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Propane Education & Research Council 1140 Connecticut Ave. NW, Suite 1075, Washington, DC 20036 Telephone: (202) 452-8975 | Fax: (202) 452-9054 PRC#
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Course Objectives
Properly determine an effective system load. Identify factors affecting selection of a properly-sized container. Select and install an appropriate container for a vapor distribution system. Identify requirements for establishing a container location. Identify how to properly select, size, and install pipe and tubing for a vapor distribution system. Explain how to analyze and prevent corrosion. Identify the steps to sizing, selecting, and installing regulators. Describe how to properly select and install a vapor meter. Discuss primary special installations that correspond with a vapor distribution system.
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INTRODUCTION
2012 Propane Education & Research Council. All Rights Reserved. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without written permission.
INTRODUCTION
TABLE OF CONTENTS
HOW TO USE THIS BOOK, ...........................................................XI MODULE 1. INTRODUCTION TO DESIGNING VAPOR DISTRIBUTION SYSTEMS............................................................. 1
Welcome, 1
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INTRODUCTION
PE Pipe and Tubing: Categories and Installation Considerations, 67 CSST: Characteristics and Connection Mechanisms, 68 Sizing Pipe and Tubing Between First- and Second-Stage Regulators, 69 Sizing Pipe and Tubing for Multiple Second-Stage Regulators, 71 Learning Activity: Select the Appropriate Piping and Tubing Size, 72 Lesson 6. Corrosion Analysis and Prevention Introduction, 73 Basics of Corrosion , 74 Types of Corrosion, 75 Atmospheric Corrosion, 76 Soil Corrosion, 77 General and Galvanic Corrosion, 78 Crevice Corrosion, 79 Pitting, 80 Check for Understanding, 81 Corrosion Prevention Methods, 82 Paint and Protective Coatings, 83 Cathodic Protection Systems, 84 Sacrificial Anodes, 85 Impressed Current Systems , 86 Gas Piping Protection, 87 Electrically Insulating Fittings, 88 Learning Activity: Corrosion Analysis and Prevention, 89 Module Summary , 90
Regulator Vent, 114 Causes of Regulator Freeze-up, 115 Preventing Regulator Freeze-up, 116 Check for Understanding, 117 Factors for Selecting Regulators, 118 Inlet Pressure, Outlet Pressure, and Total Gas Demand, 119 Overpressure Protection, 120 Regulator Performance Curves, 121 Designing the Second-Stage Regulator System, 122 Factors in Determining the Number of Second-Stage Regulators, 123 Learning Activity: Selecting Multiple Second-stage Regulators, 124 Pressure Requirements, 125 Checking Your Second-Stage Regulator Selection, 126 Selecting First-Stage Regulators, 127 Selecting 2-psi regulators, 128 Selecting Regulators: LP-Gas Code, 129 Selecting Regulators: General Considerations, 130 Check for Understanding, 131
MODULE 2 QUIZ, 91 MODULE 3. DESIGNING VAPOR DISTRIBUTION SYSTEMS: REGULATORS AND METERS....................................................... 95
Introduction, 95
MODULE 3 QUIZ........................................................................ 143 MODULE 4. PREPARING SYSTEM COMPONENTS FOR ............................................................................. 145 TRANSPORT.
Introduction, 145
INTRODUCTION
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Step 3. Check Valves and Fittings, 159 Step 4. Check Lugs and Supports for ASME Tank Inspection, 159 Step 5: Check Data Plate Markings for ASME Tank Inspection, 160 Perform a Leak Test, 161 Odorant Verification, 162 Check for Understanding, 163
Exterior Site Assessment: Other Considerations, 201 Check for Understanding, 202
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INTRODUCTION
Laying Steel Piping, 307 Check for Understanding, 308 Corrugated Stainless Steel Tubing , 309 Installing CSST: Precautions, 310 Module Summary, 311
INTRODUCTION
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MODULE 10 QUIZ, 415 CETP PRE-CERTIFICATION REVIEW.......................................... 417 CHECK YOUR WORK................................................................. 427 GLOSSARY................................................................................ 435 RESOURCES.............................................................................. 441
INTRODUCTION
INTRODUCTION
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MODULE i
CERTIFIED EMPLOYEE TRAINING PROGRAM
MODULE 1
MODULE 1
CERTIFIED EMPLOYEE TRAINING PROGRAM
SAFETY MISSION
Safety is an industry-wide responsibility that extends to everyone who handles propane. The more you know about dispensing, storing, and using propane the more you help reduce the risk of accidents. Each of us in the propane industry can contribute to a shared mission by doing all we can to increase public confidence in the safety and value of propane.
Safety Goals To fully achieve this safety mission, the propane industry has established five critical goals:
Reduce accidents and incidents. Improve safety awareness. Increase consumer confidence. Strengthen propane employees skills and knowledge. Improve regulatory compliance.
The information, learning activities, and quizzes are designed to help you safely install appliances and interior vapor distribution systems. However all personnel in the propane industry will gain a basic overview of key concepts and safety strategies for working with propane systems.
COURSE PURPOSE
MODULE 1
The purpose of this course is to provide current information, practices, and procedures to safely and efficiently design and install exterior components for residential and small commercial propane vapor distribution systems. This course is designed to be both a learning resource and a career development tool. Additionally, this course will help prepare you for NPGAs CETP certification.
Talk with your supervisor to learn about which certification program your company offers or visit the NPGA website: www.npga.org, to learn more about CETP certification.
COURSE OBJECTIVES
MODULE 1
After completing this course, you will be able to:
Properly determine an effective system load. Identify factors affecting selection of a properly-sized container. Select and install an appropriate container for a vapor distribution system. Identify requirements for establishing a container location. Identify how to properly select, size, and install pipe and tubing for a vapor distribution system. Explain how to analyze and prevent corrosion. Identify the steps to sizing, selecting, and installing regulators. Describe how to properly select and install a vapor meter. Discuss primary special installations that correspond with a vapor distribution system.
COURSE FORMAT
MODULE 1
Designing and Installing Exterior Vapor Distribution Systems is divided into nine modules, each with one or more lessons. Each module includes:
Up-to-date information, procedures, and regulations; effective as of the date of publication. Interactive learning activities to apply your knowledge. Questions to check for understanding. An end-of-module quiz.
MODULE 1
The American National Standards Institute (ANSI) The National Fire Protection Association (NFPA) The U.S. Department of Transportation (DOT)
Each of these organizations develops regulations, codes, or standards referenced throughout this course. Here are the two most common references used in these lessons:
NFPA 54, National Fuel Gas Code: This publication provides standards for the installation of fuel gas piping systems, appliances, equipment, and related accessories. Code of Federal Regulations (CFR): This government resource contains all of the federal rules and regulations that apply to the propane industry. This course references various federal regulations, including those developed by the DOT governing the construction of cylinders and the safe transportation of propane.
Always check with your supervisor to determine all of the safety codes that apply to your job responsibilities. As a general rule, it is important that you follow the manufacturers instructions when installing and using products.
MODULE 1
Increase your awareness of these important resources. Provide a general overview of how these codes and standards govern your work. Show you how these codes and standards relate to concepts presented in the training. Provide background for you to better understand rules and regulations at your place of work. Familiarize you with codes that can be used as resources during your certification test.
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MODULE 1
CERTIFIED EMPLOYEE TRAINING PROGRAM
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MODULE 2
Objectives
After completing this module, you will be to:
Determine the effective system load for a vapor distribution system. Identify the proper selection and size of containers, pipes, and tubes for a vapor distribution system. Identify proper container locations. Explain how to analyze and prevent corrosion upon installing a vapor distribution system.
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MODULE 2
Certified Employee Training Program
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Introduction
When designing vapor distribution systems you will need to select and size the equipment for your customers propane vapor distribution system. To properly select and size the equipment you will need to determine total gas demand and calculate the effective system load, commonly referred to as actual load.
Determine the total gas demand of present and future propane-fueled appliances. Calculate the effective system load of a propane vapor distribution system.
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Front of form: The front of the form documents the type of installation and information about the customers planned use of current and future appliances. Back of form: The back of the form captures the customers propane-fueled appliance Btu/hr input ratings.
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3. Take the Btu/hr input ratings for all existing and future
appliances and add them together. The sum is the total gas demand.
See Resources for more information about NFPAs input rating table.
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Total gas demand is calculated to ensure the proper sizing of regulators and distribution lines and that the container is sized properly.
True
False
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Operate at full demand only during typical operating cycles (for example, during a clothes drying cycle, or when cooking). Do not operate simultaneously.
This type of demand is a more realistic measure of actual usage and therefore requires a smaller container than total gas demand would require.
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LEARNING ACTIVITY
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MODULE 2
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MODULE 2
Certified Employee Training Program
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MODULE 2
The customers propane demand. Container vaporization or withdrawal rate and the impact of weather and environmental conditions. Whether a tank will be aboveground or underground.
Identify factors that need to be considered when sizing a propane container. Explain how these factors affect the sizing of a propane container.
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Other important factors which will be discussed in detail in this lesson include:
Vaporization Rate Factors: When a container is sized for vapor service, the goal is to ensure that the vaporization rate of the container is greater than the demand for propane. The factors affecting vaporization include wetted surface area of the container, liquid level in the container, temperature and humidity surrounding the container, and whether the container is aboveground or underground.
Type of Container Selected: When selecting and sizing a container, it is important to determine whether it will be installed aboveground or underground. For example, soil temperature and frost penetration must be considered when selecting an underground tank.
Customer and Marketer Considerations: Customer considerations, such as aboveground or underground container installation, and marketer considerations, such as delivery schedules and operating policies, also affect the sizing of containers.
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When a container is sized for vapor service, the goal is to ensure the vaporization rate of the container is greater than the demand for propane. For propane appliances to function properly, vaporization must occur at a rate that will adequately deliver propane to meet appliance demand requirements.
To learn more about vaporization, please refer to the Basic Principles and Practices of Propane course.
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Vaporization rate is high in hot weather because higher temperatures surrounding the container create more heat that is transferred to the stored liquid propane.
Low outside temperatures reduce the containers vaporization capacity. When the temperature of the liquid is lower, more heat from the wetted surface area is required to bring the temperature of the liquid propane to its boiling point. Therefore, when determining container size, the temperature used for tank sizing should be the lowest temperature anticipated for that installations location.
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When sizing ASME tanks, many service technicians and installation planners also use the rule of thumb method for estimating the vaporization capacity. This method uses ASME tank dimensions, liquid level, and a constant value for each 10% of liquid to estimate the vaporization capacity of a given tank size at 0 F.
For cylinder installations, a different rule of thumb method can be used for estimating the number of cylinders required in an installation based on vaporization rates. See Resources for more information on these rule of thumb methods.
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Aboveground Containers
Containers that are installed aboveground are sized based on whether they are horizontal or vertical. With a vertical container, only one end and the vertical sides of the container are a part of the wetted surface. With a horizontal container, both ends of the container are part of the wetted surface. Because the wetted surface area affects vaporization, different sizing methods are used for vertical and horizontal containers. DOT cylinders can only be installed aboveground, whereas ASME tanks can be installed above or underground depending on their design.
Underground Tanks
Tanks installed underground are sized differently than containers installed aboveground. The frost penetration depth affects how deep the tank is buried underground; the surrounding soil temperature is dependent on the buried depth of the tank. These factors affect vaporization and, in turn, tank sizing. Frost penetration depth in the soil is important to consider when selecting underground tanks. Underground tanks should not be used in a location where it is likely that a frost line will develop on the tank surface where propane vaporization occurs. Check with your local office of the National Weather Service (NWS) for details on frost line measurements in your area.
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Other Considerations
MODULE 2
Some other considerations also affect the selection and sizing of containers. The Authority Having Jurisdiction (AHJ) can invoke local requirements that restrict container selection, such as limits on the number of gallons or pounds of propane stored, or requirements that all storage containers be either aboveground or underground. Check with your supervisor to determine if any such restrictions exist for your customers installation. Access to the site, prevailing or potential weather conditions, and the design and layout of the site all play a role in the selection and sizing of tanks. If on-site filling is the mode of propane delivery, the bobtails delivery hose and nozzle must be able to safely reach the containers fill valve; otherwise, cylinder exchange may be required. Youve already learned some factors that affect vaporization rates. You must also consider:
Temperature, humidity, and the presence or absence, depth and density of snow cover. Geographical area and flood zones. Underground services, utilities, and terrain conditions (such as rocky soil and steep elevations).
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Which of the following is not a factor affecting the sizing of a propane container?
Customer propane load
Container manufacturer/brand
Type of container
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Introduction
In the last lesson, you learned about the various factors affecting propane storage container sizing. In this lesson, you will learn about U.S. Department of Transportation (DOT) cylinders and ASME tanks, and the criteria you should use to select the appropriate container based on the factors affecting its sizing.
Select the appropriate container type for a vapor distribution system. Determine the appropriate container size based on the vapor distribution system demand and container vaporization rates.
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DOT Cylinders
MODULE 2
When used for residential or small commercial installations, DOT cylinders typically range from 100 lb to 420 lb propane capacity and are usually vertical cylinders. DOT cylinders are only installed aboveground and can never be buried.
Exchange Cylinders
Exchange cylinders typically have a propane capacity of 100 lb and in rare cases 150 lb. They are generally used for low to medium Btu/hr applications such as space heaters, water heaters, clothes dryers, or gas logs. Exchange cylinders are typically installed in pairs, with one being the supply cylinder and the other a reserve cylinder. The two cylinders normally have an automatic changeover regulator between them that switches the propane supply to the reserve cylinder when pressure in the supply cylinder is low, indicating the cylinder is near empty.
Stationary Cylinders
Stationary cylinders are the largest type of DOT cylinder used in commercial and residential applications and are available in 100 lb, 200 lb, 300 lb, and 420 lb capacities. They are commonly used for higher Btu/hr demands for heating, cooking, water heating, and clothes drying. Stationary cylinders are filled on site from a bulk propane delivery vehicle.
