1. 4.2 Student Book © 2004 Propane Education & Research Council Preparing and Installing Vapor Distribution System Components 4.2

2. Consult local jurisdictions for applicable codes, standard and legal requirements This material is not an exhaustive treatment of the subject and does not preclude other procedures to enhance safe LP-gas operations This publication is not intended nor should it be construed to 1.Set forth procedures which are the general custom or practice in the propane industry 2.Establish the legal standards of care owed by propane distributors to their customers 3.Prevent the reader from using different methods to implement applicable codes, standards or legal require- ments. CETP Program Disclaimer

3. This training material was designed to be used as a resource only and does not replace federal, state, local, or company safety rules. The user of this material is solely responsible for the method of implementation. The Propane Education and Research Council, the National Propane Gas Association and Industrial Training Services, Inc. assume no liability for reliance on the contents of this training material. Issuance of this material is not intended to nor should it be construed as an undertaking to perform services on be- half of any party either for their protection or for the protection of third parties. CETP Program Disclaimer

4. 4.2 Student Book © 2004 Propane Education & Research Council Learning Aids—These margin notes are provided to help you identify sources, take precautions, or give guidance on your job. Symbols Warning: Important precaution that you should always remember when performing the identified task. Tools: This task requires special tools or procedures. PPE: This is a task that requires personal protection equipment. Paper Work or Forms: This task should be documented on your company’s forms for compliance or legal reasons. Safety Procedure: For your safety special precautions and safety guidelines apply to this task or operation of equipment. Company S.O.P. : Follow your company’s Standard Operating Practices (or Procedures). If you’re not sure of your company’s policy, check with your supervisor.

5. Electrical Hazard: This task involves an electrical hazard. Lockout and Tagout procedures must be followed. Explosive/Fire Hazard: This task involves a fire or explosion hazard. Use appropriate precautions. Lockout and Tagout procedures may apply. Technical Tips: This technique may be very useful as you do a task. Technical Tip The National Fire Protection Association: References to sections of the LP-Gas Codes and Standards. NFPA 54 Or NFPA 58 U.S. Department of Transportation: DOT has regulatory authority, both interstate and intrastate, over the transportation of hazardous materials. References to Title 49, Code of Federal Regulations. Department of Labor: (OSHA) administers federal employee safety and health regulations. 4.2 Student Book © 2004 Propane Education & Research Council

6. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 1 When propane cylinders are received at the bulk plant, they must be inspected to determine their fitness for service, requalification, re-filling, storage for future transportation, or for condemnation and scrapping. In this module you will learn to identify: (1)Regulations pertaining to processing cylinders that have been in service (2)Processes for receiving and examining cylinders at the bulk plant (3)procedures for processing new cylinders received at the bulk plant (4)procedures for preparing and loading propane cylinders on the delivery vehicle Preparing DOT/ICC Cylinders for Transportation and Installation 4.2.1

7. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 1 Regulations for Cylinders That Have Been in Service No person may fill a cylinder overdue for periodic requalification with a hazardous material and then offer it for transportation. Before each filling of a cylinder, the person filling the cylinder must visually inspect the outside of the cylinder. A cylinder that has a crack or leak, is bulged, has a defective valve or a leaking or defective pressure relief device, or bears evidence of physical abuse, fire or heat damage, or detrimental rusting or corrosion, may not be filled and offered for transportation.

8. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 1 Regulations for Cylinders That Have Been in Service NFPA 58, LP-Gas Code, 2.2.1.5 requires that cylinders must be filled, continued in service, and transported in compliance with DOT regulations. Further, any cylinder that is due for requalification must not be refilled until it is requalified using requalification methods prescribed by DOT. 5.2.2.2 A cylinder with an expired requalification date shall not be refilled until it is requalified by the methods prescribed in DOT regulations. NFPA 58 2001 NFPA 58 2004

9. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 2 Processes for Receiving and Examining Cylinders When cylinders are received at the bulk plant, whether they are new cylinders or ones that have been in service and picked up for refilling, they must be properly processed for storage or future transportation to customer sites After or during unloading at the bulk plant each cylinder should be inspected to determine fitness for continued service. The first item to check is its due date for requalification.

10. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 2 Processes for Receiving and Examining Cylinders Checking Requalification Due Date Figure 2. DOT Cylinder Requalification Periods Letter After Year Stamp Requalification Method Next Requalification Due (years) NoneVolumetric Expansion Test12 SProof Pressure Test7 E External Visual Inspection (CGA Inspection Method) 5

11. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 2 Processes for Receiving and Examining Cylinders Checking Requalification Due Date A DOT cylinder marked 10 01E is due for requalification before or during October 2006. The cylinder may require requalification before its due date if it is damaged or subjected to physical abuse, excessive corrosion or heat. Cylinders that have been exposed to fire must be immediately removed from service. Steel cylinders should be designated as “REJECTED”. Only cylinder manufacturers or DOT approved repair facilities may requalify steel cylinders, while aluminum cylinders must be condemned and scrapped.

12. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 2 Processes for Receiving and Examining Cylinders Checking Requalification Due Date Figure 3. Cylinder Requalification Stamp

13. 4.2.1 Student Book © 2004 Propane Education & Research Council Processes for Receiving and Examining Cylinders Checking Requalification Due Date DOT Approved Cylinder Requalification Stamps V10001 0604 E V10001 V10001 0604 E Valid for 5 years from the date Valid for 5, 7 or 12 years from the date, depending on the meaning of “ x ” Valid for 5 years from the date

14. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 3 Processes for Receiving and Examining Cylinders Determining Fitness for Continued Service Cylinder valve protection should always be in place. Exchange cylinders that require a valve cap for protection should have caps secured in place at all times except when the cylinder is on scales during filling, or when the cap is removed for valve inspection or cylinder evacuation. The valve cap should only be removed when the cylinder is on a level surface or secured to a cylinder inverter or other stable structure.

15. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 3 Processes for Receiving and Examining Cylinders Determining Fitness for Continued Service Figure 4. Cylinder Valve Protection Devices

16. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 3 Processes for Receiving and Examining Cylinders Determining Fitness for Continued Service Cylinder Inspection Tag If valve or fitting replacement is indicated, the cylinder should be marked for proper disposition using a tag or suitable marker, then moved to an area designated for cylinders requiring valve replacement. If requalification is required, this condition should be marked as well and the cylinder moved to a designated area for that purpose.

17. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 4 Processes for Receiving and Examining Cylinders Determining Fitness for Continued Service Figure 5. Processing Cylinders At a Bulk Plant

18. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 4 Processes for Receiving and Examining Cylinders Safety Considerations for Storing and Processing Cylinders Figure 5 illustrates considerations for cylinder handling, storage, and processing. Directing Relief Valves Away From Adjacent Cylinders

19. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 4 Processes for Receiving and Examining Cylinders Safety Considerations for Storing and Processing Cylinders 1.Cylinders should be arranged so that any cylinder can be accessed in the event of a service valve or other leak. 2.Proper valve protection should be maintained at all times. 3.Consideration should be given to cylinder movement through the various handling processes from unloading through loading. 4.Efforts should be made to position cylinders so that cylinder relief valve discharges are not directed at the service valves of adjacent cylinders.

20. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 5 Processes for Receiving and Examining Cylinders Checking for Proper Cylinder Labeling Figure 6. DOT Shipping Label Combination DOT Shipping Label, NFPA 704 Style “OSHA Label” & Customer Information Label

21. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 5 Processes for Receiving and Examining Cylinders Checking for Proper Cylinder Labeling A consumer information label must be applied to all portable refillable LP-gas cylinders of 100 lb. LP-gas capacity or less not filled on-site. The label shall include information on the potential hazards of LP- gas. NFPA 58

22. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 5 Processing New Cylinders New DOT cylinders should be inspected to be sure that they are not damaged and are approved for propane.  DOT and NFPA 58 required markings  Proper Valve Protection (neck ring or cap)  Proper Foot Ring Attachment  Motor Fuel Cylinders  Stationary Cylinders

23. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 6 Processing New Cylinders Purging New Cylinders Before liquid propane is introduced into new cylinders it is necessary to purge them of air. Some cylinder manufacturers pre-purge new cylinders before they are shipped, by removing air using a vacuum pump. To determine if a cylinder has been vacuum purged, a POL test gauge block fitted with a negative/positive pressure gauge and plugged outlet should be used. Figure 7. Pre-Purging Pressure Test Block

24. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 7 Processing New Cylinders Purging New Cylinders If a new cylinder is not pre-purged by the manufacturer, or has been open to the atmosphere, it must be properly purged of air, and then charged with propane vapor before it is filled with liquid propane. Figure 9. New Cylinder Air Purging Pump

25. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 7 Processing New Cylinders Purging New Cylinders Note: Follow manufacturer’s operating instructions. WARNING: Purge pumps must be used only on new cylinders which have NEVER contained any flammable substance.

26. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 8 Processing New Cylinders Purging New Cylinders Figure 10. Purging with Propane Vapor

27. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 8 Processing New Cylinders Purging New Cylinders By alternately opening valves 1 and 2 five times, charging the cylinder with propane vapor to 15 psig, each time allowing the gas/air mixture to vent until the cylinder pressure reaches atmospheric pressure, the cylinder will be purged of air and ready for liquid filling. A final vapor charge of 15 psig should be retained in the cylinder before introducing liquid propane.

28. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 8 Preparing & Loading Propane Cylinders on the Delivery Vehicle When delivering propane cylinders to residential or industrial customers, the driver is responsible for the delivery vehicle and for transporting cylinders safely and efficiently. This involves the use of various kinds of equipment designed to lift the cylinders onto and off of the delivery vehicle and to secure them while being transported.

29. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 9 Preparing & Loading Propane Cylinders on the Delivery Vehicle Protection of Cylinder Valves and Fittings – The transportation of cylinders must incorporate protection against physical damage to the cylinder valves and fittings while in transit. A cylinder must have its valves protected by one of the following methods Securely attached metal caps The valve is recessed into the cylinder or otherwise protected [valve collars] According to NFPA 58, cylinders of 45-pound propane capacity or less must have a plug, cap, or an approved quick closing coupling in place on or in the service valve when the cylinder is not connected for use.

30. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 10 Loading and Securing the Cylinder Cargo – Cylinders shall be fastened securely in a position to minimize the possibility of movement, tipping, or physical damage related to each other or to the supporting structure, while in transit. Cylinders containing Class 2 (gases) materials must be securely restrained in an upright position, loaded in racks… and securely attached to the motor vehicle to prevent the cylinders from being shifted, overturned or ejected from the vehicle under normal transportation conditions. A cylinder containing a Class 2 material may be loaded in a horizontal position when the cylinder is designed so that the inlet… to the… pressure relief device is located in the vapor space of the cylinder. Preparing & Loading Propane Cylinders on the Delivery Vehicle

31. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 10 Preparing & Loading Propane Cylinders on the Delivery Vehicle Loading and Securing the Cylinder Cargo Figure 10. Cylinders Secured Vertically Figure 11. Secured Horizontally with Relief Valves at Top (Vapor Space)

32. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 10 Shipping Papers If permanent shipping papers are used, the date and number of cylinders loaded at the beginning of the delivery route must be recorded on the permanent shipping paper (typically with a wax pencil marker).

33. 4.2.1 Student Book © 2004 Propane Education & Research CouncilPage 11 Shipping Papers Front Side Reverse Side Figure 3. Shipping Paper for Cylinder Delivery Vehicles

34. 4.2.1 Student Book © 2004 Propane Education & Research Council12 - 15 Time to See If You Got the Key Points of This Module… Complete the Review on pages 12 & 13. See if you are ready for the Certification Exam by checking off the performance criteria on pages 14 & 15.