The Ministry of Commerce and Industry’s Department for Promotion of Industry and Internal Trade (DPIIT) has proposed significant amendments to the Static and Mobile Pressure Vessels (Unfired) Rules, 2016. These proposed changes, outlined in Notification G.S.R. 272(E) dated May 7, 2024, aim to address advancements in technology and align with international standards. The amendments focus on definitions, safety measures, and operational protocols for handling hydrogen and other gases. Stakeholders are invited to provide feedback within 30 days of the notification’s publication.
MINISTRY OF COMMERCE AND INDUSTRY
(Department for Promotion of Industry and Internal Trade)
NOTIFICATION
New Delhi, the 7th May, 2024
G.S.R. 272(E).—The draft of the following rules further to amend the Static and Mobile Pressure Vessels (Unfired) Rules, 2016 which the Central Government proposes to make in exercise of the powers conferred by sections 5 and 7 of the Explosives Act, 1884 (4 of 1884), is hereby published as required by sub-section (1) of section 18 of the said Act for information of all persons likely to be affected thereby; and notice is hereby given that the said draft shall be taken into consideration after thirty (30) days from the date on which the copies of this notification as published in the Official Gazette are made available to the public;
Objections or suggestions, if any, to these draft rules may be sent to the Deputy Secretary (Explosives), Department for Promotion of Industry and Internal Trade, Ministry of Commerce and Industry, Room No. 204, Vanijya Bhavan, New Delhi – 110001 or Email: [email protected]; within the period specified above;
The objections or suggestions which may be received from any person with respect to the said draft rules, within the period so specified will be considered by the Central Government.
Draft rules
1. Short title and commencement.—(1) These rules may be called the Static and Mobile Pressure Vessels (Unfired) Rules (Amendment), 2024.
(2) They shall come into force on the date of their final publication in the Official Gazette.
2. In the Static and Mobile Pressure Vessels (Unfired) Rules, 2016 (hereinafter referred to as said rules), in rule 2 after clause (vi), following shall be inserted namely:-
“(via) “Bulk hydrogen compressed gas system” means a gaseous hydrogen system with a storage capacity exceeding 5000 standard cubic feet (141.6 Normal cubic meter) of compressed hydrogen gas and includes bulk storage source such as mobile or static cascade, tube trailer, tube bank, high pressure storage vessel that serves the piping system that transports hydrogen to the end user, transfer piping, manifold system including filling and decanting post, buffer pressure vessel, compression system having booster or online compressor, hydrogen generation system such as electrolyser, and other associated components.
(vib) “Bulk liquefied hydrogen system” means a liquefied hydrogen (LH2) system with a storage capacity exceeding 1000 litres but not exceeding 2,83,906 litres and includes static cryogenic pressure vessel for storage of liquefied hydrogen, unloading facilities for liquefied hydrogen cryogenic road tanker or ISO Tank Container, cryogenic pump, vaporizer, etc.
Provided that the facilities defined as Bulk hydrogen compressed gas system in these rules may also be included along with the facilities of bulk liquefied hydrogen system as per requirements.
“(vic) “Bulk Hydrogen Supply System” means a hydrogen supply system designed, constructed, operated, maintained in accordance with provisions of CGA H-5 as recommended by Ministry of New and Renewable Energy, National Green Hydrogen Mission or any other code accepted by Chief Controller.”
3. In the said rules, after rule 2 clause (viii), following shall be inserted namely:-
“(viiia) “Compressed Hydrogen Gas (CHG)” means hydrogen gas including Green Hydrogen consisting predominantly of hydrogen in gaseous form or hydrogen gas produced from liquefied hydrogen by pumping and vaporization; which has been compressed for use as automotive fuel conforming to specification IS 16061 or ISO: 14687 as amended from time to time or any other standards accepted by the Chief Controller.”
(viiib) “Compressed Hydrogen Gas Dispensing station” means a gaseous hydrogen dispensing station to dispense hydrogen gas as an automotive fuel in to the on-board gas cylinders fitted to vehicles and includes hydrogen pipeline from hydrogen generation unit, hydrogen buffer vessel, hydrogen compressor, gas cylinder cascades, chilling unit, hydrogen dispenser, control panels, emergency shutdown devices and other related infrastructure.
The compressed hydrogen gas dispensing station shall be designed, constructed, operated and maintained in accordance with NFPA-2 and ISO 19880- Part 1, Part 3, Part 5, Part 8 as amended from time to time or any other standard accepted by the Chief Controller.”
4. In the said rules, in rule 2 clause (xiv), after the words “vacuum insulated storage or transport tanks” following words shall be inserted namely:-
“or super insulated storage or transport tanks”
5. In the said rules, in rule clause (xv) shall be substituted namely:-
“Cylinder” or “Gas Cylinder” means any closed metal container having a volume exceeding 500 ml but not exceeding 1000 liters intended for the storage and transport of compressed gas, including any liquefied petroleum gas (LPG) container or liquefied natural gas (LNG) container or compressed natural gas (CNG) cylinder or compressed hydrogen gas (CHG) cylinder fitted to a motor vehicle as its fuel tank but not including any other such container fitted to a special transport or undercarriage and includes a composite cylinder and cryogenic container,
however, the water capacity of cylinder used for storage of CHG, CNG, nitrogen or compressed air, etc., may exceed 1000 liters up to 3000 liters provided the diameter of such cylinder does not exceed 60 cm;
6. In the said rules, in rule 2 the clause (xviii), following shall be substituted namely:-
“(xviii) “Dispenser” means an equipment having mechanical components in it, installed in a dispensing station for dispensing of liquefied petroleum gas (Auto LPG) or liquefied natural gas (LNG) or liquefied hydrogen gas (LH2) as an automotive fuel for motor vehicles and having electrical components of the type approved by the Chief Controller.”
7. In the said rules, in rule 2 after clause (xix) following shall be inserted namely:-
“(xixa) “Electrolyser” means an equipment used to generate hydrogen, designed, constructed, operated and maintained as per specifications of IS 16509 or ISO 22734 as amended from time to time.”
8. In the said rules, after rule 2 clause (xxvii), following shall be inserted namely:-
“(xxviia) “Green Hydrogen” means hydrogen produced using renewable energy, including, but not limited to, production through electrolysis or conversion of biomass and having well-to-gate emission (i.e. including water treatment, electrolysis, gas purification, drying and compression of hydrogen) of not more than 2 kg CO2 equivalent per Kg H2 as defined by Ministry of New and Renewable Energy, National Green Hydrogen Mission vide Office Memorandum Number 353 / 35/2022-NT dated 18th August 2023 and published by Press Information Bureau vide Release ID: 1950421, dated 19th August 2023.
(xxviib) “Hydrogen Generation System” means a packaged, factory assembled or site constructed hydrogen gas generation appliance or system such as an electrolyzer that uses electro‐ chemical reactions to electrolyze water to produce hydrogen and oxygen gas; or a reformer that converts hydrocarbon fuel to a hydrogen rich stream; or a gasifier that converts coal to a hydrogen rich stream of composition and conditions suitable for a type of device using the hydrogen but does not include hydrogen generated as a byproduct of a waste treatment process.
The system shall be designed, constructed operated and maintained in accordance with the provisions of NFPA-2 or IS 16509 or ISO 22734 or IS 16512 or ISO 13984 or any other standard as accepted by the Chief Controller.
(xxviic) “Hydrogen Storage System” means part of a closed system used for retaining hydrogen in gaseous or liquid form upstream of the source valve and includes cylinder or gas cylinder cascade.”
9. In the said rules, in rule 2, after clause (xxx), following shall be inserted namely:-
“(xxxa) “Liquefied Hydrogen (LH2)” means hydrogen gas in liquefied state including Green Hydrogen which has been liquefied for use as automotive fuel conforming to specification IS 16061 or ISO: 14687 as amended from time to time or any other standards accepted by the Chief Controller.”
10. In the said rules, in rule 2, after clause (xxxiii), following shall be inserted namely:-
“(xxxiiia) “Non bulk hydrogen compressed gas system” means gaseous hydrogen filled in cylinders either individual or interconnected by manifold or piping system and having aggregate volume not exceeding 5000 standard cubic feet (141.6 Newton cubic meter) at Normal Temperature and Pressure”
11. In the said rules, after rule 11 following shall be inserted namely:-
“11a Procedure for submission of documents. All the documents and drawings required for any of the transaction or license FORM covered under these rules shall be submitted online.
Provided that nothing in this rule shall apply, if the Chief Controller or Controller is of the opinion that physical submission of any of the document or drawing is necessary to verify that all or any of the provision of these rules are being complied at all the times.
12. In the said rules, in rule 16, after sub rule (3), following shall be inserted namely:-
“(4) The pressure vessel designed and approved for filling with particular gas shall not be used for filling with any other gas unless specific approval and amendment of license is obtained from the Chief Controller or Controller.
Provided that, pressure vessel designed for higher design pressure may be used for storage or transport of gas having lower design pressure after approval of the Chief Controller or Controller.”
