1

Foreword
Fire is a good servant
but a bad master

apidly growing vehicular population, coupled with the

deregulation of the downstream petroleum sector in the
past decade, has seen a large increase in the number of petrol &
diesel stations (retail outlets). Their number has crossed 45,000
as on date; IndianOil accounts for nearly half of them. Over the
years, there has been an increase in the number of accidents at
the retail outlets, a few of them resulting in loss of precious lives
and also serious injuries.
Retail outlets are hazardous workplaces that require a proper
explosives licence to operate. Various routine operations at these
outlets receipt, storage and dispensation of highly flammable
liquids on a continuous basis generate vapours. Since these
vapours are heavier than air, they remain in the premises and
accumulate at lower levels such as tank-farm area, drains,
trenches, pits, etc. When these vapours mix with air, a flammable
mixture is created, and chances of fire or explosion arise.

Fire is a good servant...

For many years now, IndianOil has been playing a leadership

role in the downstream petroleum business, with proven
credentials. IndianOilPeople and our large family of dealers are
well aware of the perils of fire and accidents at the workplace.
It is important for all of us to have proper job knowledge and be
always vigilant at our work stations. In addition, all of us must
know the proper use of fire safety equipment, including their
upkeep and maintenance, and be fully aware of the procedures
to be followed in case of emergencies.
Customers visiting our retail outlets are generally ignorant of
the safety guidelines to be observed at the time of fuelling.
Therefore, it is our responsibility to create a safe and secure
environment and seek the cooperation of our valued customers
in maintaining utmost safety in all operations at our retail outlets.
This handbook has been developed to nurture a culture of safety
in the working of our retail outlets by way of strict adherence to
the highest standards of safety.

...but a bad master

Contents
What is a Fire?

Classification of Fires

How to Put Out a Fire?

Nature of Petroleum Products

Safety Equipment
Static Electricity

8-9
10

Earthing 11
Electrical Safety
Tank-truck Unloading

12
13-14

Traffic Management

15

Engineering Works

16

Training on Safety

17

In Case of a Fire...

18

When You Spot a Fire

19

Fire-fighting Equipment

20-21

Safety Checklist

22-23

Annexure
Annexure: 1 - Daily Checklist for Retail Outlet Dealers
Annexure: 2 - Retail Outlet Safety Inspection
Annexure: 3 - Safety Checklist for Tank-Truck Decanting
at Retail Outlet

24
25-28
29

Annexure: 4 - Display of Dos & Donts Signboards at Retail Outlets

30-31

Annexure: 5 - Safety & Environment Protection Inspection

Format-Auto LPG Outlet

32-33

Annexure: 6 - Construction Safety Checklist for Retail Outlets

34-35

Annexure: 7 - Safety Inspection Register / Record

36

What is a Fire?
A FIRE is a voluntarily advancing process
of combustion of one or more inflammable
materials with release of energy.
It is a chemical reaction between Oxygen and
Carbon (or even Hydrogen and Carbon) in
which heat and light energies are released.
In scientific terms, it may be defined as
a chemical reaction of rapid oxidation
accompanied by release of light and heat.

FUEL + HEAT ENERGY + OXYGEN/AIR = FIRE

XY

T
EA

EN

A fire needs three basic elements

FUEL

Presence of fuel or vapour

Presence of Oxygen or air
Presence of heat or source of ignition
This combination causing combustion is referred to as the Fire Triangle.

Classification of Fires
Class A Fires:

Class B Fires:

Fires caused by ordinary

combustible materials,
such as wood, cloth,
paper, rubber & many
plastics.

Fires caused by flammable

liquids, combustible liquids,
petroleum greases, oils, oilbased paints, solvents and
flammable gases.

Class C Fires:
Fires that involve GAS and energised electrical
equipment where the electrical non-conductivity of the
extinguishing media is of importance (When electrical
equipment is de-energised, fire extinguishers for Class A
or Class B fires can also be used safely).

Class D Fires:
Fires in combustible metals, such as Magnesium, Titanium,
Sodium and Potassium.

How to Put Out a Fire?

There are three fire-extinguishing methods:

Starvation:

ON

By removing the fuel away from the fire.

By cutting off fuel supply (most effective for gas fires).
OFF

Smothering:
Blanketing of the fuel from air/Oxygen by a coating
material, by using gas, steam or vapourising liquid.

Cooling:
Natural cooling (water spray is the most commonly used,
effective for oxidising chemicals, tank fires, etc.)

Nature of Petroleum Products

Petroleum products, by nature, are:

Highly flammable
Emit vapours at normal temperature
Catch fire with the slightest spark or flame
Have very low flash point
Are a health hazard; Inhalation may cause dizziness, nausea and
headache. Prolonged contact with skin may result in irritation

Classification of Petroleum Products

Class A: Flash Point below 23o C (MS or Petrol)
Class B: Flash Point between 23o C and 65o C (HSD or Diesel & SKO or Kerosene)
Class C: Flash Point between 65o C and 93o C (Lubricants)
Flash point of a volatile liquid is the lowest temperature at which it can vaporise to form an ignitable mixture in air.

