IS 6044 Part 1 2018 - LPG Gas Bank Installation
IS 6044 Part 1 2018 - LPG Gas Bank Installation
Indian Standard
( Third Revision )
© BIS 2018
FOREWORD
This Indian Standard (Third Revision) was adopted by the Bureau of Indian Standards, after the draft finalized
by the Gas Cylinders Sectional Committee had been approved by the Mechanical Engineering Divisional
Council.
This standard was first published in 1971 and subsequently revised in 2000 and 2013. In this revision the following
major changes have been made:
a) Cylinder location, cylinder manifolds, pressure regulators and piping, tubes and fittings have been
modified;
b) A new Annex A has been added to include requirements of liquid off take valve multi cylinder installation;
and
c) Other technical changes for better implementation of this standard.
While implementing this standard, compliance with statutory regulations shall be ensured.
The composition of the Committee responsible for the formulation of this standard is given in Annex B.
For the purpose of deciding whether a particular requirement of this standard is complied with the final value,
observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance with
IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
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Indian Standard
LIQUEFIED PETROLEUM GAS STORAGE
INSTALLATIONS — CODE OF PRACTICE
PART 1 RESIDENTIAL, COMMERCIAL AND
INDUSTRIAL CYLINDER INSTALLATIONS
( Third Revision )
1 SCOPE IS No Title
1.1 This standard (Part 1) lays down the requirements 4576 : 1999 Liquefied petroleum gases —
for the installations of liquefied petroleum gas (LPG) Specification ( second revision )
cylinders for vapour and/or liquid withdrawal from 6044 (Part 2) Code of practice for liquefied
cylinders, the associated piping and equipment in : 2001 petroleum gas storage installations:
residential, commercial and industrial premises, where Part 2 Commercial, industrial and
cylinder manifold is provided for installation capacity domestic bulk storage installations
up to 8 000 kg. ( first revision )
1.2 The specific requirements for installation of liquid 7241 : 1981 Glossary of terms used in gas
withdrawal from cylinders are covered in Annex A. cylinder technology ( first revision )
9573 (Part 1) Rubber hose for liquefied petroleum
2 REFERENCES : 2017 gas (LPG) — Specification: Part 1
The standards listed below contain provisions which, Industrial application ( fourth
through reference in this text, constitute provisions of revision )
this standard. At the time of publication the editions 9573 (Part 2) Rubber hose for liquefied petroleum
indicated were valid. All standards are subject to : 2017 gas (LPG) — Specification:
revision and parties to agreements based on this Part 2 Domestic and commercial
standard are encouraged to investigate the possibility application ( fourth revision)
of applying the most recent editions of the standards
15683 : 2006 Portable fire extinguishers —
indicted below:
Performance and construction —
IS No Title Specification
383 : 2016 Coarse and fine aggregate for 16484 : 2017 Liquid off-take valve fitting to gas
concrete — Specification ( third cylinders or tanks (mobile or static)
revision ) for liquid petroleum gas (LPG) —
Specification
1239 (Part 1) Steel tubes, tubulars and
: 2004 other wrought steel fittings —
Specification: Part 1 Steel tubes 3 TERMINOLOGY
( sixth revision ) For the purpose of this standard, the definitions given in
2379 : 1990 Pipelines — Identification — IS 7241, and the following shall apply.
Colour ( first revision )
3.1 Installation — A designated premises in an
2501 : 1995 Solid drawn copper tubes for establishment where the complete multi cylinder system
general engineering purposes — comprising of cylinder, valve fittings, piping, manifold,
Specification ( third revision ) vapourisers, pressure regulating station etc, is installed.
2878 : 2004 Fire extinguisher, carbon dioxide
3.2 Header and Manifold — A header is the main pipe
type (portable and trolley mounted)
of an installation, that serves as a central connection
— Specification ( third revision )
for other manifolds. Manifold is a branched pipeline
3043 : 1987 Code of practice for earthing ( first of header provided with suitable pipe fittings for
revision ) individual cylinders.
3601 : 2006 Steel tubes for mechanical and
3.3 Distribution/Distributing Company — The
general engineering purposes —
company which is in the field of marketing LPG and is
Specification ( second revision )
owner of the cylinders.
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3.4 Statutory Authority — The Authority designated company. Proper motor able approach to the point
under Gas Cylinder Rules, 2016 for approving LPG of delivery shall be provided for ease in delivery/
cylinders, valves and regulators. receipt of filled/empty cylinders through vehicles.
