OISD STANDARD - 160

FOR RESTRICTED
CIRCULATION

PROTECTION TO FITTINGS MOUNTED

ON
EXISTING LPG TANK TRUCKS

OISD - STANDARD - 160

First Edition, August, 1993

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
 OISD-STANDARD-160
First Edition
August, 1993.

FOR RESTRICTED
CIRCULATION

PROTECTION TO FITTINGS MOUNTED

ON
EXISTING LPG TANK TRUCKS

Prepared by:
COMMITTEE ON LPG TANK TRUCK MODIFICATIONS, DESIGN & OPERATION

OIL INDUSTRY SAFETY DIRECTORATE

2ND FLOOR, “KAILASH”
26, KASTURBA GANDHI MARG,
NEW DELHI - 110 001
 NOTE

OIL INDUSTRY SAFETY DIRECTORATE (OISD)

publications are prepared for use in the oil and gas industry
under the Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not
be reproduced or copied and loaned or exhibited to others
without written consent from OISD.

Though every effort has been made to assure the

accuracy and reliability of data contained in these documents,
OISD hereby expressly disclaims any liability or responsibility for
loss or damage resulting from their use.

These documents are intended only to supplement and

not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. Because of various

collaboration agreements, a variety of international codes, standards and
practices have been in vogue. Standardisation in design philosophies and
operating and maintenance practices at a national level was hardly in
existence. This, coupled with feed back from some serious accidents that
occured in the recent past in India and abroad, emphasised the need for the
industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety Directorate
(OISD) staffed from within the industry in formulating and implementing a
series of self regulatory measures aimed at removing
obsolescence,standardising and upgrading the existing standards to ensure
safe operations. Accordingly, OISD constituted a number of functional
committees of experts nominated from the industry to draw up standards
and guidelines on various subjects.

The present document on “Protection to Fittings Mounted on Existing

LPG Tank Trucks’ has been prepared by the Committee on “LPG Tank
Truck Modifications, Design and Operation’. This document was prepared
based on the accumulated knowledge and experience of industry members
and the various national and international codes and practices.

Correspondence from industry members may be addressed to:

The Co-ordinator
Committee on
LPG Tank Truck Modifications, Design and Operation
Oil Industry Safety Directorate,
2nd Floor, “Kailash”
26, Kasturba Gandhi Marg,
NEW DELHI - 110 001.
 COMMITTEE

ON

LPG TANK TRUCK MODIFICATIONS, DESIGN AND OPERATION

LIST OF MEMBERS
--------------------------------------------------------------------------------------------------------------------------------
NAME DESIGNATION/ORGANISATION STATUS
--------------------------------------------------------------------------------------------------------------------------------
S/Shri

R.K. Singh DGM (Distribution), BPCL Leader

V.K. Allawadi Chief LPG Mgr.(OPS), IOCL Member

S.V. Sahni Chief OPS, Mgr., HPCL Member

S.C. Gupta Joint Director (OISD) Member-Co-ordinator

--------------------------------------------------------------------------------------------------------------------------------
In addition to the above several other experts from industry contributed in the
preparation, review and finalisation of this document.
 PROTECTION TO FITTINGS MOUNTED ON
EXISTING LPG TANK TRUCKS

CONTENTS
------------------------------------------------------------------------------------------------------------------------
SECTION DESCRIPTION
------------------------------------------------------------------------------------------------------------------------
1.0 INTRODUCTION

2.0 SCOPE

3.0 LPG TANK TRUCK FITTINGS

3.1 OPENINGS/NOZZLES

3.2 SAFETY RELIEF VALVE (SRV)

3.3 EXCESS FLOW CHECK VALVE (EFCV)

3.4 PRESSURE GAUGE

3.5 FIXED LEVEL GAUGE/DRAIN NOZZLES

3.6 ROTO GAUGE

3.7 LIQUID/VAPOUR PIPING

3.8 HEIGHT BARRIER

3.9 MOUNTING

GLOSSARY

ANNEXURES
--------------------------------------------------------------------------------------------------------------------------------
 PROTECTION TO FITTINGS MOUNTED ON
EXISTING LPG TANK TRUCKS

