RO T4S PRO.docx

PETROLEUM AND NATURAL GAS REGULATORY BOARD NOTIFICATION ======================================================= 1. Short title and commencement: ----------------------------- 1. These Regulations may be called the Petroleum and Natural Gas Regulatory Board (Technical Standards and Specifications including Safety Standards for ^1^\[dispensing of Automotive Fuels\]) Regulations, 2018. 2. They shall come into force on the date of their publication in the Official Gazette. 2. Definitions: 3. In these regulations, unless the context otherwise requires, a. "Act" means the Petroleum and Natural Gas Regulatory Board Act, 2006 (19 of 2006); b. "Annexure" means the Annexure appended to the schedule to which it relates; c. "Authorised Person "means a person trained and assigned to carry out a specific job by the owner or marketing company; d. "Approved Type" means any equipment which has specific approval for use under specified conditions by competent authority or authorized person, as the case may be, for such purpose under the law in force; e. "Board" means the Petroleum and Natural Gas Regulatory Board established under sub-section (1) of section 3 of the Act; f. "Capacity" means the maximum volume of water that can be stored in a vessel or container at 15°C at atmospheric pressure; g. "Competent Person" mean a person recognised by the concerned Statutory Authority for the purpose in respect of which the competency is required; h. "Flame-proof "means a type of protection in which an enclosure can withstand the pressure developed during an internal explosion of an explosive mixture and that i. "Hazardous Area" means the locations classified according to its Zone System which defines the probability of the hazardous material, gas or dust, being present in sufficient quantities to produce explosive or ignitable mixtures and such classification of zones are specified below, namely: - i. "Zone 0" means ignitable concentrations of flammable gases or vapours which are present continuously or for long periods of time; ii. "Zone 1" means ignitable concentrations of flammable gases or vapours which are likely to occur under normal operating conditions; iii. "Zone 2" means ignitable concentrations of flammable gases or vapours which are not likely to occur under normal operating conditions and do so occur only for a short period of time; j. "Intrinsically Safe" means a type of protection in which the electrical equipment under normal or abnormal conditions is incapable of releasing sufficient electrical or thermal energy to cause ignition of a specific hazardous atmospheric mixture in its most easily ignitable concentrations and such type of protection is referred to in these regulations as \"Ex i\"; k. "Increased Safety" means a type of protection in which various measures are applied to reduce the probability of excessive temperatures and the occurrence of arcs or sparks in the interior and on the external parts of electrical apparatus that do not produce them in normal service. which may be used with flame-proof type of protection and such type of protection is referred in these regulations to as \"Ex e\"; l. "Schedule" means the schedule appended to these regulations; m. "Shall" indicates that the provision in which it occurs is mandatory; n. "Should" Indicates that the provision in which it occurs is recommendatory but not mandatory; o. "Type n" means a type of protection applied to electrical equipment that in normal operation, such electrical equipment is not capable of igniting a surrounding explosive atmosphere and such type of protection is referred to in these regulations as \"Ex n\". 4. Words and expressions used in these regulations but not defined therein, and defined in the Act or in the rules or other regulations made there under, shall have the meanings respectively assigned to them in the Act or such rules or regulations, Application: ------------ 4. Scope: ------ 5. The provisions of these regulations shall apply to all existing and new Retail Outlets dispensing ^1^\[Automotive fuels\] such as MS, HSD, Auto LPG, CNG, ^2^\[LNG, LCNG\] and their variants. 6. The provisions of these regulations shall be construed so as to extend to cover the minimum requirements for engineering and safety considerations in layout, design, operating procedures, maintenance, inspection, safety equipment, electrical power distribution system, automation, competence assurance, emergency management plan, customer safety and awareness at retail outlets dispensing ^3^\[Automotive fuels\] such as MS, HSD, Auto LPG, CNG, ^4^\[LNG, LCNG\] and their variants. 5. Objective: ---------- 6. The standard: ------------- 7. The technical standards and specifications including safety standards for petroleum retail outlets are as specified in Schedule-I which relate to layout, design, operating procedures, maintenance, inspection, safety equipment, electrical power distribution system, automation, competence assurance, emergency management plan, customer safety and awareness. 8. The technical standards and specifications including safety standards for retail outlets dispensing auto LPG are specified in Schedule-2 which relate to layout, design, operating procedures, maintenance, inspection, safety equipment, electrical 9. The technical standards and specifications including safety standards for retail outlets dispensing CNG are specified in Schedule -3 which relate to layout, design, operating procedures, maintenance, inspection, safety equipment, electrical power distribution system, automation, competence assurance, emergency management plan, customer safety and awareness. p. Schedule-5A which relate to minimum requirements in design, operation, inspection, maintenance, safety, and emergency management for filling facility of Mobile refueller at a Petroleum Retail Outlet (PRO). q. Schedule-5B which relate to layout, design, operating procedures, maintenance, inspection, safety, emergency management plan, for parking of Mobile Dispenser (for Class B Product). 6. The technical standards and specifications including safety standards for setting up of Electric Vehicle (EV) Charging & Battery Swap Facilities at Retail Outlets are specified in Schedule - 6 which inter-alia covers minimum requirements in design, operation, inspection, maintenance, safety, emergency management etc. for EV chargers or Battery swapping stations at Retail Outlets. 7. The technical standards and specifications including safety standards for dispensing of Liquefied Natural Gas (LNG) from Installations using Prefabricated ISO Containers and Mobile Dispensing of Liquefied Natural Gas (LNG) are specified in Schedule - 7 which inter-alia covers -- a. Schedule-7A which relate to minimum requirements in design, operation, inspection, maintenance, safety, emergency management etc. for dispensing of LNG from Installations using Prefabricated ISO Containers. b. Schedule-7B which relate to layout, design, operating procedures, maintenance, inspection, safety, emergency management plan, for Mobile dispensing of LNG. 8. The technical standards and specifications including safety standards for dispensing of Compressed Natural Gas (CNG) from Mobile Refuelling Unit (MRU) are specified in Schedule - 8 which inter-alia covers minimum requirements in design, operation, inspection, maintenance, safety, emergency management etc. for dispensing of CNG from Mobile Refuelling Unit\] 7. Compliance to these regulations: -------------------------------- 10. The Board shall monitor the compliance to these regulations either directly or through an accredited third party as per separate regulations made under the Act on third party conformity assessment. 11. Any entity intending to set up a retail outlet dispensing ^2^\[Automotive fuels\] such as MS, HSD, Auto LPG, CNG, ^3^\[LNG, LCNG\]and their variants shall make available its plan including design consideration conforming to these Regulations to Petroleum and Explosives Safety Organisation (PESO) for their approval. 12. If an entity has laid, built, constructed a retail outlet, or which maybe under construction or have expanded the ^4^\[Automotive fuels\] such as MS, HSD, Auto LPG, CNG, ^5^\[LNG, LCNG\] and their variants based on some other standard, that is not meeting the requirements specified in these regulations, then, the entity shall carry out a detailed quantitative risk analysis (QRA) of its infrastructure and shall thereafter take approval from its highest decision making body or its board for non- conformities and mitigation measures and such approval along with the compliance report, mitigation measures and implementation schedule shall be submitted to Petroleum and Natural Gas Regulatory Board within six months from the date of commencement of these regulations. 8. Default and Consequences: ------------------------- 13. There shall be a system for ensuring compliance to the provisions of these 14. In case of any deviation, shortfall or default in compliance to these regulations, the entity shall be given time for rectification of such deviation, shortfall or default and in case of non-compliance, the entity shall be liable for any penal action under the provisions of the Act or termination of operation or termination of authorization to conduct business, or both. Requirements under other statutes: ---------------------------------- b. for Door-to-door delivery of Liquid Automotive fuels or for parking of Mobile Dispenser (For Class B Product). c. for dispensing of LNG from Installations using Prefabricated ISO Containers and Mobile Dispensing of LNG. d. for dispensing of CNG from Mobile Refuelling Unit\] 10. Miscellaneous: -------------- 15. If any dispute arises with regard to the interpretation of any of the provisions of these regulations, the decision of the Board thereon shall be final. 16. The Board may at any time, by order and in appropriate cases make such relaxation in any provision of these regulations as may be specified in the order. 