The approach is also required to provide free access
3.5 Authorized Agency — Person or agency or a to fire tender and firefighting personnel in case of any
corporate body authorized by distribution company emergency.
to execute the job of designing, erection, testing and
maintenance of multi cylinder installation. The access route to the point of delivery must be firm
and compact even in wet conditions and adequate space
must be provided for parking of cylinder truck making
4 GENERAL RECOMMENDATIONS delivery of cylinders.
4.1 The system shall be installed by an authorized The distance from point of delivery to cylinder
agency. The Authorized Agency shall have trained bank should not be more than 75 m and the path
manpower that is well versed with the characteristics should firm and compact even in wet condition
of LPG and is trained in good practice of handling, and minimum 600 mm wide for easy movement of
installing, testing and maintaining installations. cylinder trolley.
4.2 The system shall be installed in line with the 4.6 The colour coding of LPG liquid and vapour lines
requirements of this standard shall conform to the shall be as per IS 2379. The colour coding shall be
layout approved by the distributing company or by any clearly stated on an instruction board provided in the
other statute as applicable. shed and also at the main office. The direction of flow
shall be indicated on the pipeline with black colour
4.3 The maintenance, inspection, testing, repair, etc, of paint.
the system shall be carried out by agencies authorized
by the distribution company. 4.7 Fire extinguishers of powder type (see IS 15683)
or carbon dioxide (see IS 2878) type or stored pressure
4.4 Cylinders and valve fittings shall comply with Type A, B, C (see IS 15683) shall be provided in
the relevant Indian standard and shall be approved places where LPG cylinder installations are situated
by the Statutory Authority. All other equipment such and shall be located near such installations. The
as pressure regulators and other installation material installations with multi manifolds above 2 000 kg
shall conform to the relevant Indian Standard or any and up to 4 000 kg shall have either water sprinkler
other equivalent international standards. For LPG lines, system or gas monitoring system with local as well
threaded joints shall not be provided except for special as remote alarm system. Two buckets filled with
fittings like excess flow check valve, thermal relief sand and two with water shall be provided nearby.
valves (TRV), pressure gauges etc. Installation above 4 000 kg to 8 000 kg shall have both
water sprinkler as well as gas monitoring system. In
4.5 Point of Delivery addition, for installations above 2 000 kg, following
Location of cylinder bank and point of delivery of shall be applicable (the number, type, sizes of the fire
LPG cylinders shall be acceptable to the distributing extinguishers):
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4.7.1 Gas Monitoring System (GMS) Configuration ground floor level only. A minimum distance of 3 m
shall be maintained between such installation and public
[Link] For LPG installations from 2 000 kg and up to place, roadways, other surroundings and any building
4 000 kg other than the one where LPG from the installation is
One sensor at each corner of shed shall be provided. intended to be used. The installation shall be protected
The sensors shall be provided within 3 m from nearest from excessive weathering by sun, rain, etc. and from
cylinder of manifold. tampering by unauthorized persons. A lean-to roof with
expanded metal on angle-iron framework on the sides
[Link] For LPG installations beyond 4 000 kg and up are considered suitable for this purpose. In any case,
to 8 000 kg adequate ventilation at ground level to the outside air
In addition to [Link], two additional sensors shall be shall be provided.
provided. The additional two sensors shall be located in
middle of each of the longer sides of the shed. 5.1.7 If the installation is more than 1 000 kg,
installations in multiples of 1 000 kg with manifold,
4.8 Safety cap shall be put on all cylinders when not in safety devices, change over mechanism may be
use, whether empty or filled with gas. Storage of filled provided with minimum inter distance of 2 m from
cylinders shall be as per statutory requirement. all sides. Total number of such installations shall not
exceed 8 including standby installation.
4.9 The installation shall have caution signs such as
‘LPG’, ‘DANGER’, ‘HIGHLY INFLAMMABLE 5.1.8 Cylinders shall be installed upright with the
GAS’, ‘NO SMOKING’, etc, painted in luminous red valves upper most.
paint, outside at a prominent place.
5.1.9 Cylinder containing more than 20 kg of gas shall
5 CYLINDER LOCATION not be located on floors above ground level.
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more than 1 000 kg, then the installation shall be provisions or Indian Standards, equivalent international
provided in line with 5.1.7. standards shall be followed.
c) Cylinders shall not be installed at a place where 6.2 The individual component parts of manifolds,
they are likely to cause obstruction, suffer damage that is, piping, fittings, flexible hoses etc, which
or be exposed to conditions likely to affect safety; are subject to cylinder pressure shall be capable of
d) Cylinders installation shall not be located along withstanding a test pressure of 25 kgf/cm2 or 1.5
the drive way. Under unavoidable conditions, times the developed pressure at 65°C, whichever
minimum distance of 3 m from drive way shall is more, without bursting. Rubber hoses used shall
be maintained. Brick masonry (minimum 230 mm confirm to IS 9573 (Part 1).
thick)/concrete (minimum 100 mm thick) walls
or metallic Shields/barriers (minimum 1.63 mm 6.3 Where cylinder installations are made up with
sheet) and of minimum 2 m height shall be erected service and reserve batteries of cylinders, suitable
between drive way and cylinder installation for change-over devices or valves shall be incorporated in
the safety and security of the installation; the manifold header to prevent undue escape of the gas
e) Cylinders shall be located on a concrete or brick when cylinders are changed.
floor that is firm, at level, smooth, drained in case 6.4 In case PRV, manifold headers and automatic
of outdoor installation; and change-over devices are connected to cylinder by semi-
f) The cylinder shall be installed in upright position flexible connectors, these shall be rigidly supported.
with the valve pointing upwards and away from Copper tube pigtails are considered to be semi-flexible
any combustible materials. for this purpose.