MS or Petrol

HSD or Diesel

Lubricants

*C = Centigrade

Safety Equipment
W

hile the Explosives Licence for retail outlet specifies

provision of adequate fire-fighting equipment, it
is equally essential that every individual working at the
retail outlet is familiar with and equipped to operate these
equipment.
A fire may occur at a retail outlet despite our best efforts.
At this critical juncture, we should be equipped to handle

the fire rather than try and run away from the situation.
It is of utmost importance to keep the safety equipment
handy and positioned at appropriate places where these
can be easily reached by all individuals. A fire can be
fought only when we ensure the availability and proper
positioning of the safety equipment, that too in working
condition.

The equipment to be always available at the outlet is:

Two 10 kg / 9 kg DCP Fire Extinguishers are to be

placed on each pump island.

One 4.5 kg CO2 Fire Extinguisher has to be kept at the

Electrical Control/Switch Room.

Safety Torch

Safety Equipment

Rubber mat for Electrical Control Room

Sand buckets (at least two per DU,

minimum four)

Cordon off the Tank-truck Decantation Area

10 kg / 9 kg DCP Fire Extinguisher for safety

of tank-truck

Static Electricity
G

eneration of static electrical charge during decantation of the tank-truck or while fueling through the dispensing units
is one of the most potential sources of ignition, leading to fire at retail outlets. Static charge is likely to be produced
during product movement through the hose and the pipeline.
Static electricity, sometimes called the electricity of friction, is generated as a result of friction between two separate
bodies, either of the same material or different materials. The electrons get accumulated on the surface of the object in
the form of a static charge and continue to remain on the body of the object till they are grounded through an electrical
conductor.
Bonding is done to carry the static charge from one object to another to eliminate the difference in static charge potential
between the two. Finally, the object is grounded to eliminate a difference in static charge potential between it and the
ground.

Bonding of the tank-truck and the underground tank.

onding and grounding are effective only when the bonded objects are conductive, such as earthing strip/wire, etc.
When a charged object that is not grounded comes close to another metal body, the charge gets transmitted to that
object in the form of a spark. The spark becomes a source of fire if it comes in contact with petroleum vapours. This calls
for proper earthing/grounding of all petroleum-handling equipment in a retail outlet to avoid a fire or explosion.

Grounding

10

Earthing

Earthing
E

arthing is provided for dissipation of electrical charge created in the storage tanks, pipeline, hose, dispensing unit,
etc., as well as in electrical fittings. All the equipment or objects generating static charge are earthed by means of a
conductor that is connected to earthing electrodes buried in the soil. While proper earthing will eliminate fire, its improper
upkeep becomes a potential source of fire. Proper checks need to be carried out periodically as specified.

DOs
Ensure earthing of
all storage tanks and
pumps
All earthing
connections to be
secured with nuts and
bolts
Ensure proper earthing
of DU panel motor and
pump
Ensure proper earthing
of light pole and
junction box
Ensure separate
earthing point for tanktruck decantation
Before the
commencement of
decantation, ensure
that the tank-truck is
properly grounded and
fill pipe is bonded to
the tank

Ensure use of hose with

electrical continuity and
leak-proof coupling for
decantation

DONTs

Ensure settling time of

minimum 10 minutes
before sampling/
gauging of the tanktruck

No loose connections
of earthing strips/
cables

Check earthing
continuity and
rectification of earthing
pits periodically
Ensure measurement
of earth pit resistance
periodically

Proper earthing of
underground tank inlet.

Do not keep earthing

pits dry

Do not use nylon rope

during sampling /
gauging inside the tank
Do not undertake
tank-truck decantation
wearing synthetic
clothes and rubber
boots.

Do not fuel a twowheeler while the

customer is sitting on
the vehicle
Do not allow entry of
unbonded conductive
objects inside the
storage tank/tank-truck
Do not use nylon hose
for decantation of the
tank-truck

Hose with Electrical

Crocodile clips for bonding
Continuity for proper bonding and electrical continuity

11

Electrical Safety
E

lectricity, if not handled carefully, can cause fire as well as personal injuries. In a retail outlet, electricity being a prime
and major source of energy, knowledge of safe practices is necessary for all team members. Most of the fire incidents
are caused due to non-adherence to electrical safeguards such as use of non-flame proof electrical fittings inside the
dispensing units, improper wiring/loose connections, use of non-standard eletrical devices and fittings, etc., leading to
generation of spark, which, when it comes in contact with the flammable petroleum vapours, becomes a source of fire.
The causes of these mishaps need to be eliminated from our retail outlets by observing the following safety guidelines:

DOs
Good house-keeping
Adequate ventilation and lighting in the
switch room
All electrical panel doors/junction boxes
in the electrical switch room to close
properly
Proper sized glands for electrical cables in
the switch room and fore-court area
Rubber mats on switch-room floor
4.5 kg CO2 fire extinguisher at the
electrical switch room
Labeling of switches with connected
equipment
Separate DG earthing connection for body
and neutral
Display of electrical shock treatment chart
in the switch room
Cable marker for all underground cables

Proper Switch Room

Rubber mats

4.5 kg CO2 Fire Extinguisher

DONTs

12

Do not allow loose electrical connections

Do not use the switch-room as a store
Do not store product samples in the compressor room
No oil spillage in DG room
Do not allow temporary additional electrical
connections
No hanging wires / fixtures
No visible mark of burning on cables
No fused lamps
Do not leave the junction box open