Please review Basic Principles and Practices of Propane for further details on this topic.
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If more than one cylinder is needed to meet the effective load of the appliances, additional cylinders of the similar type and size can be manifolded together.
To learn more about this topic, please review the lesson Factors Affecting Selection of a Properly Sized Container. Check with your supervisor to obtain a vaporization chart.
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ASME Tanks
MODULE 2
ASME tanks are typically horizontal containers and can be installed aboveground or underground. ASME tanks are categorized by the amount of water they hold. Typical sizes for residential and small commercial customers range from 60 to 1,000 gallons water capacity. Some ASME tanks are designed to be installed in a vertical position, usually because of space requirements. NOTE: ASME vertical tanks can have a similar shape to DOT 420 cylinders so check all markings before selecting and installing the tank. Remember, different codes may apply to DOT cylinders and ASME tanks.
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Determine the effective system load. Consider the prevailing air temperature under which the tank will operate.
If the tanks listed in the table do not provide the vaporization rate required to meet the effective system load, consider:
Manifolding two or more tanks together. Installing an underground tank so that the winter vaporization rate will increase.
NOTE: The vaporization charts for vertical ASME tanks will differ from equivalent-sized horizontal tanks and, because of their structural design, will be different from DOT cylinders with equivalent capacities. For details on vaporization charts, contact your supervisor or see your company policy.
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The effective demand of all existing and anticipated future gas appliances. The maximum anticipated soil frost penetration depth.
Based on this information, you can select the proper size and number of tanks for the application. The chart lists the vaporization capacities of underground ASME tanks at various soil frost penetration depths.
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LEARNING ACTIVITY
LEARNING ACTIVITY
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MODULE 2
Identify National Fire Protection Association (NFPA) 58 code spacing requirements for container placement. List other requirements and factors that must be considered when selecting the location of containers.
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NFPA and Local Code Safety and Distance Requirements: All container spacing and location requirements must meet the NFPA 58 and local code safety and distance requirements. Access for Delivery: If a container will be filled on site, you need to ensure that it is located close enough to the driveway or access road so the liquid hose of a delivery truck can refill the container at the customers location. Type of Container: The type and size of container can affect distance code requirements. The container must be located in a place that is accessible and can be requalified when required. Underground Utilities: It is important to have the location marked for underground utilities before excavation. This will allow you to find an appropriate location for placement of the container. Special Location Considerations: Additional considerations such as installation near bodies of water, flood zones, and maximum snow depth need to be considered wherever applicable. Customer Preferences: The customer may have a preference as to where they want the container to be placed. Their preferences should be accommodated, but the final container location must meet NFPA 58 and local code safety and distance requirements.
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At least 10 ft in any direction from loose or piled combustible materials, weeds, and long dry grass.
NFPA 30 defines a tank as a stationary vessel that holds 60 gallons or more of a combustible or flammable liquid. This distance does not apply if the LP-gas container is 125 gallons or less and the tank that contains combustible or flammable liquid is 660 gallons or less.
Flammable liquids have a flashpoint of less than100 F. Gasoline, methanol, and ethyl mercaptan are examples of flammable liquids. Combustible liquids have a flashpoint between 100 F and 200 F. Kerosene, diesel, and fuel oil are examples of combustible liquids. For commercial structures that store hydrogen or oxygen, see your supervisor for storage distances between propane and oxygen or hydrogen. All containers filled on site at the point of use must be positioned so that the filling connection, the relief valve discharge, and the fixed maximum liquid level gauge vent discharge are situated at least 10 ft from:
Any exterior source of ignition such as window air conditioners or pool heaters. An opening into direct-vent appliances. Mechanical ventilation air intakes.
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500 gallons or less: If the total water capacity of all DOT cylinders in an installation is 500 gallons or less, then the cylinders may be placed next to a building.
501 gallons or more: If the combined total water capacity of all cylinders is 501 gallons or more, then the cylinders must be placed 25 ft or further from a building.
Banks of Cylinders: If you have several banks of cylinders, there must be at least 25 ft of separation distance from each other.
Note that cylinders are rated in pounds, but the code refers to gallons water capacity. For example, a 420 lb DOT cylinder is stamped at 1,000 w.c. in pounds and holds about 100 gallons of propane. Bank of cylinders refers to more than one grouping of cylinders manifiolded together.
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MODULE 2
DOT exchange cylinders that are not filled at a customer site must be located so the relief valve discharge is a minimum of 5 ft in any direction from exterior sources of ignition, openings into direct-vent appliances, and mechanical ventilation air intakes.
The relief valve discharge on any DOT cylinder must be placed at least 3 ft horizontally from any building opening that is located below the level of discharge.
DOT cylinders cannot be installed underneath any building or structure unless the space is open to the atmosphere for 50% or more of its perimeter. At least half of the perimeter of the structure in which the cylinder is installed must be open entirely to the atmosphere. An open window on two closed sides of a structure normally would not provide the required 50% opening.
Examples of building openings are: dryer exhaust termination, kitchen exhaust termination, other mechanical exhaust vent terminations, and doors.
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Aboveground ASME tanks must be positioned so that the relief valve discharge is located at least 5 ft horizontally from any opening in the building below the level of discharge.
Tanks between 125 and 500 gallons water capacity: Must be located a minimum of 10 ft from any building or property line that can be built upon.
Tanks between 501 and 2,000 gallons water capacity: Must be located a minimum of 25 ft from a building or property line that can be built upon.
A single aboveground ASME tank up to 1,200 gallons water capacity: Can be placed a minimum of 10 ft from buildings or property lines that can be built upon, as long as there is no other container installation of 125 gallons water capacity or more within 25 ft. In addition, tanks between 251 and 2,000 gallons water capacity must be at least 3 ft from each other. This distance is measured from shell to shell, which is the distance between any portion of the outside shells of each tank.
NOTE: All parts of an aboveground ASME tank must be separated by a minimum of 6 ft vertically from overhead electrical power lines that are more than 600 volts.
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LEARNING ACTIVITY
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Type of Container
MODULE 2
The type of container can affect its location based on distance requirements and access for delivery. It can also impact location in other ways. For example, DOT containers installed in a stationary application also need to be accessible for periodic requalification, whereas ASME containers do not have this requalification requirement. Code restrictions for a multiple DOT cylinder installation differ from those for an ASME tank: five 100 gallon DOT cylinders can be installed directly against a structure, but a single 500 gallon ASME tank must be installed 10 ft from a structure.
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Red - electric lines Yellow - gas or oil lines, or other dangerous material lines Orange - telecommunications and cable lines Blue - water systems Green - sewer lines
The new nationwide One Call number is 811. You must call this number before you start digging. For more details, please visit their website at http://www. call811.com.
Additional ground marking colors include:
White - proposed excavation or construction boundaries Pink - temporary survey markings Purple - reclaimed water and irrigation systems
NOTE: In most cases, the One Call service will not locate customer-owned lines on the property. If a utility is not a part of the One Call system, it must be contacted separately for location service. This may also apply to utilities- owned by a town or a county. You should also contact the owner or customer to find out if there are other buried lines.
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Snow Accumulation
In locations where the established maximum snow depth is greater than the height of an aboveground container (excluding the dome cover), the container must be installed in a way that will prevent its movement as a result of snow accumulation. A stake or some other marking that is taller than the average snow cover depth (up to a height of 15 ft) must also be installed.
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MODULE 2
LEARNING ACTIVITY
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Introduction
After youve established the container location, you need to select appropriate pipe and tubing for the outside lines. In this lesson, you will learn how to select appropriate materials for pipe and tubing fittings, and to properly size the outside distribution lines for a customer installation.
Identify factors that must be considered when selecting appropriate pipe and tubing materials for exterior propane vapor distribution systems. Explain how to determine the appropriate size for exterior vapor distribution lines.
To learn about the fundamental features and uses of pipe and tubing fittings for propane vapor distribution systems, review Module 8, Lesson 4 from the Basic Principles and Practices of Propane course.
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There are four basic types of materials used for pipe and tubing in propane vapor distribution systems:
Steel and Wrought Iron are approved for use indoors and outdoors, aboveground and underground. If used outdoors or underground, this type of material must be protected from corrosion.
Copper is also approved for use indoors and outdoors, aboveground and underground. Copper is a very versatile product, but different types of copper are used for specific applications.
Polyethylene (PE) is approved for use outdoors in underground service only. PE tubing can become degraded if exposed to sunlight for a period of time.
Corrugated Stainless Steel Tubing (CSST) is approved for use indoors and aboveground outdoors. It may be used underground if encased in a non-metallic, sealed conduit. CSST manufacturing varies for the intended application, so consult the manufacturers instructions for specific guidance.
NOTE: Refer to your company policy or the AHJ regarding requirements for, or restrictions on, the types of pipe and tubing that can be installed at a customer location.
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Connection Mechanisms
Threaded fittings are the most common method used to join steel and wrought iron pipes in residential and small commercial installations. Steel, malleable iron, and ductile iron fittings can be used. Do not use cast iron fittings.
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Schedule 40 pipes can be used in vapor service at operating pressures up to 125 psig, and are suitable for residential and small commercial applications. Schedule 80 pipes can be used at operating pressures over 125 psig, including lines subject to propane container vapor pressure.
Installation Considerations
Steel pipes that are part of an exterior vapor distribution system may require corrosion protection, as warranted by soil conditions. In aboveground installations, steel piping typically consists of galvanized steel or piping that has had a protective paint applied. In underground installations, steel piping typically is protected from corrosion by wrapping, applying a protective coating, or by implementing cathodic protection.
Cathodic protection will be covered in detail in the lesson, Corrosion Analysis and Protection.
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Connection Mechanisms
Copper tubing is commonly joined by:
Flaring (with brass fittings) Brazing. Copper tubing may be brazed using filler material with a melting point exceeding 1,000 F.
NFPA 58 does not specify any particular type of fitting for joining copper tubing, only that the fittings meet minimum pressure ratings.
Experience has shown that thin wall flare nuts and compression fittings are prone to failure from splitting in cold climates. For this reason, many marketers use forged fittings. NFPA 58 requires welding and brazing to be in accordance with the ASME Boiler and Pressure Vessel Code. Section IX requires a person performing these operations to be qualified by completing a qualification test involving submission and evaluation of welding and brazing samples.
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Water tubing: This type of copper tubing is sized by its inside diameter and available in two wall thicknesses:
Type L (standard thickness) is the most common and is approved for both liquid and vapor lines. Type K (heavy thickness) has greater wall thickness than type L and is used for liquid and high pressure vapor lines.
Refrigeration tubing: This type of copper tubing is sized by its outside diameter. Refrigeration tubing is approved for both liquid and vapor lines, and is usually charged with nitrogen gas to keep it clean and dry until it is used. See Resources for a chart comparing the sizes of water tubing and refrigeration tubing.
A third type of water tubing, Type M, has less wall thickness than types K & L and is NEVER approved for use with LP-gas.
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Characteristics
PE pipe and tubing are made of a thermoplastic material, and are only used underground since it can become degraded if exposed to sunlight. PE is used to route vapor at a reduced pressure from the first-stage regulator to the second-stage regulator at the service entrance to a building or an outdoor appliance. The maximum working pressure for PE is 30 psig.
Connection Mechanisms
PE pipe can be joined using manufacturer-prescribed procedures, which include the use of heat fusion, or manufacturerrecommended mechanical fittings. Technicians installing PE pipe and fittings must be qualified by the manufacturer, the supplier, or a trainer who has been qualified by the manufacturer.
Heat fusion can include butt fusion welding, socket fusion welding, and electro fusion welding.
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Iron Pipe Size (IPS): This pipe has approximately the same physical diameter as an iron pipe. Copper Tube Size (CTS): This tubing has approximately the same physical diameter as copper tubing.
Installation Considerations
When installing PE pipe and tubing, NFPA 58 requires that an electrically continuous corrosion-resistant tracer wire or tape be placed in the trench above and along the path of the underground line to help locate the line after it is buried. This tracer wire cannot be in direct contact with the PE pipe. The wire must be at least American Wire Gauge (AWG) 14.
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Characteristics
CSST is durable, highly flexible, and covered with a plastic sheath. The protective plastic jacketing should be kept in place as much as practical to protect the tubing from corrosion. CSST is typically installed indoors, but some manufacturers also produce CSST for outdoor underground use. All exposed portions or stainless steel installed outdoors must be wrapped with pipe wrap tape. The maximum working pressure for CSST is 5 psig.
Sizing
Sizing CSST involves use of an Equivalent Hydraulic Diameter (EHD) factor which is a measure of how different tubing sizes affect the flow of propane through the tube. The higher the EHD value, the greater the gas capacity of the tubing. CSST sizing also depends on the number of bends in the tubing. Always consult the manufacturers specification for the EHD and number of bends in the CSST tubing you are using.
Connection Mechanisms
Some CSST joints are metal-to-metal seals and are made with manufacturer-specified brass fittings. Note that different manufacturers products cannot be joined together. Technicians installing CSST must be qualified by the manufacturer, supplier, or a trainer who has been qualified by the manufacturer. When CSST is installed underground or through concrete, it must be routed in a non-metallic, watertight conduit. The inside diameter of the conduit must be at least " larger than the outside diameter of the CSST. No mechanical joints are permitted within the conduit. All exposed portions of stainless steel installed outdoors must be wrapped with pipe wrap tape.
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MODULE 2
Find the corresponding line length in the table. If the exact length is not shown, use the next highest length in the table. Read across the table, starting from the left, to find the first Btu/hr amount that exceeds the total gas demand. Move vertically up the column to the top of the table to locate the appropriate line size.
To size the line means to select the proper diameter of pipe or tubing that will be used in the vapor piping system. It does not refer to line length. Laying tubing in a manner that gradually drifts back and forth across the trench to account for the high expansion and contraction rates of PE.