NOTE — No installation shall be provided at basement or
below ground level. 6.5 It is recommended that joints in manifold headers
which do not have to be broken in normal use should
5.2 Portable Installations be welded or brazed using a material which shall have
When portability of cylinders is necessary, the a melting point of at least 540°C.
following requirements shall be fulfilled:
6.6 All joints between manifold headers and cylinder
a) The sum total of capacity of the cylinders connectors shall be readily accessible.
connected to each manifold shall not exceed 100
kg of LPG. The total quantity of gas thus installed 6.7 All joints in the manifold should be welded
in a workspace shall not exceed 200 kg. (except for valve fixation) and be easily accessible for
b) If cylinders are mounted on a trolley, the trolley inspection/repairs, etc.
shall be stable. Where necessary, the cylinders 6.8 Each manifold arm shall be fabricated in such a
shall be secured to prevent them from falling. way that minimum joints are provided. Only seamless
c) The regulator shall be connected directly to the pipes are recommended for use in manifolds. There
cylinder valve or to a manifold which shall be should be a minimum gap of 300 mm between the
connected to the cylinder valves by means of manifold and valve protection ring of the LPG
rigid connections to give adequate support to the cylinders.
regulator. The only exception to this requirement
is where cylinders are mounted on a trolley and 6.9 The cylinders connected to a manifold shall
the manifold is rigidly supported on the trolley. In be safely spaced for easy and safe replacement
such a case flexible or semi-flexible connections of cylinder when empty. A minimum distance of
may be used between the cylinder valves and the 400 mm shall be maintained between two nipples
manifold but not between the manifold and the provided on the manifold for connecting the cylinders
regulator. to the manifold. In case of staggered arrangement
of cylinders, a minimum distance of 150 mm shall
d) Anytime the total quantity of gas at portable
be maintained between two nipples provided on the
installations shall be in proportion to the floor
manifold.
area as specified in 5.1.1 to 5.1.7.
e) At any time the provision at 5.1.1 to 5.1.13 shall In case, the diameter of the cylinder is higher than
be ensured for all installations. 400 mm, then the minimum distance between the two
nipples shall be diameter of the cylinder plus 100 mm.
6 CYLINDER MANIFOLDS
6.10 A pressure gauge of minimum dial size of 10 cm
6.1 All materials, fittings, etc, used in cylinder manifold shall be provided in the manifold to indicate the gas
systems shall comply with the statutory provisions pressure in the manifold. The pressure gauge shall be
or relevant Indian Standards. In absence of any such suitable for a pressure range 0 to 30 kgf/cm2.
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which it is installed. An emergency operating procedure subjected to full cylinder pressure shall be conforming
shall be distinctly displayed near the ESOV. to IS 9573 (Part 1). The free nut at the end of pig tail
shall be of non-corrosive metal.
8.10 Flanges
In case of flange connections, the flanges shall be 9.5 Adaptor
machined and should preferably have raised face. For If an adaptor is used to connect the pigtails to the
LPG lines subjected to full cylinder pressure of LPG cylinder valves (self-closing) of the LPG cylinders,
liquid lines the minimum flange rating shall be 300 then it shall have non-return valve (NRV).
class rating.
9.6 Pressure Gauge
8.11 Flange Gaskets A pressure gauge with a range of 0-5 kgf/cm2 shall be
The acceptable materials for gaskets are metal or spiral provided in the pipeline after the first stage PRV. The
wound metallic gaskets. Whenever flange connection is joint at which pressure gauge is fixed shall be thoroughly
opened, gasket shall be replaced. For liquid lines, only checked for leakage. Milibar pressure gauges (0-500
spiral wound metallic gaskets shall be used. mili-bar) shall be provided in the pipelines after second
stage PRV.
8.12 Used Pipes, Fittings
Pipe, fittings, valves or other materials can be re-used 9.7 Excess Flow Check Valve
subject to conforming all the requirements prescribed The excess flow check valve shall be provided on each
in this standard. arm of the manifold to ensure stoppage of LPG supplies
in case of heavy leakage/damage to the pipeline in the
9 I NSTALLATION OF PIPING AND VALVES downstream facilities. The capacity of the excess flow
check valve shall be +10/-20 percent of designed flow rate.
