Operation And Safety lpg with operating instructions 26June 25.pdf

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Operation And Safety
Of
LPG Storage And Filling Plant
By: Zaheer Sajid
June 2025

Operation & Safety of LPG Storage And Filling Plant
1. Introduction to LPG
2. LPG Flow Chart- Pictorial
3. LPG Storage & Filling Plant Overview
4. LPG Storage & Filling Plant Process
Flow
5. LPG Storage & Filling Plant -Pictorial
6. Major Equipment Used in LPG
Storage & Filling Plant
7. Major Equipment Used in LPG
Storage & Filling Plant-Pictorial
8. Safety Measures in LPG Storage &
Filling Plant Operation
9. Safety Measures in LPG Storage &
Filling Plant Operation-Pictorial
2/23
Table of content
10. LPG Storage & Filling Plant
Operation & Maintenance plan
11. LPG Storage & Filling Plant
Operation & Maintenance-Pictorial
12. Environmental Considerations
13. Communication Protocol
14. Responsibilities- Plant Manager
15. Responsibilities-Supervisor
16. Responsibilities- Operators
17. Operating Instructions
18. Emergency response plan (ERP)
19. Evacuation plan

1. Extraction of LPG is carried out by separating propane and butane in
liquid form at moderate pressure or low temperature from natural gas
or crude oil, followed by purification and separation into its component
gases, which are then stored and distributed.
2. LPG is a mixture of hydrocarbons, primarily propane and butane, is
gaseous at normal atmospheric pressure, but may be condensed to the
liquid state at normal temperature, by the application of moderate
pressures. Although they are normally used as gases, they are stored
and transported as liquids under pressure for convenience and ease of
handling.
3. Uses of LPG includes fuel for cooking, heating, power generation,
vehicles, running production machinery etc.
4. LPG can be stored in cylinders or tanks, easy transportation & storage
and readily availability makes it widely used energy source.
5. LPG is considered a safe fuel when used properly and stored in
accordance with safety guidelines.
3/23
1. Introduction to LPG

Operation & Safety of LPG Storage And Filling Plant 4/23
Crude Pipeline
Extraction Plant Storage at
Extraction
Plant
Shipment to Bulk Storage Terminal Transport by
pipeline to Bulk
Storage Terminal
Storage at Bulk Storage
Terminal
Transport to LPG Bottling Plant by
bowser
Storage at LPG Storage & Filling
Plant
Cylinder Filing
Transport by distributor
Consumer
2. LPG Flow - Pictorial

a. From LPG Production Plants and the Bulk Storage Terminals, the LPG is transported by
pipelines or otherwise by bulk tankers to the LPG Storage & Filling Plants.
a. LPG Storage & Filling Plant receives and stores LPG, fills LPG in portable cylinders for
distribution, ensuring a steady supply of LPG to the area consumers through
distributors.
b. LPG Storage & Filling Plants are the facilities which covers the supply of LPG in specified
region and area.
c. LPG Storage & Filling Plants location and layout of a filling plant primarily driven by
current and projected consumer demand.
d. The basic operations at the LPG Storage & Filling Plant is receiving of LPG by LPG
Bowser, decanting it and transferring to the Plant’s LPG Storage Tank, Filling of LPG
Cylinders and handing over to the distributor, the required necessary pre and post
checks are performed as per SOP.
e. LPG Storage & Filling Plant enables the most efficient and safe distribution of LPG,
ensuring steady and reliable supply to the consumers in manageable quantities, making
it accessible for domestic, commercial and industrial use in the most convenient way.
3. LPG Storage & Filling Plant Overview

LPG
Production
plant
Transportation
by Pipeline,
Sea , Road
Storage at Bulk
Storage Terminal
/ Facility
Transportation
to LPG Storage
& Filling Plant
Storage
at LPG
Storage
& Filling
Plant
Collection of Empty cylinders from
consumers
Transportation of empty LPG
Cylinders through distributors
Filling of LPG in Cylinders
Transportation of Filled LPG Cylinders through
distributors
Distribution of Filled LPG Cylinders to consumers
4. LPG Storage & Filling Plant Process Flow

Receipt of LPG by Bowser
& Decanting
Storage of LPG
Checking of Empty Cylinders
Filling of LPG Cylinders
Transportation by
Distributor
5. LPG Storage & Filling Plant -Pictorial

a. LPG Storage Tank/Tanks (Spherical or Horizontal shape)
b. Bowser decanting Pumps and Compressor
c. Pumps for transfer of LPG to Cylinder Filling machines
d. Cylinder Filling machines
e. Fire water Pump sets
f. Air Compressor
g. Standby Generator
h. Fire Water network and fire safety system
i. Product Piping system
j. Emergency Shut down system
k. Earthing / grounding system
l. Electrical Power distribution system
m. Fire & Gas detection system
n. Cylinder inspection and testing system
6. Major Equipment Used in LPG Storage & Filling Plant