1.0 INTRODUCTION
This standard stipulates actions
A large number of road fed bottling required for improving some of the
plants have been put up by the Oil Industry provisions of these rules like fittings,
during the last five years. The industry fleet pressure relief, emergency shut off valves,
of tank trucks has also increased liquid level gauging device and pressure
considerably during the last decade. gauge so as to reduce chances of accidental
damage to various fittings mounted on LPG
Prior to 1981, there were no tank truck.
separate statutory regulations governing
design, fabrication, operation and licensing Some of the recommendations
of LPG tank trucks. After introduction of envisage updating existing Standards and
SMPV Rules - 1981, old tank trucks which would require amendment of the exiting
were conforming to different codes and Statutory Rules Viz. Static and Mobile
standards have been modified to the extent Pressure Vessels (unfired) Rules 1981.
possible and new tank trucks have been
fabricated and licensed in line with the The provisions which are not in
SMPV Rules, 1981 and Petroleum Industry conformity with SMPV Rules- 1981,
Standards. therefore will be made applicable after the
Rules are formally amended.
Industry, CCEE and OISD have
been analysing LPG tank truck accidents The standard excludes new tank
from time to time. Based on the experience trucks which will be fabricated in coming
gained some modifications have already years as they will be conforming to more
been introduced on piece meal basis by the stringent standard which is currently under
Industry members individually. Various road development.
accidents involving LPG tank trucks have
established that their fittings get damaged 3.0 LPG TANK TRUCK FITTINGS
due to heavy impact in the event of an 3.1 OPENINGS/NOZZLES
accident resulting in leakage of LPG which,
in turn, poses serious threat to public life LPG tank truck is provided with the
and property. There has hardly been any following openings/nozzles:
damage to the bullets and it is the fittings
which mostly give way. I) Safety Relief valves

An OISD committee consisting of ii) Excess flow check valves in

members drawn from Oil Industry therefore the liquid and vapour lines
discussed this subject in detail and after and pressure gauge nozzle.
deliberations has identified the problems
and prepared these recommendations for iii) Pressure gauge (Provided
improvements of the existing LPG tank in the vapour space of the
truck fleet to prevent leakage of LPG in the vessel)
event of LPG tank trucks overturning on the
road. iv) Temperature gauge
(Provided in the liquid
2.0 SCOPE space)

SMPV Rules - 1981 lay down v) Rotogauge (to measure the

design, fabrication, operating procedure for percentage of liquid in the
carrying compressed gases. vessel.
 to the required torque specified
vi) Manhole with cover. for its size so as to obtain
minimum engagement of 5-6
vii) Fixed level gauge threads by hand tightening and
another 1-2 threads by spanner
viii) Drain point at the bottom. tightening.

ix) Liquid/Vapour manifold. LPG tank trucks shall carry SRV

certificates issued by Inspection
3.2 SAFETY RELIEF VALVE (SRV) Agency/Competent Persons which apart
from test date and set pressures, shall also
Each tank truck is provided with two or more include the following information:
SRVs for providing the relieving capacity
under excess pressure. The SRVs are a) The number of threads
mounted on the top surface of the vessel engaged in its coupling.
either in the recessed fittings or at the shell
level with head projecting out. In the event b) The number of threads outside
of an accident causing the tank truck to fall its coupling.
off the road and topple, there is a possibility
that Safety Relief Valves which projects out c) Torque applied for tightening.
can hit against a hard surface and get
damaged or even come out of the nozzles d) Identification mark of SRVs.
as adequate protection as envisaged in the
rules has not been provided. To prevent this 3.3 EXCESS FLOW CHECK VALVES
from happening, the following measures (EFCVs.)
shall be adopted:
Each liquid/vapour pipeline and
pressure gauge nozzle shall be provided for
I) The SRV of an LPG tank truck excess flow check valve. Excess flow
shall be provided in a recessed check valve shall be of hinge unit type or
cup formation. Alternatively, it internal flow type.
may be adequately protected by
providing a guard allround as EFCVs before fitment, shall be
per the CCE approved checked using “Go/No Go”, gauges and
procedure for modification shall be tightened to the required torque
(Ref.Annexures I and II) and specified for the size to obtain minimum
design given in Fig.No.1. engagement of 5-6 threads through hand
Suitable rain caps shall also be tightening and another 1-2 threads by
provided in case of recessed spanner tightening. In addition to operation
cup. checks on EFCV at loading/unloading basis,
EFCV shall also be examined for its proper
ii) SRV shall be replaced by a new operation alongwith SRV, once a year by
SRV every ten years. If found competent person. Each EFCV shall be
defective during any of the replaced by a new EFCV every ten years. If
earlier yearly inspections, it found defective during operation or any of
shall be replaced earlier. the earlier inspection, it shall be replaced at
that time itself i.e., earlier than ten years.
iii) Unstamped (Uncertified) SRVs
shall not be used. 3.4 PRESSURE GAUGE

iv) At the time of yearly The functional parts of EFCV of

inspection/each opening, the pressure gauge shall remain within its
threads of the valve and coupling. In addition, the pressure gauge if
coupling shall be checked by an not provided in recessed cup shall be
Inspection Agency/Competent adequately protected with a shroud.
Person using “Go/No Go”
gauges. SRV shall be tightened
3.5 FIXED LEVEL GAUGE/DRAIN and within the height regulation of Road
NOZZLES Transport Authority.