9.1 Flexible Hose
9.1.1 Installations on which flexible hose is used shall 9.8 Piping
satisfy the following conditions: 9.8.1 Piping (internally and externally) shall be free of
a) Cylinder and the appliances connected to it shall cutting burrs, loose scales, dirt, dust and other foreign
be in the same room/shed; matter before the installation.
b) Length of hose shall be kept as short as possible
9.8.2 Wherever possible, joints should not be placed
and should normally not exceed 2 m; and
beneath ground level in inaccessible places, confined
c) Appliances connected shall be of portable type places (for example cellars), air or ventilating ducts,
and not mounted in a fixed position. space under flooring or lift shafts.
9.1.2 Flexible hose shall not be extended from one room 9.8.3 If joints have to be used in piping beneath ground
or verandah or one space to another and, therefore, level in inaccessible places or confined places, they
shall not be passed through doors, windows, walls, shall be welded or brazed to minimize the risk of
partitions, ceilings, or floors. leakage which may lead to collection of hazardous gas.
9.1.3 Flexible hose shall be accessible for easy 9.8.4 Where welded or brazed joints are used, they shall
inspection and shall not be connected from hole in be of adequate mechanical strength, and the material
walls, cupboards, cabinets and other obstructions. used for welding or brazing shall have a minimum
9.1.4 Flexible hose shall not be used in conditions melting point of 540°C.
where ambient temperature exceeds 52°C. 9.8.5 Joints other than welded or brazed shall be readily
9.1.5 Flexible hose shall be so installed that it is not accessible.
twisted, looped or kinked and is not subjected to any 9.8.6 Piping shall be so located or protected so as to
external pressure. avoid extremes of temperature which might give rise to
9.2 Appliances which are rigidly fixed in position shall condensation or cracking of the gas.
be connected by means of rigid piping. 9.8.7 Provision shall be made to avoid damage to the
9.3 Appliances which are portable, if connected to rigid piping from its expansion, contraction and vibration
piping, shall be connected through flexible or semi and by settlement of the building by which it is carried.
flexible connections. 9.8.8 Piping shall be protected against corrosive
9.4 Cylinder Pigtails atmospheres and materials.
The hose used for connecting the cylinders with 9.8.9 As far as possible, concealed piping shall
manifold as well as at any part of the piping which is be avoided. If concealed piping is used, it shall be
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protected against inadvertent damage, such as from 9.13 The distribution pipeline in residential buildings
nails and knocks, by its location, type of material used shall always be laid on walls with proper cleat supports/
or sheathing. hanged from the roofs with adequate clearance from
wall surface so that surface preparation and painting
9.8.10 Piping shall not be run in or through an air or will be easier. The piping shall be anchored to prevent
ventilating duct, chimney, flue or lift shaft. undue
9.8.11 Piping up to an outside diameter of 12 mm shall strains on connected equipment and shall not be
be supported at intervals of about 50 cm by means of supported by other piping. The spacing of supports in
pipe saddles or clamps in a way to avoid sagging and gas piping installations shall not be greater than 1.8 m
shifting. For larger diameter pipes, suitable longer for 12 mm/15 mm dia pipe, 2.4 m for 20 mm/25mm dia
supporting intervals may be used. pipe, 3 m for 40 mm dia pipe and above.
9.8.12 It is recommended that if the pipes are run 9.14 The pipeline connecting the storage shed to
along a surface of a structure, the supports should be the main installation should preferably be brought
so designed that the joints are sufficiently clear of the overhead without creating any hazard for the people/
surface to permit the use of tools without damage to vehicles passing through the same. In case of any
the surface. foreseen hazard the pipeline can be laid underground
9.8.13 It is recommended that when installing pipes in a trench filled up with sand of grading zone IV as
along a surface of a structure, the installation is done per IS 383 having MS/RCC cover. The underground
in such a way that moisture is not trapped between the pipe shall be provided with adequate protection like
surface and the pipeline. wrapping coating, etc, for protection against corrosion.
9.8.14 It is recommended that the piping passing 9.15 The single stage pipeline network (down the range
through walls should be protected by a covering sleeve. of first stage PRV) from the installation onward should
If it is necessary to pack the space between the piping work at pressure very close to the working pressure of
and the sleeve, a moisture-proof material which does the appliances. Under no circumstances, the pressure
not corrode the piping shall be used. of the pipelines shall exceed 1.5 kg/cm2. This should
be obtained by double stage regulation of pressure, if
9.8.15 The distance between gas piping and electrical necessary.
wiring system shall be at least 600 mm and, where
necessary; they shall be securely fixed to prevent 10 LEAKAGE TESTING
contact due to movement. The gas piping should run
below the electrical wiring. 10.1 Before any system of gas piping is finally put
into service, it shall be carefully tested as per A-8.3 of
9.8.16 The distance between the gas piping and steam Annex A to ensure that it is gas-tight. Where any part of
piping, if running parallel, shall be at least 150 mm. the system is to been closed or concealed, the test shall
The gas piping should preferably run below the steam precede the work of closing in.
piping.