13. In the said rules, in rule 21 after sub rule (15), following shall be inserted namely:-
“(16) The LH2 static installation and mobile pressure vessel shall conform to all the provisions specified in Schedule V
Note: The LH2 or compressed hydrogen gas dispensing station shall be a standalone premises”
14. In the said rules, in rule 22:-
“(a) “the sub rule (2) shall be substituted namely:-
If the aggregate water capacity of a multi-vessel installation covered under tables 1 or table 2 or table 3 exceeds 40,000 litres, the minimum safety distances from any vessel to the property line or group of buildings shall not be less than –
(a) thirty metres for corrosive, toxic or flammable gases for above ground vessel and fifteen meters for underground and mounded vessel;
(b) fifteen metres for non-corrosive, non-toxic or non-flammable gases.
(c) Layout of the pressure vessel installed in the crude oil refinery or gas processing plant, shall be as per the relevant provisions stipulated in the Petroleum Rules.
(b) The sub rule “(4)” is renumbered as sub rule “(5)” and before the renumbered sub rule “(5)”, the following sub rule shall be inserted, namely :-
(4) In case of LPG bottling plant wherein bulk storage (a) exceeds 100 MT but limited to 300 MT for above ground storage and also for (b) 450 MT in mounded pressure vessel or in combination of above ground and mounded storage of LPG and total bottling quantity not exceeding 50 MT per shift of 8 hours shall observe all the provisions of OISD 169 as amended from time to time.”
15. In the said rules, in rule 25 after the word efficient manner” following words and numerical shall be inserted namely:-
“All compressed gas delivery vehicles shall be equi-potentially bonded to the fixed storage hardware prior to the flexible hose connection.
The bonded systems shall be grounded and resistance shall be less than 1 milli ohm to earth from any part within the system.
16. In the said rules, in rule 29, after the word “Chief Controller” following shall be inserted namely:-
“The dispenser for dispensing of LH2 or compressed hydrogen gas shall be designed, constructed, tested and maintained as per provisions of the Schedule V of these rules and ISO 19880 or NFPA-2 as amended from time to time and shall be of the type approved by the Chief Controller”
17. In the said rules, the rule 30 shall be substituted namely:-
“30. Special Provisions for dispensing of Auto LPG or Auto LNG or LH2 or compressed hydrogen into fuel tanks of motor vehicles and unloading of mobile pressure vessel in auto LPG or auto LNG or liquefied hydrogen or compressed hydrogen dispensing station.–
(1) Auto LPG or Auto LNG or LH2 or compressed hydrogen shall not be filled in fuel tank of motor vehicle while the engine of the vehicle is running.
(2) During the period of unloading of Auto LPG or Auto LNG or LH2 from the mobile pressure vessel, dispensing of Auto LPG or Auto LNG or liquefied hydrogen or compressed hydrogen into fuel tanks of motor vehicles shall not be carried out.”
18. In the said rules, in rule 31 sub rule (1) after the word “vessel”, following words shall be inserted namely:-
“or any part of the premises licensed under these rules.”
19. In the said rules, in rule 31 sub rule (3)(1), the words and numerical “IS/IEC 60079-1 to 11 shall be replaced with following words and numerical namely:-
ÏS/IEC or IEC or EN 60079 series as amended from time to time or any other standard accepted in writing by the Chief Controller.”
20. In the said rules, in rule 31 sub rule (3)(2), the words and numerical “IS/IEC 60079-1 to 11 shall be replaced with following words and numerical namely:-
“IS/IEC or IEC or EN 60079-1 as amended from time to time or any other standard accepted in writing by the Chief Controller”.
21. In the said rules, in rule 32-B sub rule (2), after the word “Chief Controller” following words and numerical shall be inserted namely:-
“Note:- For hazardous area and zone classification IS/IEC 60079-10 or IEC 60079-10 or NFPA-2 or ISO 19880 or any other standard accepted to the Chief Controller shall be referred.”
The extent of hazardous area for a LNG dispenser shall be as per provisions of ISO 16924, extent of hazardous area for CNG dispenser shall be as per provisions of ISO 16923 and for liquefied hydrogen or compressed hydrogen shall as per provisions of ISO 19880; or any other standard accepted to the Chief Controller.”
22. In the said rules, in rule 39:-
(a) in sub rule (2)(i), after the word type following shall be inserted namely:-“spark ignition or compression ignition type internal combustion engine.”
(b) after sub rule (5) following shall be inserted namely:-
“(6) For vehicles operating on LNG as fuel:-
(i) The gross capacity of LNG fuel tank shall not exceed 1080 kilo grams in case of LNG fuelled vehicle
(ii) Fitment of side under run protection device as per IS 14682 for all mobile pressure vessel shall be followed. In case of side mounted LNG fuel tanks, additional safety, protection shall be provided against any external flying objects as per recommendations of original equipment manufacturer.
(iii)The installation of specific components of motor vehicles using liquefied natural gas (LNG) in their propulsion systems shall comply R 110 regulation or any recognised national or international standards.
23. In the said rules, in rule 46:-
(a) after sub rule (1)(i)(f), following shall be inserted namely:-
“(g) registered land ownership document or registered lease agreement or registered sale deed document towards legal physical possession of the land.”
(b) after the sub rule (1)(ii), following shall be inserted namely:-
“(iii) for LH2 storage and dispensing station following additional documents to be submitted:-
a. an overall layout of surrounding area depicting all the existing structures lying within 100 meters from edge of the facilities proposed to be licensed
b. Hazard and Operability (HAZOP) study and comprehensive risk assessment report prepared by reputed agency;
c. Detailed layout drawing incorporating sectional elevation views of all the facilities proposed to be licensed such as hydrogen generation system, storage system, vessels, all valves and fittings, filling and discharge pumps and fire-fighting facilities. Orientation of all facilities, capacity, materials of construction, etc forming a part of the premises proposed to be licensed shall also be depicted in the drawing;
d. Emergency response plan prepared by reputed agency as per ISO 14001 or any other National or International Standards as amended from time to time
e. Piping and instrumentation diagram for the vessels, equipments and system proposed to be installed;
f. Safety interlocks system inter-connected with hydrogen leak detection system
g. Any other documents specified by the Chief Controller or Controller;
(c) after the sub rule (2), following shall be inserted namely:-
“Provided that the Chief Controller or the Central Government may under exceptional circumstances to be recorded in writing waive off any of the requirements of these rules. This will, facilitate issuance of trial run permissions to the premises or installation or mobile pressure vessel adopting new technology for promoting research and development in the Country and data gathering. The period for trial shall be maximum one year only and can be extended further with reason recorded in writing for the period as deemed fit by the Chief Controller or by the Central Government.”
24. In the said rules, in rule 47:-
(a) In sub rule (1), after the words and numerical “LS-1B” following words and numerical shall be inserted namely:-
“ or LS-1C”
(b) In sub rule (1), after the end of the paragraph, following words and numerical shall be inserted namely:-
“(i) Where the location of storage and dispensing of flammable or toxic or corrosive gas is within the notified area of a Port or Airport under the control of the State or establishment of Indian Space Research Organisation or Atomic Energy or Railways or Mines covered under Indian Mines Act, 1952, No Objection Certificate from the District Authority referred in above rule shall not be applicable.
Provided that consent for storage and dispensing of flammable or toxic or corrosive gas from the competent authority of concerned notified area or head of the establishment, as the case may be, is obtained.
(ii)The No Objection Certificate mentioned in above rules shall also be applicable for the premises wherein mobile pressure vessel licensed in FORM LS-2 is used to transfer LNG into fuel tanks of the non transport vehicles which can never approach the LNG dispensing station or petroleum dispensing station licensed in FORM XIV of the Petroleum Rules and as defined by Ministry of Road and Surface Transport vide gazette notification GSR 673 (E) dated 27/10/2020 or into fuel tanks of boat as approved by the Maritime Board or fuel tanks of engines tested by Central Government Testing Laboratories or engine operated by Railways or any other vehicles operated in the premises which are under direct control of the Central or State Government.
a. The sub rule (7) shall be substituted namely:-
“(7) The District Authority shall grant no objection certificate or convey his refusal for granting no objection certificate with reasons thereof in writing to the applicant as expeditiously as possible, but not later than two months from the date of receipt of application from the applicant.
The no objection certificate shall be issued online by the District Authority through Licensing System for District Authority (LSDA) of Petroleum and Explosives Safety Organisation. A copy of site plan duly endorsed by the District Authority shall be uploaded online by the applicant along with other documents for grant or amendment of license as the case may be.”
25. In the said rules, in rule 49 sub rule (4) after the word and numerical “LS-2B”, following word and numerical shall be inserted namely:-
“,LS-1D”
26. In the said rules, in rule 50 sub rule (i)(a) shall be substituted namely:-
(a) in FORM AS-1, if the application is in respect of a license in FORM LS-1A to store compressed gas in pressure vessel or in FORM LS-1B to store and dispense Auto LPG as an automotive fuel or in FORM LS-1C to store and dispense Auto LNG as an automotive fuel or in FORM LS-1D to store and dispense LH2 as an automotive fuel.
27. In the said rules, in rule 51 sub rule (1) after the word and numerical “or LS-1C” following words and numerical shall be inserted namely:-
“or LS-1D”
28. In the said rules, in rule 55 sub rule (2) after the words and numerical “,LS-1C”, following words and numerical shall be inserted namely:-
“, LS-1D”
29. In the said rules, in rule 57 after the sub rule (3), following sub rule shall be inserted namely:-
“(4) Every license or approval granted under these rules shall stand cancelled, if the licensee ceases to have any right to the site of the licensed or approved premises for storage of compressed gas.”