LPG Storage Tanks Cylinder Filling
Machines
Pneumatic
Actuator
Emergency
Shut Down
Switch (ESD)
Bowser Decanting Compressor & Pump Cylinder Filling Pump (PSV) Pressure
Safety Valve
Piping System
Fire Water Pump Sets and Storage Tank LPG Transfer Hoses Standby Generator Pull Away Coupling
7. Major Equipment at LPG Storage & Filling Plants-Pictorial
(MCS) Motor
Control
Switch

a. Fire water storage tank with minimum 2 hours water storage, provision and
replenishment with reference to fire pump flow rate. Auto and manual actuated fire
pump sets, a combination of Main pump, standby pump and jockey pump.
b. Fire water storage tank and fire water network, ring main with sectional isolation valves.
covering complete licensed area including LPG storage Tanks, bowser decanting area,
cylinder filling area etc.
c. Manual and auto actuated water sprinkle system at LPG storage tanks. Manual water
sprinkle system at bowser decanting and cylinder filling areas.
d. At the LPG handling and storage areas, Leak detection and prevention systems,
Ventilation are in-place, emergency shout down switches are prominently marked and
fire safety , Emergency shutdown procedures are displayed.
e. At the LPG handling and storage areas, Leak detection and prevention systems, Fire
extinguishers are place on the entire plant premises, including security check post,
entrance and egress, administration block, LPG handling, operation and storage area.
f. All individual components and each type of fire protection and emergency equipment
that exist on site are identified on the plot plan and listed in the table for reference.
Equipment Description, quantity, Emergency Shutoff Valve, Container Internal Valve, Fire
Extinguisher/Hydrant/Monitor/ Water Sprinkler Systems, Main Electrical Panel,
Emergency plant egress (Gates) Points.
8. Safety Measures in LPG Storage & Filling Plant Operation

Fire water network, auto and manual actuated fire water sprinkler system
11/23
Fire alarm / hooter Fire fighting equipment Fire & Gas Detectors
MCS, MCP &
ESD
Waring Signs &
instructions
Fire water storage tank above ground / underground, fire pump house and fire pump sets
9. Safety Measures in LPG Storage & Filling Plant Operation-Pictorial

LPG Plant operations and maintenance involves various technical activities viz.
receipt of LPG through bowsers, transfer of LPG from bowser to Bulk Storage Tanks
& storage in Bulk tanks, Receipt of empty Cylinders, Quality checks of empty
cylinders, Filling of LPG Cylinders, quality & quantity Checks of Filled Cylinders,
Dispatch of Cylinders to market.
Maintenance of the plant:
d. Corrosion and deterioration: LPG Piping system, fire water piping system,
pump, storage vessels and etc.
e. Safety: Fire alarm, hooter, fire water storage level
f. Damaged cylinders - valves on LPG cylinders, sign of any damage, indent,
corrosion, date of revalidation
a. Hoses: Checking of Bowser decanting & cylinder filling hoses for signs of
cracks or leak and if they are suitably clamped
b. Grounding/earthing: Examining that the cable is linked to storage tank,
pumps and filling machines and in satisfactory condition
c. Operations of items: Such as level/pressure/temperature indicators, valves,
PSV, HRV and etc. Safety devices such as Gas detectors, ESDV, fire pumps,
standby generator, water sprinklers and similar items
10. LPG Storage & Filling Plant Operation & Maintenance

Checking of Hoses
13/23
Checking & periodic testing/calibration of gauges, valves, equipment & earthing system
Regular Fire Drill, checking and maintenance of alarm, F & G system, sprinklers etc.
Corrosion protection/Painting maintenance, check for leakages etc.
11. LPG Storage & Filling Plant Operation & Maintenance-Pictorial

a. Since, the complete system is closed loop, no impact is expected on the topography
during operations.
b. The storage facilities is equipped with leak detection systems. The air may have
minimal impact due to vehicular movement for receipt and dispatch.
c. Noise is generated from operation of pumps, DG sets and during vehicular movement.
The mitigation measures include acoustic enclosures for DG Sets is provided.
Provision of ear plugs for workers in high noise area, also green belts and landscaping
shall act as noise buffer. Ecological impacts as a result of the operation of the facility
are considered to be almost negligible.
d. Regular condition monitoring e.g. speed, vibration and regular preventive
maintenance including schedule lubrication will be done for the moving machines to
keep them in good condition and also to reduce noise and vibration.
e. Solid waste will be disposed through local bodies. Spent lube oil from D.G. set &
sludge from storage vessels will be disposed, accordingly. Hence no impact on flora
and fauna is. There will be no effluent discharge in the water body. Thus there is no
impact on the aquatic biota present in vicinity of proposed project.
f. There is no waste water generation from operation.
12. Environmental Consideration

CEO / MD
Supply Chain
Manager
Plant
Manager
Supervisor
Operators
LPG Producer
/ Importer
LPG Bulk
Transporter
Licensing
Authorities
Local
Authorities
Other Plant
Managers
in the area
Workers
LPG
Distributors
13. Communication Protocol

a. Fully responsible for overseeing all operations,
safety, logistics, and personnel management
related to the LPG storage and distribution of LPG
cylinders.
a. Interface with the head office, Licensing
authorities and local authorities.
b. Ensure compliance with safety, quality, and
regulatory standards.
c. Supervise staff and manage plant resources.
d. Ensure production targets are met.
e. Oversee daily plant operations, including receipt,
storage, and dispatch.
f. Manage product inventory, quality control, and
distribution
g. Coordinate Logistics and distribution to ensure
timely and accurate deliveries.
h. Maintain logs, permits, audits, and reports for
internal and external stakeholders.
14. Responsibilities-Plant Manager
i. Enforce approved SOPs.
j. Conduct/Arrange training for staff on
operating and emergency procedures.
Lead and monitor emergency response
planning and drills for different scenarios
i.e. fire, spill, evacuation, etc. Post-drill
evaluation and improvement plans.
k. Ensure asset integrity through inspections
and preventive maintenance programs.
Arrange calibration, inspections, and
audits. Ensure availability of critical
spares.
l. Represent the plant in local forums,
audits, or legal matters as required.
m. Investigate incidents, document it and
implement corrective actions to avoid
reoccurrence.