17. The Board may issue such guidelines consistent with the Act and the rules and regulations made thereunder for the proper implementation of these regulations as it may deem fit. ^1^\[SCHEDULE-I\] ================= STORAGE, HANDLING AND DISPENSING AT PETROLEUM RETAIL OUTLETS ============================================================ 1. SCOPE: 2. DEFINITIONS: a. C-Store means convenience stores, the area in which non-fuel goods or consumables are sold; b. Dispenser means equipment provided for delivering MS or HSD to the auto fuel tank of motor vehicles or approved receptacles; c. Emergency shut off means a shut off to cut off power supply as well as product supply which in an emergency, operates automatically or can be operated remotely; d. Fill Point means the point of inlet pipe connection of a bulk storage tank for MS or HSD where hose is connected for filling the products into the tank; e. Petroleum Retail Outlet (PRO) means area approved by PESO and provided with facilities, specially designed for storage and dispensing to the fuel tanks of motor vehicles and any other approved receptacles; and f. Pressure Vacuum Valve means a pressure and vacuum relief device fitted on top of the vent pipe of the tank to limit the maximum pressure and vacuum that can exist in storage tank and vessel; g. Product Classification means Class A -- Flash Point below 23 deg C. Class B -- Flash Point between 23 deg C and 65 deg C. Flash point of a volatile liquid is the lowest temperature at which it can vaporise to form an ignitable mixture in air; h. Sales Room means an office space to conduct the business of the retail outlet, housing amenities like toilets, change rooms, storage space, automation equipments and like other activities; i. Tank Truck or Tank Lorry or POL Tank Lorry means a truck mounted with a properly designed and PESO approved tank for transportation of MS or HSD in bulk to the dispensing stations. j. Vent Pipe means the pipe fitted on an underground tank for breathing; 3. LAYOUT AND FACILITIES: 1. General: i. The layout should ensure unobstructed movement of vehicles and provision for entry and exit of Tank trucks; ii. Location of the facilities, equipment, entrance, exit and paving shall be arranged in such a manner so as to avoid the risk of any collision amongst the motor vehicles; iii. All Facilities should have access to mobile fire fighting equipments; iv. The location of tanks, fill and vent pipes, dispensing equipment and tank truck decanting area, onsite buildings, shall be so designed to enable means of escape for persons, in the event of fire or any other incident; v. The fuel lines and electrical cables will have positive segregation; vi. No source of ignition shall be allowed in the hazardous areas; vii. The items to be stored, and sold from a Convenience Store (C-Store), shall keep in view associated fire hazards and open or naked flame appliances are not permitted; viii. C-Store parking should be away from entry or exit and not impede the free flow of traffic; and ix. Hazardous area classification shall be done in line with IS: 5572. 2. Storage Tanks: i. Class A and B Petroleum products shall be stored only in underground tanks in single or double membrane (walled) and its installation shall be outside the buildings; ii. Tanks shall be placed in an earthen or masonry or concrete pit, and shall be packed with sand or earth or gravel, without leaving any space around the tank and when tank is installed in earth pit, no part of the tank shall be less than 1.5 metre from any point of the marked boundary; and. iii. No part of the space over the buried tanks, shall be used for any purpose, other than installing equipment, specifically meant for the withdrawal or receipt or monitoring of contents of the tank, or for the purpose mentioned under paragraph 3.3.2.1 of this Schedule. 1. Material of construction: 3. Tank Installation: i. The underground tanks shall be either installed in the dedicated tank farm area "Away from Driveway (Remote Tank Farm)" or under the driveway with an appropriate reinforced concrete slab or alternate pavement material; ii. All tanks shall be pressure tested using pneumatic or hydro, as per the design code or operating pressure, whichever is higher, before commissioning; iii. Steel tanks shall be protected against corrosion; iv. Design and Installation shall provide protection against buoyancy; and v. Installation of tanks shall follow the manufacturer's recommendations; 2. Tanks installed under driveway: i. Underground tanks shall be installed under concrete slab or alternate pavement material and design consideration shall take care of loading either through masonry pit walls or back fill material and burying depth of tanks; ii. Manway covers (metallic or alternate material) shall be designed for the intended vehicle load and ensure safety of tank fittings; iii. RCC slab or alternate pavement for the tank pit to be designed for the intended vehicle load. 4. Fill points: i. The fill points for the tank or tanks, whether offset or direct fill, shall be located in such a manner, so that any spillage of petroleum and its subsequent ignition, does not pose any immediate threat, to the public or retail outlet staff; ii. Fill points shall be located in the open air, so that any flammable concentrations of vapours, resulting from normal filling operations or spillage, does not reach potential ignition sources, or tends to accumulate; iii. The fill points shall maintain a minimum safety distance of 3 mtrs. all round, including property boundary or any other structure, where a source of ignition is likely to be present and this distance of 3 m may be reduced, if a fire -- resistant wall is constructed, e.g. of brick or concrete, which is at least 2 m high and of 4 hours fire resistant rating (conforming to IS 1642) and if the wall is a part of a building which houses a sensitive population, such as a school, hospital or residential dwelling, then this distance should be increased to 12 m; iv. Fill pipes shall have minimum 1:200 slopes towards the storage tank, to ensure easy flow due to gravity, and also to avoid any product retention within the fill pipe; v. Fill pipe shall be carried down nearly to the bottom of the tank, to prevent fire hazard due to generation of static charge, arising out of free fall of product; vi. Identification for various types of fuels, shall be provided to avoid wrong decantation; (vii) An "earthing bus" shall be provided in the close vicinity of fill points; viii. Hose connections shall be properly tightened; ix. Fill pipe caps shall be made of softer material like brass or aluminum; x. Fill cap shall have a proper locking system, and key shall be kept under the custody of the authorized person; and xi. Fill points shall be so located, that the tank lorry under decantation, is in drive out position ^1^\[. Entities should identify Retail outlets in which drive out position is not available at present and make modification in the layout within six months of notification of this regulation, to ensure drive out position during tank lorry decantation. Alternatively, in existing Petroleum Retail Outlets, wherever the drive out position is not feasible, such Retail Outlets should be identified and relocated to other suitable location(s) within 3 years of notification of this regulation. In the meantime, as mitigation measure, for the tank lorry decantation, the requirements as specified in Annexure IX shall be complied with the retail outlets not having drive out position.\] ^2^\[\*\*\] ; 4. Pipelines: i. Pipelines from tanks to dispensing points, and vent pipes shall be routed below the ground and it shall not be under a building, or other features, which prevent access to the pipelines and Fuel Pipes should be sloped towards underground storage tank; ii. In case of pressurised system, entire piping system including the appurtenances, shall preferably be constructed with welded joints and the number of flanged joints shall be kept to a minimum; iii. Piping shall run with as few restrictions, such as elbows and bends, as conditions permit; iv. Each pipe line shall be hydro tested as per design code and alternatively, it shall be hydro tested at 1.5 times the design pressure maintained for a period of at least 30 minutes; v. Where necessary, pipe lines shall be earthed, and to maintain electrical continuity, suitable "Jumpers" are to be provided at the flanged joints; and vi. In case of metallic pipelines, the same shall be protected against corrosion, by suitable wrapping and coating, and where necessary by cathodic protection. 5..1 Material of Construction: vii. Specifications of material for metallic piping and fittings shall conform to IS-1978 or equivalent; and viii. Material specifications for non-metallic piping and fittings shall conform to UL 971, EN 14125 or equivalent. 6. Vent pipes: ix. Each tank shall be provided with independent vent pipe or pipes of adequate capacity, unless vapour recovery system is installed; x. Vent point shall not be located under any shade or cover; xi. Open ended vent pipes, shall extend to a height greater than the maximum liquid level of a road tanker that delivers petroleum to the underground tanks, and shall not be less than 4 mtrs and in case of venting above the canopy or sales building, the vent pipes shall be terminated 1.5 mtrs. above if; xii. The vent pipe opening, shall also observe minimum 4 mtr and clearance shall be in the horizontal plane, from all structures; xiii. The vent pipe shall be protected against damage, by inadvertent collision with vehicles; xiv. The outlet (opening) of the vent pipe shall be covered with two layers of non-corrosive metal wire mesh, having not less than 11 meshes per square centimeter, and a rain cap or bend downwards; xv. Vent pipe shall be gradually sloped towards the tank, to avoid chocking of vent pipe due to any water ingress, or due to product, in the event of tank overflow; and xvi. The vertical portion of the vent pipe shall not be provided with any intermediate thread joint. 7. Dispensing Equipment: xvii. Dispensers shall be located so that these are adequately ventilated; xviii. The dispensers shall maintain a minimum distance of 6 mtrs, from any above-ground structure or property boundary and for Pump islands catering exclusively to 2/3 wheelers, this distance from boundary wall or other permanent structures, may be reduced to 4M, while limiting the length of the hose pipe to 3 M; xix. The dispenser shall be installed on a firm foundation and protected against physical damage from vehicles; xx. A shear valve to be provided in dispensers in a pressurised system; xxi. The length of the hose connected to the dispenser, shall be kept minimum, keeping in view the operational requirement, and not exceed 4 m; xxii. Breakaway coupling shall be installed in dispensing hose or nozzle; xxiii. The dispensing hose shall be electrically and mechanically continuous and earthed and necessary provisions shall be available in Dispenser, to earth the receptacles other than fuel tank of vehicles; and xxiv. Installation of any electronic peripheral device, shall be done at a 1200mm, above the base level of the dispensing unit. 8. Decantation Area: xxv. The tank truck delivery locations for unloading into storage tanks, shall be level, in the open, away from the sales building, dispensing activities and emergency escape routes; xxvi. The hose used shall conform to IS 10733; xxvii. Hose length shall not be more than 5.5 m; and xxviii. The location chosen, shall allow the TT to gain access, without the need to reverse on to the site, but, reversing under supervision for positioning the road tanker for placement in drive-out position shall be permitted. 