30. In the said rules, in Schedule I, –
a. in Part A, in t
b. he table, “Sl. No. 4” and the entries relating thereto shall be renumbered as “Sl. No. 5” and before the renumbered “Sl. No. 5”, the following Sl. No. and entries related thereto shall be inserted, namely :-
| 4 | LS-1D | License to store and dispense liquefied hydrogen to motor vehicles as an automotive fuel in Liquefied Hydrogen Dispensing Station and / or to store liquefied hydrogen in connection with compressed hydrogen gas dispensing station. | Chief Controller or Controller authorized by him | Same as the license FORM LS-1A |
Note: For usage of hydrogen other than automotive fuel purpose, license will be granted in FORM LS-1A of these rules for storage of hydrogen in static pressure vessel and in FORM E & F of the Gas Cylinders Rules for filling and storage of hydrogen in gas cylinder or gas cylinder cascade.
(b) in Part B, Sl No 14 after the numerical in column 3, following words shall be inserted namely:-“per year”
31. In the said rules, after completion of Schedule IV, following shall be inserted namely:-
“SCHEDULE V
[See rule 2(xxxa), 21(16) and 29]
LH2 STORAGE, HANDLING, TRANSPORTATION, OPERATION, MAINTENANCE AND DISPENSING
These provisions shall apply to the following, namely:-
A. The requirements of the design, fabrication and installation and commissioning of LH2 storage facility using cryogenic super insulated containers of double wall constructed in accordance with approved pressure vessel codes and the requirements for safe vaporization, transfer and handling.
B. The requirements of the road transportation of LH2 in a cryogenic double walled vacuum insulated or super insulated pressure vessel for the safe transportation and handling.
C. Operation, Maintenance and Training.
D. Compressed Hydrogen Gas Dispensing Stations (HDS) & Liquid Hydrogen Dispensing Stations (LHDS)
Provided that the Chief Controller may, under exceptional circumstances and for reasons recorded in writing, waive any of the requirements of this Schedule.
SECTION–I
STORAGE INSTALLATIONS AND HANDLING
A. INSTALLATION DESIGN:
1. For LH2 cryogenic pressure vessels storage installation, the minimum safety distances between the vessel and to the nearest building or line of adjoining property shall be in accordance with the distances specified in Table (1) of this Schedule and the maximum aggregate capacity of each such Liquid Hydrogen installation shall not exceed 2,83,906 litres.
2. The LH2 installation shall be designed to withstand the following without loss of structural or functional integrity –
a. The direct effect of wind forces as per provisions of IS-875 -3 or ASCE 7-16 as amended from time to time.
b. Loading due to seismic effect as per provisions of IS 1893 or ASCE 7-10 as amended from time to time.
c. Erosive action from a spill.
d. Effect of the temperature, any thermal gradient, and any other anticipated degradation resulting from sudden or localized contact with liquid Hydrogen.
3. A clear space of at least 1 meters shall be provided for access to all isolation valves serving multiple vessels and the isolation valve of Liquid Hydrogen vessel piping shall be as close to outer vessel as possible.
4. LH2 vessels, cold boxes, piping, pipe supports and other cryogenic apparatus installed within kerb wall shall be designed and constructed in a manner to prevent damage to these structures and equipment due to freezing or frost heaving in the soil.
5. Adequate lighting arrangement suitable for installation in hazardous and for hydrogen service shall be done for facilities transferring Hydrogen during night.
6. Electrical grounding and bonding shall be provided.
7. Layout shall ensure unobstructed access and exit of the consumers and supply vehicles at all times.
8. Entrance, exit and paving shall be arranged in a manner, so as to minimize the risk of collision.
9. The operating personnel shall have an unobstructed overall view on the facilities both from the sales room and from the delivery area.
10. The designated tanker unloading location shall be so located that it does not hinder other traffic and at the same time permits tanker to be in drive out position for allowing it to come out of the premises easily in case of an emergency.
11. Crash or Impact barriers shall be installed to protect vulnerable equipment against accidents involving vehicle movements.
12. The storage area which includes pumps and the related piping shall be suitably segregated from the rest of the premises and located in a manner that it is away from the area frequented by public during their movement within the station and also from the path of vehicles entering and leaving the premises.
13. Hydrogen storage facilities shall be located so all personnel and facilities, whether involved in the operation or not, shall be adequately protected by appropriate design, including distance of separation, shielding, barricading, or other means. Consideration for the sitting of hydrogen storage is first, to protect personnel and facilities as above; and second, to protect the hydrogen storage vessel and contents from external hazards, hazards associated with the storage and use of oxidizers, or other propellants and fuels.
14. Inter-distances between various equipments, bulk liquid hydrogen system, non bulk liquid hydrogen system, hydrogen generation system, hydrogen storage system, associated facilities, etc. installed in Hydrogen dispensing station shall observe safety distances as per defined groups and Table IA, IB, IC & ID, 1E and 1F as follows:
“Definition of Groups
| Exposure | Group 1 | Group 2 | Group 3 |
| Facilities | Outer boundary wall (Lot lines) Air intake (HVAC, Air compressor) Electrical room Office area Convenience store Operable openings in buildings and structures Ignition source or open flames |
Exposed person other than those servicing the system.
Parked car. |
Building of noncombustible non fire rated construction
Unopenable openings in buildings and structures Encroachment by overhead utilities (horizontal distance from vertical planes below the nearest overhead electrical wire of building service) |
TABLE 1A
Inter distances between various facilities in LH2 Dispensing Station for pressure rating
less than or up to 414 kPa (≤ 4.2 kg/cm2)
| Minimum Distance from Bulk liquid Hydrogen Systems to Exposures by Maximum Pipe Size with Pressures ≤ 60
psig ( ≤4.2 kg/cm2) |
||||
| Pipe ID (In) | Pipe ID (mm)
(d) |
Exposure Group 1 | Exposure Group 2 | Exposure Group 3 |
| Liquid Hydrogen System to Outer Boundary Wall Without Firewall (meter) 0.34d+0.24 |
Liquid Hydrogen system to Forecourt Fence (meter) 0.20d+1.84 | Liquid Hydrogen System to exposure group 3 (meter) 0.15d+2.08 | ||
| Up to 0.5 | Up to 12.7 | 5 | 4.5 | 4 |
| 0.5 to 1.0 | 12.7 to 25.4 | 9 | 7 | 6.5 |
| 1.0 to 1.5 | 25.4 to 38.1 | 13.5 | 9.5 | 8 |
| 1.5 to 2.0 | 38.1 to 50.6 | 18 | 12 | 10 |
| 2.0 to 4.0 | 50.6 to 101.6 | 35 | 22.5 | 17.5 |
TABLE 1B
Inter distances between various facilities in LH2 Dispensing Station for pressure rating
greater than 414 kPa but not exceeding 827 kPa ( > 4.2 kg/cm2 ≤8.4 kg/cm2)
| Minimum Distance from Bulk liquid Hydrogen Systems to Exposures by Maximum Pipe Size with Pressures >60 psig ≤ 120 psig ( > 4.2 kg/cm2 ≤8.4 kg/cm2) | ||||
| Pipe ID (In) | Pipe ID (mm) | Exposure Group 1 | Exposure Group 2 | Exposure Group 3 |
| Liquid Hydrogen System to Outer Boundary Wall Without Firewall (meter)0.37d+0.53 |
Liquid Hydrogen system to Forecourt Fence (meter)0.24d+1.96 |
Liquid Hydrogen System to exposure group 3 (meter)0.19d+2.19 |
||
| Up to 0.5 | Up to 12.7 | 5.5 | 5 | 4.5 |
| 0.5 to 1.0 | 12.7 to 25.4 | 10 | 8.5 | 7.5 |
| 1.0 to 1.5 | 25.4 to 38.1 | 14.5 | 11.5 | 9.5 |
| 1.5 to 2.0 | 38.1 to 50.6 | 19.5 | 14 | 12 |
| 2.0 to 4.0 | 50.6 to 101.6 | 38.5 | 26.5 | 21.5 |
TABLE 1C
Inter distances between various facilities in LH2 Dispensing Station for pressure rating
greater than 827 kPa but not exceeding 1307 kPa( > 8.4 kg/cm2 ≤13.3 kg/cm2)
| Minimum Distance from Bulk liquid Hydrogen Systems to Exposures by Maximum Pipe Size with Pressures >120 psig ≤ 189 psig ( > 8.4 kg/cm2 ≤13.3 kg/cm2) | ||||
| Pipe ID (In) | Pipe ID (mm) | Exposure Group 1 | Exposure Group 2 | Exposure Group 3 |
| Liquid Hydrogen System to Outer Boundary Wall Without Firewall (meter)
0.38d+0.57 |
Liquid Hydrogen system to Forecourt Fence (meter)
0.25d+1.93 |
Liquid Hydrogen System to Protected Works (meter)
0.20d+2.16 |
||
| Up to 0.5 | Up to 12.7 | 6.5 | 5 | 5 |
| 0.5 to 1.0 | 12.7 to 25.4 | 12.5 | 10 | 9 |
| 1.0 to 1.5 | 25.4 to 38.1 | 18 | 14.5 | 12.5 |
| 1.5 to 2.0 | 38.1 to 50.6 | 21.5 | 17 | 14.5 |
| 2.0 to 4.0 | 50.6 to 101.6 | 43 | 34.5 | 28 |
TABLE 1D
Inter distances between various facilities in LH2 Dispensing Station for pressure rating
greater than 1307 kPa but not exceeding 1961 kPa( > 13.3 kg/cm2 ≤20 kg/cm2)
| Minimum Distance from Bulk liquid Hydrogen Systems to Exposures by Maximum Pipe Size with Pressures >189 psig ≤ 285 psig ( > 13.3 kg/cm2 ≤20 kg/cm2) | ||||
| Pipe ID (In) | Pipe ID (mm) | Exposure Group 1 | Exposure Group 2 | Exposure Group 3 |
| Liquid Hydrogen System to Outer Boundary Wall Without Firewall (meter) |
Liquid Hydrogen system to Forecourt Fence (meter) |
Liquid Hydrogen System to Protected Works (meter) |
||
| Up to 0.5 | Up to 12.7 | 7.0 | 5.5 | 5.5 |
| 0.5 to 1.0 | 12.7 to 25.4 | 13.5 | 11 | 9.5 |
| 1.0 to 1.5 | 25.4 to 38.1 | 19.5 | 15.5 | 13.5 |
| 1.5 to 2.0 | 38.1 to 50.6 | 23 | 18.5 | 16 |
| 2.0 to 4.0 | 50.6 to 101.6 | 47 | 37.0 | 30.5 |
Note :