a. Report to the Plant Manager.
b. Overseeing Plant operations, ensuring safety
and compliance, managing personnel, and
supporting smooth terminal activities.
c. Direct and assign work to terminal operators,
loaders, and maintenance crews.
d. Supervise receipt of LPG by bowser, decanting
of bowser, Storage at plant, receiving of empty
cylinders, filling of cylinders and dispatch from
plant to distributors..
e. Ensure operation of plant as per approved
SOPs.
f. Ensure proper decanting of LPG bowser,
storage of LPG in Tanks, checking and
loading/unloading of LPG cylinders.
g. Maintain daily logs and operational records
(e.g., receiving of LPG bowser, tank levels,
cylinder receipt and dispatch, incidents).
h. Ensure that plant operations meet daily delivery
targets.
15. Responsibilities-Supervisor
i. Maintain logbooks, report equipment
issues and records of maintenance
schedules.
j. Perform preventive and corrective
maintenance.
k. Troubleshoot breakdowns on piping
system and equipment.
l. Maintain Ensure availability of critical
spares.
m. Conduct safety drills, inspections, and
audits.
n. Enforce safety procedures and ensure
workers comply with HSE standards and
monitor hazardous zones.
o. Conduct toolbox talks, safety briefings,
and near-miss reporting.
p. Provide on-the-job training, guidance to
junior staff.

a. Operate and monitor LPG transfer, storage and
filling equipment.
b. Ensure PPE compliance and safe work practices
at all times.
c. Perform regular leak checks and quality control
of the plant components.
d. Check earthing and grounding.
e. Monitor and manage environmental controls
(e.g., spill containment).
f. Monitor tank levels, temperatures, and
pressures using gauges or digital systems
g. Monitor and maintain equipment operations
such as pumps, valves, filling machines and
report equipment malfunctions, issues or
abnormal operations promptly.
h. Ensure proper decanting of LPG bowser, storage
of LPG, loading/unloading of LPG cylinders.
i. and enforce strict safety procedures to prevent
spills, fires, or explosions.
16. Responsibilities-Operators
m. Support emergency response actions and
participate in drills.
n. Assist with preventive maintenance,
corrective maintenance and minor repairs.
o. Follow and enforce strict safety procedures
to prevent spills, fires, or explosions.
p. Monitor and manage environmental controls
(e.g., spill containment).
q. Monitor and control access to the depot.
r. Ensure compliance with anti-theft and anti-
tampering protocols.
s. Collaborate with security personnel and
surveillance systems
t. Communicate effectively with team members
and management

17, Operating Instruction
Bowser Decanting
Instructions
1. A qualified Operator must be in attendance at all
times during unloading
2. Inspect the transfer area, before giving driver the
signal to enter the plant area...
3. Set the brakes, turn off engine & all electrical
devices.
4. Set the chock blocks at the front and back of one of
the tractor drive wheels
5. Connect the earthing system the bowser..
6. Check the operation of the ESVs (Emergency Shut
down Valve) and pull-a-way protection installed in
the plant. If the ESVs will not operate properly, do
not continue the transfer operation.
7. Check the condition of transfer Hoses and
connectors. Do not connect if the condition is not
satisfactory
8. Check the manual shutoff valves on the transport
liquid and vapor connections to be sure they are
fully closed.
9. Check the temperature, pressure & liquid level of
storage tank and bowser.
10. Connect bowser vapor and liquid lines with storage
tank, in sequence and open valve of vapor balance
line.
11. When the vapor is balanced then open the valve of
liquid line & start transfer by pump / compressor.
12. Confirm the transfer of LPG, Turn of the
pump/compressor, note the temperature, pressure
& liquid level. Close all open valves. Release LPG
trapped in the hose pipe before disconnecting the
hoses.
13. Fill out any company inventory forms and process
them as required
14. Move the bowser only after it has been determined
the path is clear and any discharge of propane has
dissipated.
Cylinder Filling
Instructions
1. Only qualified operators to perform the activity.
2. Prior to filling cylinders at the plant, cylinders that
have been in service must be inspected to determine
their fitness for continued service..
3. Visually inspect the outside of the cylinder for a crack
or leak, bulging, a defective valve, a leaking or
defective pressure relief device, evidence of physical
abuse, fire or heat damage& detrimental rusting or
corrosion.
4. If the cylinder is good for fill then it lift up on the
filling line.
5. Cylinders must be arranged so that any cylinder can
be accessed in the event of a service valve or other
leak.
6. When new cylinders arrive at plant, they should be
inspected to ensure that they are not damaged
during transportation and are acceptable for LPG
service.
7. Carry out filling of cylinders as per capacity.
8. Detect of LPG filled cylinder valve leak if fail then sent
it to the dedicated area in order to remove or replace
the valve.
9. Put safety seal on valve on LPG filled cylinder and
then keep storage for distribution.
10. Ensure Cylinders are filled at a rate which prevents
excessive temperature rises.
11. In the event of any leakage, then filling is to be
immediately stopped and notified.
12. A check of the pressure / weight. The cylinder shall be
within its safe operating limits. It shall not be
overfilled or over pressurized. Any excess gas shall be
removed in a safe manner and the cylinder checked
for continued fitness for service.
13. Filling records shall be maintained.
.
LPG Pump / Compressor
Operating Instructions
1. A qualified Operator must be in attendance at all
times during operation.
2. Position himself nearby to the MCS (Motor Control
Switch).
3. Ensure the availability of fire extinguishers.
4. Verify valve positions (inlet/outlet isolation valves).
5. Inspect piping, flanges, and joints for signs of damage
or leaks.
6. Ensure emergency stop systems are functional.
7. Check for proper earthing & bonding of equipment..
8. Check the temperature, pressure and liquid level of
the tank from / to which the transfer is required
9. Check with the operator in the LPG bowser decanting
area / cylinder filling area.
10. Be alert for signs of erratic pump operation. If a leak
or fire develops, perform emergency shutdown
action.
11. Listen for any unusual pump/compressor noise.
Check for any overheating.
12. In case of any abnormality, inform maintenance team
and Supervisor or plant manager. Do not restart until
problem is diagnosed & resolved.
13. Periodically Check & note the pressure , temperature
& liquid level during the entire operation.
14. Await for the signal to turn the pump on.
15. When signaled by the other area operation turn off
the pump / compressor.
16. Do not use electrical devices near the leak site.
17. In case of emergency shut down, do not restart until
cleared by authorized personnel.
18. Ensure pump/compressor stops safely on power loss.
Do not attempt restart until power is stable and
system is inspected. Verify all systems are reset and
safe before resuming.

