PESO Approval Requirements for LPG / Propane Bullets in India

Why PESO Approval Is Critical for LPG and Propane Bullets

LPG and propane are widely used in industries, refineries, bottling plants, hotels, food processing units, chemical plants, steel plants, ceramic industries and large-scale heating applications. But because these gases are stored under pressure and are highly flammable, the storage system cannot be treated like an ordinary tank.

An LPG or propane bullet is not just a storage vessel. It is a statutory pressure vessel. Its design, fabrication, inspection, safety fittings, site layout, fire protection and licensing must comply with PESO requirements under the Static and Mobile Pressure Vessels (Unfired) Rules, 2016, commonly known as the SMPV(U) Rules.

The Petroleum and Explosives Safety Organisation, PESO, regulates storage and transportation of compressed gases in pressure vessels in India. PESO’s SMPV SOP states that the rules cover storage and transportation of compressed gases, including LPG, in static and mobile pressure vessels.

For any buyer, EPC contractor or plant owner, the message is simple:

Do not finalize an LPG or propane bullet only on price. Finalize it on PESO compliance, safety, documentation and fabrication capability.

What Is an LPG / Propane Bullet?

An LPG or propane bullet is a horizontal cylindrical pressure vessel designed for bulk storage of liquefied petroleum gas or propane under pressure.

These bullets are commonly used in:

• LPG bottling plants

• Industrial fuel storage systems

• Propane storage terminals

• Refineries and petrochemical plants

• Ceramic and glass industries

• Food processing and dairy plants

• Rubber, textile and chemical industries

• Auto LPG installations

• Large industrial heating applications

Unlike atmospheric tanks, LPG and propane bullets are designed to withstand internal pressure. PESO’s SOP defines a pressure vessel as a closed metal container for storage and transport of compressed gas, with water capacity exceeding 1,000 litres, including interconnecting parts and components up to the first point of connection to piping and fittings.

Which Rules Apply to LPG / Propane Bullets?

For LPG and propane storage bullets in India, the primary regulation is:

Static and Mobile Pressure Vessels (Unfired) Rules, 2016

These rules apply to storage and transportation of compressed gases in static and mobile pressure vessels. PESO specifically lists Liquefied Petroleum Gas and Liquefied flammable gases among the gases considered for approval or license under the SMPV(U) Rules.

Depending on the installation type, other standards and requirements may also become relevant, such as:

• SMPV(U) Rules, 2016

• PESO license conditions

• OISD requirements for LPG bottling plants

• Fire safety requirements

• Electrical hazardous area requirements

• Site-specific statutory approvals

• Factory / local authority approvals, where applicable

For LPG bottling plants, PESO’s SOP states that large-capacity LPG bottling plants should conform to OISD 144, and small-capacity LPG bottling plants should conform to OISD 169.

PESO License Forms for LPG / Propane Storage

PESO classifies static pressure vessel installations under different license forms based on the purpose of storage.

For static storage of compressed gas, the SOP lists the following relevant categories:

Purpose	PESO License Form
Isolated storage of compressed gas for end use	LS-1A
Storage of compressed gas for filling cylinders	LS-1A
Generation of compressed gas and filling in mobile vessels or cylinders	LS-1A
Storage of LPG for filling in cylinders	LS-1A
Storage of Auto LPG for dispensing as automotive fuel	LS-1B
LNG / LCNG automotive fuel storage	LS-1C

PESO’s SOP identifies LS-1A for LPG storage and LPG filling applications, while Auto LPG dispensing premises fall under LS-1B.

For most industrial LPG / propane bullet storage applications, LS-1A is usually the key license category, subject to the exact nature of usage and PESO’s final interpretation.

Step-by-Step PESO Approval Flow for LPG / Propane Bullets

1. Site Selection and Safety Distance Review

Before ordering the bullet, the site layout must be checked for PESO safety distance requirements. The location of the bullet, boundary wall, roads, buildings, ignition sources, electrical lines, nearby storage, filling point, pump house and fire-water system must be planned correctly.