Avoid loose electrical connections

Tank-truck Unloading
L

oading and unloading of petroleum products in the tank-truck is considered to be one of the most hazardous operations
in the petroleum industry. Even though generation of static charge is more during loading of the product, since the
operation is carried out in bulk storage locations under the direct supervision of our employees immediate corrective
measures can be initiated in case of any mishaps. Whereas unloading operations take place in the retail outlet, where
only the tank-truck crew and a few staff of the outlet are available. Emergencies in case of fire or spillage at the time of
decantation, if not attended to immediately, would result in a major fire and loss of property and/or life.
Keeping the above facts in view, the following procedure must be followed for safe decantation of MS/HSD from the tanktruck at the retail outlet:
After arrival of the tank-truck, check the
documents and make sure that the consignment
was meant for the outlet
Place the tank-truck on a level ground near the
unloading point or tank. Put off engine, isolate
battery by operating battery cut-off switch,
apply hand brake of the tank-truck. Put wheel
chokes under the front and rear wheels

Put off engine

Allow 10-15 minutes for settling and dissipation

of static charges. Take out the DCP fire
extinguisher of the tank-truck and keep it in
front of the vehicle
Before beginning unloading, cordon off the area
for banning entry of other vehicles. The area
should remain cordoned off till the completion
of unloading

Isolate Battery

Apply hand brake

Check ground level for correct dip

Earthing connection needs to be provided to the

tank-truck before commencement of unloading
of product. As a further measure of safety, the
vehicles manifold should be bonded to the
underground tank, through a flexible cable. The
crocodile clips have to be clamped on bare
clean metal surface at both ends

Checking of density

13

Tank-truck Unloading
The petroleum product should enter the tank through a
closed-coupled electrically continuous and sound hose
(rubber). with Camlock Couplings. Never use or allow
PVC hose for unloading
Naked lights or smoking are not allowed while decantation
is on. Mobile phones should not be operated
Visually check the surroundings, the tank and the
connections for any unusual or dangerous situation
Open the manhole dome cover, cap of the dip pipe and
fill pipe of the tank-truck. Do not open the fusible vent
cover of the tank-truck
Draw a composite sample from each compartment,
preferably by inserting sample thief through a metal
chain. If a bucket is used, it should be bonded and

Mobile phones should not be operated

connected to the tank-truck manifold. Check the dip of

the vehicle as per practice
Open the master/bottom valve of each compartment slowly
turn-by-turn as per the unloading sequence and monitor for
leakage, if any
During decantation, the dip pipe cover of the underground
tank should be in closed condition
The dealers representative as well as the tank-truck
crew must be present near the vehicle right through the
decantation process
In case of any leakage or abnormal situation, decantation
should be stopped immediately; the operation should be
resumed only after taking necessary corrective action

Manhole dome cover

Closed-coupled sound hose With

Camlock Couplings

Note: Safety checklist for tank-truck decantation at retail outlets should be strictly adhered to (as per Annexure 3).

14

Traffic Management
E

ven though a majority of the accidents at retail outlets are caused by electricity, there are cases where accidents/fires
have been reported due to improper movement of vehicles inside the retail outlet premises.

There have been cases of persons coming under the wheels of tank-trucks reversing within the RO premises after
decanting the product. Reversing of vehicles within the premises should be avoided and may be resorted to only under
strict supervision.
One vehicle clashed with another while fuelling was in progress. It is, therefore, important to depute a marshal to guide
incoming vehicles to different islands for fuelling.
DOs and DONTs board for customers may also be displayed prominently in the fore-court.

DOS

Pot-hole free driveway

Marshals to guide

Properly illuminated driveway during night

Display of entry/exit signs
Pot-hole free driveway surface
Marshals to guide incoming vehicle to the
respective island
Ensure spillage-free pump island
Ensure vehicle engine remains switched off
while fuelling
Hold nozzle firmly during dispensation of fuel
Fix fuel cap after each delivery
Marshals to guide for safe exit of outgoing
vehicles.

DONTS

Hold nozzle firmly

Fix fuel cap after each delivery

Do not allow entry of vehicles inside the

RO when tank-truck decantation is in
progress
Do not allow parking of vehicles at the
entrance
Do not operate mobile phones at the filling
points
Do not allow exit through ingress

15

Engineering Works
Various works are undertaken at retail outlets from time
to time for enhancing the service level. These could be
modernisation, retail automation, addition of tank and
pump, replacement of tank and pump, etc., apart from
minor electrical and pipeline works.
Extra vigil needs to be kept while undertaking such works.

Note: Construction safety checklist for retail outlets is given in

Annexure - 6

16

Training on Safety
Training is an effective tool for imparting acquired
knowledge and needs to be an integral part of the visit
by all company officials as and when they visit the
retail outlet. The film on safe decantation of tank-trucks
should be shown and explained to the dealers and all
the pump attendants by the respective field officers.
Organising mock fire drills at regular intervals will enable
all attendants to get familiarised with the various safety
equipment, and their operation and maintenance. Regular
inputs on safety to the dealers and the pump attendants
will ensure a safe and accident-free environment at the
retail outlet.

