WAGON. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED HT DG SET LOW LUBE OIL / LOW AIR PRESSURE / HIGH WATER TEMPERATURE / OVER SPEED AND EMERGENCY SHUT DOWN ARE PROVIDED AND FOUND IN WORKING CONDITION.. TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED
YES 1 1
N 1 2 SUB TOTAL:
APARATUS FILLED STRUCTURE VAPOUR ANALYSER IN WORKING CONDITIONS AND REGULAR DATA MAINTAINED. YES
TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED
1 1
N 1 2
MERCAPTAN DOSING PLANT GAS MASK, PPE'S AVAILABLE FOR PERSONNEL WORKING IN THE MERCAPTAN DOSING PLANT STANDARD OPERATING PRACTICES DULY APPROVED BY LOCATION CHARGE IS DISPLAYED YES
SUB TOTAL:
TOTAL NO. OF ITEMS APPLICABLE TOTAL MARKS OBTAINED
1 1
CALCULATION OF OVER ALL SAFETY INDEX
SECTION
SUBJECT
I II A LICENSES / APPROVALS / CERTIFICATES / DISPLAY B ACCIDENT REPORTING AND INVESTIGATION C BULK STORAGE / BULK LOADING / UNLOADING AREA D FILLING SHED / PRODUCT PUMP HOUSE / LPG COMPRESSOR HOUSE E ELECTRICAL INSTALLATION F FIRE FIGHTING SYSTEM / /SAFETY ITEMS J CRITICAL PARAMETER G /H /I TT PARKING AREA / CONSTRUCTION & MAINTENANCE SAFETY /GENERAL / HOUSE KEEPING / HYGIENE K BOILER L HOT FLARE STACK M WINCH SYSTEM OF RAIL WAY LOADING FACILITY N HT DG SET TOTAL WEIGHTED SAFETY INDEX 0.00 PENALTY MARKS ON ACCOUNT OF NON COMPLIANCE OF MDT POINTS PENDING FOR TWO YEARS OR MORE (-1) (EVEN IF APPROVAL TAKEN FOR EXTENSION OF TARGET) PENALTY MARKS ON ACCOUNT OF NOT FOLLOWING ACCIDENT REPORTING, INVESTIGATION ANALYSIS POLICY GUIDELINES (-2) OVERALL SAFETY INDEX OVERALL STATUS OF SAFETY
TOTAL APPLICABLE MARKS III
TOTAL MARKS OBTAINED IV
WEIGHTAGE V
WEIGHTED MARKS V*IV/III
0.00
0.00 NA
0.00 0 0.00
(Signature with date) LOCATION IN CHARGE Name : Designation : Date : Important Instructions 1
(Signature with date) WITNESSED BY : OP Name: Designation : Date:
(Signature with date) AUDITED BY : S&EP/HO/RO Name: Designation: Date:
Date:
STATEMENT OF DEVIATIONS IN SAFETY EQUIPMENT AVAILABILITY VIS--VIS NORMS IS TO BE PROVIDED BY LOCATIONINCHARGE AND COPY OF THE SAME IS TO BE ENCLOSED AS PART OF THIS AUDIT. SAFETY AUDIT / INDEX TO BE EVALUATED BASED ON RANDOM CHECK COVERING THE AREA THROUGH DIFFERENT ROUTES EVERY TIME. REFERENCE OF CHECK POINTS AND DOCUMENTS REFERRED DURING THE AUDIT ARE TO BE MENTIONED AND LISTED IN A SEPARATE NOTE AND ENCLOSED WITH THE AUDIT REPORT. EACH COMPLIED POINT TO BE GIVEN 1 MARK WHEREAS UNCOMPLIED POINTS CARRY ZERO MARK. IF ANSWER IS NOT APPLICABLE FOR ANY CONDITION, THAT POINT SHOULD BE IGNORED AND NOT TO BE COUNTED FOR OVERALL MARKINGS. ANY LOCATION GETTING OVERALL SAFETY INDEX LESS THAN 94% MARK OR COMES UNDER VULNERABLE CATEGORY IS TO BE TREATED AS VULNERABLE AND LOCATION MUST TAKE NECESSARY ACTION TO COMPLY WITH THE SHORTCOMINGS AND INFORM REGIONAL S&EP WITHIN A WEEK FOR