PESO’s SOP requires layout drawings to show safety distances around the vessel as per Rule 22, along with the position, capacity, material of construction, ground and elevation views of vessels, valves, fittings, pumps, fire-fighting facilities and other facilities forming part of the premises.

A wrong site layout can delay approval even if the vessel itself is well fabricated.

2. Selection of PESO Approved Fabricator

The LPG or propane bullet must be manufactured by a capable and approved pressure vessel fabricator. PESO’s SOP states that workshops fabricating pressure vessels, vaporizers and fittings shall be approved by PESO. The approval process includes inspection of technical manpower, design capability, fabrication setup, quality control, machinery, tools, equipment and available fabrication space.

This is where many projects face risk. A non-approved or poorly documented fabricator may create serious problems during drawing approval, inspection, license grant, insurance review and plant commissioning.

KRR Heavy Engineering operates PESO-approved fabrication capability for equipment such as LPG storage bullets, propane vessels, butane vessels, ammonia storage tanks, cryogenic tanks and high-pressure gas storage vessels.

3. Design and Fabrication Drawing Approval

The design must be prepared as per applicable code, service condition, design pressure, design temperature, material, corrosion allowance, nozzle orientation, supports, safety fittings and PESO requirements.

For type approval / design approval, PESO’s SOP lists key documents such as fabrication drawings vetted by an inspector, design calculations vetted by an inspector and design appraisal certificate issued by the inspector.

A good LPG / propane bullet drawing package should normally include:

• General arrangement drawing

• Fabrication drawing

• Nozzle orientation drawing

• Saddle / support details

• Material specifications

• Design calculations

• Weld joint details

• NDT requirements

• Hydrotest requirements

• Safety valve details

• Name plate and stamping details

• Painting / coating requirements

• Documentation index

4. Mandatory Safety Fittings

LPG and propane bullets require proper safety fittings. These are not accessories; they are essential statutory and operational safety components.

Typical safety fittings include:

• Safety relief valves

• Excess flow valves

• Pressure gauges

• Level gauges / level indicators

• Temperature instruments

• Isolation valves

• Drain and vent arrangements

• Earthing connection

• Fire-safe fittings, wherever applicable

• Emergency shut-off systems, depending on installation requirement

PESO’s SOP definition of fittings includes safety relief valves, excess flow valves, level measuring, temperature measuring and pressure measuring devices fitted directly on the pressure vessel.

The selection, sizing, certification and installation of these fittings must be aligned with PESO requirements and the approved drawing.

5. Inspection, Testing and Certification

A PESO-compliant LPG / propane bullet must pass inspection and testing before it can be used.

Typical inspection and testing stages include:

• Raw material verification

• Plate identification and traceability

• Welding procedure qualification

• Welder qualification

• Fit-up inspection

• Dimensional inspection

• Radiography / NDT

• Hydrostatic pressure test

• Safety relief valve test certificate

• Final inspection

• Painting and dispatch clearance

• Documentation submission

For static pressure vessel premises, PESO’s SOP lists documents such as safety relief valve test certificate, Certificate of Control or hydro test certificate, certificate of safety, fabrication drawing approval letter and fabrication drawing signed by applicant, fabricator and competent person.

Documents Usually Required for PESO Approval

For LPG / propane bullet projects, the document requirement may vary based on installation type, location, storage capacity and PESO office review. However, the following documents are commonly important:

Company and Land Documents

• Covering letter

• Application Form AS-1

• Company incorporation / partnership / proprietorship documents

• PAN / GST documents

• Land ownership document, registered lease agreement or allotment document

• Site address and applicant details

PESO’s SOP includes covering letter, Form AS-1, legal possession of land and company documents among required submissions for relevant static pressure vessel transactions.

Technical Drawings and Layouts

• Layout drawing of licensed premises

• Site plan showing surrounding area

• Safety distance marking

• Ground and elevation views

• Vessel capacity and material details

• Piping and instrumentation diagram

• Fire-fighting layout

• Electrical hazardous area details, where applicable

PESO’s SOP requires site plans showing surrounding areas within 100 metres from proposed licensed facilities; for major installations of flammable or toxic gases, the requirement may extend to 500 metres as per Rule 46(1)(i)(c).