17

In Case of a Fire
On noticing the fire, seek necessary help and try to extinguish the fire by discharging the nearest DCP or CO2 fire
extinguisher as the case may be.
Inform the local Sales Officer of IndianOil immediately.
The following telephone numbers should be available at the retail outlet for seeking necessary help:
o Local fire brigade

Tel. No.: [..........................................]

o IOCL depot / terminal

Tel. No.: [..........................................]

o HPCL depot / terminal

Tel. No.: [..........................................]

o BPCL depot / terminal

Tel. No.: [..........................................]

o Local police station

Tel. No.: [..........................................]

Raise alarm by shouting fire fire fire

If possible, control and extinguish the fire by operating the nearest fire extinguisher
If it is not possible to extinguish the fire, raise alarm

18

When You Spot a Fire

Fire-fighting Activities

Rescue Operation

Operate the nearest available fire-extinguisher(s)

Shift injured persons, if any, from the site and arrange for
their medical treatment

Use sand buckets for fire-fighting

Call for assistance
Provide back-up to the fire-fighting team
Retail Outlet Operations
Suspend all loading, unloading, dispensing operations
Switch off all electrical power
Evacuate all vehicles and outsiders

Points to Remember
Fire incidents happen due to carelessness and
ignorance of safe practices
Observe fire prevention rules strictly, without any
deviation
Ensure that the fire-fighting equipment installed at the
retail outlet is visible and easily accessible

Close product line valve, if any, and DU operation

Do not tamper with the fire-fighting equipment in any

way

Administrative & Support Activities

Be sure that everyone working in the retail outlet knows

how to use the fire-fighting equipment

Contact local fire services and neighbouring retail

outlets for help
Arrange for safe evacuation of people and vehicles
from the outlet

Keep a list of phone numbers of neighboring industries,

Government authorities, fire services, etc., ready at a
convenient place.

19

Fire-fighting Equipment

fire may occur despite our best efforts to make our work place a safe zone. In such instances,
it is very important for each one of us to know about the two main types of fire-extinguishers
suitable for retail outlet fires and the proper way of handling them to put out fires:

1) 10 kg / 9 kg Dry Chemical Powder (DCP)

Fire-Extinguisher

Uses dry chemical powder as fire extinguishing agent.

Effective against fires caused by inflammable liquids like
petrol, diesel and kerosene, and burning gases such as
butane, along with other natural gases.

How to use:

20

Lift on shoulder and run to the fire incident spot

Place it on the ground

Remove the safety clip

Hold discharge nozzle in open position in one hand

Strike knob on the top with the other hand, keeping

your face away

Aim discharge nozzle towards seat of fire in line with

the wind direction

Send the fire extinguisher for recharging after use

DCP Fire-extinguishers
Note:
Dry powder fire-extinguishers, when used
in confined areas, may reduce visibility
for a few minutes, which may temporarily
jeopardise escape, rescue or other
emergency action.

2) 4.5 kg Carbon Dioxide (CO2) Fire-Extinguisher

Uses Carbon Dioxide (CO2) as fire extinguishing agent,

by cutting off supply of Oxygen. Mainly used on electrical
equipment fires to avoid electrocution. Also used for extinguishing
fires of inflammable liquids such as gasoline, paints,
varnishes and natural gases, besides fires in machinery.

How to use:

Open valve in anti-clock wise direction

Aim nozzle at the source of fire

Keep on moving the nozzle briskly until carbon dioxide

continues to gush out

Close valve after use

Carbon Dioxide CO2 Fire-extinguishers

21

Safety Checklist
Requirement of Fire-fighting Equipment
Each dispensing unit shall be covered by at least two
ISI-marked 10 kg / 9 kg DCP fire extinguishers placed
at a safe location within 3 meter radius.

Fire extinguishers are to be periodically tested as per

below schedule :

Minimum one 4.5 kg CO2 fire extinguisher conforming

to IS: 2878 shall be available in each electrical meter
room.

- Condition of DCP, hose, nozzle & safety chip

Monthly

Minimum four sand buckets filled with dry sand should

be available at the premises For each dispensing unit,
a minimum of 2 dry sand buckets of 9 litres capacity
with large round bottom to be provided.

- Visual Check Daily

- Weight Check of CO2 cartridge Quarterly (CO2

cartridge to be replaced if gas weight loss is more
than 10%)
- Performance testing Yearly
- Pressure testing Every 3 years

22

Safety Checklist
Deviations to be observed and recorded
at ROs during inspection
Earth pits not available/not maintained properly.
Whether earthing strip from earth pit is extended up to
the decantation point for proper earthing of the tanktruck
Electric wiring not properly dressed or loose
connections observed.
RO employees not fully trained in fire safety and
equipment

Leakage of product
Poor house-keeping in electrical panel room
4.5 kg CO2 fire extinguisher not provided for electrical
switch/control room
Sealed decantation of the tank-truck using camlock
coupling not being done
Double earthing is not provided for DG neutral

Fire extinguishers not maintained properly/quarterly

test certificate not available

Posters on no-smoking, non usage of mobile phones,

etc., not displayed at prominent places

Spare CO2 cartridges and dry chemical powder not

available at the outlet

Dos & donts on safety not displayed

Safety checklist for TT decantation not being followed

Poor Overall housekeeping

Dry Vegetation in and around tank-farm area

23

Annexure
Annexure -1

Daily Checklist for Retail Outlet Dealers

Name of the Outlet:

No.