17, Operating Instruction-Urdu
.
‫ہدایات‬ ‫کی‬ ‫بھرنے‬ ‫سلنڈر‬
‫دیں۔‬ ‫انجام‬ ‫آپریٹرز‬ ‫یافتہ‬ ‫تربیت‬ ‫اور‬ ‫مستند‬ ‫صرف‬ ‫کام‬ ‫یہ‬
‫جو‬ ‫جائے‬ ‫کیا‬ ‫معائنہ‬ ‫کا‬ ‫سلنڈرز‬ ‫ن‬ُ‫ا‬ ،‫پہلے‬ ‫سے‬ ‫بھرنے‬ ‫سلنڈر‬ ‫میں‬ ‫پالنٹ‬
‫استعمال‬ ‫دوبارہ‬ ‫وہ‬ ‫کہ‬ ‫سکے‬ ‫جا‬ ‫جانا‬ ‫یہ‬ ‫تاکہ‬ ‫ہوں‬ ‫چکے‬ ‫ہو‬ ‫استعمال‬ ‫پہلے‬
‫نہیں۔‬ ‫یا‬ ‫ہیں‬ ‫قابل‬ ‫کے‬
‫ک‬ ‫نقائص‬ ‫ذیل‬ ‫درج‬ ‫تاکہ‬ ‫کریں‬ ‫معائنہ‬ ‫بصری‬ ‫کا‬ ‫حصے‬ ‫بیرونی‬ ‫کے‬ ‫سلنڈر‬
‫ا‬
‫سکے‬ ‫جا‬ ‫چالیا‬ ‫پتا‬:
‫ساؤ‬ ِ
‫ر‬ ‫یا‬ ‫دراڑ‬,‫والو‬ ‫ناقص‬ ‫یا‬ ‫خراب‬
‫ڈیوائس‬ ‫ریلیف‬ ‫پریشر‬ ‫ناقص‬ ‫یا‬ ‫ہوا‬ ‫ہوتا‬ ‫لیک‬
,‫عالمات‬ ‫کی‬ ‫پھولنے‬
‫نشانات‬ ‫کے‬ ‫پیٹ‬ ‫مار‬ ‫یا‬ ‫نقصان‬ ‫جسمانی‬
‫نقصان‬ ‫سے‬ ‫حرارت‬ ‫یا‬ ‫آگ‬
‫سنکنرن‬ ‫یا‬ ‫زنگ‬ ‫دہ‬ ‫نقصان‬
‫جائے۔‬ ‫اٹھایا‬ ‫پر‬ ‫الئن‬ ‫فلنگ‬ ‫اسے‬ ‫تو‬ ‫ہو‬ ‫قابل‬ ‫کے‬ ‫بھرنے‬ ‫سلنڈر‬ ‫اگر‬
‫س‬ ‫آسانی‬ ‫تک‬ ‫سلنڈر‬ ‫بھی‬ ‫کسی‬ ‫کہ‬ ‫جائے‬ ‫رکھا‬ ‫سے‬ ‫ترتیب‬ ‫اس‬ ‫کو‬ ‫سلنڈرز‬
‫ے‬
‫ہو۔‬ ‫لیکج‬ ‫سے‬ ‫جگہ‬ ‫اور‬ ‫کسی‬ ‫یا‬ ‫والو‬ ‫اگر‬ ‫پر‬ ‫طور‬ ‫خاص‬ ،‫ہو‬ ‫ممکن‬ ‫رسائی‬
‫یقین‬ ‫یہ‬ ‫تاکہ‬ ‫جائے‬ ‫کیا‬ ‫معائنہ‬ ‫کا‬ ‫ان‬ ‫تو‬ ،‫آئیں‬ ‫میں‬ ‫پالنٹ‬ ‫سلنڈر‬ ‫نئے‬ ‫جب‬
‫ی‬
‫پی‬ ‫ایل‬ ‫اور‬ ‫ہوئے‬ ‫نہیں‬ ‫خراب‬ ‫دوران‬ ‫کے‬ ‫حمل‬ ‫و‬ ‫نقل‬ ‫وہ‬ ‫کہ‬ ‫سکے‬ ‫جا‬ ‫بنایا‬
‫ہیں۔‬ ‫موزوں‬ ‫لیے‬ ‫کے‬ ‫سروس‬ ‫جی‬
‫جائے۔‬ ‫بھرا‬ ‫مطابق‬ ‫کے‬ ‫گنجائش‬ ‫مقررہ‬ ‫کی‬ ‫ن‬ُ‫ا‬ ‫کو‬ ‫سلنڈرز‬
،‫چلے‬ ‫پتہ‬ ‫کا‬ ‫ہونے‬ ‫لیک‬ ‫جی‬ ‫پی‬ ‫ایل‬ ‫سے‬ ‫والو‬ ‫کے‬ ‫سلنڈر‬ ‫گئے‬ ‫بھرے‬ ‫اگر‬
‫مرمت‬ ‫کر‬ ‫نکال‬ ‫کو‬ ‫والو‬ ‫تاکہ‬ ‫جائے‬ ‫بھیجا‬ ‫میں‬ ‫عالقے‬ ‫مخصوص‬ ‫سے‬ُ‫ا‬ ‫تو‬
‫سکے۔‬ ‫جا‬ ‫کی‬ ‫تبدیلی‬ ‫یا‬
‫اور‬ ‫جائے‬ ‫لگایا‬ ‫سیل‬ ‫حفاظتی‬ ‫پر‬ ‫والو‬ ‫کے‬ ‫سلنڈر‬ ‫جی‬ ‫پی‬ ‫ایل‬ ‫گئے‬ ‫بھرے‬