Safety and Compliance Documents

• HAZOP and risk analysis report, where applicable

• No Objection Certificate for flammable / toxic / corrosive gases

• Safety relief valve test certificate

• Hydro test certificate

• Certificate of Control

• Certificate of Safety

• Fabrication drawing approval letter

• Approved fabrication drawing

• Undertaking that premises conform to SMPV(U) Rules

For major installations of flammable or toxic gases, PESO’s SOP includes HAZOP study and risk analysis report prepared by a reputed agency.

Safety Distance and Fire Protection: The Most Common Approval Bottleneck

Many buyers focus only on the storage capacity of the LPG bullet: 5 MT, 10 MT, 20 MT, 50 MT, 100 MT or more.

But PESO approval depends heavily on where and how the bullet is installed.

Important site factors include:

• Distance from property boundary

• Distance from buildings

• Distance from roads

• Distance from ignition sources

• Distance from other storage tanks

• Approach for fire tender movement

• Fire-water availability

• Hydrant and monitor coverage

• Earthing and lightning protection

• Electrical classification

• Drainage and gas dispersion safety

• Unloading area layout

PESO’s SOP states that licensed premises must observe safety distances as per applicable Rule 22 tables, including separate tables for liquefied flammable gases, LPG bottling plants above 100 MT, LPG bottling plants below 100 MT and Auto LPG dispensing premises.

This is why early-stage layout review is critical. Correcting the layout after fabrication or civil work can become expensive.

Above-Ground, Mounded and Underground LPG Bullets

LPG / propane bullets can be installed in different configurations depending on safety, space, capacity and project requirement.

Above-Ground Bullets

These are common for industrial storage and are easier to inspect and maintain. However, they require proper safety distances, fire protection and exposure protection.

Mounded Bullets

Mounded bullets are covered with a protective mound and are used where safety distance, thermal protection or risk reduction is a major concern.

Underground Bullets

Underground bullets may be selected for specific space and safety requirements, but inspection, corrosion protection and maintenance planning become very important.

PESO’s SOP states that underground and mounded pressure vessels shall conform to Schedule III of the SMPV(U) Rules.

Why Buyers Should Not Treat LPG Bullets as Ordinary Pressure Vessels

A normal industrial pressure vessel may only require mechanical design, fabrication and inspection as per agreed code.

An LPG / propane bullet requires more:

• PESO approved fabrication route

• Correct statutory drawing approval

• Safety fittings as per rules

• Fire protection compatibility

• Licensed premises approval

• Proper safety distance compliance

• Competent person / inspector involvement

• Hydro test and safety certification

• Proper documentation for site license

• Coordination between buyer, fabricator, consultant and PESO

A low-cost supplier may deliver a vessel. But a compliant supplier delivers a vessel that can be approved, installed, insured and operated safely.

Common Mistakes That Delay PESO Approval

1. Ordering the Bullet Before Checking Site Feasibility

The vessel capacity should be selected after reviewing available safety distance, fire protection and statutory layout requirements.

2. Incomplete Drawing Submission

Missing nozzle details, unclear safety distance marking, incomplete P&ID, absent fire-fighting layout or unsigned drawings can delay approval.

3. Non-Compliant Safety Fittings

Safety relief valves, excess flow valves, level gauges and pressure instruments must match approved specifications.

4. Wrong Capacity Selection

Oversizing the bullet without checking site space and safety distance can make the installation difficult to approve.

5. Poor Documentation

For PESO-related work, documentation is as important as fabrication. Material certificates, NDT reports, hydrotest certificates, safety valve certificates and approved drawings must be properly maintained.

6. Selecting a Fabricator Without PESO Experience

The fabrication shop should understand design approval, inspection stages, documentation and site license requirements. PESO’s SOP clearly states that the workshop fabricating pressure vessels, vaporizers and fittings shall be approved by PESO.