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NFPA 58 requires that metal pipe and tubing buried underground be installed as follows:
MODULE 2
A minimum of 12" of ground cover over the piping. This minimum is increased to 18" inches if external damage to the pipe or tubing is likely to result from vehicle traffic, construction equipment, or storage of heavy materials. If the 12" minimum cannot be maintained, the piping needs to be bridged or shielded, or installed in conduit. If piping is installed under driveways, roads, or streets, appropriate actions should be taken to protect the piping and tubing from possible vehicle damage.
NOTE: Check local laws regarding the requirement to add warning signs for piping systems that run under a public right of way.
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The first-stage regulator must be located at the container. When a first-stage line branches into two or more lines at some distance from the regulator outlet, the total Btu/ hr load of the line from the regulator outlet to the point where the lines split must be calculated. The line up to the split must be able to meet the total gas demand. The pressure drop along the lines must also be calculated. Keeping a map or diagram of the lines in the customer file is highly recommended in order to help locate them in the future.
NOTE: NFPA 58 requires that all LP-gas vapor piping systems downstream of the first-stage regulator be sized so that all appliances operate within their manufacturers specifications. Systems must also be sized using specifically-designated tables that are provided in NFPA 58 or by engineering methods.
LEARNING ACTIVITY
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INTRODUCTION
Corrosion is the deterioration of a metal due to an electrochemical reaction with the environment surrounding it. Corrosion of propane storage containers and vapor distribution piping can be a significant problem. However, the corrosion process can be controlled by using different preventive protection procedures. This lesson will provide an overview of corrosion and preventive corrosion methods. Specific procedures for installing corrosion protection will be taught later in the course.
Explain the causes of corrosion. Explain how corrosion affects propane containers and metal vapor distribution lines. Identify different types of corrosion and prevention methods. Explain the different procedures used to protect containers and metal vapor distribution lines from corrosion.
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Basics of Corrosion
MODULE 2
Causes of Corrosion
The primary factors affecting the rate or extent of corrosion are:
Preventing Corrosion
Methods commonly used to protect propane containers and metallic piping from the effects of corrosion include the use of:
Paints and protective coatings, including wrapping materials. Cathodic protection systems (for underground tanks and piping). Electrically insulating fittings.
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Types of Corrosion
MODULE 2
A number of factors cause corrosion of metals. The broad categories of corrosion types and factors are listed here, and will be covered in more detail later in this lesson.
Atmospheric Corrosion
Atmospheric corrosion occurs on metal surfaces due to humidity and oxygen in the air. Contaminants in the air, such as sulfur and salts, can accelerate the corrosion process.
Soil Corrosion
Soil can also be a significant source of corrosion for underground tank installations and piping installations. The nature of the soil and certain other environmental factors, such as water content and aeration, affect the rate of corrosion. Soil is most corrosive when it has a high moisture content, high electrical conductivity, high acidity and high levels of dissolved salts.
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Atmospheric Corrosion
MODULE 2
Prevention
The most common method of protecting containers, regulators, and metallic piping from atmospheric corrosion is to apply paints and protective coatings. The selection and application of an appropriate paint or coating for aboveground metallic components usually depends on the location and atmosphere of the vapor distribution system. To identify the proper type of paint or coating, consider the atmosphere of the surrounding area. Typically, atmospheres are classified according to the potential severity of corrosion: Industrial atmospheres are more corrosive than rural atmospheres because of sulfur-based contaminants generated by the burning of fuels.
Certified Employee Training Program
Causes
Atmospheric corrosion occurs on metal surfaces due to humidity and oxygen in the air. Contaminants in the air, such as sulfur and salts, can accelerate the corrosion process.
Marine atmospheres are found in coastal areas and can be very corrosive. For example, corrosion of unpainted steel on the seacoast can be 400 to 500 times greater than in a desert area due to salts in the air.
Rural atmospheres are the least corrosive due to lower concentrations of contaminants.
In addition, local conditions need to be considered when protecting metallic vapor distribution system components from corrosion. For example, water conditioning units that expel salt water and certain chemicals from swimming pools can accelerate corrosion. NOTE: If you are unfamiliar with the paint and coatings used to protect containers and other metallic vapor distribution system components, check with your supervisor or contact your equipment supplier for more information.
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Soil Corrosion
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Causes
Metal corrosion in soil is affected by the nature of the soil and other environmental factors such as water content and aeration.
Soil texture is the distribution of particles in the soil. Sand, silt, and clay refer to decreasing coarseness of soil texture. Soils with a high proportion of sand have very limited water retention capacity and are generally less corrosive than clays, which have very high water retention capacity. Soil electrical resistivity has historically been used as a broad indicator of a soils corrosiveness. Higher resistivity soils are generally less corrosive than low resistivity soils. However, a high soil resistivity alone will not guarantee the absence of serious corrosion.
Soil with high moisture content, high electrical conductivity, high acidity, and high levels of dissolved salts tend to be the most corrosive.
Prevention
Corrosion protection measures, such as external coatings and cathodic protection, should always be considered for metallic pipe installations.
Corrosion protection: Remember that this course was developed under the 2011 NFPA 58 code. Always refer to the most current code that applies in your state or area.
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Prevention
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General corrosion can be controlled by the use of paints or protective coatings. Piping that goes through walls should be sleeved or coated to prevent corrosion. In addition, cathodic protection can help prevent corrosion of underground tanks and piping. However, a holiday, which is a breakdown in the protective coating on a piece of equipment, can result in localized corrosion, which then occurs at an accelerated rate. If the coating is not repaired, unobserved corrosion can continue until it penetrates through the wall and causes leakage.
An anode is a metal that is oxidized and consumed while giving up its electrons to a cathode.
Prevention
Galvanic corrosion can be eliminated by installing electrically-insulating fittings (such as dielectric unions) at the transition point between the two different metals.
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Crevice Corrosion
MODULE 2
Causes
Crevice corrosion is a localized corrosion that frequently occurs on the underside of cylinders where the foot ring is attached to the bottom head. The area between these two adjacent metal surfaces (the crevice) is wide enough to allow moisture in, but not wide enough to let moisture out at the same rate that it is let in. As a result, the crevice becomes a zone in which corrosion occurs at an accelerated rate. The same action can occur where the legs on an ASME tank attach to the container walls.
Prevention
Crevice corrosion can progress completely unnoticed if the cylinder is not adequately coated (or painted) and visually inspected on a regular basis, such as at each requalification period.
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Pitting
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Certified Employee Training Program
Causes
Pitting is a form of extremely localized corrosion that leads to small voids or pock marks in metal. It can be initiated by a small surface defect, such as a rock scratching the surface of the metal, or damage to the protective coating. The products of corrosion, such as rust, often hide pits on a containers metal surface. Once a pit has developed, it will continue to penetrate the wall of the container or pipe unless some form of remedial action is taken to stop the corrosion process.
Prevention
The most effective way to prevent pitting on aboveground or underground containers is to ensure that paints or protective coatings are properly applied. Performing visual inspections of exterior, aboveground vapor distribution system components before a container is filled can help identify early indications of pitting. A similar inspection of the visual portion of an underground tank should also be conducted before filling. All newly installed underground tanks must have cathodic protection systems installed to prevent corrosion, such as pitting.
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An underground tank installed in an area where the soil has high moisture content and high levels of dissolved salts is less susceptible to corrosion than a tank installed in a hot and dry area where the soil is sandy, with limited water retention capacity.
True
False
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Cleaning surfaces: Before applying the coating, all uncoated areas, weld joints, fittings, and areas of damaged coatings must be cleaned of foreign surface materials such as rust, mill scale, dirt, oil, grease, and moisture. Priming and coating materials: Use primers and coating materials specified by the container and pipe manufacturers. Applying coatings: Manufacturer specifications must be followed to ensure that coatings are applied under proper conditions, including correct temperature, thickness, and curing procedures. Handling and storing materials: Pipe and container coating materials are often classified as hazardous materials. They are often flammable. You should consult Manufacturer Material Safety Data Sheets (MSDS) for proper material handling and storage procedures, and to determine if Personal Protective Equipment (PPE) is required while mixing, applying, or curing coating materials. Handling coated surfaces: Containers and pipes that are coated for corrosion protection must be stored, lifted, handled, and transported with care to ensure that the coatings are not damaged prior to installation. Inspecting and repairing holidays: Even when careful handling methods are used, protective coatings often become damaged. Thorough inspection and repair of holidays helps increase a coatings ability to provide corrosion protection.
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Sacrificial Anodes
MODULE 2
Sacrificial anodes protect a tank and its metallic piping from corrosion by providing an electrical current to the entire surface area of both components. Burying a sacrificial anode and connecting it to an underground tank creates a potential differential between the anode and the tank. This differential produces an electric current, which provides cathodic protection to the tank and the attached piping. Sacrificial anodes are used in residential and small commercial installations where:
Electrical current requirements to protect the metal tank and piping are low. Steel components are properly coated, wrapped, or protected. Corrosion protection is required by code.
Three common types include: Magnesium alloy anodes: commonly used because they work best in the majority of underground conditions in the United States. Zinc anodes: used to protect underground ASME tanks in coastal areas where salt content in the ground water can increase the potential for corrosion. High potential magnesium anodes: used in dry or sandy areas where it is important for greater voltage and, therefore, more current.
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Coated steel or black iron gas pipes where a dielectric union is installed at the building or gas utilization equipment.
Coated copper gas pipes where a dielectric union is installed at the building or gas utilization equipment.
Steel or black iron piping used for gas service must be coated if buried underground. Copper tubing and fittings do not have to be coated if buried underground and used as part of a cathodic protection system.
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Dielectric Unions
A dielectric union has a piece of molded nylon or other insulating material that prevents the union end and union face from making electrical contact with the union nut and the other end of the union. Dielectric unions must be installed at the transition from metallic piping or tubing such as copper tubing to steel piping at the building service entrance, often between the pipes and regulator, and may also be used at the tank connection where buried steel distribution lines are used. Dielectric unions are not required for PE distribution lines because of the non-conductive properties of these types of lines.
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Module Summary
MODULE 2
Some important points to remember from this module are:
You need to determine total gas demand and calculate effective system load in order to properly size and select containers, distribution lines, and regulators. When selecting and sizing a container, you must ensure that the container is large enough to supply the required system demand under the most severe conditions anticipated for the installation location. There are two types of propane containers: DOT cylinders and ASME tanks. A variety of factors determine the appropriate container type and size for an installation, including total gas demand, container vaporization rate, and environmental conditions. Several factors affect container location, including code requirements, delivery access, container type, underground utilities, nearby bodies of water, snow depth, and customer preference. To select appropriate pipe and tubing for an installation, you must be familiar with different types of pipe and tubing materials, their characteristics, service applications, and limitations. Corrosion commonly occurs on the exterior surfaces of metal components. The corrosion process can be controlled using different preventive protection methods such as paints and protective coatings, cathodic protection systems (for underground tanks and piping), and electrical insulation.
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Module 2 Quiz
MODULE 2
Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
1. There are primarily three steps to determine total gas demand. Which of these steps does NOT belong?
a. Locate the propane-fueled appliances currently installed in the customers home. b. Determine the Btu/hr input ratings of all appliances currently served by the propane system and all appliances that may be added in the future. c. Determine the average load factor for each appliance. d. Take the Btu/hr input ratings for all existing and future appliances and add them together.
2. Effective system load is used to determine the amount of propane required to operate appliances at a reduced demand
and assumes the customers appliances: a. Operate at full demand only during typical operating cycles, for example, during a clothes drying cycle or when cooking. b. Do not operate simultaneously. c. Both a and b. d. None of the above.
3. When determining container size, the temperature used for tank sizing should be the
anticipated for that installations location. a. Highest b. Lowest c. Ambient d. Annual average
________ temperature
4. Frost penetration depth in the soil is important to consider when selecting aboveground tanks.
a. True b. False
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5. When sizing aboveground ASME tanks, you need to determine the effective system load and you must_____.
a. Consider the location of the tank at the customers property. b. Consider the brand of the tank that your customer prefers. c. Consider the most severe conditions under which the tank will operate. d. Keep in mind the presence of combustible materials on the customers property.
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6. The two deciding factors for sizing underground tanks are the effective demand of all existing and anticipated future gas
appliances and ______. a. The maximum anticipated soil frost penetration depth. b. The maximum average annual rainfall in the surrounding area. c. The maximum anticipated temperature in the surrounding area. d. The minimum anticipated temperature in the surrounding area.
7. All containers filled on site must be positioned so that the filling connection, the relief valve discharge, and the fixed
maximum liquid level gauge vent discharge are situated at least 10 ft from all of the following EXCEPT: a. Any exterior source of ignition such as windows, air-conditioners, or pool heaters b. An opening into direct-vent appliances c. Mechanical ventilation air intakes d. Concrete or grassy areas
8. Aboveground tanks with less than ___ gallons water capacity may be placed next to a building and must be at least __
ft horizontally from any building opening that is below the level of discharge. a. 125/ 3 b. 125/ 5 c. 125/ 10 d. None of the above
9. The most common method for joining steel and wrought iron pipes in residential and small commercial installations is:
a. Threaded fittings b. Welding c. Brazing d. Flaring
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10. When sizing pipe and tubing for multiple second-stage regulators, the line from the first-stage regulator to the secondstage regulator must be sized based on the total Btu/hr demand beyond any and all second-stage regulators. a. True b. False
MODULE 2
11. The primary factors affecting the rate or extent of corrosion for propane storage containers and vapor distribution piping
are __________. a. Type of metal and type of paints and protective coatings b. Type of metal and environment in which metal is exposed c. Type of metal and type of electrically insulated fittings d. Water content and aeration/ atmospheric corrosion
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MODULE 2
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MODULE 3
Objectives
After completing this module, you will be able to:
Identify the appropriate size and selection of regulators and meters. Determine types of regulators based on individual vapor distribution systems.