9. Sales Room: xxix. Any building or room, intended to serve as a control point, shall preferably be so located, that an attendant in the sales room, can see the forecourt and the dispensing area clearly. i. The canopy shall not adversely affect the ventilation or access to the equipment; ii. Canopy heights installed at fuel fore court, shall have at least 300mm clearance from the maximum permitted height, recommended by Central Motor Vehicle Rules,1989 for the vehicles to be fueled; iii. Wind and seismic load for the canopy design, shall be considered as per IS: 875 and IS: 1893 respectively; and iv. Canopy structure shall be properly earthed as per IS: 3043. 4. Electrical Power Distribution System: i. Total electrical load for the entire Retail Outlet; ii. Availability, Suitability and Reliability of the State Electricity Board (SEB) grid; iii. Fault (KA) rating of the SEB Feeder; iv. Load to be fed from back-up; v. Load which need stabilized or Uninterrupted Power Supply (UPS) supply, or both to function smoothly; and vi. Rated load of the connected and future equipment. 5. Elements of Protection: a. Protection shall be provided to guard against sudden failures viz. disconnection of "Neutral" and against overload, short-circuit and earth fault; b. The motors shall be protected against short circuit and overload; and c. Protection shall be provided for variation in voltage, frequency and phase imbalance. 6. Backup Power Supply: 3. The following shall be considered to arrive at the capacity of the Diesel Generator (DG) set or Renewable Energy system and like other set or system, if provided; namely: - iv. "Critical" lighting fixtures; and v. The Backup rating shall be sufficient enough, to sustain the starting power requirements, of the connected motors, without disturbing normal operation of the other loads. 4. When operating before sunrise or after sunset, emergency lighting shall be provided for safe operation of power backup equipment. 7. Layout and Installation: i. For HT supply, the substation shall mainly consist of lightning arrestor, HT fuse, transformer and SEB metering cubicle and for retail outlets with an outdoor type of HT or LT substation, a DP structure surrounded with barbed wire fence, entry gate shall be provided and alternatively, a packaged sub-station shall be provided. ii. The power distribution panel, automatic voltage stabiliser and UPS shall be installed with following clear spaces for ease of safe operation and maintenance activities: - \< 200 mm (if approach is not required) - \< 200 mm. (if approach is not required); iii. Electrical room shall be provided with proper ventilation to extract the heat generated in the power distribution equipments; iv. All electrical equipment shall be as per IS: 5571 in line with hazardous area classification and the zone classification has been depicted in Annexure-I; v. Cable entry shall be through gland plate either at top or bottom and further spare holes, if any, in the gland plates shall be blocked; vi. Cables shall be neatly dressed, clamped and tag marked to easily identify the feeder and device it connects; vii. The cable entry holes on the building wall in cable trench or overhead shall be sealed to prevent entry of water; and viii. For underground laying under different conditions of terrain the methods may be as follows; namely: - a. For direct burial within PRO, top of the topmost layer of cable shall be laid at a minimum depth of 600 mm from surface of ground and each subsequent layer at the bottom shall maintain a minimum vertical clearance of 150 mm; and b. For road crossings, cables shall be routed at a minimum depth of 600mm from surface and thru pipe and the pipe may be of GI or steel reinforced hume pipe or HDPE pipe. 8. Earthing System: i. All metallic structure, pipe fittings and enclosures of electrical equipments shall be connected to earth. ii. For Equipment rated up to 230 V, 1-phase supply, the enclosure shall be grounded at least at one point. iii. And for Equipment rated above 400 V, 3-phase supply, the enclosure shall be grounded at least at two separate points. iv. Two nos. earth pits shall be provided for each of transformer or DG set neutral earthing / equipment earthing. v. All earthing pits except DG neutral, structure, T/T Unloading point and instrument or IT earthing shall be connected through grid or grids; and vi. In areas prone to lightning, a risk assessment shall be carried out for need of lightning protection and guidelines given in IS 2309 shall be followed. 9. Emergency Stop System: i. Emergency stop system shall be provided to cut off the power supply to all metering pumps or dispensing equipment and associated equipment, other than certified intrinsically safe equipment at PDP, and in or on sales building and on actuating any of these push buttons, electrical power supply to entire PRO, except yard lights, shall be isolated instantaneously; and ii. The push button shall be of red colour, mushroom type, marked and with a key to open. 10. Illumination System: -- -- -- -- 5. Automation: 11. Components of Forecourt Automation: i. Forecourt controller (FCC); ii. Back office system; iii. Local area network (LAN); iv. Wi-Fi access points; v. VSAT or GPRS or broadband routers cum modem; vi. Automatic tank gauging system (ATG); vii. Electronic price signs (EPS); viii. Payment terminals; ix. Thermal receipt printers; x. Attendant tag readers; and xi. Close Circuit surveillance systems (CCTV); 12. Installation of Automation Components: i. The components installed in Zone-0 and Zone-1 shall be certified for use by competent certifying agencies; ii. The integrity of the dispenser shall remain intact, while adding additional cables for communication, as well as power supply to OPT or printer and similar devices; iii. The installation of auto tank gauging equipment probe, shall be carried out in compliance to relevant standards, using safe arrangement for joining of the cable at the tank manhole area; iv. The height of pedestals used for installing, printers, outdoor payment terminals and similar equipments shall not be less than 1.2 mtrs. from the base frame of the dispensing unit; and v. The integration of automation components and its installation shall be done under the supervision of qualified and trained personnel 0. OPERATING PROCEDURES: 1. General: i. Operating personnel shall possess adequate knowledge and experience of handling MS or HSD to ensure safe and efficient functioning. ii. Dos and don'ts in consonance with paragraph 12.2 of this Schedule shall be prominently displayed; iii. Action in the event of emergency shall be clearly established, understood and displayed prominently; and iv. The following are the critical activities, namely: - a. Decantation; b. Management of the forecourt or fueling area; and c. Sampling. 2. Decantation of Tank Lorries: 1. On receipt of tank lorry from the supply point, dealer or his authorized representatives shall check the supply point documents with respect to seal numbers, number of compartments and quantity or product contained therein and the unloading operations shall be done in presence of the authorised personnel of retail outlet and tank truck crew and the following precaution shall be followed up, namely: - i. During unloading of the product from the tank truck to the bulk storage vessels, the tank truck shall be parked in the identified space; ii. Dispensing fuel to motor vehicles, shall be suspended during the period of unloading of fuel, from tank truck to the storage tanks ^1^\[ alternatively, for Retail Outlets with drive out the requirements as specified in Annexure-X shall be complied with\]; iii. Operations shall be suspended during the period of evacuation of product from storage tank for maintenance and testing; iv. MS or HSD shall not be filled in the fuel tank while the engine of the vehicle is running; and v. The operating procedures shall be displayed for the unloading of tank truck. The safety checklist for tank lorry decantation should be as per Annexure VII. 2. Refueling: i. Guide the vehicle to the designated position; ii. Vehicle should not be left unattended during refueling; iii. Sources of ignition, such as pilot lights, electrical devices or appliances or gadgets and engines shall be turned off before dispensing of fuel to the vehicle; and iv. Riders or pillion shall dismount before the commencement of refueling. 3. Handling of Fuel Samples: v. The samples shall be taken in approved containers; vi. The samples shall be stored safely in the designated area which is not used for any other activity; vii. For class A product, total storage in sample containers shall not exceed 30 litres; and viii. The samples shall not be poured back directly to the storage tank and the samples shall be collected in a separate receptacle for each product and transferred to storage tank through a container which is bonded to tank. 0. INSPECTION AND AUDITS: i. A well-designed system of periodic inspection of all facilities shall be ensured to maintain it in safe operable condition and checklist shall cover conformity with the design intention, operating and maintenance procedures, preventive measure and protection systems and safety practices; ii. Safety audit should be undertaken as per format provided in Annexure -V; (iii)Recommendations of the safety audit or inspections shall be complied in a time bound iv. The system of "permit to work" shall be established for non-routine works and such works shall be undertaken with full knowledge and approval by authorised person; v. Dispensing unit shall be tested, maintained, repaired and replaced as recommended by the manufacturer and approved by the concerned authority; vi. The Resistance to Earth shall be checked at least once a year; and vii. The periodicity of inspections and audit shall be as given below, namely: - -- -- -- -- -- -- -- -- -- -- -- -- 0. MAINTENANCE: 1. GENERAL: i. A comprehensive maintenance system of all facilities shall be formulated for safe operable condition; ii. Preventive maintenance schedules shall be drawn for all equipment, in accordance with manufacturer's recommendations, and established mandatory or recommendatory standards. records of all preventive maintenance undertaken shall be maintained; iii. Repairs involving non-routine maintenance work, shall be carried out after issuance of work permit, as per the procedure and format provided in Annexure -- VI (a) and VI (b). iv. The work permit shall be issued by company authorized person or dealer or manager, at the retail outlet, as per the class of activities detailed in succeeding clauses (v) and (vi); v. Work Permits issued by dealer or manager or company