10.2 Naked flames shall never be used for checking
9.9 Suitable line shut-off valves shall be fitted for each gas-tightness of the installations.
appliance or burner.
10.3 It is recommended that the location of leaks should
9.10 A main valve shall be fitted in the piping as near as be detected by the use of soap solution or similar
possible to its point of entry into building with proper materials.
sealing arrangement.
10.4 Defective pipes or fittings shall be replaced and
9.11 It is recommended that the number of fittings shall not be repaired in-situ.
used in an installation should be kept to a minimum
in order to reduce the risk of gas leakage. As far as 10.5 Electronic gas leak detectors duly approved by
possible, straight lengths of piping should be used. statutory authority along with control panel for giving
Where there are bends in the pipeline, these should audio/visual alarms shall be used for leak detection
have a radius of at least five times the diameter of the especially in commercial/industrial installations and
pipe. in domestic/residential housing complexes, where
combined capacity of all installations is exceeding
9.12 The open ends of piping and fittings (with the 1 000 kg or where reticulated system has been provided.
exception of terminal taps or valves in regular use)
shall always be made gas-tight by means of either an 11 MAINTENANCE
appropriate terminal fitting or a plug, welded or brazed
in position. Welding or brazing material shall have a 11.1 The distribution company shall design an elaborate
melting point of at least 540°C. work permit format for the maintenance work which
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shall be used by the service provider for carrying out 12 INSTRUCTIONS TO CONSUMERS
any maintenance work. It shall be the responsibility
of the service provider to make necessary inspection 12.1 Consumers shall be instructed by the distribution
in line with the work permit before commencement of company on the following aspects:
the work. a) Operation of the whole system;
11.2 The user shall get the inspection of the cylinder b) How to recognize gas leaks;
manifold, distribution piping, safety system, equipment, c) Action to be taken in case of leakage;
valves fittings, auto change over system, gas monitoring d) Action to be taken in case of fire; and
system, hydrant hoses, etc, regularly as per the periodicity
e) Action to be taken in case of damage to, or failure
defined by the Distributing Company. However,
of, any part of the installation.
minimum periodicity of inspection shall be once a year
and the records have to be maintained. The inspection 12.2 Part of the Installation working at cylinder pressure
shall include checking the health, performance of all to be tested at 25 kgf/cm2 or 1.5 times the developed
equipment like valves, PRV, auto change over system pressure at 65°C, whichever is more, once in a year.
for proper operation (wherever installed), underground
piping, etc. Work permit system developed by the LPG 12.3 Downstream part of the installation after PRV to
distribution company shall be followed. be tested atone and a half times the maximum outlet
pressure that may be given by an adjustable PRV or
11.3 The repair, maintenance of any defective piping, 2 kgf/cm2, whichever is more, once in a year
manifold or any other equipment has to be carried out
by agencies approved by the LPG distribution company 12.4 Portions of installation not subjected to cylinder
or distributing company itself. pressure but carrying gas at pressure more than 30 gf/
cm2 to be tested at 2.5 times the working pressure for
11.4 Pneumatic testing and hydro testing of piping shall 2 min, once in a year
be done once in five years by agencies approved by
distribution company. 12.5 Portions of installation subjected to gas pressure of
30 gf/cm2 or less, to be tested at 2.5 times the working
11.5 All PRV shall be throttled once a year for its pressure for 2 min, once in a year.
accurate throttled pressure and safe operation. 12.6 Handling and Use
11.6 The pigtails shall be checked visually every time a) Cylinders shall be adequately supported during
when empty cylinder is replaced. handling and shall not be dropped or should not
be allowed to fall upon one another.
11.7 Hydro test of pig tails and flexible LPG hoses shall
be carried out on yearly basis. b) Trolleys and cradles of adequate strength shall as
far as possible be used when moving the cylinders.
11.8 The distribution company shall conduct a safety c) Use of high powered magnets for lifting the
awareness camp for the consumers particularly for cylinders and chains for slinging the cylinders
residential and commercial consumers. shall not be permitted.
11.9 A fire hydrant line wherever provided, shall be d) No lubricant should be used on the valve or any
in the vicinity of the installation and a hydrant point other fitting on the cylinder.
with hoses to take care of any exigency or emergency e) Open flames, lights, lighting of fires, welding and
situation. smoking shall be prohibited in close proximity.