1. The distance shall be measured from the part of the bulk LH2 system closest to the exposure.
2. The pressure used in application of table 1A, 1B, 1C, 1D shall be determined based on the maximum operating pressure of the tank.
3. The internal diameter of the piping system size used in application of table 1A, 1B, 1C, 1D shall be determined based on that portion of the system with the greatest internal diameter.
TABLE-1E
INTER DISTANCES BETWEEN VARIOUS FACILITIES IN LH2 DISPENSING STATION
| Sl. No. | Minimum Distance from Bulk liquid Hydrogen Systems to Exposures by Maximum Pipe Size with Pressures | Minimum distance from edge of impoundment or vessel drainage system to property line | Minimum distance Between storage vessels | Minimum distance Between storage vessel and dyke wall(Inner edge of the Dyke wall and outer shell of the storage vessel) |
| 1. | Less than 4.2 kg/cm2 | Refer Table-1A | 1.0m | 1.0m |
| 2. | Greater than 4.2 but less than 8.4 kg/cm2 | Refer Table-1B | 1.5m | 1.5m |
| 3. | Greater than 8.4 but less than 13.3 kg/cm2 | Refer Table-1C | 2.0m | 2.0m |
| 4. | Greater than 13.3 but less than 20 kg/cm2 | Refer Table-1D | 3.0m | 3.0m |
TABLE-1F
MINIMUM DISTANCES BETWEEN EQUIPMENTS/ ITEMS INSTALLED OUTSIDE THE DYKEWALL AND OUTER EDGE OF DYKE WALL
| Sl. No. | Equipment/Items | Dyke wall(Outer Edge) |
| 1. | Property Line/Fencing | As per Table-1E of this schedule |
| 2. | Center of Truck Unloading Platform | Min.4.0m (and also min 9m from the adjoining boundary/property). The fill point shall observe 9.0 meter safety distance to the adjoining boundary. |
| 3. | Priority panel | Outside dyke wall |
| 4. | CHG Cascade(ForLH2station) | The safety distance as per Table I A, 1B, 1C and 1D of Gas Cylinders (amendment) Rules, 2024 from edge of the dyke. The cascade shall be segregated from LH2 facility by providing concrete wall up to the height of the cascade. |
| 5. | On site building/Control room/sales office | Outside the safety distances as per Table-1E of this schedule. |
| 6. | LH2 and CHG dispensers (if LH2 station) | Min.6.0 m (and also min 6.0 m from centre of hardstand). |
| 7. | Distance between Dispenser Islands | Min. 6.0 m |
HYDROGEN CRYOGENIC STORAGE VESSEL – General design requirements:
Foundation:
1. Hydrogen vessels foundations shall be designed by a qualified engineer and constructed in accordance with recognized structural engineering practices and prior to the start of design and construction of the foundation, a subsurface investigation shall be conducted by a qualified geo-technical engineer to determine the stratigraphy and physical properties of the soils underlying the site.
2. The design of saddles and legs for the Hydrogen vessel shall include erection load, wind loads and thermal loads.
3. Foundation and support shall have a fire resistance rating of not less than two hrs.
4. Hydrogen vessels installed in areas subject to flooding shall be secured to prevent release of Hydrogen or floatation of the vessel in the event of a flood.
5. Where LH2 storage vessel are required to be elevated the tank supports shall be noncombustible structures, and capable of withstanding damage by cryogenic liquid spillage.
6. The foundation on which the equipment is installed shall be made of concrete or any other suitable non-flammable material.
b. Vessel Design:
1. The vessel meant for storage of Hydrogen including piping between inner and outer vessels shall be designed in accordance with ASME Boiler and Pressure Vessel Code Section VIII Div I or EN 13458 or / ASME: B.31.12, process piping or equivalent code acceptable to Chief Controller.
2. Design pressure of LH2 cryogenic storage vessel shall not exceed 20 Kg/cm2.
3. The inner vessel shall be designed for the most critical combination of loading resulting from internal pressure, liquid heads and the inner vessel supports system shall be designed for shipping, seismic, and operating loads.
4. The outer vessel shall be equipped with a relief or other devices as per provisions of CGA 341-2017 to release internal pressure and shall have discharge area of at least 0.34 mm2/lit of the water capacity of the inner vessel but not exceeding 2000 cm2 (for 283.906 Cubic meters inner vessel capacity, the discharge area shall be 965.28 cm2) and have pressure setting not exceeding 25 psi.
5. Thermal barriers shall be provided to prevent outer tank from falling below its design temperature.
6. Those parts of LH2 vessel which come in contact with Hydrogen and all materials used in contact with LH2 or cold hydrogen vapour shall be physically and chemically compatible with hydrogen and intended for service at – 253°C.
7. All piping that is a part of hydrogen vessel including all piping internal to the vessel, within void space, and external piping connected to the vessel up to the first circumferential external joint of the piping shall be in accordance with ASME Boiler and Pressure Vessel Code, Section VIII or ASME B 31.12orequivalent.
8. Hydrogen vessels shall be designed to accommodate both top and bottom filling unless other positive means are provided to prevent stratification.
9. Any portion of the outer surface area of a hydrogen vessel that could accidentally be exposed to low temperatures resulting from the leakage of Hydrogen or cold vapor from flanges, valves etc., shall be intended for such temperatures or protected from the effects of such exposure.
10. Seismic loads shall be considered in the design of the LH2 support systems.
2. FITMENTS:
1. Each compressed hydrogen gas vessel and LH2 double walled vessel shall have at least 2 numbers of safety relief valves capable of achieving the required relief capacity on standalone basis and shall be sized to relieve the flow capacity determined for the largest single contingency or any reasonable and probable combination of contingencies and shall include conditions resulting from operational upset, vapor displacement and flash vaporization.
2. Relief devices shall be vented to the atmosphere via vent stack designed as per CGA-G5.5 and each safety relief valve shall be provided with isolation valve..
3. Safety relief valve shall be designed and installed to prevent any accumulation of water, or other foreign matter at its end.
4. For LH2 vessel, the minimum pressure relieving capacity in kg/hr shall not be less than 3% of the full tank contents in 24 hours.
5. All liquid connections to the liquid hydrogen vessel except relief valve and instrumentation connection shall be equipped with manual isolation valves and automatic fail-safe product retention valves.
6. The automatic shut off valves shall be designed to close on occurrence of any of the following conditions, namely: –
- fire detection.
- uncontrolled flow of hydrogen from vessel
- manually and remotely operated.
7. Such of the automatic shutoff valves that require excessive time to operate during emergency i.e. sizes exceeding 200 mm shall be pneumatically operated and also have means of manual operation.
8. All LH2 shall have a device that prevents the vessel from becoming liquid full or from covering the inlet of the relief valve with liquid when the pressure in the vessel reaches the set pressure of relieving device under all conditions.
9. Every LH2 vessel shall be provided with independent high liquid level alarm which may be part of the liquid level gauging devices, however, the high liquid level flow cutoff device shall not be considered as a substitute for the alarm.
10. Every LH2 vessel shall be equipped with at least two liquid level gauging device and the devices shall be designed and installed so that they can be replaced without taking the tank out of operation and the level and pressure shall be visible to the operating personnel during unloading or loading and transfer.
11. Each LH2 vessel shall be equipped with a high liquid level flow cut off device.
12. Each LH2 vessel shall be equipped with pressure gauge connected to the vessel at a point above the maximum intended liquid level as the case may be.
13. Instrumentation for storage and vaporization facilities shall be designed in such a way that if a power or instrument air failure occurs, the system will proceed to a failsafe condition and maintain that condition until the operator takes appropriate action to reactivate or secure the system.