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Introduction
The regulator is the heart of the propane vapor distribution system. It is a mechanical device that reduces a higher inlet pressure to a preset lower outlet pressure and controls the flow of propane to appliances based on operating demand. This lesson provides an overview of the regulator system.
Identify the components of a regulator. Identify the purpose of each type of regulator. Explain how a regulator operates. List the factors to consider when selecting a regulator system.
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Purpose of Regulators
MODULE 3
Regulators control the flow of propane in the vapor distribution system and deliver propane vapor through the piping system to the appliances at the required operating (or delivery) pressures.
Regulators:
Compensate for changes in container pressure and demand. Deliver a steady flow of propane to appliances.
A regulator needs to satisfy a downstream gas demand while maintaining the downstream system pressures within acceptable limits.
When gas demand is low, the regulator restricts the flow and the flow rate decreases.
When gas demand increases, the regulator opens and flow increases.
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Regulator Components
MODULE 3
There are seven components common to most regulators. Each component performs a specific job which allows the regulator to function properly.
The lower body contains the regulators inlet and outlet fittings. The inlet connection is female National Pipe Thread (NPT), POL, or inverted flare. The outlet connection is usually female NPT. The lower body can also be used as a mount for attaching the regulator to a stationary surface or mounting bracket.
The upper spring case is frequently referred to as a bonnet. There are two springs in the upper case. A large spring is compressed by an adjusting screw or tab to change the outlet pressure set point; a smaller spring, mounted inside the larger spring, controls the regulators internal relief valve. The bonnet cap on most regulators has a stem that acts as the back stop to ensure that the relief valve will open to prevent overpressure in downstream distribution piping. For the regulator to operate properly, the regulator cap should always be closed tight except for the brief time required for adjustments by a qualified technician. Make sure that a gasket or other sealing method is in place in the cap or bonnet opening if required by the manufacturer.
The diaphragm is flexible and acts as a gas seal between the lower body and upper spring case. It senses the amount of gas in the regulator, allowing more gas to flow as demand increases and less gas when demand decreases. The diaphragm assembly typically has a rigid metal plate which supports the diaphragm and distributes gas pressure evenly over its entire surface. The regulator main spring helps control gas delivery, depending on inlet pressure and gas demand changes. The force applied by the spring determines the outlet pressure of the regulator.
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The orifice and plunger seat disc assembly work together with the diaphragm and the main spring to control the amount of gas flow through the regulator. The orifice size determines the maximum gas volume that can flow through the regulator. Larger orifices allow more gas flow. The seat disc is attached to
the diaphragm by a lever assembly. When the seat disc is in full contact with the orifice, it stops gas flow. Whenever changes in demand move the diaphragm, the seat disc moves with it, controlling the gas flow through the orifice. If the seat disc becomes damaged for any reason, it might not seal against the orifice properly. This can cause overpressurization in the downstream piping which, if not relieved by the regulators internal relief valve, can cause damage to the appliance gas controls or possibly cause a leak in the downstream piping system. The internal relief valvea factory set spring and valve assembly mounted in the center of the diaphragm assemblyis designed to relieve some of the excess downstream pressure that might build up. When the relief valve opens, gas is allowed to pass into the upper spring case and out of the regulator through the vent.
In the upper spring case, the vent is an opening to the atmosphere that allows the regulator to breathe. During normal regulator operation, air is drawn in or pushed out of the upper spring case through the vent. Manufacturers usually install a screen in front of the vent opening to help prevent dirt and insects from getting into the bonnet, which could block the vent opening. Most regulators have a drip lip vent, to route water away from the vent and help prevent ice from closing it off.
Note: Check with the manufacturer of the regulator before any repairs are made.
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Types of Regulators
MODULE 3
While all regulators reduce pressure and control flow, applications can be significantly different and require different types of regulators. Regulator selection is based on downstream gas demand and service requirements. To increase efficiency in the system you may decide to use multiple regulators.
Single-stage regulators First-stage regulators Second-stage regulators High-pressure regulators Integral 2-stage regulators Automatic changeover regulators Line-pressure regulators Integral 2-psi service regulators
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Single-Stage Regulators
MODULE 3
Single-stage regulators are designed to reduce the vapor pressure from the container to the required operating pressure of the appliances, usually less than pound per square inch gauge (psig). It is the only regulator in the system between the container and the appliances, and is attached to the service valve of the container. Effective June 30, 1997, NFPA 58 prohibits the installation of single-stage regulators in fixed piping systems except in propane vapor supply systems for small portable appliances and outdoor cooking appliances with input ratings of 100,000 Btu/hr or less. Their installation is prohibited in new or modified fixed piping systems for the following reasons:
In the event of regulator failure, a single-stage system offers no safeguard to control container pressure to the appliances. A two-stage system provides more uniform pressure to the appliances since the second-stage regulator does not have to compensate for widely varying inlet pressures. A two-stage system will also reduce the possibility of regulator freeze-up which is addressed in detail later in this lesson.
Effective June 30, 1997, NFPA 58 prohibits the installation of single-stage regulators in fixed piping systems except in propane vapor supply systems for small portable appliances and outdoor cooking appliances with input ratings of 100,000 Btu/hr or less.
Your companys policies may prohibit supplying propane to any customer with a fixed piping system equipped with a singlestage regulator. Check with your supervisor to determine whether you must change out the single-stage regulator if a customer has this type of installation. All fixed piping systems that serve psig appliance systems are required to use a 2-stage regulator system, an integral 2-stage regulator, or a 2-psi regulator system.
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FIRST-STAGE REGULATOR
SECOND-STAGE REGULATOR
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High-Pressure Regulators
MODULE 3
High-pressure regulators are designed to reduce pressure from the container to a lower pressure. Usually this means any pressure greater than 1 psig. These regulators are occasionally used in residential applications for high Btu/hr demand systems, such as swimming pools and spa heaters, and where there are unusually long buried distribution lines. More typically, they are used in commercial settings where gas demands are very high. Roofing tar heaters and small crop dryers are examples of commercial, propane-fueled equipment that generate very high demand for gas. Some high-pressure regulators are designed for use in vapor service only, while others are designed for use in vapor or liquid service. High-pressure regulators with capacities exceeding 500,000 Btu/hr and equipped with overpressure protection devices may be used in small commercial buildings if the second-stage regulators include integral or separate overpressure protection devices.
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LINE-PRESSURE REGULATOR
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Regulator Operations
MODULE 3
When a regulator is operating properly, its components work together to deliver a steady flow of propane to the appliances. Proper flow rate will satisfy the systems downstream gas demand while maintaining the system pressure within acceptable limits. However, the regulator components operate differently depending on various conditions and requirements, including: Satisfying gas demand. Adjusting container pressure to an acceptable outlet pressure. Relieving excess pressure. Regulators breathing ability. Regulator freeze-up.
Lets look at how a regulator operates within the vapor distribution system to satisfy appliance demand for gas.
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When the service valve is first opened and no appliances are on:
There is no gas pressure in the vapor distribution system. The regulator spring has forced the diaphragm down, fully opening the regulator orifice.
The diaphragm is forced upward. The orifice is completely closed off, creating a condition called lockup.
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MODULE 3
Pressure drops in the piping system downstream of the regulator. Pressure under the diaphragm immediately decreases. The diaphragm moves downward, causing the seat assembly to move away from the orifice allowing gas to flow.
The diaphragm moves up and down in response to those changes in demand. The orifice opens and closes, causing the valve disc to supply the proper amount of gas. This, in turn, causes the valve disc to supply the proper amount of gas by automatically opening and closing the orifice. Similarly, the regulator compensates for changes in the inlet pressure from the container.
When an appliance in the system is turned on, the pressure under the diaphragm immediately decreases. The drop in pressure allows the diaphragm to move downward, which lets the seat assembly pull away from the orifice, allowing the flow of gas. As additional appliances are turned on, the demand for propane increases and the seat assembly pulls further away from the orifice allowing more gas to flow.
In summary, when appliance burners are operating, the regulator maintains a steady outlet pressure despite changes in the inlet pressure and appliance demand. This is referred to as the systems flow condition. The second-stage regulator and any other downstream regulators operate in the same manner, except at lower inlet and outlet pressures.
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Regulator Vent
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When the regulator seat assembly disc moves up against the orifice to restrict gas flow, the diaphragm moves upward and the air is expelled through the vent. As the gas load increases, the diaphragm moves downward and the seat assembly disc moves away from the orifice. Air is then pulled in through the vent. During normal system operation, as the diaphragm moves, the vent must allow air to be pushed out from or come into the upper spring case. This diaphragm movement maintains the proper pressure balance so that the regulator can react appropriately to changes in downstream pressure. Also, when overpressure occurs, vapor flows through the relief valve into the upper case and out the vent. After the overpressure is relieved and the propane vapors are vented, the upper case returns to atmospheric pressure. In either case, the process is referred to as breathing. A regulator must be able to breathe to perform properly. So, ensuring the regulator vent is clear is extremely important to the entire propane delivery system and appliance operation.
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High pressure gas expands as it goes through the regulator orifice, creating a refrigeration effect. If gas demand is high and there is enough moisture in the propane, small water droplets can freeze and block the orifice. This type of freeze-up can occur even when the outside temperature is well above 32 F because of the refrigeration effect. Moisture from the atmosphere can freeze in the upper case area of the regulator. In sub-freezing temperatures, condensation can occur in the upper spring case, restricting movement of the diaphragm due to ice formation. Ice can build up externally on the vent opening and block the regulator from breathing, which prevents proper operation.
A pigtail is a flexible length of tubing or hose that connects two or more pieces of equipment (for example a container valve, regulator, torch) together allowing for the flow of vapor or liquid.
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Install the regulator with the vent pointed downward. Make sure the regulator vent is pointed downward in all installations, including those where a hood or protective cover is selected. Regulators are designed to drain condensate from the upper spring case when the vent is directed down vertically. If a regulator vent cannot be installed pointing downward, then install a pipeaway adapter that ends pointing downward.
See your supervisor for instructions on how and where the regulator is to be installed to avoid damage caused by falling snow or ice.
Freeze-up caused by moisture laden propane vapor entering a regulator can be prevented by eliminating moisture in the system. This is done by:
Properly preparing a container prior to putting it into service (methanol injection). Properly purging all new containers and lines before putting them into service. Making sure the valves on empty containers are fully closed to prevent moisture from entering. Making sure the supplier is meeting industry specifications.
When installing a first-stage regulator, if possible, install the regulator inlet higher than the service valve outlet so that moisture can drain back into the container. Freeze-up caused when ice forms in the pigtails can be prevented if the pigtail loop is placed upward to prevent moisture from collecting and freezing at the bottom of the loop.
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When the service valve on the regulator is closed and there is no gas pressure on the system, the ____ has forced the ____ down, fully opening the regulator ____.
orifice, container spring, diaphragm
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All of these factors are charted on a regulator performance curve, and are used with manufacturer appliance specifications to help determine the appropriate regulator.
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Use the ratings in the regulator manufacturer literature to select the appropriate regulator based on the maximum Btu/hr load that it can handle. This rating should be higher than the total gas demand required by the system.
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Overpressure Protection
MODULE 3
The regulator relief valve is designed to prevent excessive pressure from building in the system and damaging the appliances. Excessive pressure, also called overpressure, can result from a failed regulator component, debris under the regulator seat, or blockage of the regulator vent from such things as freezing water. If this were to happen, flames could escape from an appliance combustion chamber and ignite nearby combustibles or otherwise give unsafe and inefficient combustion performance. The relief valve for a single-stage regulator may not be the same as for a second-stage regulator. NFPA 58 outlines in detail the type of relief valve required for each type of regulator. In some cases, a separate overpressure protection device may be installed to provide additional protection. Other systems may require multiple regulators. Consult your company policy concerning when external overprotection devices should be installed. You can also consult your propane equipment supplier or a specific regulator manufacturer for assistance in selecting and sizing regulators and external relief valves.
Although outdoor regulators must be installed and protected so their operation wont be affected by the weather, unusually extreme weather conditions can cause ice buildup that goes beyond mandated testing.
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1. Select the line on the chart that matches your inlet pressure, typically
10 psig for a second-stage regulator.
2. Move left along the appropriate inlet pressure line until it intersects
with the customers total gas demand.
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If only one second-stage regulator is required, the total gas demand can be used for selecting the regulator.
However, if multiple second-stage regulators are needed, the output capacities of the regulators should meet the demands of the appliances they are supplying. In addition, multiple second-stage regulators may be required for appliances that require different inlet pressures.
Some high demand appliances have specific requirements for secondstage regulators. For example, many manufacturers of pool and spa heaters require the second-stage regulator be installed as close as possible to the heater control.
Once you have determined the number of second-stage regulators needed and the propane demand required of each of them, you are now ready to determine the delivery or outlet pressure required for the regulator and the input pressure required from the first-stage regulator to achieve the desired output in Btu/hr.
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Pressure Requirements
MODULE 3
For residential and small commercial applications, the system delivery, or inlet, pressure for appliances is typically 10.5" to 14" w.c. Check the data plate or manufacturers specifications for each appliance to determine the minimum delivery pressure required. The delivery pressure of the first-stage regulators is set at the factory and is typically 10 psig. Since the delivery pressure of most first-stage regulators remains relatively constant year round, its an accepted practice to use the normal outlet pressure of the first-stage regulator as the minimum inlet pressure to a second-stage regulator
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Has the flow capacity to meet the total gas demand of all the appliances connected to the regulator. Is able to supply the gas at the minimum required operating pressure for the appliances. Is able to supply the gas at the minimum required operating pressure when the inlet pressure is at its minimum level.
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Rated with a capacity in excess of the total gas demand. Designed to supply delivery pressures within the range needed for the second-stage regulator inlet pressures, typically 5 to 10 psig.