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ANNEX A
( Clause 1.2 )
REQUIREMENTS OF LIQUID OFF TAKE VALVE
MULTI CYLINDER INSTALLATION
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4) Date of test and test pressure, in kg/cm2; and d) No screwed connection shall be allowed. In case,
5) Manufacturer’s identification symbol. due to any reason screwed connection is used, the
pipe used shall be of SCH 80 only.
e) The typical installation layout, piping and distance
is provided in Fig. 1 to Fig. 6 as directional e) The valves, sight flow indicator, thermal relief
guidelines for installation up to 8 000 kg capacity. valve, NRV, etc, shall be of 300 class rating. Only
Any modifications and changes shall be as cast steel ball valves with fire safe feature shall be
accepted by the distribution company. used.
f) All flanges used shall be of carbon steel, SA105,
A-4 PIPE AND PIPE FITTINGS FOR PIPING 300 class rating with dimensional standard
MANIFOLD AND HEADER UP TO PRV as per specifications approved by distribution
a) The pipe fittings used shall be forged fittings of company. No screwed connections should
SCH 80, as per specifications approved by the be provided except for the special fitting as
distributing company. specified in 4.4.
b) All fittings of less than 50 NB shall also be forged g) All weld joints provided on the line shall be
fittings of 300 class rating. accessible and shall be hydro-tested for 25 kgf/cm2
pressure. The welding shall be fusion welding.
c) The pipe used for liquid line that is upto vapourizer
shall be seamless steel pipes as per specifications h) Only metallic/spiral wound metallic gaskets shall
accepted by distribution company. Pipes of below be used for liquid line that is up to vapourizer and
50 NB shall be of SCH 80 and pipes of 50 NB also down stream of vapourizer.
and above shall be of SCH 40. Copper tubing j) Each arm of the manifold shall have a control
manifolds shall not be allowed. The pipe used valve. To each arm of the cylinder manifold,
for vapour service (after vapouriser) shall be as cylinders shall be connected through a pigtail.
specified in 8. A check valve and an isolation valve shall be
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provided with each cylinder pigtail connection or heater less. In case electrical vapourizer is used,
to protect the system from back flow of LPG in it shall have FLP connections.
event of any flexible pigtail rupture. The distance b) A minimum distance of 2 m of vapourizer from
between two pigtail connections on manifold shall cylinder installation shall be maintained.
be minimum 300 mm.
c) The vapourizers shall be provided with suitable
k) Cylinder manifold is subjected to full cylinder automatic means to prevent liquid LPG passing
pressure at all times. The fabrication/welding from the vapourizer to gas discharge piping.
of the manifold should be of the best available
quality. All such manifolds shall be designed A-6 FLEXIBLE HOSE
to a pressure equivalent to the maximum
developed cylinder pressure (assessed at 65°C) a) The hoses connecting cylinder with manifold shall
of LPG that is 16.87 kgf/cm2. The test pressure be in line with IS 6044 (Part 2), and shall be used
should be 1.5 times the maximum pressure for connecting the cylinder to manifold. The hoses
(assessed at 65°C) that is 25 kgf/cm2 for a shall be as per IS 9573 (Part 1) The hoses shall
period of 2 min. be hydro tested at 25 kg/cm2 pressure once in six
months.
m) Painting — Piping manifolds and the supporting
structure shall be painted with two coats of red b) The design, material and construction of hoses
oxide primer and with two coats of first quality shall be suitable for grade of LPG. Currently, it
synthetic enamel paint. The colour of the LPG is envisaged that LPG as per IS 4576, shall be
lines shall be as per IS 2379. supplied.
c) The flexible hoses should have electrical continuity
A-5 VAPOURIZER of 0.75 Ω/m.
a) The vapourizer used shall be approved by statutory d) All flexible hoses used before first stage PRV
authority. Vapourizers may be low pressure steam and after second stage PRV shall be tested at
heated, hot water heated, electrically heated type 3.5 MPa (35 kgf/cm2) during initial manufacture
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and should be designed to withstand a minimum 4) Hydro testing of manifold and pneumatic
bursting pressure off our times the maximum testing of pipelines should be done once in
working pressure. 5 years.
e) The flexible hose/pigtail shall be in the same room c) Vapourizer shall be checked as per maintenance
and its length shall not exceed 2 m. Flexible hose/ schedule.
pigtail shall not pass through doors, windows, d) The burners shall be regularly cleaned.
walls, ceiling (or) floors. The pigtails shall be
e) Pigtails shall be checked every time empty cylinder
accessible for inspection.
is replaced by a filled cylinder and replaced in case
f) In case the ambient temperature exceeds 52°C, of any physical damage.
flexible hose shall not be used.
f) The PRV should be checked once in a year for
g) The flexible hose shall not be twisted, looped or correct settings and performance as well as for
kinked. It should not be subject to any external corrosion and mechanical damage.
pressure.
g) The pressure gauges should be calibrated once in a
h) The hose shall be tested half yearly and proper year and proper records should be maintained. The
records of testing, etc, shall be maintained. dial of the gauge should be clearly visible.