authorized person a. Access to a building or canopy roof; b. Access to a building canopy cavity; c. Electrical switch board work; d. Excavation including forecourts up to 1meter depth; e. Forecourt surface repair; f. Water removal from underground tank through hand pump; g. Repair of electrical and electronic equipments inside hazardous area (operation of all electrical and electronic instruments inside hazardous areas, unless certified intrinsically safe); h. Promotional activities on forecourts; i. Signage, including canopy signage or lighting works; and j. Replacement or installation of dispensing Units; vi. Work Permits issued by company authorized personnel only: k. Repair or rework or cleaning of the tanks and pipeline work; l. Tank removal and decommissioning; m. Non-routine maintenance or replacement or major electrical work within hazardous area; n. Entry in oxygen deficient or inert gas area; o. Pneumatic or hydrostatic pressure testing; p. Cleaning of oil interceptor, oil or water separator and like other things; q. Hot work including but not limited to welding or grinding or gas cutting; r. Demolition and revamping (remodeling); s. All activities capable of producing a spark inside a hazardous area; t. Excavation including forecourts exceeding 1-meter depth; u. Concrete cutting in the hazardous Zone; and v. Setting up of temporary equipment including product recovery equipment e.g. compressor, water or sand blasting equipment and like other things. i. Each dispensing unit shall be provisioned with 1 no. ISI marked 9 kg DCP fire extinguishers placed near the island, but, at outlets with single dispensing unit, a minimum of two no. ISI marked 9 kg DCP fire extinguishers shall be provided; ii. Minimum 1 no. 4.5 kg CO2 fire extinguisher conforming to IS: 2878 shall be available in each electrical meter room; iii. Minimum 4 nos. sand buckets filled with dry sand should be available; iv. All employees must be conversant with the safe handling of petroleum products and have first-hand knowledge of fire fighting and emergency handling; v. Only insulated pliers or screw drivers, non-sparking tools and flameproof torch shall be used; vi. Periodic tests shall be carried out by competent or authorized persons, as applicable and records shall be maintained; vii. Fire extinguishers are to be periodically tested and maintained as per IS standard; and viii. The fire extinguishers are to be checked, tested and maintained as per following schedule and complying with IS standard, namely: - a. Visual check of the extinguisher : Daily b. Condition of DCP, Hose, Nozzle and safety clip : Every month c. Weight checking of CO2 cartridge : Every Quarter d. Performance testing and DCP extinguisher : Every Year e. Pressure testing of extinguisher : As per IS 15683 (currently 5 years) 0. EMERGENCY PLAN AND PROCEDURE: i. A comprehensive ERDMP shall be developed in accordance to the Petroleum and Natural Gas Regulatory Board (Codes of Practices for Emergency Response and Disaster Management Plan (ERDMP)) Regulations, 2010 and the copies of the ERDMP shall be available to all concerned personnel; ii. Provision of minimum 2 points for emergency shutdown shall be maintained; iii. The operating company having control shall draw an operational emergency plan incorporating the following, namely: - a. Major failure of fittings resulting in spillage; b. Accidents or other emergencies; c. Electrical Emergencies; d. Civil emergencies; and e. Any other risk arising from the existence or operation. iv. The retail outlet in-charge shall maintain close liaison with Fire Service, Police and District Authorities; v. Important telephone numbers for emergency use shall be displayed prominently; vi. Means of communication shall be always at the disposal of the In charge of the retail outlet; vii. Emergency action plan should be tested with mock drill at least once a year. viii. First aid kit shall contain items to handle possible emergencies as per Rules applicable to factories in the concerned State for such purpose; and ix. Electrical shock treatment chart written in bilingual (English and local languages) and RO attendants shall be given training on how to treat an electrocuted person before help from a doctor is available. 0. COMPETENCE, ASSURANCE AND ASSESSMENT: 1. The objective is to provide understanding of all the facets of dispensing activities including operations, procedures, maintenance and hazards of petroleum and the risks associated with handling of the product and training shall ensure that the jobs are performed in accordance with the laid down procedures and practices, namely: - i. Every entity shall develop, implement, and maintain a written training plan to instruct all petroleum retail outlet personnel with respect to the following, namely: - a. Carrying out the emergency procedures that relate to their duties as set out in the procedure manual and providing first aid; b. Permanent maintenance, operating, and supervisory personnel with respect to the following, namely: - i. The basic operations carried out; ii. The characteristics and potential hazards of dispensing station; and iii. The methods of carrying out their duties of maintaining and operating the PRO as set out in the manual of operating, maintenance and transfer procedures; iv. Fire prevention, including familiarization with the fire control plan, fire fighting, the potential causes of fire or accident and the types, sizes, and likely consequences of a fire or accident and v. Recognizing situations when it is necessary for the person to obtain assistance in order to maintain the security. 2. Each oil company shall develop training module of their own which should include inter- alia of the following, namely: - a. Hazardous nature of product handled; b. Familiarization with operational procedures and practices; c. Hands on experience on operation of equipment; d. Knowledge of emergency and manual shut down systems; e. Immediate and effective isolation of any spill; f. Safety features and accident prevention; g. Fire fighting facilities, its upkeep and operation; h. Evacuation and safe egress of the vehicles in an emergency; i. Housekeeping; j. Decantation; k. First aid; l. Dos and Don'ts; and m. Emergency plan or drills 3. Records for the training and refresher courses shall be maintained. 1. Display of important information: i. The particulars of license, emergency telephone nos. of local fire service, police and marketing company shall be conspicuously displayed; and ii. Suitable caution boards or pictographs shall be displayed at areas where required. 2. DOs and DON'Ts during Refueling: Dos: i. Switch off the engine before commencement of refueling; ii. Ensure that a 9 kg DCP fire extinguisher is available near the dispenser; and iii. In case of any spill, overflow of product, fire or smoke observed, press the "EMERGENCY STOP" button on the dispenser. i. Do not start the engine or drive away the vehicle till the filling nozzle has been disconnected from the filler cap of the vehicle; ii. Do not refuel the vehicle during the period MS or HSD is being decanted into the tank; iii. Do not smoke; iv. Do not use naked flame; and v. Do not operate mobile phones. Annexure -- I ------------- A. UG Tanks and Fill Points: -- -- -- -- -- -- a. Fill points in manhole chamber: b. Offset fill points in manhole chamber: c. Above ground offset fill points: ![](media/image3.jpeg) B. Vent Pipes: -- -- -- -- -- -- Annexure II Components of Retail Automation ------------------------------------------- ![](media/image5.jpeg)CMS 1. Forecourt controller (FCC): 2. Back Office: 3. Local LAN network: 4. Wireless Access points: 5. VSAT or GPRS or Broadband Routers cum Modem: 6. Automatic Tank Gauging System (ATG): a. ATG probes: Installed inside the tank. b. ATG Controller: The unit is installed inside the sales building. It is capable of connecting to multiple tank probes and may have display to show the tanks status. It communicates with FCC. 7. Electronic Price Signs (EPS): 8. Payment terminals: c. Fixed location outdoor Payment Terminals (OPT): d. Mobile payment devices: e. Card Reader in Dispensers (CRIND): 9. Receipt Printers: 10. Attendant Tag Readers: 11. Close Circuit surveillance system (CCTV): f. Cameras: g. Digital Video Recorder (DVR) or Network Video Recorder (NVR): Annexure -- III Weekly Check List --------------------------------- Date: Time: -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ANNEXURE- V =========== -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- ANNEXURE -- VI (A) ================== WORK PERMIT (For issue by RO Manager or Operator or Dealer) ----------------------------------------------------------- THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE PERMIT \[ \[ \] -- ---- -- ---- ---- \[ \[ \[ \[ \] \[ \[ \] 5. Blocking of sources of product or \[ \] \[ \] vapour in pipeline or tank or equipment 1. Following personal protective equipment are required (check all items required) Safety helmet or safety gloves or protective goggles or safety shoes or safety belt 2. In case of fire alert, all work must be stopped. All personnel must leave work site and proceed to designated or on site directed areas. 3. Remarks on toxic or hazardous chemicals, if any (Eg., sludge, oil spillage or like other toxic or hazardous chemicals) 4. Alternate means of escape available or provided/not required. 5. This permit must be available at work site at all times. 6. Additional items, if any: Signature of Issuer [ ] Signature of Receiver [ ] Signature of Issuer [ ] Signature of Contractor [ ] a. Access into a building or canopy roof. b. Access into a building canopy cavity. c. Electrical switch board work. d. Excavation including forecourts up to 1 metre depth e. Forecourt surface repair. f. Water removal from underground tank through hand pump g. Repair of electrical and electronic equipments inside hazardous area (operation of all electrical and electronic instruments inside hazardous areas, unless certified intrinsically safe) h. Promotional activities on forecourts. i. Signage, including canopy signage or lighting works j. Replacement or installation of dispensing units. ANNEXURE-VI (B) =============== WORK PERMIT (For issue by officer of the oil company) ----------------------------------------------------- Item -- -- ------ ------- -- \[ \] \[ \] \[ \[ \] -- ---- -- ---- ---- -- \[ \[ \[ \[ \[ \[ \] \[ \[ \[ \[ \[ \[ \[ 1. Following personal protective equipment are required (check all items required): safety helmet or safety gloves or protective goggles or safety shoes or safety belt 2. In case of fire alert, all work must be stopped. All personnel must leave work site and proceed to designated or on site directed areas. 3. Remarks on toxic or hazardous chemicals, if any. 4. Alternate means of escape available or provided or not required. 