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10.1 Application

This section covers plants for the filling of cylinders of LPG and the handling and storage of cylinders at such plants. This may include the refilling of cylinders at consumers’ premises for their consumption.

10.2 Cylinder filling locations and platforms

10.2.1 General requirements

10.2.1.1 Cylinder shall be filled with LPG only in buildings designed for that purpose or in the open air. The filling of cylinders shall not be done in basements or upper storeys of a building.

10.2.1.2 Floors may be near ground level or raised to vehicle platform height. If floor is raised, the space underneath should preferably be filled in or, if it is left open, it shall be unobstructed and without depressions to ensure ventilation. The open space beneath the floor shall not be used for any storage purpose and shall be kept clean and free from any combustible material.

10.2.1.3 As far as possible, the floor of the building or area should be without channels, or other depressions which could accumulate gas. Where channels or pits in buildings are necessary for conveyors or other equipment they shall be adequately ventilated by ducts to the outside of the building.

10.2.1.4 A covered cylinder filling platform may be used, provided that at least two sides of the platform are not enclosed or alternatively, means of ventilation shall be provided for the approval of the relevant authority.

10.2.1.5 If the filling is not carried out within a fenced area, a fence of at least 2 m high shall be provided to enclose the filling and storage areas. A building or fenced area shall have at least two means of exit located as far apart as practicable. Doors or gates shall be opened outwards, shall not be self locking, and shall be capable of being opened readily from the inside.

10.2.1.6 No duct, drain, or blow-off line shall be directed into or discharged near sewer systems or drains used for other purposes.

10.2.1.7 Water drains from the filling building or area, where they pass to an outside drainage system, shall be provided with effective seals.

10.2.1.8 Piping, where it passes through a concrete or brick wall, shall be protected by a casing within which it is free to move.

10.2.1.9 Adequate lighting shall be provided to illuminate the working and storage areas.

For Public Comment

10.2.2 Safety distances

The cylinder filling building or filling area in the open shall be located in relation to buildings (other than buildings used specifically for storage and handling of LPG), property boundaries, cylinder storage area, LPG tankers discharge/filling locations, flammable and combustible liquids storages and bulk LPG storage containers in accordance with the minimum safety distances in Figure 8.

10.3 Cylinder filling

10.3.1 Inspection of cylinder prior to filling

10.3.1.1 Prior to filling, cylinder shall be visually inspected for mechanical damage.

Damage caused by denting or corrosion and any unsafe cylinder shall be rejected. Visual inspection shall include an examination of the cylinder valve and a check on whether the cylinder is due for periodic test. Cylinders must be retested or requalified in accordance with Annex L.

10.3.2 Filling system

10.3.2.1 Cylinder shall be filled accurately and checks made to ensure that overfilling does not take place. Filling may be by mass or volume. Filling of cylinders by volume may be carried out when the cylinder is fitted with a fixed liquid level gauge.

Without prejudice to the safety requirements, all cylinders shall not be under filled to less than labelled weight.

10.3.2.2 The system shall be designed in such a way to minimise discharge minimum leakage when the connection to the cylinder valve is released.

10.3.2.3 Conveniently accessible stop valves shall be fitted to the end of each branch filling line from the header immediately before the filling unit. An approved emergency shutdown device shall be fitted to the liquid supply line to the filling platform.

10.3.2.4 Hydrostatic relief valves shall be fitted in pipeline where liquid may be trapped between closed valves.

10.3.3 Filling limits

The maximum quantity of LPG filled into a cylinder shall be in accordance with the requirements of Section 9.

10.3.4 Venting of overfilled and leaking containers

When the contents of an overfilled cylinder are adjusted by venting, a suitable vent shall be used to carry the vented gas from the filling building for dispersal in a safe place.

Alternatively, venting may be done in a safe place in the open air.

10.3.5 Inspection after filling

Each cylinder valve and cylinder after filling shall be inspected to ensure that it is free from leaks and satisfactory for service.

For Public Comment

Aggregate capacity of storage Minimum safety distance (m) Water capacity of storage (kl) Nominal mass of LPG storage

(tonne)

Figure 8. Saf

e

For Public Comment

10.3.6 Acceptable limit of leakage

A cylinder with a leakage of not more than 1.5 g/h is acceptable for use (see note). Cylinders of suspected leakage of more than 1.5 g/h shall be tested as shown in Figure 9 to determine the actual amount of leakage. A cylinder with a leakage of more than 1.6 g/h shall not be used.

NOTE. For cylinder there may occur insignificant leakages that are impracticable to detect under normal production conditions even if the operator makes great efforts with suitable equipment. For this reason a leakage of not more than 1.5 g of escaped gas per hour is considered acceptable. A leakage of 1.5 g/h clearly manifests itself and can be check-measured by immersing a cylinder in water and using a special graduated glass as shown in Figure 9.