‫جائے۔‬ ‫رکھا‬ ‫لیے‬ ‫کے‬ ‫تقسیم‬ ‫کے‬ ‫کر‬ ‫ذخیرہ‬ ‫اسے‬ ‫پھر‬
‫درجہ‬ ‫کہ‬ ‫جائے‬ ‫بھرا‬ ‫سے‬ ‫رفتار‬ ‫ایسی‬ ‫کو‬ ‫سلنڈر‬ ‫کہ‬ ‫جائے‬ ‫بنایا‬ ‫یقینی‬ ‫یہ‬
‫ہو۔‬ ‫نہ‬ ‫اضافہ‬ ‫ضروری‬ ‫غیر‬ ‫میں‬ ‫حرارت‬
‫او‬ ‫جائے‬ ‫دیا‬ ‫روک‬ ‫عمل‬ ‫کا‬ ‫فلنگ‬ ً‫ا‬‫فور‬ ‫تو‬ ‫ہو‬ ‫لیکج‬ ‫کی‬ ‫قسم‬ ‫بھی‬ ‫کسی‬ ‫اگر‬
‫ر‬
‫جائے۔‬ ‫دی‬ ‫اطالع‬ ‫کو‬ ‫حکام‬ ‫متعلقہ‬
‫ہونا‬ ‫اندر‬ ‫کے‬ ‫حد‬ ‫آپریٹنگ‬ ‫محفوظ‬ ‫سلنڈر‬ ‫جائے۔‬ ‫کی‬ ‫جانچ‬ ‫کی‬ ‫وزن‬ ‫اور‬ ‫دباؤ‬
‫مقدار‬ ‫کی‬ ‫گیس‬ ‫اگر‬ ‫ہو۔‬ ‫دباؤ‬ ‫زیادہ‬ ‫ہی‬ ‫نہ‬ ‫اور‬ ‫جائے‬ ‫بھرا‬ ‫زیادہ‬ ‫تو‬ ‫نہ‬ ‫چاہیے۔‬
‫مزید‬ ‫کی‬ ‫سلنڈر‬ ‫اور‬ ‫جائے‬ ‫نکاال‬ ‫سے‬ ‫طریقے‬ ‫محفوظ‬ ‫اسے‬ ‫تو‬ ‫ہو‬ ‫زیادہ‬
‫جائے۔‬ ‫کی‬ ‫جانچ‬ ‫لیے‬ ‫کے‬ ‫استعمال‬
‫جائے۔‬ ‫رکھا‬ ‫ریکارڈ‬ ‫مکمل‬ ‫کا‬ ‫فلنگ‬
‫پمپ‬ ‫جی‬ ‫پی‬ ‫یل‬
/
‫کمپریسر‬ I
‫ہدایات‬ ‫کی‬ ‫چالنے‬
‫کی‬ ‫آپریٹر‬ ‫یافتہ‬ ‫تربیت‬ ‫اور‬ ‫مستند‬ ‫ایک‬ ‫وقت‬ ‫ہر‬ ‫دوران‬ ‫کے‬ ‫آپریشن‬
‫ہے۔‬ ‫الزمی‬ ‫موجودگی‬
‫سوئچ‬ ‫کنٹرول‬ ‫موٹر‬ ‫کو‬ ‫آپریٹر‬ (MCS) ‫چاہیے۔‬ ‫رہنا‬ ‫موجود‬ ‫قریب‬ ‫کے‬
‫جائے۔‬ ‫بنایا‬ ‫یقینی‬ ‫کو‬ ‫دستیابی‬ ‫کی‬ ‫ایکسٹنگوشرز‬ ‫فائر‬
‫پوزیشن‬ ‫کی‬ ‫والو‬
(
‫انلیٹ‬
/
‫والوز‬ ‫آئسولیشن‬ ‫لیٹ‬ ‫آؤٹ‬
)
‫کریں۔‬ ‫چیک‬ ‫کو‬
‫نق‬ ‫کے‬ ‫قسم‬ ‫کسی‬ ‫تاکہ‬ ‫کریں‬ ‫معائنہ‬ ‫کا‬ ‫جوائنٹس‬ ‫اور‬ ،‫فلینجز‬ ،‫پائپنگ‬
‫یا‬ ‫صان‬
‫سکے۔‬ ‫جا‬ ‫چالیا‬ ‫پتہ‬ ‫کا‬ ‫لیکیج‬
‫کریں‬ ‫تصدیق‬ ‫کی‬ ‫کرنے‬ ‫کام‬ ‫پر‬ ‫طور‬ ‫درست‬ ‫کے‬ ‫سسٹمز‬ ‫اسٹاپ‬ ‫ایمرجنسی‬
‫۔‬
‫کریں۔‬ ‫چیک‬ ‫کو‬ ‫بانڈنگ‬ ‫اور‬ ‫ارتھنگ‬ ‫مناسب‬ ‫کی‬ ‫سامان‬
،‫حرارت‬ ‫درجہ‬ ‫کے‬ ‫اس‬ ،‫ہے‬ ‫کرنا‬ ‫ٹرانسفر‬ ‫میں‬ ‫جس‬ ‫یا‬ ‫سے‬ ‫ٹینک‬ ‫جس‬
‫کریں۔‬ ‫جانچ‬ ‫کی‬ ‫سطح‬ ‫مائع‬ ‫اور‬ ،‫دباؤ‬
‫ایریا‬ ‫ڈیکینٹنگ‬ ‫باؤزر‬ ‫جی‬ ‫پی‬ ‫ایل‬
/
‫آپریٹ‬ ‫موجود‬ ‫میں‬ ‫ایریا‬ ‫فلنگ‬ ‫سلنڈر‬
‫ر‬
‫کریں۔‬ ‫رابطہ‬ ‫سے‬