5. This permit must be available at work site at all times. 6. Additional items, if any: a. Repair or rework or cleaning on the tanks and pipeline work b. Tank removal or decommissioning. c. Non-routine maintenance or replacement or major electrical work within hazardous area. d. Oxygen deficiency or inert gas entry. e. Pneumatic or hydrostatic pressure testing. f. Oil interceptor (like oil or water separator and like other interceptor) cleaning -- where entry into the interceptor is required. g. Hot work including but not limited to welding or grinding or gas cutting. h. Demolition or revamping. i. All activities capable of producing a spark inside a hazardous area. j. Excavation including forecourts exceeding 1 metre depth. k. Concrete cutting in the hazardous Zone. l. Setting up of temporary equipment including product recovery equipment E.g. compressor, water or sand blasting equipment and like other equipment. ANNEXURE - VII ============== Safety Checklist for Tank-Truck Decanting at Retail Outlet ---------------------------------------------------------- Annexure -- VIII REFERENCES --------------------------- i. Petroleum Rules -- 2002. ii. Marketing Discipline Guidelines. iii. IS 2062: Steel for General Structural Purpose. iv. IS 1239: Part 1: and IS 1239: Part 2: Steel Tubes and Other Wrought Steel Fittings. v. IS-5572: Hazardous Area Classification. vi. IS 10987: Code of Practice for Design, Fabrication, Testing and Installation of Underground / Above ground Horizontal Cylindrical Storage Tanks for Petroleum Products. vii. IS 2309: Code of Practice for the Protection of Building and Allied Structures Against Lighting. viii. IS 3043: Code of Practice for Earthing. ix. UL 1316: Glass-Fiber-Reinforced Plastic Underground Storage Tanks for Petroleum Products, Alcohols, and Alcohol-Gasoline Mixtures. x. UL 971: Nonmetallic Underground Piping for Flammable Liquids. xi. EN 14125: Thermoplastic and Flexible Metal Pipe Work for Underground Installation at Petrol Filling Station. xii. IS-1978: Indian Standard Specification for Line Pipe. xiii. UL 87- Power Operated Dispensing Device for Petroleum Product or Relevant Standards. xiv. UL 79- Power Operated Pumps for Petroleum Dispensing Products or Relevant Standards. xv. IS: 5571 - Guide for selection and installation of Electrical equipment in hazardous areas. ^1^\[Annexure- IX ----------------- 1. In all existing Retail outlets, where tank lorries decantation in drive out position is not feasible, tank lorries decantation shall be undertaken only after complete stoppage of dispensing activities and closure of all activities necessitating visitors at the Retail outlet premises. 2. Interlocks shall be provided in Retail Outlet Automation to lock all Dispensers once tank lorry is undertaken for decantation. 3. The drive out path of the tank lorries shall be planned and clearly marked at the Retail Outlet by way of permanent floor markings and barricades or cones. The same shall be kept clear during decantation. In case, more than one exit routes are available, all such routes shall also be marked by way of permanent floor markings and kept clear during decantation. 4. The area at the backside of the tank lorries shall be cordoned off so that in case of exigency, tank lorries can reverse without any hindrance. 5. Decantation shall be done in presence of tank lorry crew, the dealer or retail outlet supervisor. 6. Dedicated person shall be deployed to control or manage traffic to ensure that no obstruction in the path of tank lorries by way of parking, customer movement during the period of decantation. 7. Movement of the customer vehicles and of any person shall be prohibited on the reversing path of the tank lorry during decanting operation and its evacuation. 8. Prominent signage should be displayed along the tank lorries exit path and cordoned off path at the back with the following message: \"Warning: Reserved path for Tank Truck exit. Do not block. 9. Prominent signage should be displayed at entry or exit of Retail outlet stating that tank lorries unloading is underway and sales have been stopped. Annexure- X ----------- 1. The Retail Outlet shall have tank lorry decantation in drive out position. 2. Retail Outlets shall have masonry or non-perforated boundary wall of minimum height of 1.2 m. 3. An area of 9 m radius from the centre of Tank Lorry, an area of radius 3 m from centre of fill point and 4 meter from corresponding vent shall be cordoned off. This area shall be clearly marked on the floor and cordoned off. No dispensing or movement of vehicle or any other activity shall be undertaken within this area during tank lorry decantation. 4. All other activities at Retail Outlets such as C-Store, ATM, EV charging shall be stopped within the 9 m radius from the centre of Tank Lorry during decantation. 5. Decantation shall be done in presence of tank lorry crew, the dealer or retail outlet supervisor. 6. The drive out path of the tank lorry under decantation shall be kept clear. Dedicated person shall be deployed to control or manage traffic in this area to ensure that no obstruction in the path of tank lorries by way of parking, customer movement etc. during the period of decantation. 7. Decantation of only one tank lorry shall be undertaken at any point of time. Further, no loading or unloading of any other products such as LPG, CNG or LNG shall be allowed. SCHEDULE 2 ========== STORAGE, HANDLING AND DISPENSING AT AUTO LPG DISPENSING STATIONS ================================================================ 1. SCOPE: 2. DEFINITIONS: a. "Auto LPG" means a mixture of certain light hydrocarbons derived from petroleum, which are gaseous at normal ambient temperature and atmospheric pressure but may be condensed to liquid state at normal ambient temperature by the application of moderate pressure, and which conforms to IS :14861; b. "Auto LPG Dispensing Station (ALDS)" means the premises used for storing and dispensing auto LPG to the motor vehicles for automotive purpose; c. "Auto LPG Tank" means a steel container for storage and transport of Auto LPG, fitted permanently in a motor vehicle or vehicle as its fuel tank, for automotive fuel and filled in that position and conforming to IS:14899 and as approved by the Petroleum and Explosives Safety Organisation under Gas Cylinder Rules, 1981; d. "Auto LPG Tank Truck" means a truck mounted with a properly designed vessel/tank for transportation of auto LPG in bulk to the dispensing stations; e. "Bob tail" means a truck mounted with a properly designed vessel or tank with flowmeter pump skid for transportation of LPG in bulk to the dispensing stations. f. "Bulk storage" means the facilities for storing LPG in stationary pressure vessels exceeding the capacity of 1000 Lt and these pressure vessels shall conform to the Static & Mobile Pressure Vessels (Unfired) Rules, 1981. g. "Dispenser" means the equipment provided in the ALDS for delivering LPG to the Auto LPG Tank of motor vehicles; h. "Emergency shut off valve" means a shut off valve which, in an emergency, operates automatically or can be operated remotely; i. "Filling Point" means the point of inlet pipe connection of a bulk storage tank for MS or HSD or LPG, where hose is connected for filling the products into the tank; j. "LPG Tank Truck Unloading Hard Stand" means the area specially prepared in a Auto LPG Dispensing Station beside the LPG fill point for unloading from tank truck to bulk storage vessel; k. "LPG vent" means the vertical pipe provided on the vessel for discharge of LPG vapours from safety relief valve at a height of at least 2 meters above the top level of the vessels but not less than 3 meters from the ground level; l. "MS or HSD Vent" means the vertical pipe open at the top, fitted on an underground tank in retail outlets for breathing; m. "Retail Outlet or MS or HSD Service Station" means the segregated area provided with facilities and specially prepared, for storage and delivering MS or HSD to the fuel tanks of motor vehicles; and n. "Safety Relief Valve" means a pressure relief device fitted on a pressure vessel to protect the vessel against maximum allowable pressure; 3. LAYOUT AND FACILITIES: 1. General Guidelines: i. The layout should ensure unobstructed movement of all vehicles together with adequate provision for entry and exit of Tank trucks; ii. Location of the facilities, equipment, entrance, exit and paving shall be arranged in a such manner to avoid the risk of any collision amongst the motor vehicles; iii. The fuel lines shall have a positive segregation with electrical cables; iv. It is preferable that there should be unobstructed view of the operating and dispensing areas from the salesroom; v. Access for mobile fire fighting equipment to all the ALDS facilities shall be ensured; vi. In case of above ground bulk storage vessels, provision of storage of adequate fire water shall be made; vii. Provision of escape route for personnel and vehicle in emergency shall be made; and viii. The LPG bulk storage area at ALDS shall be enclosed by an industrial type fencing at least 2 M high erected on a kerb or toe wall of at least 0.3 M high and fill point shall be at the inner edge of this fencing and such area shall be suitably guarded against vehicular impact. Such fence shall have at least two means of exit and the gates of such exits shall open outwards and shall not be self-locking. 