If the highest Btu/hr output capacity for a single first-stage regulator is not sufficient to meet total gas demand, two firststage regulators can be used in a parallel installation. NOTE: Do not use a high-pressure regulator designed for commercial or industrial applications in place of a firststage regulator designed for residential or small commercial installations. High-pressure regulators typically have delivery pressure ranges from 12 to 15 psig, but can go as high as 100 psig.
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Ensure that the first-stage regulator has sufficient Btu/hr capacity to supply all installed and anticipated future appliances. Ensure that suitable line-pressure regulators (upstream of the appliance regulators) are selected and properly located to supply connected appliances with adequate gas volume and pressure. Verify that the 2-psi service regulator for each required service entrance has sufficient Btu/hr capacity to supply all installed and anticipated future appliance demand for the distribution piping served by the 2-psi service regulator.
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The regulator should be constructed of materials that are compatible with LP-gas service and the external environment, including exposure temperatures. While regulators are sized using minimum inlet pressures to ensure that they can offer full capacity under all circumstances, also consider the maximum inlet and outlet pressure ratings in the selection process.
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Manufacturers information
Customer preferences
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Introduction
Vapor meters are used to measure the quantity of propane vapor delivered to a customers appliances. Typically, meters are used when multiple customers receive propane from a common storage tank or when customers are billed on a usage basis rather than a bulk delivery. Both the propane marketer and the customer rely on a meters accuracy, which can only be assured with proper installation and maintenance of the meter. The meter must be installed in accordance with the manufacturers instructions and in a way that minimizes the potential for damage. Diaphragm vapor meters are used in propane vapor distribution systems for residential and small commercial applications. In this lesson, you will learn about determining vapor meter size and vapor meter accessories.
Explain how vapor meters operate. Determine proper vapor meter size for lb and 2-psi systems. Identify propane vapor meter accessories and options. Identify typical meter installations. Explain precautions to be taken while storing and handling meters.
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Example: 80 CFH x 2,500 Btu/CF = 200,000 Btu/hr Typically, the propane capacity ratings of vapor meters range from as little as 80 CFH to more than 6,000 CFH. This corresponds to a range from 200,000 to 15,000,000 Btu/hr. Manufacturers typically rate vapor meter capacity based on the specific gravity of natural gas because vapor meters are more widely used in the natural gas industry. A conversion factor is used to translate the natural gas rating of a vapor meter to a propane meter. This conversion factor, also called the capacity conversion factor, is the ratio of the specific gravities of natural gas and propane measured as a force of gravity (Fg), and is 0.63. The following formula converts the natural gas rating of a vapor meter to a propane meter:
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Pressure Factors
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Operating Pressure
Most propane vapor meters are designed to operate with an inlet pressure of 11" w.c. If the inlet pressure is higher or lower than 11" w.c., the meter will not measure the flow of propane vapor accurately. When the inlet pressure is above 11" w.c., more propane vapor will enter the measuring chamber each time it fills. As a result, the meter will measure vapor usage slower than the actual rate of consumption. Conversely, when the inlet pressure is below 11" w.c., less propane vapor will enter the measuring chamber each time it fills. As a result, the meter will measure vapor usage faster than the actual rate of consumption. The operating pressure can be controlled to remain constant by using a 2-stage regulator system, verifying that all distribution lines are properly sized, and ensuring that the second-stage or 2-psi service regulator is located close to the meter inlet.
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Temperature Compensation
If the propane vapor temperature is higher than the standard temperature at which the meter was calibrated, the gas expands and becomes less dense. As a result, less gas passes through the measuring chamber each time it fills and empties. This causes the meter to measure vapor usage faster than the actual rate of consumption. If the gas temperature is below the standard temperature, the meter will be slower in measuring vapor usage than the actual rate of consumption. On average, there is a 1% error in accuracy for each 5 F change in temperature. To compensate for gas temperature variations, most manufacturers provide special meters that automatically correct for changes in temperature.
Elevation
Vapor meters are affected by both the gas pressure inside the meter and the atmospheric pressure on the outside. When the meter is installed at higher altitudes, the pressure on the bellows is less and compromises the factory settings, which are based on pressures at sea level. The National Institute of Science and Technology (NIST) requires vapor meter readings to be corrected for elevations above sea level.
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MODULE 3
You have determined that the total gas demand for a customer residence is 450,000 Btu/hr and you need to select a vapor meter for installation. Your company has a variety of vapor meters available, but they are all rated based on the specific gravity of natural gas. From the list below, select the appropriate meter for this installation.
180 CFH
100 CFH
200 CFH
300 CFH
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Meter Indexes
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A meter index measures the volume of gas used in cubic feet or cubic meters. There are three basic types of indexes used in propane meters.
Direct Indexes
A direct index displays the volume of propane used. The meter records and displays the volume of propane used during a period of time. This index has a small circular dial and indicator hand, commonly referred to as a proving dial. The proving dial is used when the meter is tested for accuracy. It may also be used to determine if the meter is operating and to check the distribution lines for leaks when it is first put into service.
Circular Indexes
A circular index commonly has four dials that record the volume of gas used. When reading the dials of a circular index, start with the dial furthest to the right and proceed to the left.
Observation Indexes
The observation index is similar to the circular index, but has an oversized proving dial. Observation indexes are used on special test meters designed to check the accuracy of other vapor meters and should not be installed in distribution systems.
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Meter Bars
Meter bars are pre-assembled units designed to connect gas meters to supply piping. Their use prevents the transmission of piping stresses to the meter body. When planning an installation, the meter must be plumb and level in all directions. A meter installed in a tilted position could cause an inaccurate measurement of gas volume. To correct this, a meter bar or meter mounting bracket should be used to ensure the meter is properly supported and level in each direction.
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Module Summary
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Some important points to remember from this module are:
Regulators control the flow of propane in a vapor distribution system and deliver propane vapor to appliances at the required operating (delivery) pressures. While all regulators reduce pressure and control flow, different installations require different types of regulators. You need to consider inlet pressure, outlet pressure, and total gas demand when selecting a regulator. Vapor meters measure the quantity of propane vapor delivered to a customers appliances. A vapor meter is typically connected immediately downstream of the second-stage or 2-psi service regulator at the building service entrance.
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Module 3 Quiz
Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
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2. When the service valve on the container is closed and there is no gas pressure on the system, the ____ has forced the
____ down, fully opening the regulator ____. a. orifice, regulator spring, diaphragm b. regulator spring, diaphragm, orifice c. diaphragm, orifice, regulator spring d. regulator spring, orifice, diaphragm
3. To prevent regulator freeze-up due to vent blockage caused by ice formation or condensation, the regulator should be
mounted so that the ________ to allow drainage of moisture that forms above the diaphragm. a. vent points upward b. diaphragm points upward c. vent points downward d. regulator points downward
4. For a residential vapor distribution system involving a first- and second-stage regulator, the highest Btu/hr output
capacity for a single first-stage regulator is not sufficient to meet total gas demand of the system. What is the best solution? a. Install a commercial high-pressure regulator b. Install two first-stage regulators in a parallel installation c. Install two second-stage regulators in a parallel installation d. Install two first-stage regulators in series
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6. When sizing vapor meters for lb systems, select the meter according to its capacity at 2" w.c. pressure drop.
a. True b. False
7. A circular meter index commonly has four dials that record the volume of gas used. When reading the dials of a circular
index, start with the dial ____________. a. furthest to the left and proceed right b. furthest to the right and proceed left c. in the center and proceed outward d. anywhere, because it doesnt matter
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Objectives
After completing this module, you will be able to:
Explain how to verify container conditions. Identify the procedures for performing a leak test on a container. Identify the procedures for loading containers onto service vehicles. Explain the regulatory requirements for transporting containers.
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Introduction
After you have selected and sized the equipment for a propane vapor distribution system, but before you transport it to a customer site, you must verify that the propane storage container is in satisfactory condition. This lesson will address the steps involved in inspecting containers, performing a leak test on a container, and ensuring that an odorant has been added to the propane before delivery.
After completing this lesson, you will be able to explain how to:
Inspect DOT cylinders and ASME tanks to verify their fitness for service. Perform a leak test on a container. Verify odorant is present in propane being delivered to a customer.
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The month and year of the last requalification. The Requalification Identification Number (RIN). A single letter to indicate the requalification method that was used (unless the hydrostatic test is used).
All cylinders must be requalified before their requalification date. A DOT cylinder that does not have a current requalification date must be removed from service and cannot be refilled until it has been retested or requalified. A cylinder may require requalification before its requalification date if it is damaged or subjected to physical abuse, excessive corrosion, or extreme heat. Aluminum cylinders that have been exposed to fire must be removed from service immediately and cannot be put back in service under any circumstance.
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Condemn: The cylinder is unserviceable for the continued transportation of hazardous materials in commerce, and may not be restored by repair, rebuilding, requalification, or any other procedure. Cylinders with a series of XXX over the DOT specification number and service pressure or marked with CONDEMNED on the shoulder, top head, or neck are condemned cylinders. They must not be refilled or continued in service. Defect: The cylinder has an imperfection requiring its removal from service. Filled or charged: The cylinder has had a hazardous material introduced into it. Repair: The cylinder has been inspected but cannot be requalified in its current condition. It must be immediately removed from service and repaired or transported for repair. After repair, it can be reinspected and either requalified to return to service or condemned. Rejected: The cylinder cannot be continued in service without repair, rebuilding, and requalification. Requalification: The cylinder requires a complete visual inspection and possibly testing to determine its suitability for continued service.
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Cracks or leaks. Bulging. Significant denting or gouging. Defective valve or valves. Damage to the cylinder valve protection, or cylinder foot rings. Evidence of physical abuse, fire or heat damage, or excessive rusting or corrosion.
Steel cylinders subjected to fire must be requalified, reconditioned, or repaired. Repairs must be performed by the original manufacturer or a DOT authorized repair facility. Aluminum cylinders subjected to fire must be removed from service permanently.
NOTE: If any of these conditions are found, the cylinder must not be refilled or transported until it has been requalified according to DOT regulations.
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To learn more about this topic, please review the Propane Delivery Operations and Cylinder Delivery course.
Service valve handwheels and stems Filler and relief valves and rain caps Fixed maximum liquid level gauge Cylinder valve protective collars or valve caps and threads Float gauge dial faces and operation of float gauges where included Foot rings and welds
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Answer: The shipping name is propane and the hazard class is 2. For more information, consult Basic Principles and Practices of Propane.
Consumer Information/Warning Label: NFPA 58 requires a consumer information label for all portable, refillable propane cylinders of 100 pounds or less that are not filled on site. This label includes information on the potential hazards of propane.
OSHA Warning Label: To help commercial customers meet OSHA requirements, many marketers attach an OSHA warning label to cylinders that will be handled by their customers employees. This label warns employees about the hazardous material stored in the cylinder.
All three of these labels may be combined into a 3-in-1 label. These labels can also be combined into a 4-in-1 label. This label has additional propane marketer identification and emergency contact information for company-owned cylinders that are leased to customers.
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1. Verify the amount of propane in the tank. 2. Check the condition of the tank coating. 3. Check the condition of valves and fittings. 4. Check the tanks lifting lugs and supports. 5. Check data plate markings.
After you have completed your inspection of the ASME tank, be sure to perform a leak test and verify the presence of odorant, which will be discussed later in this lesson.
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To learn more about this topic, please review the Propane Delivery Operations and Cylinder Delivery course.
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Service for which the container is designed. You must verify that the container is designed for propane. Name and address of container supplier or trade name of container. Water capacity of container in pounds or U.S. gallons. You must verify that you are getting the proper container. Maximum Allowable Working Pressure (MAWP) in pounds per square inch (psi). You must verify that the container is usable for propane. The following statement: This container shall not contain a product that has a vapor pressure in excess of ___psig at 100 F. Outside surface area in square feet. Year of manufacture. Shell thickness and head thickness: Shell thickness is the thickness of the wall of an ASME container. Head thickness is the thickness of the end portion that is welded to the main body of the tank. OL (overall length), OD (outside diameter), HD (head design). Manufacturers serial number. This number is used to properly identify the container to be serviced. ASME Code Symbol. Minimum design metal temperature, measured in F at MAWP psi. This is to make sure the container is usable for propane. Type of construction: W for welded. Degree of radiography RT. This means the manufacturer has performed Radiography Testing.
This list is in accordance with 2011 NFPA 58. Remember that older tanks built under previous codes may have been built under different marking requirements.
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All seams and welds, including the foot ring connections on DOT cylinders. All connections, threaded and flanged, in which valves, gauges, or plugs are installed. All valves.
Also look for signs of oil building up around welds and valve installation points as this is a sign of a leak. If you have a leak, mark the leak, put the cylinder in a safe area, and check your company policy for evacuating, repairing, or discarding the container.
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Odorant Verification
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Before you transport a propane container to a customer site, you should verify the presence of an odorant. You can do this by performing a sniff test. This is the most widely used method to check whether an odorant has been added to the propane and is performed by smelling the propane. Propane that has been odorized smells like rotten eggs, a skunks spray, or a dead animal.
Always take the following precautions when performing the sniff test:
Protect yourself by wearing appropriate Personal Protective Equipment (PPE). Only vent a small amount of propane. Close the vent before you sniff. If venting liquid, only sniff after propane liquid has vaporized.
NOTE: Make sure you know your company policies and procedures for performing a sniff test. Contact your supervisor if you suspect propane is not properly odorized. See Resources for alternate methods to verify propane odorization.
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Since ASME tanks have many welds and openings for valves and gauges, you should select random samples of the welds and connections for leak testing.
True
False
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Explain applicable DOT hazardous materials regulations for transporting DOT cylinders and ASME tanks. Identify the types of vehicles and equipment used for the delivery of DOT cylinders and ASME tanks. Explain how to properly load and secure DOT cylinders and ASME tanks onto service vehicles. Identify additional job tools and materials necessary for container installation. Explain pre-departure and in-transit responsibilities to safely transport DOT cylinders and ASME tanks.