REINSPECTION. WITH REFERENCE TO POINT.A16 : THE AUDIT CHECK LIST SHALL BE APPLICABLE AND OUTLINED UNDER LATEST OISD144/145/169 ETC. WITH REFERENCE TO POINT.C-6 : THE DETAILS MAY BE REFERRED AS PER OISD-130. WITH REFERENCE TO POINT.J-15 : IF EVACUATION VESSEL ARE ABOVE 1 MT FALL UNDER SMPV RULES 1981 AND TO BE TESTED ACCORDINGLY. WITH REFERENCE TO POINT.D-19 : IN OLD MODEL LPG PUMP WHERE THIS SYSTEM IS NOT AVAILABLE SINCE COMMISSIONING MAY BE EXEMPTED. WITH REFERENCE TO POINT J-19 : FOR LOCATIONS IN ROCKY AREA, THE GRID AND CONTACT RESISTANCE LIMIT TO BE MET. WITH REFERENCE TO POINT E-4 : THE EMERGENCY LIGHT TO BE PROVIDED IN THE FOLLOWING CRITICAL AREA OF THE PLANT; FIRE PUMP HOUSE, PMCC, EMPTY SHED ,FILLINING SHED, PRODUCT PUMP HOUSE, TANK LORRY DECANTATION SHED/TANK LORRY FILLING SHED , TT PARKING AREA, ADMIN BUILDING AND ENTRY/EXIT GATE. WITH REFERENCE TO POINT I-6 THE SCRAP DISPOSAL WHERE THE ORDER HAS BEEN PLACED FOR DISPOSAL IS UNDER PROCESS FOR ALL THE ITEMS OLDER THAN ONE YEAR SHALL MEAN COMPLIED AND SHALL BE TREATED AS YES. WITH REFERENCE TO POINT NO. I-7: TRAINING TARGET AND ITS EVALUATION IS FOR PREVIOUS FINANCIAL YEAR. TARGETS TO BE ACHIEVED ARE FOR STAFF (BCW AND WCW) 35% AND FOR TT CREW / CONTRACTOR LABOUR / SECURITY 100%. IF THE TARGET IS NOT ACHIEVED, ZERO MARK TO BE GIVEN. WITH REFERENCE TO POINT.I-18 : APPROVED TARGET MEANS THE TARGET DECIDED DURING MDT INSPECTION OR SUBSEQUENTLY REVISED AND DULY APPROVED BY STATE HEAD BUT WITH A VARIATION UPTO 20%. FOR THE PURPOSE OF REWARD / INCENTIVE SCHEME, SAFETY INDEX WHICH EVER IS LOWER EITHER OF ORIGINALLY EVALUATED DURING MDT INSPECTION OR THE SAFETY INDEX RE-EVALUATED DURING REPEAT INSPECTION, SHALL ONLY B E CONSIDERED. ONE (1) MARK TO BE DEDUCTED FROM OVER ALL SAFETY INDEX MARKS OF THE LOCATION ON ACCOUNT OF NON COMPLIANCE OF MDT POINTS PENDING FOR TWO YEARS OR MORE. APPROVAL FOR DEVIATION OF TARGETS FROM STATE HEAD FOR TWO YEARS OR MORE SHALL NOT BE VALID. LOCATION FAILING TO FOLLOW ACCIDENT REPORTING, INVESTIGATION ANALYSIS POLICY GUIDELINES (SEP/110 DATED 16.03.07 OR ANY REVISION THEREOF) SHALL LOSE TWO (2) MARKS FROM OVERALL SAFETY INDEX MARKS OF THE LOCATION. TLD TANK LORRY DECANTATION, PPH PRODUCT PUMP HOUSE, DCVT DOUBLE COMPACT VALVE TESTOR, AVTS AUTOMATIC VALVE TESTING SYSTEM, ICU INTEGRATED CORRECTION UNIT, SQC STATISTICAL QUALITY CONTOL, EFCV EXCESS FLOW CHECK VALVE, ILSD INTER LOCK SHUT DOWN, ROV REMOTE OPERATED VALVE, SRV SAFETY RELIEF VALVE, TSV THERMAL SAFETY VALVE, ETB EMERGENCY TRIP BUTTON, MCP MANUAL CALL POINT, ST STATUTORY TESTING, IS INDIAN STANDARDS, OISD OIL INDUSTRY SAFETY DIRECTORATE, ABS ANTI LOCK BRAKE SYSTEM.
3 4 5 6 7 8 9 10 11
12
13 14 15
16
17
18
(Signature with date) LOCATION IN CHARGE Name : Designation : Name: Designation : Name: Designation:

OISD STD 236 Refrigerated Storage1

Загружено:

Сведения о документе

Исходное описание:

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

OISD STD 236 Refrigerated Storage1

Загружено:

Авторское право:

Доступные форматы

Page No.

Draft Document OISD-STD-236

FOR RESTRICTED CIRCULATION ONLY

Jai Hind! Executive Director Oil Industry Safety Directorate

Page No. III

LIST OF FUNCTIONAL COMMITEE (FC) MEMBERS

Position in the FC Leader

Member Member Member Member coordinator

REFRIGERATED LPG STORAGE AND HANDLING FACILITIES - PROCESS

DESIGN CONSIDERATIONS REFRIGERATED STORAGE TANKS

FIRE PROTECTION, SAFETY AND EMERGENCY SYSTEMS GENERAL

relied upon to detect their presence.

OPERATIONS OF REFRIGERATED LPG STORAGE INSTALLATION:

Condensation of the refrigeration compressor discharge:

INSPECTION & MAINTENANCE OF REFRIGERATED LPG STORAGE INSTALLATION:

Major overhauling of the compressor as per the period specified by OEM

COMMISSIONING AND DECOMMISSIONING :

Frequency Daily Monthly Yearly Six Monthly Yearly

dit / Inspection by Target Date 5

Review Date 6 (Status)

Sr No F-09 F-10 F-11 F-12 F-13 F-14

Signature of inspecting officer

Signature of Location I/C

Name of the location

Remarks/ Renewal Application Date

Signature of Location Incharge

l m n D a (i) (ii) (III) (iv) (v) (vi) (vii) (viii) b c d e f g h i j k E a b

Sr. No. 1.1.7.13 1.1.7.14 1.1.7.15 1.1.7.16 1.1.7.17 1.1.8 1.1.9

MARKS MAX. AWARD

1.2.2 1.2.3 1.2.4 1.2.5

Sr. No. 1.3.1 1.3.1.1

MARKS MAX. AWARD

1.3.2 1.3.2.1 1.3.2.2 1.3.2.3

1.3.3.2 1.3.3.3 1.3.3.4

1.3.4 1.3.4.1 1.3.4.2

Sr. No. 1.3.4.3

MARKS MAX. AWARD

1.3.5 1.3.5.1 1.3.5.2 1.3.5.3 1.3.5.4

1.3.6 1.3.6.1 1.3.6.2 1.3.6.3

2.0 2.1 2.1.1

Sr. No. 2.1.3

MARKS MAX. AWARD

2.1.8 2.1.9 2.1.10 2.1.11

2.1.12 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6

Sr. No. 2.2.7 2.2.8 2.2.9 3.0 3.0.1

MARKS MAX. AWARD

3.0.3 3.0.4 3.0.5 3.0.6 3.0.7 3.0.8

3.0.9 3.0.10 3.0.11 3.0.12 3.0.13 3.0.14 3.0.15

MARKS MAX. AWARD

Sr. No. 4.0.15 4.0.16 4.0.17

MARKS MAX. AWARD

4.0.18 4.0.19 4.0.20 5.0 5.1 5.1.1

5.1.2 5.1.3 5.1.4 5.1.5

5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.1.11 5.1.12 5.1.13

Sr. No. 5.1.14

MARKS MAX. AWARD

5.1.15 5.1.16 5.1.17

5.3.4 5.3.5 5.3.6 5.3.7

Sr. No. 6.0 6.1 6.1.1

MARKS MAX. AWARD

6.1.5 6.1.6 6.1.7 6.1.8

6.1.14 6.2 6.2.1

Sr. No. 6.2.2 6.2.3 6.2.4