‫لیک‬ ‫کوئی‬ ‫اگر‬ ‫دیں۔‬ ‫توجہ‬ ‫پر‬ ‫اشاروں‬ ‫کے‬ ‫کارکردگی‬ ‫معمولی‬ ‫غیر‬ ‫کی‬ ‫پمپ‬
‫ڈاؤن‬ ‫شٹ‬ ‫ایمرجنسی‬ ‫پر‬ ‫طور‬ ‫فوری‬ ‫تو‬ ،‫آئے‬ ‫پیش‬ ‫صورت‬ ‫کی‬ ‫لگنے‬ ‫آگ‬ ‫یا‬
‫دیں۔‬ ‫انجام‬ ‫عمل‬ ‫کا‬
‫بھی‬ ‫کسی‬ ‫دیں۔‬ ‫دھیان‬ ‫پر‬ ‫آوازوں‬ ‫معمولی‬ ‫غیر‬ ‫کی‬ ‫کمپریسر‬ ‫یا‬ ‫پمپ‬
‫کریں۔‬ ‫معائنہ‬ ‫میں‬ ‫صورت‬ ‫کی‬ ‫اوورہیٹنگ‬
‫کو‬ ‫مینیجر‬ ‫پالنٹ‬ ‫یا‬ ‫سپروائزر‬ ،‫ٹیم‬ ‫مرمت‬ ‫تو‬ ‫ہو‬ ‫ظاہر‬ ‫خرابی‬ ‫کوئی‬ ‫اگر‬
‫کی‬ ‫چالنے‬ ‫دوبارہ‬ ‫تک‬ ‫ہونے‬ ‫حل‬ ‫پر‬ ‫طور‬ ‫مکمل‬ ‫مسئلہ‬ ‫دیں۔‬ ‫اطالع‬ ً‫ا‬‫فور‬
‫کریں۔‬ ‫نہ‬ ‫کوشش‬
‫سطح‬ ‫کی‬ ‫مائع‬ ‫اور‬ ‫حرارت‬ ‫درجہ‬ ،‫دباؤ‬ ‫سے‬ ‫وقفے‬ ‫وقفے‬ ‫آپریشن‬ ِ‫دوران‬
‫رہیں۔‬ ‫کرتے‬ ‫نوٹ‬ ‫اور‬ ‫جانچ‬ ‫کی‬
‫کریں۔‬ ‫انتظار‬ ‫کا‬ ‫سگنل‬ ‫سے‬ ‫ایریا‬ ‫دوسرے‬ ‫لیے‬ ‫کے‬ ‫کرنے‬ ‫آن‬ ‫کو‬ ‫پمپ‬
‫پمپ‬ ‫پر‬ ‫سگنل‬ ‫کے‬ ‫ایریا‬ ‫دوسرے‬
/
‫کریں۔‬ ‫بند‬ ‫کو‬ ‫کمپریسر‬
‫کریں۔‬ ‫نہ‬ ‫استعمال‬ ‫آالت‬ ‫برقی‬ ‫کوئی‬ ‫قریب‬ ‫کے‬ ‫جگہ‬ ‫والی‬ ‫لیک‬
‫بغیر‬ ‫کے‬ ‫منظوری‬ ‫کی‬ ‫عملے‬ ‫مجاز‬ ،‫میں‬ ‫صورت‬ ‫کی‬ ‫ڈاؤن‬ ‫شٹ‬ ‫ایمرجنسی‬
‫کریں۔‬ ‫نہ‬ ‫شروع‬ ‫دوبارہ‬
‫پمپ‬ ‫تو‬ ‫جائے‬ ‫ہو‬ ‫بند‬ ‫بجلی‬ ‫اگر‬
/
‫ہون‬ ‫بند‬ ‫سے‬ ‫طریقے‬ ‫محفوظ‬ ‫کا‬ ‫کمپریسر‬
‫ا‬
‫اسے‬ ‫تک‬ ‫معائنے‬ ‫مکمل‬ ‫کے‬ ‫سسٹم‬ ‫اور‬ ‫بحالی‬ ‫کی‬ ‫بجلی‬ ‫ہے۔‬ ‫ضروری‬
‫کے‬ ‫تصدیق‬ ‫کی‬ ‫ہونے‬ ‫محفوظ‬ ‫اور‬ ‫سیٹ‬ ‫مکمل‬ ‫کے‬ ‫سسٹم‬ ‫چالئیں۔‬ ‫نہ‬ ‫دوبارہ‬
‫کریں۔‬ ‫شروع‬ ‫آپریشن‬ ‫دوبارہ‬ ‫ہی‬ ‫بعد‬
‫ڈیکینٹنگ‬ ‫باؤزر‬
‫ہدایات‬
‫ڈیکینٹنگ‬
‫آپریٹ‬ ‫یافتہ‬ ‫تربیت‬ ‫اور‬ ‫مستند‬ ‫ایک‬ ‫وقت‬ ‫ہر‬ ‫دوران‬ ‫کے‬
‫ر‬
‫ہے۔‬ ‫الزمی‬ ‫موجودگی‬ ‫کی‬
‫پہلے‬ ‫سے‬ ‫دینے‬ ‫سگنل‬ ‫کا‬ ‫داخلے‬ ‫میں‬ ‫ایریا‬ ‫پالنٹ‬ ‫کو‬ ‫ڈرائیور‬
‫کریں۔‬ ‫معائنہ‬ ‫مکمل‬ ‫کا‬ ‫ایریا‬ ‫ٹرانسفر‬
‫دیں۔‬ ‫کر‬ ‫بند‬ ‫آالت‬ ‫برقی‬ ‫تمام‬ ‫اور‬ ‫کریں‬ ‫بند‬ ‫انجن‬ ،‫لگائیں‬ ‫بریک‬