D. EQUIPMENT:
1. Pumps and compressors employed in LH2 source shall be provided with a pressure relieving device on the discharge to limit the pressure to the maximum safe working pressure of the casing and downstream piping and equipment.
2. Each pump shall be provided with adequate vent, relief valve, or both that will prevent over-pressuring the pump casing during the maximum possible rate of cool down.
3. The discharge valve of each vaporizer and the piping components and relief valves installed upstream of each vaporizer outlet valve / spec break flange shall be designed for operation at LH2 temperatures.
4. Two inlet valves shall be provided to isolate an idle, manifolded vaporizer to prevent leakage of LH2 into the vaporizer and a safe means of disposing of the Hydrogen or gas that can accumulate between the valves shall be provided in case the vaporizers are of size having inlets more than 50 mm diameter.
5. (i) The ambient air vaporizers shall be installed inside the containment area.
ii. Where the heated vaporizer is located 15 meter or more from the heat source, the remote and additional manual shutoff valve location shall be at least 15 meters from the vaporizer.
iii. Where the heated vaporizer is located less than 15 meter from the heat source, it shall have an automatic and additional manual shut off valve in the Hydrogen liquid line located at least 3 meter from the vaporizer and shall close when either of the following occurs:
1. Loss of line pressure (excess flow),
2. The occurrence of a fire is detected by an instrument designed for the purpose and located to detect a fire in the covered area,
3. Low temperature in the downstream of the vaporizer,
4. Manual ESD trip.
iv. a. Any ambient vaporizer or a heated vaporizer installed within 15 meter of an LH2 shall be equipped with an automatic and manual shutoff valve in the Hydrogen liquid line;
b. The automatic shutoff valve shall be located at least 3 meter from the ambient or heated vaporizer and shall close in either of the following situations, namely: –
1. Loss of line pressure (excess flow).
2. Abnormal temperature sensed in the immediate vicinity of the vaporizer(fire)
3. Low temperature in the downstream of the vaporizer.
4. Activation of Emergency Shut Down System(ESD).
c. If the facility is attended, manual operation of the automatic shut off valve shall be from a point at least 15 meter from the vaporizer, in addition to the requirement as specified in para (b)above.
v. The above conditions shall be applicable for LH2 vaporizers for purposes other than pressure building coils or hydrogen systems.
6. A distance of minimum 1 meter shall be maintained between vaporizers.
7. Vaporizers shall be designed, fabricated and inspected as per the requirements of ASME Boiler and Pressure Vessel Code, Section VIII Div. 1 or any other equivalent code acceptable to Chief Controller.
8. The material of construction of LH2 vaporizers is recommended as suitable for hydrogen usage and depending on design pressures.
9. Manifold vaporizers shall be provided with both inlet and discharge block valves for each set of vaporizers.
10. Any ambient vaporizer installed within 15 meters of the LH2 vessel shall be equipped with an automatic and manual shut off valve in the liquid line and this valve shall be located minimum at least 3 meters from the vaporizers and shall close when loss of line pressure occurs, or abnormal temperature is sensed in the immediate vicinity of the vaporizer or when low temperature in the vaporizer discharge line occurs.
11. Each set of vaporizer shall be provided with a safety relief valve(s) sized in accordance with the following requirements, namely: –
a. Ambient vaporizers–relief valve capacity shall allow discharge equal or greater than 150% of the
rated vaporizer hydrogen flow capacity without allowing the pressure to rise 10% above the vaporizer maximum allowable working pressure.
b. Relief valves on heated vaporizers– same as sub-clause (a) above, however, it shall be located such that they are not subjected to temperatures exceeding 60 °C during normal operation.
12. Automation shall be provided to prevent the discharge of either liquid hydrogen or vaporizer gas into a distribution system at the temperature either above or below the design temperature of the send out system.
13. Vaporizers shall be provided with outlet temperature monitors.
E. PIPING SYSTEM:
1. All piping system and components shall be designed as per ASME B 31.12–
a. To accommodate the effects of thermal cycling fatigue to which the systems shall be subjected.
b. To provide for expansion and contraction of piping and piping joints due to temperature changes.
2. Piping, fittings, gaskets, thread sealant, valves, regulators and other accessories shall be suitable for liquid or gaseous hydrogen service as applicable and for the pressures and temperatures involved. Consideration shall be given to the thermal expansion and contraction of piping systems when exposed to temperature fluctuations of ambient to liquid hydrogen temperature
3. Joints in piping and tubing should be welded, brazed, flanged or screwed. Electrical continuity shall be maintained throughout the system.
4. Means shall be provided to minimise exposure of personnel to piping operating at low temperatures and to prevent air condensate from contacting piping, structural members and surfaces not suitable for cryogenic temperatures.
5. Un-insulated piping and equipment, which operates at below air condensation temperature, shall not be installed above asphalt surfaces or other combustible materials in order to prevent contact of liquid air with such materials. Drip pans may be installed under un-insulated piping and equipment to retain and vaporise condensed liquid air.
6. Where it is necessary to run gaseous hydrogen pipelines in the same duct or trench used for electrical Gables, then all joints in the hydrogen pipelines in the ducted/trenched section shall be welded or brazed. The hydrogen pipeline should be run at a higher elevation than other pipelines in compliance with provisions of EIGA DOC/06/02/E.
7. Shut-off valves shall be provided for all vessel connections except connections for liquid level alarms and connections that are blind flanged or plugged.
8. All the piping section between the two valves where the liquid may be trapped shall have the thermal relief valve.
9. The pipes shall be tested as per ASME B 31.12
10. The hydrogen pipeline system in the installation shall be in accordance with EIGA IGC Doc 121/14 or ASME B 31.12
F. TRANSFER OF HYDROGEN:
1. Manual Isolation valves shall be installed so that each transfer system can be isolated at its extremities and if power-operated isolation valves are also installed, an analysis shall be made to determine the closure time so that it does not produce a hydraulic shock capable of causing line or equipment failure.
2. Adequate check valves shall be provided to prevent back flow and shall be located as close as practical to the point of connection to any system from which backflow might occur.
3. Electrical grounding and bonding shall be provided
4. At-least one number of Hydrogen Gas detector sensors per bay shall be installed in the vicinity of loading/unloading area and shall be connected along with suitable alarm.
G. PUMP AND COMPRESSOR CONTROL:
In addition to a locally mounted device for shutdown of the pump or compressor drive, a readily accessible, remotely located device shall be provided at least 8 meters away from the equipment and outside the safety distance to shut down the pump in an emergency.
H. TANK VEHICLE UNLOADING FACILITIES:
1. The tank vehicle unloading area shall be of sufficient size to accommodate the vehicles without excessive movement or turning.
2. Transfer piping, pumps, and compressors shall be located or protected by barriers so that they are safe from damage by vehicle movements.
3. Isolation valves and bleed connections shall be provided at the unloading manifold for both liquid and vapor return lines so that hoses and arms can be blocked off, drained of liquid, and depressurized before disconnecting and bleeds or vents shall discharge in a safe area.
I. EMERGENCY SHUT DOWN SYSTEM (ESD System):
1. Each hydrogen facility shall incorporate an ESD system that when operated isolates or shuts off sources of hydrogen and shuts down equipment that add or sustain an emergency if continued to operate.
2. The ESD system shall be of a failsafe design and shall be installed, located, or protected from becoming inoperative during an emergency or failure at the normal control system.
3. Initiation of the ESD system shall be manual, automatic, or both manual and automatic. Manual push buttons shall be located in an area accessible in an emergency and at least 15 meters away from the equipment they serve, and shall be distinctly marked with their designated function.
4. ESD system shall comply with ISO 13850 and IEC 60204/1 or equivalent standard.
J. FIRE PROTECTION FACILITIES:
1. Each hydrogen storage facility shall be provided with hydrogen gas leak detectors, which shall activate visual and audible alarms.
2. Flammable gas detection system shall activate an audible and a visual alarm at level not higher than 25% of the LEL of the gas being monitored. Hydrogen detection apparatus used in hydrogen sensing and monitoring systems should comply with, and meet the accuracy requirements of IS 16253 or ISO 26142 or equivalent standard.
3. Fire detectors shall activate an alarm at the plant site and at a constantly attended location and if determined by an evaluation that it is necessary then fire and gas detectors shall be permitted to activate the ESD system.
4. A fire water supply and delivery system shall be provided based on the comprehensive risk assessment. However, as a minimum a fire water storage tank of 20 % of hydrogen storage tank capacity or 5000 liter whichever is higher with pumping facilities and hose reel system away from the Hydrogen storage facility shall be provided for dispersion of Hydrogen vapor cloud in case of leakage or spillage.
5. Sprinkler systems shall be provided in accordance with NFPA-13 or equivalent standard at the unloading area, bulk storage and compressor /pump rooms.
6. Portable or wheeled fire extinguishers of DCP and/or foam type shall be made available at strategic locations and at least 4 such extinguishers of 10 kg capacity each shall be provided.
7. Fire extinguishers provided in the Hydrogen installations shall be based on high expansion foam and dry chemical powder.
8. The use of water on vent stacks shall be strictly avoided.
K. PERSONAL PROTECTION:
Every person operating the equipment in the Hydrogen installation shall be equipped with the following personal protective equipment, namely: –
i. Suitable goggles for protection of eyes from hydrogen spray,
ii. Hand gloves suitable for cryogenic liquid handling,
iii. Protective apron,
iv. Safety Shoes.