With experience these fittings have 3.9 MOUNTING

been found to be redundant. Therefore, to
minimise the openings in the tanker, these U-Bolts used for mounting of the
fittings shall be plugged (After necessary mounting of the pressure vessel on the
amendment to the SMPV Rules, 1981). chassis shall conform to ASTM 193 B7 and
Plugging shall be approved by Competent the nuts to A194 Gr.2H. The number and
Persons/Inspection Agency. size of bolts should be as per the design
requirements for the particular chassis and
load thereon.
3.6 ROTO GAUGE
GLOSSARY
These fittings shall be housed in a
recessed cup formation, when fitted on 1. The term “LPG” i.e., Liquefied
longitudinal sides of vessel to avoid any Petroleum Gas as referred in
accidental damage to bleed valve or seal. this standard refers to a
The rotogauge shall also be protected with a mixture of gaseous
provision of hinged cover of 5 mm thick hydrocarbon fractions which
plate. get into liquid phase under
pressure at ambient
3.7 LIQUID/VAPOUR PIPING temperature with a maximum
RVPof 120 psig at100Deg.
The pipes shall conform to the F(8.45 Kg/CM2g at 37.8
ASTM A-106B, schedule 80 standards. Deg.C) conforming to IS-4576.
Liquid/Vapour piping shall be single piece
and the end flanges shall be of ASA-300 2. The term “Bullet” refers to
rating. Metal jacketted gasket shall be used horizontal cylindrical pressure
for the piping system. vessels with dished ends
on LPG service.
In addition, sturdy guard shall be
provided between the propeller shaft and 3. “Inspection Agency/Competent
the elbow of the piping. Adequately strong Person” means the Agency or
arrangement shall be provided to fix the Person recognised by the
piping rigidly to the bullet/chassis to Statutory Authority for the
minimise the effect of vibrations. purpose of inspecting the
vessel and its fittings in
3.8 HEIGHT BARRIER accordance with the approved
Design, Specifications or Code
Whenever cabin height is less than and mandatory requirements.
the height of the vessel and fittings on top of
it, a height barrier shall be provided all 4. “Statutory Authority” in this
along the width of the cabin in the form of a case is normally Chief
cage either 50mm diameter pipe or 50 X 50 Controller of Explosives (CCE)
X 3 MM angle frame on the top of vessel and/or his representatives only.
 ANNEXURE - I

PROCEDURE * FOR MODIFICATION TO

EXISTING LPG ROAD TANKERS

I) Degas the storage vessel (Bullet ) taking standard safety precautions.

ii) Remove the fittings.

iii) Fabricate the pad plates/protection shroud plates/gussets plates as shown in draining B-
1382 (Rev-A). All gas out edges to be ground smoothly. Check for laminations, if any in
the plates.

iv) Weld the pad plates over the Bullet and then the shroud plates/gussets to the pad plate
strictly as shown in drg.: B-1382 (Rev-A) using low hydrogen 7018 Electrodes. Check for
thickness of weld with standard welding gauge.

v) Locally stress relieve the area around the safety fittings.

vi) Carry out pneumatic test of the bullet at 6 Kg/Cm2 after fixing all the fittings.

vii) Test all fillet welds with magnetic particle test.

viii) Hydrotest the Bullet up to test pressure.

ix) The entire work to be supervised and certified by CCOE approved third party Inspection
Agency.

* (Approved by CCE)
 ANNEUXRE -II

CALCULATIONS FOR SUITABILITY OF SHROUD AROUND SAFETY VALVES

REF. DRAWING OF SHROUD ARRANGEMENT (B 1382 REV. - 0)

DESIGN DATA : MAX.SIZE & DIA. ROAD TANKER AT 40 KMPH TOPPLING

OVER ASSUME MAX. LOADING DUE TO
MOTION=3G

TANK : 2350 mm I/D X 9254 mm Overall Length, mounted on Double

Axle Trailor

: Total Payload = 18000 Kgs (39672 lbs)

: Permissible

GLW. = 35000 Kgs (77140 lbs)

EFFECTIVE WEIGHT : GLW-(Wt.of Cabin + Prime Mover + Vth Wheel)

= 35000 Kgs.
(-) 6000 Kgs.
= 29000 Kgs. = (63916) lbs)

SHROUD - MOC : CS A 515 Gr.70, Shear Stress 1/3 of UTS

: i.e, 1/3 of 70,000 psi

: Stress Value “S”
: Length “L” 1000mm = 40”
: Width ‘B’ 600 mm = 24”

:’E’ = Joint efficiency for butt weld (CI UW - 12)

= 0.6

: R = Height of shroud above C.G. of Tank

= 50”

THICKNESS ‘’t’’ UNDER : 3XW

t= ------------------------ (3G effect)
2(L + B) X S X E
 : = 3 X 63916
----------------------------------- = 0.107”=2.7mm.....(1)
2(40+20) X 23333 X 0.6
‘‘t” DUE TO THE BENDING
MOMENT : WxR 63916 x 50
-------------------- = ---------------------------
(L x B)XSXE 960 X 23333 X 0.6

= 2237 = 6.04 mm ......(2)

TOTAL THICKNESS REQUIRED =2.7+6.04 = 8.74mm
Provided 10mm (Safe)

CALCULATIONS FOR SUITABILITY OF SHROUD AROUND SAFETY VALVES

REV
DATE: 21-3-92 A-1504
0