‫اور‬ ‫آگے‬ ‫کے‬ ‫وہیل‬ ‫ڈرائیو‬ ‫ایک‬ ‫کسی‬ ‫کے‬ ‫ٹریکٹر‬ ‫کو‬ ‫بالکس‬ ‫چاک‬
‫رکھیں۔‬ ‫پیچھے‬
‫جوڑیں۔‬ ‫سے‬ ‫سسٹم‬ ‫ارتھنگ‬ ‫کو‬ ‫باؤزر‬
‫والوز‬ ‫ڈاؤن‬ ‫شٹ‬ ‫ایمرجنسی‬ ‫نصب‬ ‫میں‬ ‫پالنٹ‬ (ESVs) ‫پل‬ ‫اور‬
-
‫اگر‬ ‫کریں۔‬ ‫چیک‬ ‫کارکردگی‬ ‫کی‬ ‫پروٹیکشن‬ ‫اوے‬ ESVs ‫درست‬
‫رکھیں۔‬ ‫نہ‬ ‫جاری‬ ‫آپریشن‬ ‫ٹرانسفر‬ ‫تو‬ ‫رہے‬ ‫کر‬ ‫نہیں‬ ‫کام‬
‫حالت‬ ‫اگر‬ ‫کریں۔‬ ‫معائنہ‬ ‫کا‬ ‫حالت‬ ‫کی‬ ‫کنیکٹرز‬ ‫اور‬ ‫ہوزز‬ ‫ٹرانسفر‬
‫کریں۔‬ ‫مت‬ ‫کنیکشن‬ ‫تو‬ ‫ہو‬ ‫نہ‬ ‫بخش‬ ‫تسلی‬
‫مائع‬ ‫کے‬ ‫ٹرانسپورٹ‬ (liquid) ‫ویپر‬ ‫اور‬ (vapor) ‫پر‬ ‫کنیکشنز‬
‫ہوں۔‬ ‫بند‬ ‫مکمل‬ ‫وہ‬ ‫تاکہ‬ ‫کریں‬ ‫چیک‬ ‫والوز‬ ‫آف‬ ‫شٹ‬ ‫دستی‬
‫سطح‬ ‫مائع‬ ‫اور‬ ‫دباؤ‬ ،‫حرارت‬ ‫درجہ‬ ‫کا‬ ‫باؤزر‬ ‫اور‬ ‫ٹینک‬ ‫اسٹوریج‬
‫کریں۔‬ ‫چیک‬
‫ٹ‬ ‫اسٹوریج‬ ‫کو‬ ‫الئنوں‬ ‫مائع‬ ‫اور‬ ‫ویپر‬ ‫کی‬ ‫باؤزر‬ ‫ساتھ‬ ‫کے‬ ‫ترتیب‬
‫ینک‬
‫کھولیں۔‬ ‫والو‬ ‫کا‬ ‫الئن‬ ‫بیلنس‬ ‫ویپر‬ ‫پہلے‬ ‫اور‬ ‫جوڑیں‬ ‫سے‬
‫اور‬ ‫کھولیں‬ ‫والو‬ ‫کا‬ ‫الئن‬ ‫مائع‬ ‫تو‬ ‫جائے‬ ‫ہو‬ ‫برابر‬ ‫دباؤ‬ ‫کا‬ ‫ویپر‬ ‫جب‬
‫کریں۔‬ ‫شروع‬ ‫ٹرانسفر‬ ‫ذریعے‬ ‫کے‬ ‫کمپریسر‬ ‫یا‬ ‫پمپ‬
‫پمپ‬ ‫پر‬ ‫ہونے‬ ‫مکمل‬ ‫ٹرانسفر‬ ‫کی‬ ‫جی‬ ‫پی‬ ‫ایل‬
/
‫کری‬ ‫بند‬ ‫کمپریسر‬
،‫ں‬
‫بند‬ ‫والوز‬ ‫کھلے‬ ‫تمام‬ ‫کریں۔‬ ‫نوٹ‬ ‫سطح‬ ‫مائع‬ ‫اور‬ ‫دباؤ‬ ،‫حرارت‬ ‫درجہ‬
‫کریں۔‬
‫سے‬ ‫طریقے‬ ‫محفوظ‬ ‫کو‬ ‫جی‬ ‫پی‬ ‫ایل‬ ‫ہوئے‬ ‫پھنسے‬ ‫میں‬ ‫پائپ‬ ‫ہوز‬
‫کریں۔‬ ‫الگ‬ ‫کو‬ ‫ہوز‬ ‫پھر‬ ،‫کریں‬ ‫خارج‬
‫کے‬ ‫کار‬ ‫طریقہ‬ ‫مطلوبہ‬ ‫اور‬ ‫کریں‬ ‫پر‬ ‫فارم‬ ‫انوینٹری‬ ‫کے‬ ‫کمپنی‬
‫کریں۔‬ ‫پراسیس‬ ‫مطابق‬
‫ہو‬ ‫تصدیق‬ ‫کی‬ ‫بات‬ ‫اس‬ ‫جب‬ ‫دیں‬ ‫حرکت‬ ‫وقت‬ ‫اس‬ ‫صرف‬ ‫کو‬ ‫باؤزر‬
‫نہیں‬ ‫باقی‬ ‫اخراج‬ ‫کوئی‬ ‫کا‬ ‫پروپین‬ ‫اور‬ ‫ہے‬ ‫صاف‬ ‫راستہ‬ ‫کہ‬ ‫جائے‬
‫رہا۔‬