SECTION 2
ROAD TRANSPORTATION
A. DESIGN – GENERAL REQUIREMENTS:
The safety relief valves provided on the inner vessel of the hydrogen transport tank shall be sized to meet most stringent condition of simultaneous occurrence of loss of vacuum and external fire and the combined capacity of the safety valves shall be sufficient to limit the pressure in the vessel to the test pressure-
1. The transport vessel shall be designed and constructed as per the ASME Boiler and Pressure Vessel Code Section VIII Div I pressure vessel code, EN13530, ISO 20421or equivalent code approved by Chief Controller and the design temperature of the vessel, piping and valves shall be such that it is suitable for requirement sustaining cold shock caused by a loading of liquid nitrogen or argon or helium or hydrogen into the vessel during its testing and commissioning.
2. Each vessel shall have super insulation that will prevent the vessel pressure from exceeding the relief valve set pressure within the specified holding time when the vessel is loaded with hydrogen at the design condition of–
a. Specified temperature and pressure of the hydrogen,
b. The exposure of the vessel to the average ambient temperature of 5 °C.
3. The outer vessel or jacket of the cryogenic vessel for transportation of hydrogen shall be made suitable for hydrogen application at design pressure & temperature of no other material other than steel.
4. No aluminum valve or fitting external to the wetted outer vessel shall be installed on hydrogen transportation vessels and each transportation vessel shall consist of a suitably supported welded inner vessel enclosed within an outer shell with vacuum insulation between the two.
B. STRUCTURAL INTEGRITY:
1. The design and construction of each vessel used for transportation of Hydrogen shall be in accordance with ASME Boiler and Pressure Vessel Code Section VIII Div. 1, EN13530, ISO 20421 or any other code approved by Chief Controller and the vessel design shall include calculation of stress due to design pressure, the weight of lading, the weight of structure supported by the vessel wall, and the effect of the temperature gradients resulting from lading and ambient temperature extremes.
2. In order to account for stresses due to impact in an accident, the design calculation of the vessel shell and heads shall include the load resulting from the design pressure in combination with the dynamic pressure resulting from a longitudinal deceleration of 2g. For this loading condition, the stress value used shall not exceed 75% of the yield strength of the material of construction.
3. The fittings and accessories mounted on the vessel shall be protected in such a way that damage caused by overturning cannot impair operational integrity and this protection may take the form of cylindrical profile of the vessel, of strengthening rings, protective canopies or transverse or longitudinal members so shaped that effective protection is given.
4. The welding of the appurtenances to the vessel wall shall be made of attachment of the mounting pad so that there shall be no adverse effect upon the loading retention integrity of the vessel.
C. PRESSURE RELIEF DEVICES, PIPING, VALVES AND FITTINGS:
1. Hoses shall be suitable for the service and shall be designed as per ISO 10380 or EN14585-1 or equivalent standards for a bursting pressure of at least five times working pressure.
2. Flexible hoses carrying LH2 should be vacuum jacketed. The inner flexible hose should be the load-carrying member.
3. If a threaded pipe is used, the pipe and fitting shall be Schedule 80 or higher rating.
4. Each hose coupling shall be designed for a pressure of at least 120% of the hose design pressure and there shall be no leakage when connected.
5. Piping shall be protected from damage due to thermal expansion and contraction, jarring and vibration and slip joints shall not be used.
6. Each valve shall be suitable for the vessel design pressure at the vessel design service temperature.
7. All fittings shall be rated for the maximum vessel pressure and suitable for the coldest temperature to which they will be subjected in actual service.
8. When a pressure building coil is used on the vessel, the vapor connection to that coil shall be provided with a valve or check valve as close to the vessel shell as practicable to stop flow in case of damage to the coil and the liquid connection to the coil shall also be provided with a valve.
9. Each vessel shall be rated for its holding time, the holding time being the time as determined by testing that will elapse from loading until the pressure of the contents, under equilibrium conditions reaches the level of the lowest pressure relief valve setting.
10. All the discharge lines of relief valves, vent valve, bleed valves etc, shall be connected to a vent stack which shall vent at a safe height.
11. Bursting discs shall not be used on the hydrogen transport vessels.
12. The outer vessel shall be protected by any accidental accumulation of pressure in the annular space by using a relief plate or plug or a bursting disc and the relief device shall function at a pressure not exceeding the internal design pressure of the outer tank, the external design pressure of the inner tank, or 25 psi whichever is less.
D. ACCIDENT DAMAGE PROTECTION:
1. All valves, fittings, pressure relief devices and other accessories to the vessels, which are not isolated from the vessel by closed intervening shut off valves or check valves shall be installed within the motor vehicle framework or within a suitable collision resistant guard or housing and appropriate ventilation, shall be provided and each pressure relief device shall be protected so that in the event of the upset of the vehicle on to a hard surface, the device’s opening will not be prevented and its discharge will not be restricted and the threaded end connection safety valves are preferred in stainless steel body construction.
2. Each protective device or housing and its attachment to the vehicle structure shall be designed to withstand static loading in any direction that it may be loaded as a result of front, rear, side or side wise collision or the overturn of the vehicle and all the valves of tank shall be at rear inside on operation box (cabinet) of suitable size and does not project out of tank diameter and the thickness of cabinet shall be minimum 3mm.
E. REAR END PROTECTION:
1. Rear end vessel protection devices shall consist of at least one rear bumper designed to protect the
transport vessel and piping in the event of a rear end collision and the rear end vessel protection device shall be designed as per IS 14812 so that it transmits the force of the collision directly to the chassis of the vehicle. The rear end vessel protection device and its attachments to the chassis shall be designed to withstand a load equal to twice the weight of the loaded cargo vessel and attachments, using a safety factor of four based on the tensile strength of the materials used with such load being applied horizontally and parallel to the major axis of the transport vessel.
2. Every part of the loaded transport vessel and any associated valve, pipe, and enclosure or protected fitting or structure shall be at least 35.5 cm above ground level.
F. DISCHARGE CONTROL DEVICES:
1. Each liquid filling and liquid discharge line shall be provided with a shut off valve located as close to the vessel as practicable and unless this valve is manually operable at the valve, the line shall also have a manual shut off valve.
2. Each liquid filling and liquid discharge line shall be provided with an on vehicle remotely controlled self- closing shut off valve.
3. Each control valve shall be of fail-safe design and spring-based.
4. Each remotely controlled shut off valve shall be provided with on vehicle remote means of automatic closure, both mechanical and thermal.
5. Each remotely controlled shut off valve shall be provided with on-vehicle remote means automatic closure, both mechanical and thermal. One means may be used to close more than one remotely controlled valve and remote means of automatic closure shall be installed at the ends of the tanker farthest away from the loading or unloading connection area.
G. SHEAR SECTION:
Unless the valve is located in a rear cabinet forward of and protected by the bumper, the design and installation of each valve, damage to which could result in loss of liquid or vapor shall incorporate a shear section or breakage groove adjacent to and outboard of the valve and the shear section or breakage groove shall yield or break under strain without damage to the valve that would allow the loss of liquid or vapor.
H. SUPPORTS AND ANCHORING:
In case, the transport tanker vehicle is designed and constructed in such manner that the vessel is not wholly supported by the vehicle frame, the transport vessel shall be supported by external cradles or load rings and the design calculations for the supports and load bearing vessel and the support attachments shall include beam stress, shear stress, torsion stress, bending moment and acceleration stress for the loaded vehicle as a unit, using a safety factor of four based on the tensile strength of the material and static loading that uses the weight of the transport vessel and its attachments when filled to the design weight of the loading. Minimum static loadings shall be maximum of the following individually, namely: –
i. Vertically downward of two (2);
ii. Vertically upward of one and half (1.5);
iii. Longitudinally of one and half (1.5); and
iv. Laterally of one and half (1.5).
I. GAUGING DEVICES:
a. Liquid level gauging devices: The vessel shall have one liquid level device that provides a continuous level indication ranging from full to empty and that is maintainable or replaceable without taking the vessel out of service.
b. Pressure gauges: Each vessel shall be equipped with a pressure gauge connected to the vessel at a point above the maximum liquid level that has a permanent mark indicating the maximum allowable working pressure of the tanker and the pressure gauge shall be housed in a canopy of the tanker.
SECTION 3
OPERATION, MAINTENANCE AND TRAINING
A. Each LH2 installation shall provide for written operating, maintenance and training procedures. Such procedures shall be drawn based on experience, knowledge of similar facilities.
B. Every installation shall meet the following requirements, namely:-
1. Have written procedures covering operation, maintenance and training.
2. Keep up-to-date drawings of plant equipment’s.
3. Have written emergency plan as part of the operations manual.
4. Shall be in liaison with local authorities like Police, Fire Department, Health Authorities and keep them informed about emergency plans and their role in emergency situations.
5. Have documents wherein safety related malfunctions are identified and analyzed for the purpose of determining their causes and preventing the possibility of reccurrence.