2. Siting and Layout: TABLE - 1 ========= -- -- -- -- -- -- -- -- -- -- -- -- TABLE -- 2 ========== Minimum Safety Distances (in meters) between facilities associated with storage and dispensing of LPG in ALDS ------------------------------------------------------------------------------------------------------------- ------- -- -- -- -- -- -- -- -- **N** ------- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- i. If the aggregate water capacity of a multi vessel installation exceeds 40 KL, the minimum safety distance from any vessel to the property line or group of buildings shall not be less than 30 m for above ground vessels and 15 m for underground vessels; ii. The distances specified in clause (i) are required to be measured from the nearest point on the periphery of the vessel; iii. Minimum 6 m distance shall be kept between LPG bulk storage vessel and Storage vessel of the other petroleum products and iv. Typical layout of installation is specified in as annexure -- I. 2. Bulk Storage Vessel: i. The mechanical design of the storage vessel shall be based on following considerations, namely: - a. The storage vessel shall be designed in accordance with the codes i.e. PD -- 5500, ASME-Sec VIII, IS:2825 or equivalent duly approved by PESO. Design shall also take into account the requirements specified in Static and Mobile Pressure Vessels (Unfired) Rules, 1981; b. A single code shall be adopted for design, fabrication, inspection and testing i.e. ASTM and BS shall not be combined; c. Material: Carbon steel conforming to ASTM A516 Grade 60 / 70 or A537 Class d. Design Temperature: -27 °C to +55 °C; e. Design Pressure: Maximum Vapour pessure of LPG conforming to IS: 14861 at 55 °C and shall be taken as 14.5 kg/cm2; f. Other Design Considerations: i. Corrosion Allowance: 1.5 mm (minimum); ii. Radiography: 100 %; iii. Stress relieving: 100% irrespective of thickness; (iv)Wind pressure: as per IS: 875; 1. Above Ground Storage Vessel: i. The bulk storage vessel shall be placed on a firm foundation; ii. There shall be single nozzle at the bottom for liquid inlet or outlet with ROV as first valve. The first flange shall be at least 3 m away from the shadow of the vessel; iii. In multi vessel installation, top of the vessels shall be in the same plane, and (iv)Suitable arrangement for draining of water from storage vessel shall be 2. Mounded or Underground Storage Vessel: iv. The specific consideration shall be given to a. Internal vapour and hydraulic pressure b. External loading on the vessel; and c. Internal vacuum; v. The dimensions (diameter and length) of the vessel shall be decided based on site conditions, soil mechanics and other design considerations; vi. The vessel shall be protected against corrosion by appropriate anti corrosive coating and provided with cathodic protection. Alternatively, steel tank can be designed for the service life and shall be taken out of service on completion of design service life with periodic inspections to verify the veracity of design parameters; vii. The cathodically protected pipelines or vessels or other like things shall be isolated from the unprotected structures or surfaces; viii. Reference points on inner surface of the vessel shall be ^1^\[maintained for\] non- destructive testing for subsequent inspections; ix. The underground vessel shall be installed on a firm foundation and firmly secured to the foundation so as to prevent movement or floatation; x. The underground vessel shall be placed within a concrete or brick masonry pit with a minimum gap of 1 m between the walls of the pit and the vessel as well as in between the vessel; xi. The vessels shall be covered by earth or sand or any other non-corrosive material and thickness of the covering material above the top surface of the vessel shall not be less than 0.5 m; and xii. The fittings or mountings on the vessel shall be in such a way that these can be operated and maintained without disturbing the earth cover. 4. Fittings: 1. Safety Relief Valve: i. Each safety relief valve shall be set to discharge at not more than 110 % of design pressure and have relieving capacity adequate to prevent the maximum pressure in the vessel from exceeding 120 % of the design pressure. Each safety relief valve shall be provided with a lock open type isolation valve between it and the vessel so that one of the two valves can be removed from testing without emptying the vessel. ii. The set and reset pressure of the safety valve shall meet the requirements of Auto LPG conforming to IS: 14861; and iii. The relieving capacity of the safety valve storing LPG in mounded and underground storage vessel shall be at least 30 % of that for above ground storage vessel in fire condition. 2. Emergency Shut off Valve i.e. Remote Operated Valves: iv. Emergency shut off valves of remote operated type shall be provided on all liquid and vapour connections i.e. filling, discharge, pump by pass and vapour return lines of the bulk storage vessels except those for safety valves or instruments tapping and those not exceeding 3 mm diameter for liquid and 8 mm diameter for vapour. ROV\'s shall be operable from sales room or control panel and from operating area; v. The remote operated valves shall be fire safe valves with a closing time not exceeding 15 seconds; vi. ROV\'s shall have an open or closed position indicator; and vii. Additionally, isolation valves of ball type shall be installed at shortest distance from ROV. 3. Excess flow check valves (EFCV): viii. Excess flow check valve shall be provided on the liquid lines. The closing flow of the EFCV shall not be more than 120 % of the rated flow of the line or as recommended by the manufacturer. Excess flow check valve shall be provided with a breathing arrangement to allow equalisation of pressure; and ix. In closed position, the opening of the EFCV shall not be more than 2 mm2. 4. Manual Shut Off Valves: 5. Tank Truck Unloading Facilities: i. The layout of the unloading location shall be such that tank truck being unloaded shall be in drive out position; ii. Suitable provision shall be made for evacuation of LPG from bulk storage vessels to tank truck to empty the vessel in case of emergency or for statutory testing iii. Tank truck shall be unloaded using hose with the breakaway coupling with isolation arrangement on both ends so that no release of liquid LPG take place at the end of the unloading. Alternatively, loading arms can be provided; iv. The hose - coupling or flange joint shall be of 300 lb rating with metallic gasket. The hose coupling shall be provided with a cap or blind flange by which the nozzle can be closed when not in use; v. The LPG hose used shall conform to Indian standard or API or EN codes; vi. Hose length shall not be more than 5.5 m; vii. The pipeline and the hose shall be laid so as to be above the ground to prevent any damage. viii. The fill point shall be provided with non-return valve and quick shut off isolation valve; ix. Proper arrangement for earthing and bonding shall be made; and x. The vent pipe, if required, shall be at height of at least 3 m from the grade and 6 m away from potential sources of ignition or likely places of vapour accumulation. 6. LPG Pump: 5. External LPG Pump: x. Each pump shall have suitable arrangement for weather protection as per manufacturers recommendations; xi. Pump and motor shall be effectively earthed; xii. Pumps shall be provided with arrangement to protect the pump casing from over pressure when pumping against a closed discharge. The bypass shall discharge into the LPG storage vessel at predetermined pressure; and xiii. The maximum discharge pressure of the pump (shut off pressure) shall be less than the design pressure of the piping system. 6. Submersible Pump: xiv. Pump shall be installed in properly designed well; xv. Design shall be based on combined load of pump, vessel and forces generated by operation; (iii)Design shall be such that installation and removal of the pump can be done at any level of iv. Suitable arrangement for closing the flow of LPG from vessel to pump well shall be provided; v. No LPG shall escape outside from the conduit or well during normal operation, maintenance or sudden breakdown of any component; vi. Provision of purging the well or pump with nitrogen for complete gas freeing, prior to removal of pump cover plate, shall be provided; vii. Provision of a pressure gauge shall be made at the discharge line of the pump; viii. Piping connections on well cover shall be provided with excess flow check valve; ix. Pump shall have in built safety interlock to stop automatically in the event of low level, high temperature and dry condition; and x. Motor should be suitable for usage as per hazardous area classification. 7. Dispenser: i. The dispenser for Auto LPG Dispensing Stations shall be designed, constructed, tested and maintained in accordance with the requirements laid down in SMPV Rules (unfired), 1981; ii. The dispenser shall be provided with an excess flow check valve, a remote operated shut off valve and a pipe shear provision in that order in the liquid inlet pipe; iii. The dispenser shall be installed on a firm foundation and protected against physical damage; iv. A breakaway device with excess flow valves or quick action cut off valves on both sides of the breakaway device, conforming to UL 567 or equivalent shall be provided on the delivery line from the dispenser so as to prevent spillage of liquefied petroleum gas from both sides of the breakaway point in the event of its breakage; v. The dispensing nozzle at the end of the hose shall be of self-sealing type matching with filler connection of multifunction valve conforming to IS: 15100, fitted on the Auto LPG Tank of the vehicle. The liquid released on disconnection shall not exceed 5 ml; vi. The hose for delivery of liquefied petroleum gas by the dispenser to motor vehicles shall be suitable for Auto LPG. The design pressure of the hose shall be minimum 25 kg/cm2 with a safety factor of five. The hose shall be electrically and mechanically continuous; vii. The length of the hose connected to the dispenser shall be kept minimum keeping in view the operational requirement and shall not in any case exceed 5.5 m; viii. Clearly identified emergency shut down switches or circuit breakers shall be provided at easily accessible location not less than 6 m away from the dispenser to cut off power supply in the event of fire, accident or other emergency. The switches or circuit breakers shall be visible from point of dispensing liquefied petroleum gas to motor vehicles; ix. Flexible hoses shall have permanent markings indicating the manufacturer\'s name or identification, applicable code, working pressures and suitability of use with LPG; x. Provisions shall be kept to stop all operations simultaneously through push buttons located near dispenser or sales room; xi. Means shall be provided on the outside of the dispenser to readily shut off the power in the event of fire or accident; and xii. An excess flow check valve, or an emergency shut off valve shall be installed before the connection of dispensing hose. A differential pressure valve shall be considered as meeting this provision. 