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Each container must be constructed and marked as required by the ASME code. Must be equipped with safety devices as required by NFPA 58. Must be secured to the vehicle to prevent movement.
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Each container must be constructed and marked as required by the ASME code. Must not exceed the containers maximum permitted filling density. Prior to loading the container must be inspected for leaks, corroded or abraded areas, dents, distortions, weld defects, or other condition that may render the container unsafe for transportation. A record of the inspection must be legibly signed and dated by the trained and qualified person conducting the inspection. The person signing the record must certify the container has been inspected and has no defect that would render it unsafe for transportation.
The record must include the date of inspection; the inspectors contact phone number, the container serial number, container size, estimated amount of propane, and the origin and destination of the shipment. The completed record must be retained by the container owner for two years. Only one container may be transported on the vehicle in this manner. When loading, the container must be lifted by using slings completely wrapped around the container and lifting lugs may not be used to lift the container. The lifting slings must be rated to handle the total weight of the container and the propane in the container. Slings must meet ASME code requirements and be visually inspected prior to each use. Any sling showing evidence of tears, fraying, or other signs of excessive wear may not be used.
The storage container is within the vehicle frame, secured against movement, and no weight is placed on the supporting legs during transport. Tow trailers used to transport tanks in this manner must be equipped with rear end protection. ASME tanks of less than 125 gallons water capacity may be transported with propane in compliance with DOT filling density requirements.
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Tanks with water capacities between 125 and 999 gallons must be labeled on both sides using either flammable gas labels or LP-gas placards.
Tanks with water capacities between 1,000 and 5,000 gallons, must be labeled on both sides and both ends using either flammable gas labels or LP-gas placards.
Any tank not permanently attached to the vehicle must be secured to prevent movement during transportation. We will review specific measures for properly positioning and securing ASME tanks later in this lesson.
Flammable gas labels are sometimes called 4" x 4" shipping labels.
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Placard holders should be located on the front, back, and both sides of the cylinder service vehicle. If the cylinders have a gross aggregate weight of 1,001 lb or more, you must display the appropriate placard in each holder.
In addition to the placarding requirements, each cylinder must be marked with the proper shipping name, propane or Liquefied Petroleum Gas (LPG), and the United Nations (UN) identification number UN1075. Any cylinder not permanently attached to the vehicle must be secured to prevent movement during transportation. Specific measures for properly positioning and securing DOT cylinders will be reviewed later in this lesson.
Any cylinder not permanently attached to the vehicle must be secured to prevent movement during transportation.
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Shipping Papers
Shipping papers must be available for authorities in the event of an accident or an inspection. They must be within immediate reach inside the vehicle when driving with a lap safety belt in place, in a holder mounted on the inside of the drivers side door, or visible to someone entering the cab. Shipping papers must contain the hazard identification information as it applies to the cargo of the service vehicle, including:
Proper shipping name. UN identification number/proper shipping number. Hazard class division. Indication that the shipment is noncorrosive. The total quantity of hazardous materials, by mass or volume, including an indication of the applicable unit of measurement.
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A current copy of the Hazmat Certificate of Registration. Another document bearing DOT Hazmat Registration Number. For example, sometimes this information is included on permanent shipping papers.
Description of the hazardous material. Immediate precautions to take in the event of an incident. Risks of fire or explosion and immediate methods for handling small and large fires. Initial methods for handling spills or leaks in the absence of fire. Immediate hazards to health and preliminary first aid measures. Emergency response telephone numbers.
This information must either be on the shipping papers or kept with the shipping papers. Additional information on DOT regulations, including further details regarding placards and vehicle documents is available in the CETP training program in the Propane Delivery Operations and Cylinder Delivery book.
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According to DOT requirements, which of the following containers cannot be transported on public roadways to the customer site?
Stationary DOT 420 lb cylinder filled to 80% capacity
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Service/Installation Trucks
Service/installation trucks are equipped with a utility body, and may have a lift gate for handling cylinders, cylinder dollies, smaller ASME tanks, or tank dollies. Typically they have a flat deck service bed of steel or wood, and fitted with pockets and rails for use with tank securing devices. These pockets may also be used with removable stake panels or cylinder racks. Some service beds combine stake panels and permanently attached racks to allow for cylinder and ASME tank transportation and handling.
Crane Trucks
Crane trucks are straight trucks with a crane attached. They are used mainly to install ASME tanks at residential and small commercial customer locations, but can also be used for stationary cylinder installations.
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Exchange Cylinder Dolly: is suitable for moving exchange cylinders with up to 100 lb propane capacity.
Stationary Cylinder Dolly: can move large stationary cylinders when a truck-mounted crane is unavailable or impractical. It typically has heavy foot ring lifting points, securing straps and ratchet binders, and lockable tilting levers capable of handling heavy loads. It also has larger, heavier wheels than exchange cylinder dollies and may have a rear-stabilizing pivot wheel. It can be equipped with a gasoline engine for propulsion.
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Use caution when moving cylinders with a dolly. Dropping or tipping over the cylinder can damage valves, releasing pressurized and flammable gas. Use the appropriate type of dolly. Secure the cylinder on the dolly so it is stable during movement. Always wear PPE to avoid contact with liquid propane and prevent freeze burns. When using the trucks lift gate, make sure it is large enough and properly rated to hold the dolly so it doesnt roll off when loading and unloading cylinders. This is especially important if your vehicle is parked on an uneven surface. Secure the cylinder dolly to prevent it from moving during transportation. Store the dolly in a readily-accessible location on the vehicle.
NOTE: When using a motorized dolly, remember to follow the manufacturers instructions to avoid hurting yourself or the equipment.
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Precautions
There are some precautions that you want to be aware of when operating lift gates:
Never ride, or let others ride, on the lift gate. Keep your hands off the lift gate when raising and lowering it. Keep your feet clear of the lift gate landing area.
Low reservoir levels or hydraulic fluid leaks. Excessively worn or damaged hydraulic hoses or fittings. Pivot point bearing lubrication. Excessive corrosion on mounting bolts, cylinder mounts, travel arms, or lift gate pieces. Frayed or loose cables or cable-attaching mechanisms. Cracked or broken welds. Misaligned arms or other travel components. Loose or damaged electrical wiring.
If you notice any of these signs, report it to your supervisor. Refer to your company policy and follow the specific manufacturers instructions when using a lift gate.
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Center the load on the lift gate to help prevent it from tilting or falling. Ensure everyone is in a safe location before operating the control levers or switches. Do not try to catch a load if it falls.
3. Use the lift gate to load cylinders on the service vehicle so their
weight is evenly distributed. Keep in mind:
An ideal load places most of the weight on the front and rear axles with both side-to-side and front-to-back distribution. An unbalanced load is extremely dangerous; it could cause poor handling due to insufficient ground contact. It could even cause the truck to overturn.
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Only designated personnel may operate a truckmounted crane. What are safe working procedures? Who should use PPE? Any special tank handling requirements?
Read and follow the manufacturers instructions for inspecting, maintaining, and operating the crane. Know the cranes maximum lifting capacity.
Per DOT, a designated person is an individual who has been selected or assigned by the employer as being qualified to operate a truck crane.
NOTE: You and anyone working with you should always follow the manufacturers requirements for operating this equipment.
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1. Park the crane truck on level ground. Set the parking brakes.
Inspect the lifting hook and swivel to ensure that they are not damaged and make sure the safely latches are in place. Also check for locking pins or set screws to secure the hook and swivel. Inspect the chains and hooks of the lifting bridle or slings. They should be in good condition and have proper load ratings to handle the tank.
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4. If the tank contains more than 5% liquid, the tanks lifting lugs or
eyes should not be used. Instead, use slings that have adequate load ratings and secure them under the bottom of the tank to make the lift.
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Slings must be selected in accordance with their intended use based on the size and type of load, and the environmental conditions of the workplace. The different types of slings include chains, wire rope cables, and fabric web strap-type slings. Visually inspect all slings before use to ensure their effectiveness. When inspecting alloy steel chain slings, pay special attention to any stretching, wear in excess of allowances made by the manufacturer, and nicks and gouges. These signs indicate that the sling may be unsafe and should be removed from service. Wire rope slings, fabric rope, and web slings cannot be used if they show signs of wear and tear or damage.
6. Determine how you will use the crane to lift the tank, how you will
arrange the sling(s), and if you require additional slings or other equipment for the load. Slings should have load ratings well in excess of the weight of the tank and its contents. If slings are not arranged to lift vertically, the load capacity of the sling decreases as the sling angle moves from vertical to horizontal. Under DOT regulations, lifting slings must be rated to handle the weight of the container and lading when loading tanks between 125 and 500 gallons with more than 5% liquid.
7. Attach the slings, and determine the path of the tank lift and travel.
Attach guide ropes as needed.
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8. Connect the lifting hook to the sling or tank. Then, carefully lift the
tank off the ground. Slowly rotate and position the tank so it can be lowered onto the truck bed. Do not leave the tank suspended by a crane boom or lift. Never stand or walk beneath the lifted tank.
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9. With the boom still connected to the sling or tank, secure the tank
to the truck bed with tie-down straps or chains, to meet federal requirements.
DOT transportation regulations require tanks with more than 5% liquid must rest in cradles or saddles so that supporting legs will not have any weight placed on them during transportation. Container bracing must conform to DOT requirements. Straps or chains used as tie-downs must be rated to exceed the maximum load being transported and comply with DOT requirements. Tanks must not extend beyond the sides or rear of the vehicle.
10. Remove all slings and guide ropes, then secure them to the truck. 11. Return the crane to the original position and lock it in place,
according to the manufacturers instructions.
See Resources for more information on wear and tear of wire rope slings, fabric rope, and web slings.
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Lifting mechanisms: May use chain hoists that move along an I-beam at the top of the lifting superstructure, a crank-type cable hoist, or an electrical, motorpowered hydraulic cable winch or hydraulic cylinders. The lifting superstructure is basically a heavy-duty steel A-frame secured to the trailer chassis. Braking systems: Most tank setting trailers have electric/hydraulic brakes or coupler-activated hydraulic brakes. Bunk Securing Methods: You can secure bunks to the trailer frame with clevis pins, clips, locking channel fittings, or a combination of these devices.
On electric/hydraulic brake systems, the electrical current flows when the towing vehicles brake lights are activated. Proper operation of the brake lights is critical to the operation of the trailer braking system, along with proper electrical connection to the towing vehicle. On coupler-activated hydraulic systems, proper lubrication and movement of the trailer tonguemounted hydraulic cylinder levers is critical to proper braking system operation. Bunk: Removable tank support cross-members that connect to the trailer chassis.
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Hydraulic System Electrical System Mechanical Components Mounting Hardware Fluid Level in Brake Master Cylinder Reservoir Lights Reflectors Bunks Safety Breakaway Mechanism Safety Chains Rims and Tires Placard Holder If you are towing a trailer on public roadways, then DOT regulations require a pre-trip inspection.
Contact your supervisor or consult your company policy to determine if you must inspect additional tank setting trailer components before using a tank setting trailer.
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NOTE: Always follow the manufacturers instructions for loading and using a tank setting trailer.
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Do not use a tank setting trailer that has any mechanical or structural defect, including defective lifting or tank-securing components, until repairs or replacement service work has been done. Ensure the towing hitch is rated to carry the load of the trailer. Ensure the trailer tongue weight does not overload the towing vehicle hitch. If too much weight is carried on the rear axle of the towing vehicle, it can cause loss of steering control, fishtailing, or unstable braking. Ensure the trailer hitch is secured and locked on the towing vehicles towing hitch before lifting the tank. Check the condition of the trailers lifting equipment before attaching or lifting a tank. Do not place hands, arms, or any other body part beneath a suspended tank. Secure any loose tools, slings, or chains in a toolbox on the trailer or towing vehicle before transporting the tank, or after setting a tank and returning to the bulk plant.
Ensure the towing hitch is rated to carry the load of the trailer.
Check the condition of the trailers lifting equipment before attaching or lifting a tank.
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All materials and supplies needed for installation at the customer site are considered cargo and must be secured under DOT regulations, including:
Piping Regulators Valves Meters Fittings Masonry foundation blocks Chock blocks Dollies Materials of Trade (MOT)
Remember! All vehicles transporting portable containers must be equipped with one or more fire extinguishers with a minimum capacity of 18 lb of dry chemical with a B:C rating. Gravel and rocks often catch in the feet of tanks, and are lifted with the tank onto the truck bed. Be sure to clean out any loose debris on a tank prior to loading.
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Transporting MOT
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You may transport small amounts of hazardous materials for use at an installation site; for example, paint, paint thinner, methanol, or wasp spray. Limited quantities of flammable liquids and other hazardous materials may be transported as MOT without placards, shipping papers, or emergency response information.
DOT regulations define MOT as hazardous materials that are carried on a motor vehicle to:
Protect the driver or passengers. Support the operation of the motor vehicle. Directly support the business.
Hazardous MOT must be secured in approved containers in external vehicle toolboxes, secured in racks, or placed in protected areas on the bed or cargo area of a service truck. You cannot transport MOT in the cab of a service vehicle, or in any unprotected area where the container cannot be secured. See Resources for more information about transporting flammable liquids as MOT.
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Complying with DOT licensing and driving requirements. Conducting pre-trip inspections on your vehicle. Ensuring required maintenance is performed on your vehicle. Driving defensively.
Before leaving the plant, you must ensure placards are properly attached to the vehicle, and are visible, and in good condition.
Detailed information on these and other related topics are included in the CETP training program Propane Delivery Operations and Cylinder Delivery.
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Module Summary
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Some important points to remember from this module are:
Check the cylinder manufacturer or requalification date. Determine the overall fitness of the cylinder; identify required cylinder markings. Perform a leak test. Perform a sniff test to verify the presence of odorant.