C. OPERATING PROCEDURES MANUAL:
Every installation shall have a written manual of emergency procedures that shall include a types of emergencies that are anticipated and shall include the following procedures, namely:-
1. Start up and shut down procedure including initial start up of the hydrogen facility.
2. Purging and inerting components.
3. Cooling down components.
4. Identify the possibility of abnormal conditions.
5. Safety precautions requirement to be taken while repairs or maintenance in the installation is being carried out.
6. Procedures for responding to controllable emergencies including notifying personnel and use of equipment’s i.e. appropriate to handling of emergency.
7. Procedure for recognizing an uncontrollable emergency and for taking action to ensure that harm to the personnel in the premises and to the public outside is limited.
8. Procedure for immediate notification of the emergency to the local authorities.
9. Procedure for coordinating with local authorities in the preparation of any evacuation plan which may be required to protect the public in the event of emergency.
B. MAINTENANCE:
1. Every installation shall have a written procedure based on experience and knowledge of similar facilities and conditions under which the installation shall be maintained.
2. The procedure shall incorporate the need to carry out periodic inspection, tests (including vacuum test for checking the loss of vacuum in cryogenic vessel) on every equipment and system in service to verify that the equipment is maintained in accordance with the equipment manufacturer’s recommendations.
3. The written manual shall set out inspection and maintenance programme for each components forming part of the installation and in addition to fixing a schedule for inspection and tests, the procedure to be followed during repairs so as to ensure safety of persons and property shall also be laid down.
C. TRAINING :
Every installation shall be provided with a training plan and the manner in which it will be implemented and maintained and the training manual shall comprise of under mentioned components-
1. Procedure of basic operation to be carried out in the installation in the normal course.
2. Carrying out of emergency procedures that relate to duties at the installation for each concerned personnel.
3. The characteristics and potential hazards of Hydrogen during operation and maintenance of the facility, including dangers from frostbite that can result from contact with hydrogen.
4. The methods of carrying out duties of maintaining and operating the facility as set out in the manual of operating and maintenance procedures.
5. The hydrogen transfer procedure.
6. Fire prevention, including familiarization with the fire control plan of the installation, fire fighting, the potential causes of fire in a facility, and the types, sizes and likely consequences of a fire in the installation.
7. Recognizing situations in which it is necessary to obtain assistance in order to maintain the security of the facility.
SECTION 4
LH2 DISPENSING
This section lays down the requirements for Hydrogen dispensing station and facilities.
A. GENERAL:
1. Hydrogen refueling sites dispensing hydrogen with personnel in the immediate vicinity shall provide barriers walls or equal protection in order to protect the refueling operator and vehicle.
2. All facility piping other than the refueling hose to the vehicle shall be behind a barrier, which in the case of an equipment or device malfunction deflects the saturated hydrogen upward.
3. Hydrogen dispenser shall observe minimum 8 m clear safety distance from the property line.
B. SYSTEM COMPONENT QUALIFICATION:
1. Vehicle Fueling Dispenser:
a. The type of the dispenser used for dispensing hydrogen shall conform to specification and be of a type approved by the Chief Controller.
b. The dispenser shall be protected from vehicle collision damage.
c. An ESD shall be provided that includes a shutoff valve for stopping liquid supply and shutting down transfer equipment.
d. An ESD actuator, distinctly marked for easy recognition with a permanently affixed, legible sign, shall be provided near the dispenser, vehicle unloading facility and in sales/control room.
e. The maximum delivery pressure at the fueling nozzle shall not exceed the maximum allowable working pressure of the vehicle fuel tanks.
f.
(i) Hose or arms shall be equipped with a shutoff valve at the fuel end and a breakaway device to minimize release of liquid and vapor in the event that a vehicle pulls away while the hose remain connected.
( ) Such a device shall be installed and maintained in accordance with the OEM component manufacturer’s maintenance/safety instructions.
(i) A breakaway device shall be arranged to separate using a force not less than 20 kgf and not greater than 125 kgf where applied in any direction that the vehicle would move.
g. The hose shall be secured to protect it from damage when not in use.
h. (i) Where a hose or arm of nominal 76 mm diameter or larger is used for liquid transfer or where one of nominal 100 mm diameter or larger is used for vapor transfer, an emergency shutoff valve shall be installed in the piping of the transfer system within 3.1 meter from the nearest end of the hose or arm.
(ii) Where the flow is away from the hose, a check valve shall be permitted to be used as the shutoff valve.
(iii) Where either a liquid or vapor line has two or more legs, an emergency shutoff valve shall be installed either in each leg or in the feed line before the legs.
i. The OEM manufacturer’s instructions shall be posted near the dispenser.
j. Operating instructions identifying the location and operation of emergency controls shall be posted conspicuously in the facility area.
k. Hydrogen fueling facilities transferring Hydrogen during the night shall have permanent, adequate lighting at points of transfer and operation.
l. The transfer of Hydrogen into vehicular onboard Hydrogen containers shall be performed in accordance with the onboard Hydrogen container and refueling component OEM manufacturer’s instructions.
2. Vehicle Fueling Connector:
j. A fueling connector and mating vehicle receptacle shall be used for reliable, safe, and secure transfer of Hydrogen or gas vapor to or from the vehicle.
k. The fueling connector either shall be equipped with an interlock device that prevents release while the line is open or have self-closing ends that automatically close upon disconnection.
3. Installation of Emergency Shutdown Equipment(ESD):
l. ESD shall be provided near to the dispenser, Hydrogen unloading facilities and sales or control room.
a Instrumentation for hydrogen fueling facilities shall be designed so that, in the event of a power or instrumentation failure, the system goes into a fail-safe condition until the operators either reactivate or shut down the system.
b All ESDs shall be manually reset.
SECTION 5
NON-FUELING FACILITIES IN HYDROGEN STATIONS
Non fueling facilities like small convenience stores, service station, ATM, PCO, whenever provided, shall be beyond safety distance mentioned in this schedule. In addition, a minimum distance of 8 meter from the hydrogen dispensers shall be maintained and the accessibility to such non fueling facilities shall not be through operational area. While providing such facilities, factors like degree of congestion in the premises, easy entry and exit of the vehicle coming for refueling and easy maneuverability of Hydrogen Road tanker while moving out of the premises in the event of emergency shall also be taken into consideration.
SECTION 6
BOIL OFF GAS MANAGEMENT
When Hydrogen station is being set up, the capacity of storage tank may be optimized so as to minimize the BOG venting. For effective BOG management, the operator may use the gas to avoid venting with the approval of the Chief Controller.
SECTION 7
EMERGENCY PLAN
LH2 dispensing station shall have a written emergency plan as per provisions of NFPA 2 or ISO 19880 in place to control the hazards from serious hydrogen leakage or fire and this plan shall contains instructions for emergency shutdown of the station, warning to customers and other people in the surrounding, calls for assistance, usage of firefighting equipment’s among others and the plan shall be tested from time to time for evaluation of its adequacy and shall be updated and modified as required.
An on-site emergency plan shall be prepared as per provisions of the MSIHC Rules as amended from time to time and submitted to the licensing authority. The occupier or holder of license shall ensure that a mock drill of the on-site emergency plan is conducted every six months; A detailed report of the mock drill conducted under sub-rule (4) of Rule 13 of the MSIHC Rules shall be made immediately available to the licensing Authority.
32. In the said rules, in FORM AS-1:
(a) The heading of FORM AS-1 shall be substituted namely:-
“APPLICATION FOR GRANT, AMENDMENT, TRANSFER OR RENEWAL OF A LICENCE IN FORM LS-1A OR LS-1B OR LS-1C OR LS-1D TO
i. Store compressed gas in a pressure vessel or vessels or
ii. Auto LPG in a pressure vessel or vessels and dispense Auto LPG in Auto LPG Dispensing Station or
iii. LNG in a pressure vessel or vessels and dispense Auto LNG as an automotive fuel or
iv. Liquefied hydrogen in a pressure vessel or vessels and dispense liquefied hydrogen or compressed hydrogen gas as an automotive fuel
DOCUMENTS LISTED IN THE NOTE MUST BE ENCLOSED WITH THIS APPLICATION
(b) In Sl No 4 after sub clause (f), following shall be inserted namely:-
“(g) Latitude and Longitude”
(c) In Sl No 7 sub clause (i) after the words “Auto LPG”, following words shall be inserted namely:-“LNG or liquefied Hydrogen”
(d) In Sl No 7 sub clause (ii) after the words “Auto LPG”, following words shall be inserted namely:-“LNG or liquefied Hydrogen”
(e) In Sl No 7 sub clause (iii) after the word “if any”, following words shall be inserted namely:-“Not applicable for premises licensed in FORM LS-1C or LS-1D of these rules.”
33. In the said rules, in license FORM LS-1B, after condition 1, following condition shall be inserted namely:-
“(1a) The licensed premises may be part of the premises already licensed in FORM XIV of the Petroleum Rules only.
34. In the said rules, in license FORM LS-1C, after condition 1, following condition shall be inserted namely:-
“(1a) The licensed premises may be part of the premises already licensed in FORM XIV of the Petroleum Rules. Such combined premises shall not have any other premises licensed under the rules administered by Petroleum and Explosives Safety Organization other than FORM XIV premises.
Provided that, nothing in the above condition shall apply to the premises already licensed on the date of publication of these rules.