8. Automation: 8. Piping: i. All metallic piping for LPG service shall be rated and designed to ASME-B-31.3 or equivalent with minimum design pressure 25 kg/ cm2 with a factor of safety of four. The materials of pipe shall be low carbon or alloy steel conforming to American Standard ASTM-SA-333 grade 6, or SA-106 grade B Schedule 40 (for above ground) and Schedule 80 (for underground), or equivalent. The pipeline shall be tested at one and half times of the design pressure, if hydro tested, or ten percent in excess of the design pressure if pneumatically tested. Joints of pipeline above 40 mm diameter shall be welded or flanged. Threaded or screwed connection shall not be provided except for special fittings like excess flow valve, pump connections upto 50 mm diameter; ii. Piping shall be protected against physical damage, collision and corrosion; iii. Pipe length shall be short and diameter shall be kept as small as practicable; iv. Entire piping system including the appurtenances shall wherever possible be constructed with welded joints and where necessary with flanged joints. The number of flanged joints shall be kept down to a minimum; v. Piping shall be run as directly as practical from one point to another and with as few restrictions such as elbows and bends as conditions will permit; vi. Provision shall be made in the piping including connection to the bulk storage vessel to compensate for expansion, contraction, jarring, and vibration; vii. Wherever threaded joints are used, a seal weld shall be provided. All threaded joints and socket weld pipe fittings shall be rated at least 3000 lb to BS 3799 or at pressure class 3000 to ASME B 16.5 or equivalent; viii. All gaskets shall be of flexi-metallic type. Whenever a flange is opened gasket shall be replaced; ix. All flanged joints shall be rated at least class 300 to BS 1560: part 2 or ASME: B: 16.5 or equivalent; x. Flexible piping connections shall be introduced into fixed piping systems wherever it is necessary to absorb vibration or where a rigid connection is impractical. Flexible connections shall be short and not exceed 500 mm in length and shall be of an approved metallic construction suitable for auto LPG service and braided on outside with stainless steel wire. The design parameters for flexible piping connections shall be identical to other piping network. The non - metallic pipe, tubing or hose for permanently interconnecting storage vessels shall not be used; xi. All sections of pipe in which LPG liquid can be trapped by the closing of the valves shall be fitted with thermal safety valves and shall be located in fenced area; and xii. Upon mechanical completion of the ALDS, a complete set of as built installation drawings shall be maintained. 9. Control Panel: xiii. A remotely located and easily accessible control panel for normal operations shall be installed preferably at the sales room. It shall have provisions and indications of on or off, low pressure of instrument air, high temperature trip of LPG pumps and quantity of product in the vessel. It shall also have an alarm and indication for high level cut off. All indications connected with emergency shut off switch shall be provided on this control panel along with and \"Reset\" provisions; xiv. Piping and Instrumentation Diagram (P and ID) of entire LPG system shall be displayed near the control panel. (Typical P and ID is specified Annexure -- II); and xv. All switches shall be clearly marked for its purpose in the field. 11. Electrical Equipment or Fittings: i. Entire space within the dispenser enclosure cabinet and 46 cm horizontally from the exterior of enclosure cabinet and up to an elevation of 122 cm above dispenser base and the entire pit or open space beneath the dispenser shall be Zone 1; ii. 46 cm vertically above surrounding ground level and horizontally beyond 46 cm up to 6 m on all sides of the dispenser enclosure cabinet shall be Zone 2; iii. The area up to 1.0 m around the fill point shall be taken as Zone 1 and area within 1.5 m of LPG vent shall be considered as Zone 1. The area beyond 1.0 m and up to 4.5 m from fill point and beyond 1.5 m and up to 3 m from LPG vent shall be taken as Zone 2; and iv. The electrical power distribution system shall be as per clause 4.0 of Schedule -- 1 of these Regulations. 12. Fire Fighting Facilities: i. ALDS having only underground or mounded LPG storage vessels, two numbers of 70 kg dry chemical type fire extinguishers shall be provided; ii. ALDS having above ground LPG storage vessels, hydrants with minimum water pressure of 7 kg/cm2 shall be provided at convenient positions for all round coverage of storage vessels and handling area, and water sprinklers with spray density of 10 lpm / m2 shall be provided. The fire water pump shall be preferably diesel engine driven with capacity to deliver water at the aforesaid rate and pressure. The minimum fire water storage at the premises shall be that needed for fighting fire at least for one hour; and iii. Additionally, two numbers of 9 kg DCP fire extinguishers shall be provided near tank truck unloading area and one number shall be provided near each dispenser and transfer pump location. 0. OPERATING PROCEDURES: 1. General: i. Adequate training shall be imparted to the operators, service engineers and the persons doing like jobs and records thereof shall be maintained; ii. Operating personnel of ALDS shall possess adequate knowledge and experience of handling LPG to ensure functioning of the station in a safe and efficient manner; iii. During unloading of the product from the tank truck to the bulk storage vessels, the tank truck shall be parked in the space marked for the purpose; iv. During the period of unloading of fuel from tank truck to the storage vessels, operation of dispensing fuel to motor vehicles shall be suspended; v. During the period of unloading of LPG from tank truck to bulk storage vessel and also while evacuating the storage vessel for maintenance, testing and like other operation all dispensing, maintenance operations and like other operation at ALDS including that for MS or HSD shall be suspended; vi. LPG shall be dispensed only into the fuel tank container of a motor vehicle duly approved by the PESO; vii. LPG shall not be filled in the fuel tank of motor vehicle while the engine of the vehicle is running; viii. The operating procedures shall be displayed at relevant locations for activating the ALDS, unloading of tank truck, LPG dispensing and like other operation; ix. Dos and Don'ts shall be prominently displayed in ALDS; x. Safe ingress, fueling and egress of all vehicles shall be ensured; xi. System of periodic inspection and maintenance of ALDS facilities shall be established as an integral part of operations; xii. Action in the event of emergency shall be clearly established and understood by all concerned and displayed prominently; xiii. Important operational activities shall be logged and records of such activities highlighting receipt, inventory, level, pressure, temperature, equipment running and like other operation shall be maintained; xiv. All repairs, maintenance work and like other operation shall be carried out after issuance of work permit by authorized person. xv. LPG unloading operations shall be carried out under the supervision of authorised person of ALDS and TT crew; xvi. Limits of operating parameters including level, pressure and any other condition as set for sound and safe operations shall not be exceeded. In case any abnormal operating conditions are encountered, the causes shall be investigated and corrective actions be taken; xvii. The operating staff shall maintain vigilance for detection and control of any leakage at the dispensing station; and xviii. During the operations, LPG leaks should be monitored with explosimeter. 2. Receipt of Bulk LPG at ALDS: 1. All Checks essential for ALDS safety as given against serial No.1.2 in annexure - III shall be carried out for each tank truck before starting unloading at ALDS in the following manner, namely: i. Bulk LPG at ALDS shall be unloaded preferably in non-peak hours; ii. Unloading of bulk T/T shall be carried out only at location as approved by PESO; iii. The unloading of LPG shall be done in presence of the authorised person at ALDS and TT Crew; iv. Fire extinguishers (2 nos of 9 Kg DCP type) to be positioned as an immediate aid to extinguish any fire except that of liquid LPG; v. Storage tank pressure, temperature and level shall be recorded. Crew or operating staff at ALDS shall closely monitor unloading activities; vi. Tank truck shall be placed in drive out position; vii. After placement, engine master control switch shall be switched off, if applicable; viii. Minimum two wooden chokes shall be placed under wheels; ix. Chassis and LPG vessels are to be earthed independently for which bare metal cleats shall be provided; x. Liquid and vapour hose shall be connected after examining integrity of joints using proper studs and the bolts shall not to be used; xi. The main control panel and other panels shall be energized to activate automatic over fill protection, emergency shut down systems, remote operated valves and compressed air systems; xii. The readings of the level gauges provided on the tanks at ALDS shall be recorded; xiii. The tank trucks valves shall be crack opened and checked for leaks; xiv. LPG level in the storage tanks shall be monitored at regular intervals so that it does not exceed 85 %; and xv. On completion of unloading operation, following activities shall be carried out in sequence, namely: - a. Close the valves rigid liquid and vapour lines connected to the tank truck; b. The hose contents should be forced into the tank truck by controlled nitrogen pressure. Alternatively, use loading arms or hoses with isolation valves at both ends. Only vapours shall be vented through the vent; c. Isolate the valves at fill point; d. Remove hose connection and electrical-bonding wires; e. Cap the vapour or liquid outlet lines of the tank trucks; f. Remove chokes placed under the wheels; and g. Record the roto gauge, pressure gauge, temperature gauge readings and final readings provided on the fixed gauging systems of the storage tanks at ALDS; 3. Storage of Bulk LPG: i. Filling shall not exceed 85 % of the capacity; ii. The visible portion of vessels shall be inspected daily for any LPG leakage and corrective action if required shall be taken; iii. All gauges like high-level alarm, level indicating devices, temperature and pressure gauges shall be kept in operating conditions at all times and shall be checked daily; iv. Product gauging shall be done before commencement of dispensing operations and also at the time of closing the operations of the ALDS every time; and v. Functioning of remote operated valves shall be checked prior to receiving of product into the storage tanks. 