24

Date:

Particulars

Y/N

All dispensing units (DUs) are clean (internally / externally). There is no

spillage of product and inflammables inside the DU

All piping connections in DUs and tank-farm area are leak-free and there
is no sweating at the joints

Wire mesh in the tank vent is completely clean and not choked

Fire-extinguishers are in place and valid for use as on date

Roads and pathways are clear of any obstruction

Safety signs are in place (No Smoking / Do not operate mobile phone
messages, Dos & Donts display board, tank-truck decantation
procedure, etc)

Tank farm is clean and free of dry vegetation

Sand in the buckets is dry and without any lumps

All light fixtures in the periphery, canopy and sales rooms are in working
condition

10

No employee in the retail outlet is in an intoxicated state

11

Daily briefing of Dos & Donts on safety has been carried out before start
of the shift

12

General house-keeping is good

13

There are no electrical faults observed in the retail outlet

14

Earthing connections are in perfect condition at all the places, viz.,

DU (pump/motor/panel), DG, TT decanting point, etc and records are
maintained

15

Irregularities, if any, are being logged in the Action Plan Register

16

Any other unsafe condition observed

17

The manager/shift supervisor of the retail outlet is well conversant with

the safety practice to be adopted in case of emergencies

Remarks

Signature &
Name and of the Dealer / Dealers Representative

Annexure
Annexure - 2

Retail Outlet Safety Inspection

R/O: _________ Dist: _________________ Div. Off: ________________State Off: ____________Reg.:__________
Cat: __________Yr of Comm:_______________Prop:________ Insp. by:_______________Date :______________
Sr.
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9

2
2.1

2.2

2.3
2.4
2.5
2.6

2.7
2.8

Description
Y/N
Statutory Requirement Certificates & Licenses / Display
Is Copy of CCOE license and approved drawing available.
Check validity.
Does the drawing correctly reflect all the as built facility
Are telephone number of Local Police, Fire Brigade,
nearest Hospital displayed at prominent place
Consent letter for registration under Pollution Control act
available
Earthing Test certificate available & earth pit tested once in
year & test value displayed near earth pit with test date.
Are NO SMOKING, Tank lorry under decantation and
Explosive License number displayed?
Dos and Donts prominently displayed in local language
Safe Operating procedures prominently displayed at
relevant locations for critical operations like TT unloading,
Dispensing of fuel etc.
Caution boards displayed near the dispenser for customer
awareness viz:
Stop engine before refueling
No smoking
Do not operate mobile phone
Safety & Fire Fighting Facility / Protection
2 Nos. of DCP type (10 kg / 9 kg) fire extinguishers per
outlet / Pump available? (Cartridge type / stored pressure
(as applicable).
Each dispensing unit shall be covered by at least 2 nos.
ISI marked 10 kg / 9 kg DCP fire extinguishers (stored
pressured type / cartridge type) placed at safe location
within 3 m radius.
Minimum 1 no. 4.5 kg CO2 fire extinguisher available at
Electrical Meter room
Do fire buckets (9 ltr. Capacity) having round bottom (min
4 nos.) and cover contain dry sand?
All employees working in the premises are conversant
with operation of Fire Extinguishers.
All periodic tests carried out by competent / authorized
persons as applicable and records maintained.
For 10 kg / 9 kg DCP FE
Visual checks of extinguisher daily
Condition of DCP hose, nozzle and safety clip - Every
month
Weight checking of CO2 cartridge Quarterly
Hydro test of fire extinguisher Every three years
Date of Hydro test & quarterly test date written on the
outer body of extinguisher
Minimum 4 nos 200 Gms CO2 cartridge and 4 nos.
10 Kg / 9 kg DCP powder bags available in stock

Observations

Recommendations

25

Annexure
Sr.
Description
Y/N Observations Recommendations
2.9 First Aid Kit available to handle possible emergencies.
2.10 Minimum 2 nos. Emergency Shutdown Switch provided
for power shutdown. Physical test to be done during
inspection.
3. Tank & Tank Farm Area

3.1 Is the dip pipe provided with proper cover?

3.2 Is the vent pipe located as per the approved CCOE
drawing?
3.3 Is the wire mesh of 11 mesh gauge available in the vent
pipe?
3.4 Is the manhole chamber free of :
Rubbish (i.e. cotton waste / rags etc.)
Oil Spillage
3.5 Are tank curb walls / pipe railings in good condition?
3.6 Are TT discharge points distinctively painted as per IOCL
standard?
3.7 Tank inlet riser provided with Cam lock couplings and
proper cover?
3.8 During TT decantation, area near the TT is segregated by