35. In the said rules, in license FORM LS-2, after condition 15, following additional conditions shall be inserted namely:-
“Additional conditions for dispensing of LNG from mobile pressure vessel:-
1. The mobile pressure vessel shall have valid license in FORM LS-2 of these rules and No Objection Certificate issued under Rule 47 of these rules from the concerned Authority shall be submitted along with documents for grant of license.
2. LNG shall be dispensed only in the fuel tank of vehicle or boat or railway engine duly approved by the Chief Controller and shall have valid filling permission.
3. The mobile pressure vessel shall be loaded in the specially prepared area and covered under license FORM LS-1A of these rules.
4. The mobile pressure vessel shall be parked on a designated and dedicated place duly earmarked for parking of mobile pressure vessel during transfer of LNG into fuel tanks.
5. A clear safety distance of 30 meters all around shall be kept clear at all the times during dispensing of LNG from the mobile pressure vessel.
6. The refueling operation shall be undertaken in presence authorized responsible person who is well versed with the hazards of LNG as well as all the provisions of the rules and conditions of license FORM. The LNG transfer operation shall be carried out under direct supervision of responsible person trained by Oil Marketing Company.
7. The mobile pressure vessel shall be designed as per ASME Section VIII Div 1 only and shall have maximum allowable working pressure of not exceeding 7 Bar (gauge).
8. The hose and couplings for transfer of LNG from mobile pressure vessel shall be suitable for LNG service, shall be mechanically and electrically continuous and shall be tested at minimum four times of the operating pressure.
9. LNG shall be dispensed only in the non transport vehicles operating within the area of mines covered under the Indian Mines Act, 1952, ports notified by Ministry of Shipping, fuel tanks of locomotives of Indian Railway, fuel tanks of ships or boats operated on inland or seaborne waterways approved by Maritime Board or fuel tanks of engines tested by Central Government Testing Laboratories. The Chief Controller in exceptional circumstances for reasons recorded in writing may consider refuelling of fuel tanks of heavy equipments and machinery or other heavy vehicles which cannot be brought to the LNG dispensing station licensed under these rules.
10. The list of vehicles proposed to be refueled with LNG shall be vetted by Directorate General of Mines Safety or Conservator of Ports or any other Competent Authority under whose jurisdiction the premises exists and the vehicles are to be operated.
11. Every care shall be taken to avoid spillage and leakage of LNG from the mobile pressure vessel or hose or coupling or the fuel tank of vehicle.
12. Site specific emergency plan for each site shall be prepared for implementation in case of emergency and the copy of such emergency plan shall be submitted to the District Authority.
36. In the said rules, after the license FORM LS-1C following shall be inserted namely:-
“FORM LS-1D
(See rules 50, 51, 54 and 55)
License to store and dispense liquefied hydrogen as an automotive fuel in Liquefied Hydrogen Dispensing Station to
motor vehicles
and / or
to store liquefied hydrogen in connection with compressed hydrogen gas dispensing station.
Licence No : _______________________
Fee Rs. _______________________
Licence is hereby granted to___________________________________________ for storage of liquefied hydrogen
in the cryogenic pressure vessel or vessels and to dispense liquefied hydrogen or in connection with compressed hydrogen gas dispensing station in the premises described below and subject to the provisions of the Indian Explosive Act, 1884 (4 of 1884) and the rules made there under and to the further conditions of this licence.
| Vessel No. | Water capacity of vessel in cubic meter | Quantity of Hydrogen stored in Kgs |
The licence shall remain in force up to the 30th day of September 20___________ .
The __________________20
Chief Controller of Explosives or Controller of Explosives
DESCRIPTION OF LOCATION AND FACILITIES OF THE LICENSED PREMISES
The licenced premises, the layout, boundaries and other particulars of which are shown in the attached approved plan No._______________ dated _________________ are situated at (address)_______________________________________________________ and consists of (in addition to storage vessels mentioned above) of :-
| Sl. No. | Equipment | Capacity | Quantity |
| 1 | Dispenser having dispensing capacity and pressure | Kgs /Hr
……… Kg/Cm2 |
|
| 2 | Unloading pump | ……… Cu Mtr/Hr | |
| 3 | Transfer pump | ……… Cu Mtr/Hr | |
| 4 | High pressure vaporizer | ……… Kgs /Hr | |
| 5 | Low pressure vaporizer | ……… Kgs /Hr | |
| 6 | Compressor | ………… Kgs /Hr
………… Kg/Cm2 |
other facilities ______________________
SPACE OF FOR ENDORSEMENT RENEWALS
| The license shall be renewable without any concession in fee for five years in the absence of contravention of the provisions of the Indian Explosives Act, 1884 or Static and Mobile Pressure Vessels (Unfired) Rules, 2016 framed there under, or of the condition of the license. | Date of Renewal | Date of Expiry | Signature and Office Stamp of the Licensing Authority |
This license is liable to be cancelled if the licensed premises are not found conforming to the description and conditions attached hereto and for contravention of any of the rules and conditions of this license and the holder of this license is also punishable under the Explosives Act, 1884.
CONDITIONS
1. The licensed premises shall conform to the description of location and facilities and to the approved plan, as mentioned on the body of the licence.
2. The licensed premises shall be used only for the purpose it is licensed for.
3. Every licensed premises under these rules shall have prominently marked thereon the number of the licence held for it.
4. Liquefied hydrogen shall be stored only in one or more pressure vessels installed aboveground, as per provisions of these rules.
5. The storage vessel, pumps, vaporizer, dispenser, piping and other fittings shall be of a design suitable for liquefied hydrogen service.
6. Storage vessels shall not be installed within any building or shed.
7. A hard stand for parking the tank-truck for the purpose of unloading liquefied hydrogen into the storage vessels shall be provided as per rules.
8. The facilities and equipments of the licensed premises shall meet the safety distance requirements as specified in Schedule V.
9. Liquefied hydrogen shall be dispensed only into those containers of motor vehicles, which are approved by the Chief Controller, and have passed the periodic statutory tests under Gas Cylinders Rules, conducted by a testing station recognised by the Chief Controller.
10. The dispenser used for dispensing liquefied hydrogen shall conform to Schedule-V and specification approved by the Chief Controller.
11. All piping and fittings shall conform to Schedule-V.
12. No person shall enter or cause to repair or repair either by the use of fire, welding, hot riveting or brazing any vessel used for the storage of flammable gas unless it has been thoroughly cleaned and gas-free or otherwise prepared for safely carrying out such hot work and certified in writing, by a competent person.
13. The operation of the licensed premises shall be under the supervision of a person having knowledge of the equipments used in the premises and trained in handling compressed gas, and other operators shall be conversant with the hazards associated with the liquefied hydrogen, compressed hydrogen gas and fire fighting operations.
14. Liquefied hydrogen shall not be filled into or removed from the vessel except by means of transfer facilities shown in the approved plan attached to the licence.
15. Smoking, naked lights, lamps, source of fire or any other stimulant capable of igniting flammable vapours shall not be allowed inside the premises and every person managing or employed on or in connection with licensed premises shall abstain from any act whatsoever which tends to cause fire or explosion and which is not reasonably necessary and to the best of his ability, shall prevent any other person from doing such act.
16. The vessel shall not be filled between the hours of sunset and sunrise without written permission of the Chief Controller.
17. All electrical equipment such as motors switches, starters, control panel, compressor, dispenser, instrumentation, etc, used for transfer or compression or dispensing of liquefied hydrogen shall conform to IS/IEC or IEC or EN 60079 series standards and shall be of a type approved by Chief Controller.
18. At least two numbers of nine kilograms capacity dry chemical type fire-extinguishers shall be provided near the tank-truck unloading area and one number similar extinguisher shall be provided near each dispenser and transfer pump location. In addition, fire fighting facilities specified in Schedule V shall be provided.
19. During the period of unloading of Liquefied hydrogen from tank-truck to the storage vessels dispensing operation to the vehicles or compression operation for filling gas cylinder or cascade shall not be carried out.
20. The emergency telephone numbers of local fire service, police PESO office under whose jurisdiction the premises exists and the principal marketing company or supplier of the compressed gas, and emergency instructions shall be conspicuously displayed in the licensed premises.
21. All valves on the vessel and pipelines in the premises shall be permanently marked in a manner clearly indicating the direction of opening and closing.
22. Free access to the licensed premises shall be given at all reasonable times to any of the officers specified in rule 70 and every facility shall be afforded to such officer for ascertaining that the rules and the conditions of this licence are duly observed.
23. If the licensing authority calls upon the holder of a licence by a notice in writing to execute any repairs in the licensed premises which are, in the opinion of such authority, necessary for the safety of the premises, the holder of the licence shall execute the repairs within such period as may be specified in the notice.
24. Any accident, fire, explosion or untoward incident occurred within the licensed premises shall be immediately reported to the Chief Controller, PESO office under whose jurisdiction the premises exists, nearest police station and the District Magistrate by the most quickest mode of communication.”.
[F. No. 2(1)/2017-Expl ]
Dr. SANDHYA BHULLAR, Jt. Secy.
Note : The principal rules were published in the Gazette of India, Extraordinary, Part-II, Section 3, Sub-section (i) vide notification G.S.R. 1109 (E), dated the 1st December, 2016 and subsequently amended vide G.S.R 388(E), dated the 20th April, 2018, G.S.R 148(E), dated the 25th February, 2019 and G.S.R. 609 (E) dated 31/08/2021.