10.4 Handling and storage of cylinders

10.4.1 Handling of cylinders

10.4.1.1 Unless otherwise specifically required, filled cylinders shall be handled in the vertical position. Cylinders shall be placed so that the safety relief valve is always in direct communication with the vapour space.

10.4.1.2 Cylinders shall be handled with care, at all times avoiding damage to the cylinder and to the valve.

Figure 9. Check for gas leakage in cylinder

10.4.1.3 Valve outlet plugs or caps shall not be removed without making sure that the cylinder valve is closed.

10.4.1.4 Valves on empty cylinders shall be closed and where a valve protecting cover is supplied it shall be in place.

10.4.1.5 No attempt shall be made to heat a cylinder.

10.4.1.6 Tests for suspected leaks shall be made using a gas detector, soapy water or water immersion BUT NEVER WITH A NAKED FLAME.

Conversion scale:

10.4.2 Storage of cylinder

10.4.2.1 The layout of the cylinder store shall be such as to facilitate quick removal of cylinders in case of emergency and the safety distances in Figure 8 shall be observed.

10.4.2.2 Cylinders shall not be in proximity to corrosive or highly flammable substances.

10.4.2.3 When cylinders are stored outside, precautions shall be taken to:

a) provide them with clean dry standing;

b) prevent access by unauthorised persons; and c) prevent accidental damage by vehicles etc.

10.4.2.4 Cylinders shall be stored only in a place with adequate floor level ventilation.

10.4.2.5 Cylinders shall always be stored at or above ground level and away from basements, drains, hollows, etc. where vapour might collect.

10.4.2.6 Cylinders shall not be exposed to excessive heat.

10.4.2.7 Fire extinguishers shall always be available and shall be kept convenient to and outside the store.

10.4.2.8 Cylinders in store shall have valves closed even though they may be empty.

10.4.2.9 Cylinders shall be stacked in storage in such a manner that all cylinders are at all times accessible for inspection and that any cylinder may be readily removed. Cylinders shall be placed so that the safety relief valve is always in direct communication with the vapour space.

10.4.2.10 Valve caps and/or plugs, where provided, shall be in position on filled cylinders when in storage or during transport.

10.5 Decanting

10.5.1 Restriction

This requirement relates to decanting by which transfer of product from cylinder to cylinder is carried out, without the use of a pump, using only the product differential pressure. Decanting shall be permitted only for the following situations:

a) for legitimate sampling purposes;

b) for evacuation of product during emergencies; and c) for leaking or overfilled cylinders.

Decanting for the purpose of resale or distribution is prohibited.

For Public Comment

10.5.2 General requirements

10.5.2.1 Decanting shall be only from cylinder into cylinder.

10.5.2.2 The cylinder to be filled shall be in good condition.

10.5.2.3 Pipe work, hoses and fittings used for decanting purposes shall be of high-pressure quality (3.2.9). The hose shall not be more than 10 mm nominal bore and not more than 3 m long.

10.5.2.4 There shall be prominently displayed at the decanting point with adequate instructions for the decanting procedure which shall include a warning to stop filling as soon as the fixed liquid level gauge indicates that the maximum permitted liquid level has been reached.

10.5.2.5 The cylinder being decanted shall be upright and the cylinder being filled shall be arranged for filling so that the fixed liquid level gauge and the safety relief valve are exposed to the vapour space.

10.5.2.6 Persons experienced in the decanting operation shall be in attendance throughout such operation.

10.5.3 Security

When decanting equipment in an area accessible to the public ceases to be under general supervision, as when closing for the night, the dispensing point shall be protected from tampering by one of the following:

a) the whole of the decanting equipment including the cylinder shall be stored in a locked ventilated enclosure outside any building; or

b) decanting apparatus shall be removed for secure indoor storage and the operating valve shall be rendered inaccessible to the public.

10.5.4 Location and safety distances

The decanting point shall be located outdoors and the following safety distances from the decanting point shall be maintained:

a) to an opening into a building: 2 m;

b) to an ignition source: 10 m;

c) to buildings or to any flammable materials stored above ground on neighbouring property: 5 m;

d) to streets and roads: 3 m; and e) dispensers for any type of fuel: 3 m.

For Public Comment

10.6 Cleanliness

10.6.1 Readily ignitable material such as weeds, long grass, or any combustible material shall not be allowed to remain within 6 m of the cylinder filling or decanting or cylinder storage areas.

10.7 Signs and notices

10.7.1 The following messages in the form of signs (notices maybe included if so wished) shall be clearly displayed at the filling area or decanting point or storage area.

a) No smoking;

b) No naked lights;

c) Nearby material is a fire risk; and d) No handphone.

Signs shall be in accordance with Annex M and of suitable size. Warning notices shall be in letters of at least 50 mm high.

For Public Comment