providing a chain /Tape. TT Crew remain present during

decantation of TT.
3.9 Dip pipe tank opening is kept closed all the time as well as
during decantation to avoid any vapour accumulation
3.10 Engine of the tank truck is not running and the battery
switch in OFF position during decantation
3.11 Nylon /PVC hose is not used for decantation
3.12 Rubber hose with external continuity wire is used
3.13 Tank truck brought for decantation has CCOE approved
spark arrestor
3.14 Is the earth & Bonding wire connected properly during
decantation?
3.15 Is FE positioned near the T/L & easily accessible during
T/L unloading?
4. Pumps & Pump Island
4.1 Inside of the DU pumps/Motors are kept clean?
4.2 Are the electric motors & Body of the DU properly earthed?
4.3 DU is Located as per the CCOE approved drawing?
4.4 Is there any loose wiring inside the DU? Electric wires
running inside the dispensing pumps are passing through
conduits
4.5 Is there allen screw/ Bolts missing in the flameproof JB?
4.6 Dry sand filled in the gap below pump & pump pedestal?
4.7 Cable entry at junction box is through certified double
compression glands. No additional wires taken through
the FLP Gland.
4.8 The pump island is not slippery & is free from spillage of
oil
4.9 Is there any Non-FLP electrical fittings or PC kept near
the pump island?
5. Electrical
5.1 Loose wiring in the switchboard/Panel absent
5.2 Earthing provided as per standard

26

Annexure
Sr.
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
6.
6.1
6.2
6.3
6.4
6.5
7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.
8.1

8.2
8.3

Description
Y/N
All the light fixture at the periphery, canopy and the sales
room are in working condition?
Are all the equipments labeled?
Are all the cable / wire properly terminated?
Are all spare cable entry holes in all electrical panels
blocked?
All panel doors are earthed with flexible braided
connection?
All panel doors are closed properly & no dirt or dust
accumulation inside the panels?
Are all electrical equipments earthed as per
recommendations?
Are Neutral point of transformer and DG set earthed?
The lightning / surge arrestors are in place and in working
condition and are connected to earth?
The insulation resistance of all power cable is tested once
in a year and the same is more than 1 Mega Ohm?
Electrical room is maintained clean, free from water
seepage / accumulation?
Hot spots observed in any parts of panels/ any equipment?
Electrical insulation mat provided in front of the electric
panel
Office Building & Other Facilities
Adequate lighting in building and operating area
Is there any work shop adjacent to the RO carrying out
HOT work?
ELCBs of 30 mA rating provided in building
Are any other flammable materials like LPG cylinders,
cardboard cartons etc., are stored in the generator room?
Whether generator room properly ventilated, clean and
dry?
Service Station
Adequate capacity oil water separator provided
Compressor room is kept neat and tidy. Workers clothing
& other materials are not stored.
House keeping in the service bay area is good
Hydraulic ramps are checked for quantity of oil
No smoking sign displayed in the service bay
Safety valve of the compressor is tested and in working
condition
Water is drained from the compressor every day. No
material, viz. lubes, etc. are stored in compressor room
Air vessel of the compressor is tested by competent
authority once in a year and records available.
Wire gauge / metal guard is provided on belt of air
compressor
General
Are the good housekeeping practices (e.g. provision of
metal dustbin, garbage disposal / cotton waste disposal,
cleaning of drainage) being observed?
No unauthorized work (like welding etc) or any operation
not approved by CCE being carried out at RO
Condition of driveway?

Observations

Recommendations

27

Annexure
Sr.
8.4
8.5
8.6
8.7
8.8

Description
Driveway is clean of any rubbish and other material
No smoking by workers / visitors observed at the outlet
Record general house keeping of all area / facilities
High tension wire is not passing over RO
Excavation and Work at height is done with proper safety
precaution & permit.
8.9 Safety Training of RO staff conducted regularly on
emergency handling
8.10 If ALDS facility is available in the RO, during decantation
of LPG TT, other fuelling operations in the RO is not done.
8.11 Check List is filled up before Decantation by driver &
authorized RO staff and records maintained.
8.12 Above checklist is cross checked by Field Officer and
action taken.
S. N.

28

Y/N

Observations

Any other observations

Recommendations

Remarks

Signature with date

Signature with date

Signature with date

___________________________

___________________________

___________________________

Proprietor / Manager of
Distributor

Audited By:
S&EP / HO / RO
SO / DO

Witnessed by:
Field Officer / Engg. Officer DO

Name :

Name :

Name :

Design:

Design:

Design:

Date:

Date:

Date:

Annexure
Annexure - 3

Safety Checklist for Tank-Truck Decanting at Retail Outlet

Name of the Outlet:

Date:

Particulars
1
2
3

Tank-Truck Registration No.:

Total quantity in kl:
Products:
MS:______ kl

Challan No:
/

HSD: _____ kl

/ XP: _____ kl

XM: _____ kl

Sr.
Activity Check
No.

Yes / No

Only one tank-truck is being decanted at the retail outlet at a given time

No delivery/re-filling is being done near the decanting point.