There are different methods for loading DOT cylinders and ASME tanks onto delivery vehicles, and specific guidelines apply to loading each type of container. Follow manufacturers instructions and adhere to company policies when loading propane storage containers for transportation. After loading the container you are responsible for the service vehicle itself and for safely transporting the container. When transporting cylinders or tanks containing propane, you must carry shipping papers, a hazmat certificate of registration, and emergency response information.
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Module 4 Quiz
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Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
1. If you want to find the most recent requalification date of a DOT cylinder that had previously been visually inspected, look
for: a. The date imprinted along the top of the container b. The month and year card with the most recent date hole-punched c. The month and year followed by the letter E d. Documentation that must always accompany the container
2. All of the following are examples of physical defects that would disallow a container to be refilled EXCEPT:
a. Bulging b. Discoloration along the container wall c. Cracks d. Damage to the cylinder foot rings
3. ASME tanks used for LP-gas storage that have a water capacity of 125 gallons or greater cannot be transported over a
public roadway when filled to more than ______ of their water capacity. a. 20% b. 15% c. 10% d. 5%
4. The steps to performing a leak test are as follows: Step 1: Select a leak checking device; Step 2: Choose an appropriate
place in the plant to perform the inspection; Step 3: ________; Step 4: Use a leak detector to test for leaks. What is step 3? a. Pressurize the container b. Notify supervisor of potentially unsafe containers c. Connect a vapor hose to the container d. Spray fluid on valve and look for bubbles
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5. DOT regulations classify ASME containers with a capacity greater than ____ gallons as bulk containers.
a. 75 b. 50 c. 125 d. 120
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6. If you are transporting cylinders or tanks containing propane, you must carry _______.
a. Shipping papers, placard holders, and emergency response information b. Shipping papers, a hazmat certificate of registration, and emergency response information c. Shipping papers, a hazmat certificate of registration, and a cylinder dolly d. Towing hitch, a hazmat certificate of registration, and emergency response information
7. Which of the following procedures for loading and securing propane cylinders on a vehicle is NOT correct?
a. Park your vehicle at the dock or on the level ground before moving the dolly and cylinder onto the lift gate b. Take precautions before operating the lift gate, including centering the load on the lift gate to help prevent it from tilting or falling c. Use the lift gate to load cylinders on the service vehicle so most of the weight is on the front axle with side-to-side distribution d. Load and position the cylinders on the vehicle so that each cylinders pressure relief valve is in direct communication with the vapor space at all times and secure them in this position
8. Not all materials and supplies needed for installation at the customer site are considered cargo; only non-perishable
materials must be secured under DOT regulations. a. True b. False
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Objectives
After completing this module, you will be able to:
Identify the procedures for installing aboveground containers and underground ASME tanks. Identify pre- and post-installation procedures. Describe the procedures for testing and trouble-shooting a cathodic protection installation.
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Introduction
When you arrive at a site to install the exterior components of a vapor distribution system, review the work order and any other information you have related to the installation before you begin. This review will help ensure a safe and reliable installation. This lesson addresses pre-installation activities that you must complete before installing the exterior components of a vapor distribution system. After completing this lesson, you will be able to explain the activities you must perform and the factors you must consider before installing the exterior components of a vapor distribution system. The CETP course Placing Vapor Distribution Systems and Appliances in Operation provides specific requirements and methods for conducting the interior site assessment, including testing and verification procedures.
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Greet the customer and review the work order to confirm it is consistent with the customers request and needs. Verify with the customer that there are no known or planned changes to the buildings on the property or to the property itself that could affect the container or regulator location. Such changes may include adding central air conditioning, building modifications, or installing childrens play equipment. Verify with the customer that the vehicular traffic will not be operating near the tank. Verify the total gas demand, including any planned future appliance installations, to confirm that the selected equipment and the sizing are correct for the installation.
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Type and size of delivery vehicle. Type and size of container. Method used to unload the container. Layout of the customers site, including accessibility to the selected container location. Existence of septic systems, sprinkler systems, and drainage pipes that could be damaged.
Set the parking brake. Follow your company policy on the use of chock blocks, which help prevent the vehicle from rolling forward or backward.
Check the immediate area for any potential safety hazards, such as overhead power lines and other obstructions.
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To review the details on presence and location of underground utilities, refer to the Establishing Container Location lesson in the Designing Vapor Delivery Systems module of this course.
Confirm the locations of underground utilities. Verify that the local one-call service has been contacted and that underground utilities have been identified. Confirm the locations of customer-owned underground systems. Ask your customer if there are any other underground systems on the premises. These systems may include a sprinkler system, septic system, or electric lines for any reason. The one-call service or the local utility that was called to identify and mark lines will typically not locate lines or underground systems on the property that are owned by the customer, like the propane gas lines. Ensure that the buried tank or piping will not interfere with pre-installed utilities or systems. Conduct a walk-around inspection of the customers property to verify that you can install the tank and piping as planned taking into consideration any underground utilities and other systems.
NOTE: Follow your company policy regarding verifying and documenting customer-owned underground lines and systems.
The nationwide One Call number is 811. You must call this number before you start digging. For more details, please visit their website at http://www.call811. com.
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National Fire Protection Association (NFPA) spacing requirements Physical damage from vehicles High water levels or flooding Maximum snow depth Damage to regulator from falling snow or ice Access to bulk trucks and cylinder dollies
To review the details on spacing requirements, please refer to the Establishing Container Location lesson in the Designing Vapor Delivery Systems module of this course.
If you need to change the proposed container location, explain the reason and proposed changes to your customer before proceeding. The container location must comply with all state and local requirements.
Consider access to bulk trucks and cylinder dollies when making your exterior site assessment.
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Which of the following is not a factor in the pre-installation activities for an aboveground container?
Physical damage from vehicles
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Explain general safety precautions for installing containers. Explain how to install DOT cylinders, including multiple exchange cylinders and stationary cylinder manifold systems. Explain how to install aboveground ASME tanks, including multiple tanks in a manifold system. Identify components and accessories used for container installation.
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Use three-wire (grounded) or double-insulated electrical tools as prescribed by the National Institute for Occupational Safety and Health (NIOSH), American National Standards Institute (ANSI), and Occupational Safety & Health Administration (OSHA) standards. Use three-wire electrical extension cords with proper ground lugs and a grounded power supply. Never place any electrical tools or extension cords in water puddles.
Only authorized and properly trained personnel should assist during installation. Make sure everyone knows who is in command. Do not ask for or accept assistance from a customer when installing a propane storage container. Do not allow the customer or any children or pets to be in the immediate work area during installation. Explain the possibility of injury and politely ask them to stay away from the installation area. Do not leave equipment and tools unattended. Return all tools and equipment to the service truck and secure them according to your company policy. In addition to these safety precautions, consult state and local codes, as well as your company procedures, for additional safety precautions.
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Use three-wire electrical extension cords with proper ground lugs and a grounded power supply.
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2. Prepare the Area. Make sure the area to set the cylinder base on
is level and firm. Sand or other non-combustible material may be needed to ensure a level foundation.
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4. Unload and Install the Cylinder. Lower the vehicles lift gate and
remove all tie-down straps or chains from the cylinder and cylinder dolly. Use the dolly and lift gate to carefully unload each cylinder from the truck. Do not remove the protective service valve collar until the cylinder is in place. Inspect the paint or protective coating on the cylinder to ensure that it was not damaged during transport. Touch up any damaged areas on the paint or protective coating. If you are only installing one cylinder, place it upright in the center of the foundation. If you are installing two cylinders, place them both on the foundation at least 2" to 3" apart for service access and maintenance. Repeat this procedure until all cylinders have been installed.
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If applicable, remove the protective cap from the neck of all cylinders. Ensure that all cylinder service valves are closed tightly. Verify that all caps or plugs are installed in valves as appropriate.
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Exchange
In an exchange system, two cylinders are connected to a changeover regulator. However, only one cylinder supplies propane at any time. When one cylinder is almost empty, the regulator must be manually changed or it may be of the type that automatically switches to the reserve (full) cylinder. The cylinder that is almost empty is then replaced with a new full one. Exchange cylinder installations are often used at residences in rural areas, especially in locations that would be impractical or impossible for a bobtail truck to access.
Stationary
In a stationary system, two or more cylinders are connected to a standard regulator. Unlike an exchange system, all cylinders in a stationary system supply propane simultaneously. When the cylinders are almost empty, they are refilled with propane from a bulk truck. Stationary cylinder installations are often used at small commercial locations, such as a pizza shop or coin-operated laundromat, which usually require more propane than a typical residence. You can use either DOT cylinders or ASME tanks in a multiple container installation but be aware they have very different code requirements, which will be discussed later in this lesson.
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Automatic
When the vapor pressure in the supply cylinder drops below a level adequate to supply propane to the appliances, the automatic changeover regulator switches to the reserve (full) cylinder automatically and does not interrupt the supply to appliances. The arrow on the regulator pointer knob initially points to the cylinder in service. When the empty cylinder indicator appears, the arrow then points to the empty cylinder. The pointer knobs arrow is reset by the cylinder delivery person. Because this regulator incorporates a check valve, it allows empty containers to be filled or replaced without interrupting the customers service. Normally, this regulator is connected to two cylinders or two banks of cylinders.
Manual
A manual regulator, typically an integral 2-stage regulator, serves installations with small effective system loads or where the use of propane is infrequent. To manually switch from one propane container to another, either:
Open the exchange cylinder service valve on the reserve cylinder and close the exchange cylinder service valve on the empty cylinder. Or, if a connecting T-block is used, move the change over knob on the T-block valve away from the empty cylinder and toward the reserve cylinder.
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There are three types of connections for pigtails that are available in lengths up to 60":
POL by POL " National Pipe Thread (NPT) by POL " inverted flare by POL
The pigtail you select for an installation depends on the type of connection at the inlets of the regulator and the length required. Allow enough extra length in each pigtail to include a loop in the tubing. Verify the compatibility of fittings prior to connecting pigtails.
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For systems consisting of four or six cylinders, assemble a manifold using T-block fittings and pigtails.
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T-Checks
The simplest way to install a manual changeover system is by using a T-check and two pigtails. A T-check is a T-block with a built-in floating check valve. When the service valve of the empty cylinder is closed, the pressure in the reserve cylinder forces the check valve to shut. This allows the empty cylinder to be replaced without interrupting service to the appliances or discharging propane from the reserve cylinder.
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Thread-Sealing Compounds
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When selecting materials for a pipe manifold, such as nipples, shutoff valves, and Ts, always select a thread-sealing compound approved for propane service. Before assembling a threaded pipe connection, apply the compound to all male threads after the leading two threads. This helps ensure the manifold will be gastight. Always remove any excess thread-sealing compound with a clean rag before assembling the pipe joint. Do not apply thread-sealing compound to the seats of fittings that make soft metal-to-metal sealing joints. For example, do not apply thread-sealing compound to:
POL fittings. The center coupling mating surface of ground-joint pipe unions. The copper tubing inside, outside, or inverted flare connections.
The contours of these joint materials and the o-rings or gaskets in flanges create a gas tight seal. Applying thread-sealing compound to these contours could interfere with that gas-tight sealing. If compound enters a pipe, it could flow with gas to regulators or other equipment and potentially cause critical equipment to malfunction.
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In an automatic changeover system, which component automatically switches the supply of propane vapor from the supply cylinder to the reserve cylinder when the pressure in the supply cylinder drops to a low level?
Pigtail
Container
Regulator
Pressure gauge
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LEARNING ACTIVITY
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Defining a building as important is at the discretion of the AHJ. Some reasons a building might be labeled as important include human occupancy, value of the contents inside the building, replacement value of the building, and the effect of the building on fire control activities by emergency responders.
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Reinstall the blocks on the base, and recheck the level. The tank or blocks may need adjustment after filling due to the ground settling after the fill. Repeat as needed until the blocks and the foundation are level. The foundation should be installed so that the bottom of the tank is approximately 6" above the ground. The foundation must provide enough access to clean and paint the underside of the tank. Check your state and local codes for exact clearance requirements between the ground and the bottom of the tank.
Tanks are generally brought to the site with less than 5% or less liquid. If for some reason you need to handle or remove a tank with more than 5% liquid, do not use the lifting lugs or eyes. Instead, use slings that have adequate load ratings and secure them under the bottom of the tank to make the lift.
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As long as each foundation block is level, the blocks supporting each leg of the tank can be at different heights or elevations relative to each other.
True
False
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PARALLEL LAYOUT
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A manifolded tank installation has two additional steps that a single ASME tank installation does not have.
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LEARNING ACTIVITY
LEARNING ACTIVITY
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Introduction
This lesson will address how to install underground ASME tanks. Underground ASME tanks contain specific features so they can be buried or mounded.
Identify NFPA 58 requirements for installing underground ASME tanks. Explain how to install underground ASME tanks. Explain how to install and test the cathodic protection system for underground ASME tanks. Explain how to manifold multiple underground ASME tanks.
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If the nameplate on the tank will be covered when buried, the information contained on the nameplate must be duplicated and installed on an adjacent pipe or on a structure in a clearly visible location. Connections to underground ASME tanks must be within a covered dome or housing. The vents from any pressure relief device, including regulator vents, must extend above the normal maximum water table. Where flood zones and high water tables could cause flotation of the tanks, they must be securely anchored. In areas with no vehicle traffic, underground containers must be installed at least 6" below grade. In areas where vehicle traffic is expected, the container must be a type designated for underground service only and be installed at least 18" below grade, or, the container must be protected from damage due to vehicle traffic.
Refer to the Selecting the Appropriate Container lesson in the Designing Vapor Delivery Systems: Containers and Lines module in this course for more details.
NOTE: Under special circumstances, NFPA 58 permits reduced spacing for underground tanks. Check with your supervisor for additional information regarding these special provisions.
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Underground Utilities
Verify that the local one-call service has been contacted and that underground utilities have been identified as applicable. Ask your customer if there are other underground systems on the premises, such as a sprinkler system, septic system, or electric lines for ornamental lighting. Before excavating, check any utility markings to ensure that they do not cross the planned tank and line locations.