3. Dispenser Operation: i. Ensure that the area is safe for refueling; ii. Guide the vehicle to the position at the designated area of the ALDS facing the direction of exit; iii. Do not leave the vehicle unattended during refueling operation; iv. Ensure that sources of ignition, such as pilot lights, electrical ignition devices, electrical appliances or gadgets, and engines located on the vehicle being refueled are turned off before dispensing of LPG to a vehicle; v. Check for stamping of Road Transport Authority in the registration certificate of vehicle prior to refueling; vi. The operator at ALDS shall satisfy himself before commencement of filling in the vehicle in respect of following, namely: - a. The vehicle is fitted with only approved Conversion Kit and Auto LPG Tank with standard fittings as per AIS 026 or equivalent; b. A "COMPLIANCE PLATE" is installed near the filling connection which is clearly visible, displaying following information, namely: - A. Auto LPG Tank identification number; B. Date of installation; C. Water capacity (Litres) of total installation; D. Date of last retest; E. Vehicle Registration or Identification No.; F. LPG installation complies with the safety requirements of AIS 026; and G. Installed by (indicate the designation); c. That a green coloured label of size 80 mm x 80 mm with the text "LPG" is affixed either close to the vehicle number plate or on left side of the wind screens; d. Check for the 'Automatic Fill Limiter (AFL)', which shuts off fuel supply to tank at 80 % of tank capacity, on the fill point of the Auto LPG Tank. e. LPG filling shall not be carried out for vehicles having Auto LPG Tank due for retesting as per Gas Cylinder Rules, 1981. Ensure that the emergency shut-off valve and the manual isolation valves are open on both delivering and return lines. vii. Set the dispenser meter at the quantity or value to be filled; viii. Position the fill nozzle on the vehicle container and couple securely; ix. Check that the vehicle fill connection is in sound condition in terms of tightness and leakage; x. Energize the system through push button and allow flow of LPG into the auto LPG Tank; xi. When using a filler nozzle with a nozzle bleed valve, open the valve to empty the nozzle before disconnection; xii. Return the nozzle to correct position after the filling is over; and xiii. At the end of the day's work, ensure that valves are closed, hoses are properly stowed and electrical equipment is switched off. Note: - Commissioning and de commissioning procedure for the ALDS is given in Annexure 0. INSPECTION AND MAINTENANCE: i. A well-designed system of periodic inspection of all facilities of ALDS shall be formulated to maintain it in safe operable condition all the time. Safety audit of the ALDS shall be undertaken and certificate of fitness declaring integrity with respect to equipment, facilities, operations and safety procedures shall be accordingly issued. Check list for inspection is specified in Annexure -III; ii. All recommendations of the safety audit or inspections shall be complied in a time bound manner and records maintained thereof; iii. Disassembly or removal of the facilities and components of equipment whilst any part of the system is under pressure is hazardous and shall not be undertaken unless the system is depressurised, gas freed and certified; iv. The system of permit to work shall be established for non-routine works in line with the work permit issued by authorised person and such works shall be undertaken with full knowledge and approval by authorised person for such purpose. The work permit shall be in line with Annexure-vi (A) and vi (B) of Schedule -- 1; v. Equipment appurtenances, protection devices associated with the dispensing unit as incorporated in the design and approved by PESO shall be tested, maintained, repaired and replaced as recommended by the manufacturer; vi. Checklist shall be in conformity with the design intention, operating and maintenance procedures, preventive measure and protection systems and safety practices; vii. Preventive maintenance schedules shall be drawn for all equipment in accordance with manufacturer's recommendations and established mandatory or recommendatory standards. Records of all preventive maintenance undertaken shall be maintained and updated from time-to-time; and viii. Calibration of dispenser shall be carried out in line with statutory applicable. 0. TESTING OF RELIEF AND PROTECTION SYSTEM: i. All periodic tests shall be carried out by competent or authorised persons in this behalf, as applicable and records shall be maintained; ii. For in house testing of safety relief valve, only properly built, testing facilities shall be used; iii. After the calibration or re-calibration of the safety relief valve and excess flow check valve, it shall be certified by competent person; and iv. A schedule for testing of Relief Valves and Protection System of various equipment shall be developed. The checks shall be done as specified by manufacturer. The frequency of testing shall be either as given below or as recommendation by manufacturer whichever is of shorter period, namely: - -- -- -- -- -- -- -- -- -- -- -- -- a. The Excess Flow Check Valve (EFCV) installed inside the vessels or underground vessels which are not accessible easily and EFCVs installed without isolation valves, shall be bench tested for their flow rating measurements, once in 5 years through competent person. The functionality test of these valves shall be done once in a year. b. Excess Flow Check Valve (EFCV) in dispenser or located outside the vessel with isolation valves or having isolation provisions, shall be bench tested for their flow rating measurement, once in a year. c. The functionality test of these valves shall be done once in a quarter.\] 7. SAFETY INSPECTIONS and AUDIT: -- -- -- -- -- -- 8. EMERGENCY PLAN AND PROCEDURE: i. A comprehensive ERDMP shall be developed in accordance to the Petroleum and Natural Gas Regulatory Board (Codes of Practices for Emergency Response and Disaster Management Plan (ERDMP)) Regulations, 2010. The copies of the ERDMP shall be available to all personnel in the Auto LPG Dispensing Station; ii. The entity having control over the ALDS shall draw an operational emergency plan keeping in view the following, namely: - a. Loss of, or interruption to, the gas supplies due to leaks or failure of pipeline; b. Major failure of LPG fittings; c. Accidents or other emergencies, which can affect the ALDS; d. Civil emergencies; e. Any other risk arising from the existence or operation of the ALDS; iii. Each ALDS shall be provided with at least 3 shut down devices located in convenient locations near storage vessels, dispenser and office/ sales room; iv. The in-charge of the ALDS shall maintain close liaison with Fire Service, Police, District Authorities and LPG marketing company; v. Important telephone numbers for emergency use shall be displayed prominently in the ALDS and vi. Means of communication shall be always at the disposal of the In-charge of the ALDS. 9. COMPETENCE ASSURANCE AND ASSESSMENT: vii. The objective is to provide good understanding of all the facets of dispensing activities including operations, procedures, maintenance and hazards of LPG and the risks associated with its handling. Training shall ensure that the jobs are performed in accordance with the laid down procedures and practices; viii. Every entity shall develop, implement, and maintain a written training plan to instruct all ALDS with respect to the following, namely: - f. Carrying out the emergency procedures that relate to their duties at the ALDS as set out in the procedure manual and providing first aid; g. Permanent maintenance, operating, and supervisory personnel with respect to the following, namely: - i. The basic operations carried out at the ALDS; ii. The characteristics and potential hazards of ALDS and other hazardous fluids involved in operating and maintaining the ALDS, including the serious danger from frostbite that can result upon contact with POL products including LPG; iii. The methods of carrying out their duties of maintaining and operating the ALDS as set out in the manual of operating, maintenance and transfer procedures; iv. Fire prevention, including familiarization with the fire control plan of the ALDS; fire fighting; the potential causes of fire or accident in ALDS; the types, sizes, and likely consequences of a fire/ accident at ALDS; v. Recognizing situations when it is necessary for the person to obtain assistance in order to maintain the security of the Petroleum Retail Outlet; ix. Training shall be imparted by competent personnel to the staff attached with the LPG dispensing station at the time of induction, which is to be followed up by periodic refresher courses. The training programme shall inter alia cover following aspects, namely: - h. Hazardous characteristics of LPG; i. Familiarisation with operational procedures and practices; j. Commissioning of new facilities and equipment; k. Hands on experience on operation of equipment; l. Routine checks and maintenance activities of the facilities; ii. Knowledge of emergency and manual shut down systems shall inter alia cover following aspects, namely: - a. Immediate and effective isolation of any LPG leak; b. Accounting of product; c. Safety regulations and accident prevention; d. Fire fighting facilities, its upkeep and operation; e. Evacuation and safe egress of the vehicles in an emergency; f. Housekeeping; g. Safety in transportation of LPG; h. First aid; and i. Emergency plan. or drills; and iii. Proper records for the training and refresher courses shall be maintained at the installation. 0. CUSTOMER SAFETY AND AWARENESS: 1. Display of important information: i. Caution boards shall be displayed near the dispenser for customer awareness as below, namely: - a. Stop the engine before refueling; b. No smoking; c. No flames or pilot lights or use of electrical gadgets; d. Avoid contact with liquid LPG; e. Do not fill LPG beyond 80 % capacity; and f. Keep distance from vehicle being fueled. ii. A display board shall be prominently placed at ALDS for the benefit of the Customer highlighting behavioral characteristics of LPG in bilingual i.e. Hindi or English and local language as below, namely: - g. Auto LPG is stored and delivered as a liquid under pressure; h. While changing from liquid to gas, LPG expands approximately 260 times its original volume; i. Leakage of liquid LPG is more dangerous than gaseous LPG and it has distinct odour; and j. LPG vapour is approximately 1.5 times heavier than air, LPG vapour tends to settle down. 2. DOs & DON'Ts: iii. Do not start the engine or drive away the vehicle till the filling nozzle has been disconnected from the filler cap of the vehicle; iv. Do not refuel the vehicle during the period LPG is being decanted the storage vessel; v. Do not handle LPG without protective hand gloves and safety glasses; and vi. Do not fill in the Auto LPG Tank which is overdue for pressure retesting. Dos: i. Switch off the mobile phone at the ALDS; ii. Switch off the engine before commencement of refueling of Auto LPG; iii. Check vehicle tank spout valve and its rubber seal; iv. Squeeze trigger fully and hold; v. Ensure a 9 kg DCP Fire Extinguisher is available near the LPG Dispenser; vi. Connect Nozzle to avoid cross threading; and vii. In case of any leakage or fire observed, press the "EMERGENCY STOP" button on the LPG Dispenser. ![](media/image16.jpeg) INSPECTION OF THE AUTO LPG DISPENSING STATION ============================================= -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --

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