A-8 SAFETY AND INSPECTION A-8.2 Inspection
a) The consumer has to be trained to use the LOT a) All the manifold installations shall be checked
cylinder installation. A trained personnel who has once in six months by the authorized agency or
minimum qualification as diploma in engineering the LPG distributing company and record to be
or a science graduate at supervisory level shall be maintained at the installation location.
responsible for the installation from customer’s
b) The installation shall be checked once in a year by
end. However for daily operation of connecting
the sales officer of the LPG distributing company
and disconnecting the cylinders and for other
or by their authorized third party inspection
operation a trained ITI technician is preferred.
agency.
b) Distributing company shall assist the consumer in
c) The area of LOT installation should be free of any
organizing regular safety programmes, drills, etc,
uncontrolled weed growth and accumulation of
and will also provide regular training on use of
waste products.
LPG.
c) Empty cylinders shall be placed in a safe place and A-8.3 Leak Testing
proper safety cap shall be provided on the valve so
as to ensure that no leakage takes place. a) It shall be ensured that the manifold provided
has been subjected to the hydro test pressure
A-8.1 Maintenance of Cylinder Manifold of 25 kgf/cm2 atleast for a minimum period of
30 min and inspected by the authorized agency or
Maintenance of the cylinders manifold and the the distribution company.
equipments shall be undertaken regularly and the
periodicity of the maintenance shall be as under: b) It shall be ensured that the fire extinguishers and
sand buckets are provided and installations are
A-8.1.1 Periodicity of Checks and Maintenance adequately protected from weather conditions.
c) The gas piping system should be carefully tested
a) Valves
for ensuring gas tightness.
1) All the valves that is safety valves, TRV shall
d) Naked flames shall never be used for checking gas
be checked once a year.
tightness of the installation.
2) All the other valves should be checked once
e) Leak detection should be done using soap solution
a year for free and full range of movement,
or similar material.
positive shut off, mechanical damage, etc.
f) All defective pipes should be replaced and no
b) Piping and manifold
repair should be carried out in-situ.
1) It should be checked once a year visually for
corrosion, any physical damage. All supports A-8.4 Warning Signals
of manifold should also be checked for any
a) Smoking or naked flames shall not be permitted
corrosion, etc.
within the Safety Zones of the installation. ‘NO
2) The manifold should be internally cleaned once SMOKING’, ‘HIGHLY INFLAMMABLEGAS’,
a year and should be free from contaminants. ‘DANGER’, boards shall be provided.
3) The strainer provided on the manifold should b) Sign boards, instruction boards for ‘DOs’ and
be cleaned at least once in a month. ‘DONTs’ shall be provided.
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c) Instruction board with emergency telephone safety cap on the valve of the cylinder. Never
numbers and important telephone numbers shall repair the appliance or any other part of system
be provided. when in use.
d) Instruction board prohibiting unauthorized entry c) The matter should be immediately reported
shall be provided. to the in charge and the officer of distribution
e) It shall be ensured that all signage are in place and company.
are legible.
A-9 EARTHING AND ELECTRICAL
A-8.5 Source of Leakages P ROTECTION
a) Cylinders: a) The cylinder manifold installation, the vapourizer
1) Welded seams; installation and the downstream installation shall
2) The cylinder/valve connection bung joint; and be earthed at two places. Two earth pits as per
IS 3043, shall be provided and the earthing
3) Cylinder valve.
resistance should not exceed 1Ω.
b) Check Leakage from PRV at:
b) The system should be tested for electrical
1) Near the joints; continuity and resistance to earth.
2) In the PRV itself; c) The earthing resistance shall be checked twice a
3) Check leakage from the piping and manifold year once during the summer season and once
PRV; during winter and records for same shall be
maintained.
A-8.6 Action to be Taken when Leakage is Detected d) Only flame proof electrical fittings approved
a) Leakage of Cylinder — Any cylinder which by statutory authority shall be used in the area
develops a leak should be promptly removed to segregated for LOT installation. These shall be
an isolated open place away from any source of earthed at two points:
ignition. 1) Only flame proof hand torches shall be used;
b) In case of leakages of piping, appliances or and
pressure regulators, close the valves and isolate 2) Copper jumpers shall be provided at flange.