Buyer Checklist Before Ordering an LPG / Propane Bullet

Before issuing a purchase order, ask these questions:

1. Is the supplier a PESO approved fabricator?

2. Has the site layout been checked for PESO safety distance?

3. What license form applies to the installation?

4. Is the bullet above-ground, mounded or underground?

5. What is the design code?

6. What is the design pressure and temperature?

7. What is the required storage capacity in MT and water capacity?

8. Are safety fittings included in the scope?

9. Is fire-fighting layout included?

10. Who will prepare the PESO drawing package?

11. Who will coordinate with the competent person / inspector?

12. Are hydrotest, NDT and safety valve certificates included?

13. Are installation and commissioning support included?

14. Are piping, unloading system and pumps included or excluded?

15. Is documentation clearly listed in the offer?

This checklist alone can prevent major project delays.

Why Choose KRR for LPG / Propane Bullets?

KRR Heavy Engineering is a trusted Indian manufacturer of pressure vessels, storage bullets and heavy engineering equipment for oil & gas, chemical, petrochemical, fertilizer, refinery and industrial sectors.

For LPG and propane bullet projects, KRR supports customers with:

• PESO-approved fabrication capability

• Pressure vessel design and fabrication experience

• LPG / propane storage bullet manufacturing

• Material traceability and quality documentation

• NDT, hydrotest and inspection coordination

• Safety fittings integration

• Fabrication drawing and documentation support

• Heavy engineering manufacturing infrastructure

• Experience with statutory and third-party inspection requirements

KRR’s PESO-approved shop page lists LPG storage bullets, propane vessels, butane vessels, ammonia storage tanks, cryogenic tanks and high-pressure gas storage vessels among its fabrication capabilities.

Final Word: PESO Approval Is Not a Final Step — It Starts at Design Stage

The biggest mistake in LPG / propane storage projects is treating PESO approval as an activity to be handled after manufacturing.

In reality, PESO compliance starts from day one:

• Site selection

• Capacity selection

• Layout planning

• Safety distance review

• Fabricator selection

• Drawing preparation

• Inspection planning

• Documentation control

• Fire safety planning

• Final license submission

When these are planned correctly, the project moves smoothly from design to approval, fabrication, installation and commissioning.

For LPG / propane storage bullets, safety is not only an engineering requirement. It is a statutory responsibility.

Call to Action

Planning an LPG or propane storage bullet for your plant?

Share your required capacity, gas type, site location, operating pressure, available plot layout and end-use details with KRR Heavy Engineering. Our team can support you with PESO-compliant pressure vessel manufacturing, documentation and technical guidance for safe project execution.

KRR Heavy Engineering Pvt. Ltd.Email: info@krr.co.inWebsite: www.krr.co.inBusiness Enquiry: +91 93456 25050 / +91 99400 98749

FAQ

1. Is PESO approval required for LPG storage bullets in India?

Yes. LPG is covered under the SMPV(U) Rules, 2016 for storage and transportation in pressure vessels. PESO approval and licensing requirements depend on the storage capacity, installation type and end use.

2. Which PESO license form is used for LPG storage bullets?

For static storage applications, LS-1A is commonly applicable. Auto LPG dispensing premises are covered separately under LS-1B. Final applicability should be confirmed based on project use and PESO review.

3. Can any pressure vessel manufacturer fabricate LPG bullets?

No. PESO’s SOP states that workshops fabricating pressure vessels, vaporizers and fittings shall be approved by PESO.

4. What documents are required for PESO approval?

Common documents include Form AS-1, land documents, company documents, layout drawing, site plan, P&ID, safety distance drawing, safety relief valve certificate, hydrotest certificate, certificate of safety, approved fabrication drawing and other documents required by PESO.

5. What is the difference between LPG bullet and propane bullet?

Both are pressure vessels used for liquefied gas storage. The design conditions, material, safety fittings and approval requirements depend on the gas composition, pressure, temperature, capacity and end-use.

6. What causes delay in PESO approval?

Common reasons include wrong site layout, inadequate safety distance, incomplete drawings, non-compliant safety fittings, missing certificates, unclear scope between buyer and supplier, and selection of a non-approved fabricator.

7. Does KRR manufacture PESO-approved LPG / propane bullets?

Yes. KRR Heavy Engineering has PESO-approved fabrication capability for pressure vessels including LPG storage bullets and propane vessels.