Decantation area is demarcated by a chain during tank-truck decantation

Tank-truck brought for decantation has CCOE - approved spark arrestor

No Smoking board is displayed prominently

Tank inlet discharge riser provided with camlock coupling

An earthing point has been provided near the fill point and the bonding wire connected
while decanting the tank truck

Dip pipe of the underground tank opening has been kept closed to avoid any vapour
accumulation during decantation

8
9

The engine of the tank-truck has been switched off and the battery switch is in Off
position

10

Mobile phones of the tank-truck crew and the retail outlet staff assisting them have been
switched off / Mobile phone should not be operated

11

The 10 kg / 9 kg DCP fire-extinguisher of the tank truck has been taken out and kept next
to the tank-truck

12

Nylon hose is not being used during decantation

13

Rubber hose with external continuity wire and male-female camlock coupling is being
used

14

Only bonded metallic bucket is being used for drawing samples

15

The driver, khalasi and the designated retail outlet supervisor are present during the entire
process of decantation

Verified that all precautions have been taken with regard to decantation as detailed above:

(Signature &
(Name of Driver)

(Signature &
(Name /Designation of authorised RO staff)

29

Annexure
Annexure - 4

Signboard to be displayed at the entrance of the outlet

ATTENTION
No Smoking
No Naked Flame Inside this Retail Outlet
Do not operate Mobile Phone

Signboard to be displayed at Underground Tank Area

DO'S & DON'TS

Dos:

No Smoking

Keep all openings of the underground tank tightly closed

Keep air vent free from clogging

Ensure sealed decantation of tank-truck through electrically continuous hose with Camlock
Couplings

Ensure proper earthing of tank-truck while unloading

Use bonded metallic bucket for sampling

Position 10kg / 9 kg DCP type fire-extinguisher before commencing decantation

Ensure good house-keeping at all times

Donts:

30

Do not smoke or use naked flame

Do not operate Mobile Phone

Do not use plastic buckets or containers for product sampling

Do not use plastic hose for decantation

Do not use serial lights (used for decoration during festivities)

Do not allow entry of other vehicles into decantation area

Annexure
Annexure - 4

Signboard to be displayed at Pump Island / Driveway

DO'S & DON'TS

Dos:

No smoking

Do not operate Mobile Phone

Switch off engine before refuelling

Remove delivery hose from the vehicle after refuelling

Two and three-wheelers to drag their vehicle from pump Island without starting engine

Donts:

Do not allow leakage/spillage

Do not litter in the area

Do not use non-flameproof lights near dispensing units / underground tank area

Do not move the vehicle while refuelling is on

Do not carry out maintenance of the vehicle at the retail outlet

Signboard to be displayed at the meter room/

electrical switch/panel room

DO'S & DON'TS

Dos:

Test before you touch

Display DANGER sign on panel

Use correct rating of HRC fuse

Keep the panel room clean, tidy & well ventilated

Ensure availability of 4.5-kg CO2 fire-extinguisher for use in emergency

Donts:

Do not allow loose wiring/temporary connections in panel

Do not keep any POL containers in the electrical switch/panel room

Do not keep the door of the panel board open

Do not operate any switch until authorised

Do not allow unauthorised persons to carry out electrical jobs

31

Annexure
Annexure - 5

Safety & Environment Protection Inspection Format

Auto LPG Outlet

R/O: _________ Dist: _________________ Div. Off: ________________State Off: ____________Reg.:__________

Cat: __________Yr of Comm:_______________Prop:________ Insp. by:_______________Date :______________
Sr. No. Check list Item
1.
Bulk Storage Area :
Vessels are cathodic protected.
a)
b)
c)
d)
e)

Allen bolts are provided on FLP equipments.

NIL leakage observed in the area with explosimeter.
2 x 75 kg DCP F/Extinguisher duly tested quarterly and positioned nearby.

f)

Isolation valves for SRVs locked in open condition; rain cap provided for
SRV vents.

g)

ROVs found operational.

h)

Facility provided for water draining from vessels with two isolation valves
and spools piece with EFCV in between. Draining instruction prominently
displayed.

i)
j)
k)
l)
m)
n)
o)
p)
q)
2.
a)
b)
c)
d)
e)
f)
g)
h)
i)

32

Continuity jumpers are provided across flange joint.

LPG pipeline earthed.

Two level instruments & HLA provided & working.
Pressure & Temperature gauges are operative.
No smoking and caution boards prominently displayed.
TSVs are provided on liquid and vapour lines with isolation valves
underneath.
Pipeline maintained in good condition
Decantation pump is double-earthed
Guards provided over rotary parts of decanting pump
Adequate illumination exist in the bulk storage area during night time.
Bulk Truck Unloading Facility :
Decantation area is prominently marked and demarcated from other areas.
Provision exists for TT earthing.
Metallic chocks provided.
TT battery cut-off switch is in OFF position during unloading.
TT unloading hose is periodically tested.
Unloading operations are supervised.
CCE approved spark arrestor is installed at TT exhaust.
Emergency stop switch / button is operative.
10 kg / 9 kg DCP fire extinguisher positioned at the time of bulk truck
unloading

Yes / No

Remarks

Annexure
Annexure - 5
Sr. No.
3.
a)
b)
c)
d)
e)
f)
g)
h)
i)
4.
a)

Check list Item

LPG Dispensing Unit :
NIL LPG leakage observed with explosimeter.
Only FLP lights installed above dispenser.
All electrical apparatus are found FLP.
Space under dispenser & extending alleys are fully sand filled & blocked at
the other end.
Emergency stop switch / button is operational.
EFCVs are installed on filling hose.
Tested filling hose provided.
Leather gloves are worn by employee dispensing LPG.
2 Nos 10 kg / 9 kg DCP fire extinguisher positioned and tested as per
norms

Yes / No

Remarks

Certificates and Licenses :

CCE license is valid and displayed.

b)
c)
d)
e)
f)
g)
h)

Important telephone numbers are displayed.