a. ERP- ensures preparedness to handle emergencies such as gas leaks, fires, explosions, or natural disasters.
b. Application of ERP- applies to all personnel present at the LPG bottling plant and covers LPG storage area,
cylinder filling area, Bowser decanting area and administrative buildings.
c. LPG leaks- (from cylinders, valves, piping system, vents), Fire and explosions, Cylinder bursts, Vehicle
accidents in loading areas, Equipment failure (pumps, valves, control systems) and Natural disasters
(earthquakes, floods, lightning)
d. Type of emergency- Minor leak or fire-handled internally, Moderate leak/fire-may require external
support & Major emergency-requires full evacuation and coordination with civil authorities.
e. Emergency Response Team (ERT)-Plant manager, supervisor, operator, helpers, admin & security staff.
f. Emergency Equipment-Fire Alarm/hooter, Fire extinguishers (CO₂, dry chemical), Fire Water system, Gas
detectors and alarms Flameproof lighting and electricals, First-aid kits and stretchers & PPE: fire suits, gloves,
helmets.
g. Response Sequence-Gas Leak-Trigger alarm, Isolate gas supply, Ventilate area, Evacuate non-essential
personnel, locate source of leakage, Deploy fire team for repair/containment.
h. Fire or Explosion-Sound evacuation alarm, check fire water system, Call fire department and notify
authorities, top management of company, near by similar facilities, Evacuate to assembly points, Account for all
personnel.
i. Cylinder Burst- Clear the area immediately, Isolate supply and prevent ignition sources, Use shielding
methods if safe and Call emergency services.
j. Natural Disasters- Shut down operations, Secure hazardous areas, Follow predefined evacuation routes.
k. Contact List-prominently displayed at the entrance and includes Local fire brigade, Hospitals and ambulance
services, Police and civil defense. LPG regulatory bodies, company’s key persons.
18. Emergency Response Plan (ERP)

19. Evacuation Plan
Impounding
Pit
LPG Storage &
containment
Area
Bowser
Decanting
Area
Fire water
Storage Tank
FW Pump
house
Gen Set &
Panel
Room
Admin
block
LPG
Pump
Guard
Post
Security office &
Guard Post
Guard
Post
Operators
Room
Cylinder
Filling
Shed/Area

23/22
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Operation And Safety lpg with operating instructions 26June 25.pdf

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Operation And Safety lpg with operating instructions 26June 25.pdf