the part, disconnect the cylinders and place the
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ANNEX B
( Foreword )
COMMITTEE COMPOSITION
Gas Cylinders Sectional Committee, MED 16
Organization Representative(s)
Petroleum and Explosive Safety Organization, Shri N. T. Shahu (Chairman)
Nagpur Shri Ashendra Singh (Alternate)
All India Industrial Gases Manufacturers Association, Shri Anish Patel
New Delhi Shri K. R. Sahasranam (Alternate)
Ashok Leyland Limited, Chennai Shri M. Ravi
Shri Ved Prakash Gautam (Alternate)
Bharat Petroleum Corporation Ltd, Mumbai Shri Sumit Roy
Shri A. Prabhakar (Alternate)
Bhiwadi Cylinders Pvt Ltd, New Delhi Shri Manvinder Singh
Shri Rajneesh Chopra (Alternate)
Everest Kanto Cylinder Ltd, Mumbai Shri P. M. Samvatsar
Shri A. K. Khamkar (Alternate I)
Shir H. D. Khatri (Alternate II)
GSPC Gas Co Ltd, Ahmedabad Shri Ravi Ravipalli
Hindustan Petroleum Corporation Ltd, Mumbai Shri P. N. Kanth
Shri Debashish Chakraverty (Alternate)
Indian Oil Corporation Ltd, Mumbai Shri Shankar Sharan
Shri Sanjay Gupta (Alternate)
Indraprastha Gas Limited, Delhi Shri Ujwal Bhandari
Shri Alok Sharma (Alternate)
INOX India Ltd, Vadodara Shri Deepak V. Patwardhan
Shri Deepak V. Acharya (Alternate)
International Industrial Gases Ltd, Kolkata Shri Devendra K. Garg
Shri Nikhile K. Garg (Alternate)
Kabsons Gas Equipments Ltd, Hyderabad Shri Satish Kabra
Shri. S. Gopalaiah (Alternate)
Kosan Industries Ltd, Mumbai/Surat Shri Sunil K. Dey
Shri S. B. Bolmal (Alternate)
LINDE India Ltd, Kolkata Shri Ramana Vutukuru
Shri Pradeep (Alternate)
LPG Equipment Research Centre, Bangalore Shri K. K. Thakur
Shri A. K. BERA (Alternate)
Mahanagar Gas Limited, Mumbai Shri S. Murali
Shri Arun Nayak (Alternate)
Ministry of Defence (DGQA), Pune Shri J. P. Tiwari
Shri K. Sudhakaran (Alternate)
Research & Development Estt (Engineers), Pune Shri P. K. Chattopadhyay
Shri A. Basu (Alternate)
Sakha Engineers Pvt Ltd, New Delhi Shri Amarjit S. Kohli
Shri R. Padmanaban (Alternate)
Society of Indian Automobile Manufacturers Shri K. K. Gandhi
(SIAM), New Delhi Shri Amit Kumar (Alternate)
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Organization Representative(s)
Steel Authority of India Ltd, RDCIS, Ranchi Shri Debashis Karmakar
Dr Anjana Deva (Alternate)
Supreme Cylinders Ltd, Delhi Shri M. L. Fathepuria
Tata Motors Ltd, Pune Shri Pallipalayam. Gowrishankar
Shri Shaillendra Dewangan (Alternate)
Tekno Valves, Kolkata Shri Y. K. Behani
Shri R. Behani (Alternate)
The Automotive Research Association of India, Dr S. S. Thipse
Pune Shri S. D. Rairikar (Alternate)
Trans Valves (India) Pvt Ltd, Hyderabad Shri A. K. Jain
Shri P. K. Mathur (Alternate)
Vanaz Engineers Ltd, Pune Shri S. J. Vispute
Shri A. S. Latke (Alternate)
BIS Directorate General Shri Rajneesh Khosla Scientist ‘E’ and Head (MED)
[Representing Director General ( Ex-officio )]
Member Secretary
Shri Chandan Gupta
Scientist ‘C’ (MED), BIS
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Organization Representative(s)
Shri Shakti Cylinders Pvt Ltd, Hyderabad Shri D. V. Rajasekhar
Shri. Younus Geelani (Alternate)
Steel Authority of India Ltd, Salem/Delhi Shri M. Prabakaran
Shri N. K. Vijayavargia (Alternate)
Supreme Cylinders Ltd, Delhi Shri M. L. Fathepuria
The Supreme Industries Ltd, Halol, Gujarat Shri Pradeep Kamat
Tata Iron and Steel Company Ltd, Jamshedpur Shri Sudipto Sarkar
Dr A. N. Bhagat (Alternate)
Time Technoplast Ltd, Mumbai Shri Naveen Kumar Jain
Shri Venkateshwaran N. (Alternate)
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BIS is a statutory institution established under the Bureau of Indian Standards Act, 2016 to promote harmonious
development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.
Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without
the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the
standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to
copyright be addressed to the Director (Publications), BIS.
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘BIS Catalogue’ and ‘Standards: Monthly Additions’.
This Indian Standard has been developed from Doc No.: MED 16 (11682).