Earth test certificates available.
Hydrotest certificate for LPG vessels.
LPG hose test certificate as per OISD-135.
Consent under air and water pollution.
SRV & TSV test certificates.
Cable insulation resistance test certificate.

5.
a)

Training / House Keeping / Fire Preparedness :

Work undertaken with CCOE approval.

b)

All employees are trained in handling of LPG and fire extinguishers as per
OISD-154.

c)

100% spare DCP & CO2 cartridges provided.

d)

No Smoking is strictly implemented and sufficient no. of No Smoking

boards are visible at site.

e)
f)
g)
g)
h)

House keeping is found satisfactory.

Mobile phones are not operated near LPG facilities.
Car engine is kept switched off during LPG filling.
FLP / Intrinsically safe torch provided & operative.
Dos and Donts displayed

6.
a)
b)
c)
d)

Electric Control Panel / Air Compressor

Loose electrical wiring is absent
Space adequate for movement of personnel
Electrical panel is earthed
1 x 4.5 kg CO2 fire extinguisher is available

e)

Electrical hand gloves provided

33

Annexure
Annexure - 6

Construction Safety Checklist for Retail Outlets

Name of the Retail Outlet: _______________________________________________________
Nature of the Work: _____________________________________________________________
Work Order No.: ________________________________________________________________
Period of Contract: _____________________________________________________________
Name of the Contractor: _______________________ __________________________________

Dos
Before commencement of any work, give
sufficient input to the workers on safety
requirements of the job
Use personal protective equipment (safety

of the pit
Ensure that mechanised excavators are
operated only by a well-trained, experienced

belt, safety shoes, safety helmet, etc.) at

operator. Ensure the wheel/belt of the

construction site. Safety belts (ISI approved)

excavator are suitably jammed to prevent

must be used when working at heights above

accidental movement

three metres
Keep the site free from all unwanted materials
and store the equipment properly for easy
access
Keep visitors away from the construction site
Keep fire-fighting equipment handy at the site
Keep the escape route clear
Provide adequate lighting at the site
Use electrical hand tools with double
insulation or fitted with ELCB protection
Maintain safe angle of repose while excavating
pit exceeding 1.5 metre depth. (450). Suitable
bench of 0.5 m width at every 1.5 m depth of
excavation in all soils to be provided (expect
in case of hard rock) or proper shuttering and

Ensure use of metallic scaffolding designed for

maximum load
Check for any overhead electric wire running
over the construction site. If any exist, ensure
the same are de-energised
Cordon off the excavated pit with proper red &
white band / caution board
Provide suitable rubber mats around electrical
panels/switches
Provide first aid kit with proper medicine at the
site
Manholes, etc., should always be kept in
closed condition
Cordon off the area where field radiography is
being carried out
Ensure that all electrical and water

shoring. Necessary steps to be provided for

connections have been cut off before start of

escape

demolition

Protect neighbouring structures from collapse

where excavation is planned

34

Make necessary arrangement for de-watering

Use only 24 Volt FLP lamp fitting for

illumination inside confined spaces

Annexure
Annexure - 6

Do's
Every tank being repaired or exhumed, shall be cleared of all petroleum and of all flammable vapours. When
a tank in position is opened for clearing or repairs, no electric or other lamps, electric cable or electric fans
and no articles, appliances or equipment capable of igniting flammable vapour shall be bought near the
manhole of the tank until the tank has been certified in writing to be gas free by a competent person.

Donts
Do not start the job without a proper work permit
Do not start any work in the absence of the contractors skilled supervisor
Do not wear loose clothing while working near rotating machines or while working at heights
Do not keep/store inflammable material, waste and debris near the construction site
Do not carry out hot work where inflammable materials are present and also while carrying out painting
jobs
Do not keep the excavated earth within one metre of the edge of the pit
Do not allow vehicles within two metres distance from the edge of the pit
Do not allow personnel to come within one metre of the extreme reach of the mechanical shovel
Do not exceed safe working load marked on lifting equipment
Do not use unarmoured electric cable in construction site
Do not allow electricians without licence to carry out electrical jobs
Do not use bare wire ends in the socket
Do not use temporary electrical connections
Do not use barrels, boxes, loose bricks, etc., as working platforms
Do not allow welding work if the welder is not in dry condition and not wearing protective goggles /
face shield
Do not keep any load / equipment near the edge of the excavated pit
Do not enter confined spaces such as empty product tank without proper safety checks and in the
absence of competent persons
Do not demolish any structure without initial survey and before formulating the method of demolition
Do not keep lighted gas torch left unattended
Do not throw or drop material / equipment from a height

35

Annexure
Annexure - 7

Safety Inspection Register / Record

(To be maintained at Retail Outlet)

Sr. No.

36

Date of Inspection

Name of the Officer

Designation

Remarks

Notes

37

Notes

Notes

Corporate Communications / May 2013

Indian Oil Corporation Ltd., Marketing Division, G-9, Ali Yavar Jung Marg, Bandra (East), Mumbai - 400 051.

www.iocl.com