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Petroleum Oil, Lubricants (POL) & Liquefied petroleum gas (LPG) tanker vehicles are special application segment that holds a significant Market share for commercial vehicles. These vehicles need to comply additional Safety regulations specified by Petroleum and explosives safety organization (PESO). For compliance to Rule-70, Protective heat shield on exhaust system needs to be designed and validated in order to avoid any catastrophic failure. The paper demonstrates the methodology to identify the worst case scenario for the existing commercial vehicle segment. Based on detail digital mock up (DMU) review Metallic heat shield was designed on after treatment system (ATS). The flexible heat shield was designed for exhaust pipe & joints in order to restrain the heat flow to the surrounding aggregates. After finalising design, CFD analysis was carried out to find out the thermal effects on various components and results within acceptable limits.