The nationwide One Call number is 811. You must call this number before you start digging. For more details, visit their website at http://www.call811.com.
Code Requirements
When determining a tank location, ensure that it meets the code requirements for:
Distance from property lines. Distance from building and ignition sources. Distance from vehicular traffic.
Soil Stability
It is also important to determine the stability of the soil when selecting a tank location. Soil with high water content or containing mostly sand, gravel, or some other mixture, could be unstable and possibly a safety hazard during the excavation and tank setting steps.
Other Requirements
When determining an underground ASME tank location, always consider the distance from low lying areas where water may collect.
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4. Add another 6" to 18" to the measured height, depending on the amount
of protective ground cover needed above the tank. Ensure the final finished grade provides at least 6" of coverage if it will not be subjected to vehicle traffic. If the final finished grade will be subjected to vehicle traffic, ensure it provides at least 18" of coverage. If the finished grade will be subjected to weight greater than just a vehicle (for example, a delivery truck and its cargo), then the depth of coverage may need to be more than 18".
For multiple tank installations, remember to include the required separation distances between the tanks and adequate space for crane or hoist access at the ends or sides of the tanks. NOTE: Check with your supervisor for any additional depth or cover requirements (for example, concrete slabs) that could be established by the local authority having jurisdiction (AHJ).
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Follow these safety precautions to ensure that no potential cave-ins occur during or after digging.
If a hole or excavation is deeper than 60", OSHA requires that you either slope the walls or shore them with plywood. OSHA does not require support for the walls of an excavation or hole that is 60" deep or less. You should wear proper safety glasses, work gloves, and safety shoes or boots when digging a hole to protect your eyes, hands, and feet. In addition, you should wear head protection if there will be equipment overhead, such as truck-mounted cranes. Do not park vehicles and heavy equipment, or stockpile any material, closer than 2 ft from the edge of an excavation or hole.
With your excavation site complete, you are now ready to prepare the base.
If a hole or excavation is deeper than 60, OSHA requires that you either slope the walls or shore them with plywood.
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According to NFPA 58, if any underground tank isnt protected from damage due to vehicle traffic, then how many inches below grade must an underground tank be where vehicle traffic is expected to cross the location of the tank?
16
15
18
12
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When installing one anode, dig a hole at the center of the base so the tank can be placed on top. When installing two anodes, you can dig holes next to where the feet of the tank will be. Alternately, you can place the anodes on opposite sides of the tank, at opposite ends of the tank, or at opposite diagonal corners of the tank. For installations with a concrete base, dig the holes for your anodes directly next to the slab, and at opposite sides or opposite ends of the tank. You will likely need two anodes for these installations to provide adequate cathodic protection.
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2. Remove the outer shipping package but not the cloth bag
that holds the anode and moisture absorbing material. Wet each anode with an acceptable amount of water to ensure electrical conductivity. You can wet the anode by soaking it in a bucket of water before you place it in the hole, or pouring water over it after youve put it in the hole. Ensure anodes are wet and that the water soaks in. This procedure ensures moisture retention and good soil contact for anodes, and helps the anodes distribute current more evenly.
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it to the top of the excavation with a rock or clod of dirt. Do not let anodes come into contact with the tank, as this would neutralize the current.
Once you complete these steps, you are ready to unload the tank and place it in the hole.
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If you have poured a concrete slab in the excavation, secure the tank to the ground anchors with metal straps. If a concrete slab was not poured, check with your supervisor to determine the procedures that your company requires for floodplains and high water tables.
If you are manifolding multiple tanks, there are additional steps. These will be discussed later in this lesson. After you have completed all steps, you are ready to backfill the excavation site.
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When backfilling, be careful not to scratch the surface of the tank. You should:
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MODULE 5 4. Fill in the area around the dome so the soil is graded
down and away from the dome cover. It is extremely important that the top of the multivalve be higher than the finished grade after landscaping. This way, when the dome collects water, the multivalve components will not be affected by the water. This is especially important in areas where water could be subjected to freezing temperatures. In areas with high water tables, it may be necessary to raise the tank fittings above the water level and mound the backfill over the tank. Installing plastic drain piping that leads away from the dome, and surrounding the dome area with coarse rock to provide drainage will also prevent water from accumulating in the underground tank dome. NFPA 58 requires anyone involved in construction or excavation near an underground tank to determine the location of the tank and piping, and protect them against damage from vehicles.
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Manifolding underground ASME tanks is similar to manifolding aboveground tanks, with these additional considerations:
The regulator must be protected from the soil. You must bury the regulator so the soil is not touching it. Sometimes a separate housing is used to protect a regulator from soil, although the regulator can also be mounted inside the dome of one of the tanks. The regulator must be protected from water which can cause internal corrosion, improper delivery pressure, and the potential for total regulator failure if the water freezes. If water could get into the regulator vent, you should install a regulator vent pipe-away assembly. The vent pipe-away is a U-shaped adapter installed at the highest point available at the top of the dome. It prevents ground or surface water from entering the regulator, and the U-shape helps create an air trap. This assembly should terminate above the anticipated water level, pointing downward to prevent water from entering the regulator.
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An open-bottom water meter or valve box. A poured-in-place concrete vault with a loosefitting manhole cover. Installation inside the dome of one of the tanks.
No matter what method is used, ensure the tank has adequate drainage. If water accumulates under the tank, water could enter the regulator vent and could freeze. Adequate drainage will also reduce the potential for water to buoy the tank, causing it to rise or shift.
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Identify the procedure for testing a cathodic protection system. Identify the steps to troubleshoot a cathodic protection installation. Describe retrofitting for corrosion protection and when it should be used.
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The voltage can be measured with voltmeter and a copper sulfate electrode. Verify the electrode and other testing equpment has been properly maintained according to the manufacturers instructions.
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4. Take a position above the side of the tank, stick the tip of the
electrode into the moist ground, and take a reading. Record the data according to your company policy. The voltage reading on a protected tank should be -0.85 volts or greater; in this instance, greater means a higher negative number such as -0.90. If the voltage reading is low or close to the voltage of steel (-0.50 volts), there is likely a problem with the cathodic protection system. The anode may not be connected to the tank properly, or the electrode may not be making good contact with the soil. Its also possible that the number, size, or quality of anodes is insufficient. Check all possible causes, make corrections, and retest until readings are acceptable.
It is possible to record a good reading above -0.85 volts on one end or one side of a tank and have a bad reading below -0.85 volts on the opposite end or opposite side of a tank. When this happens, the areas of the tank that have readings above -0.85 volts are protected while an area with a reading below -0.85 volts is not protected and could still suffer corrosion damage.
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12 to 18 months after the initial test And then, upon successful verification and in consideration of the previous test results, periodic follow-up testing shall be performed at intervals not to exceed 36 months.
If the system fails the test it must be repaired as soon as practical unless climatic conditions prohibit this action, in which case the repair must be made not more than 180 days thereafter. Once the repairs have been made, the testing schedule must start again as if the system was a newly installed container. All tests results must be documented and the results of the two most recent tests must be retained. Check your company policy or with your supervisor for specific requirements for testing and documentation of the test results.
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Troubleshooting
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In a previous lesson, you learned that corrosion protection is accomplished through sacrificial anodes connected to and buried with the tank. You must perform periodic tank-to-soil tests to determine if anodes are working properly. When a reading at an installation is zero volts, there is a problem and you will need to troubleshoot. Answering these questions will guide you when troubleshooting. If you answer no to any of these questions, then you will need to solve that particular problem before continuing to troubleshoot.
Is the voltmeter on? Is the battery good? Have you taken off the rubber boot on the copper sulfate electrode? Have you set the voltmeter switch to the lowest DC volt scale? Have you connected the negative lead wire to the copper sulfate electrode? Have you connected the positive lead wire to the multivalve or anode wire securely? Does your copper sulfate electrode have a blue liquid in it? Have you set the electrode firmly on the ground? Have you poured a sufficient amount of water on the ground if the ground is dry? Are your lead wires and their connections good?
If everything you have checked aboveground is satisfactory, and the meter reading is still below -0.85 volts, use this second checklist of questions to continue troubleshooting. Not all of these checklist items will be a problem at the same time. If you answer no to any of these questions, then solve the problem before continuing to troubleshoot. Consult company policy on how to specifically fix these issues.
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Troubleshooting, CONTINUED
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If the tank is connected to the structure with copper tubing or a steel service pipe, is there a dielectric or insulating union in the piping system? Is the coating on the tank intact and not peeling in the dome? Is there electrical continuity between the multivalve or anode wire and the pipe into the building? Check this using the ohms-resistance setting and a jumper wire between the multivalve or anode wire and the pipe at the building. A reading less than 20 ohms indicates there is continuity between the tank and the building. Is the anode wire securely connected to the tank and not the metal dome?
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Retrofitting
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When testing determines that installed anodes do not provide sufficient voltage to cathodically protect that system, one or more anodes may need to be added. This process is called retrofitting.
For an existing installation that never had any anodes. Immediately after a system is installed and backfilled, if the anodes that were originally installed do not provide sufficient voltage. After anodes deteriorate and lose their charge, which will happen over time. Different factors, including soil conditions, drive the rate of anode deterioration. In salty or brackish environments where zinc anodes are required. Consult with your vendor for proper selection when retrofitting these environments.
Determine if the piping system requires cathodic protection. If so, you must consider protecting the piping system when choosing the size and number of anodes. For details on how to retrofit an installation, refer to the PERC Cathodic Protection Manual. Before excavating, call your Local One-Call Service (811) to identify underground utilities and prevent damaging structures.
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Step 1: Verify there are no sprinkler lines, low voltage electric wires, propane service lines, or other ownerinstalled flower bulbs or wires where you plan to dig.
Step 2: With a shovel, cut out a plug of grass ve feet from the side of the dome and set it aside.
Step 3: Dig a vertical hole at least 3 ft deep. If this isnt possible, you may have to lay the anode down horizontally. In dry environments, the anode may work better if it is laid horizontally in a ditch 18" deep where a sprinkler or rain water will wet the anode. If the tank is in a desert environment, set a PVC pipe in the hole above the anode so that water can be poured into the pipe to wet the anode.
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Step 4: Place the anode in the hole and pour water on it.
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Step 5: Touch the anode wire to the multivalve while taking a tank potential reading. The reading should be above -0.85 volts. If it is, continue with the installation. If the reading is not good, refer to the troubleshooting list presented earlier in this lesson.
Step 6: With the shovel, wedge the grass apart from the anode to the dome, and push the wire down below the grass into the dirt.
Step 7: With a portable electric drill, drill a hole through the dome and insert a rubber grommet or short length of vinyl tubing in the hole. Then, push the wire through the hole into the dome.
Step 8: Connect the wire to the tank at the stud under the multivalve, or to the riser pipe using a band clamp. Any secure, waterproof connection between the anode wire and the riser pipe or multivalve will cause the tank potential readings to shift to the protected level of -0.85 volts or greater.
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Step 9: Fill the anode hole with the dirt removed during digging and use the shovel handle to tamp the dirt around and on top of the anode. This lls in the voids between the anode and the hole you dug. If you dont do this, there will be a gap between the anode and the hole that the current cannot ow across. This will reduce the amount of current your anode creates, and cause the readings to be lower than what is possible. Replace the plug of grass on top of the anode hole and push the separated grass back together where the anode wire was run. Step 10: Once you have completed these steps, test the soil again. Remember to take four readings, one on each side of the tank and on each end, with a healthy reading being any voltage equal to or greater than -0.85 volts. In the unlikely event that one anode does not increase the readings to a protected level of -0.85 volts or greater all around the tank, install a second anode on the opposite side of the tank. Once you complete the installation, follow your companys policy and local codes to document your work for future reference. If after following all these procedures your reading still does not increase to -0.85 volts or greater, it is possible the container is too corroded and may need to be removed from service. Check with your supervisor for company policy regarding these guidelines.
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Module Summary
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Some important points to remember from this module are:
Before you unload a container, you should verify total gas demand, determine where you will unload the container, and perform an exterior site assessment. Following these steps will help ensure a safe installation. The steps for installing DOT cylinders and ASME tanks aboveground are similar; however, there are some key differences. You must be familiar with the procedures for installing each type of container. If the vapor distribution system load requirements exceed the vaporization capacity of a single propane storage tank, or if additional storage is preferred, you will need to manifold multiple ASME tanks. For underground ASME tanks, you may have to install one or more anodes to provide cathodic protection to the tanks. When you install a cathodic protection system with an underground ASME tank, you need to test the anodes to verify they are providing adequate protection against corrosion. Follow-up testing is also required by code to verify continued protection of the underground steel tank.
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Module 5 Quiz
Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
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1. Which of the following must be performed before excavating underground tanks and piping?
a. Confirm the locations of underground utilities b. Confirm the locations of customer-owned underground systems c. Ensure that the buried tank or piping will not interfere with pre-installed utilities or systems d. All of the above
2. During an aboveground container installation, when using electrical tools you should:
a. Use three-wire (grounded) or double-insulated electrical tools b. Use custom coil electrical extension cords c. Use three-wire electrical extension cords with proper ground lugs and a grounded power supply d. Both a and c
3. Which of the following is used to keep the vapor distribution piping from being too rigid and more susceptible to leaks
from a gradual or sudden shifting of the ground, piping, container, or service line? a. T-blocks b. Manual changeover valve c. Thread-sealing compound d. Pigtail loop
4. The most important factor affecting the choice of T-blocks is whether the cylinder changeover system is manual or
automatic. a. True b. False
5. When determining a tank location, ensure that it meets the code requirements for:
a. Distance from property lines and distance from building and ignition sources b. Distance from property lines and distance from fire hydrants c. Distance from municipal lines and distance from building and ignition sources d. Distance from property lines and distance from water sources
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6. During which step in installing underground ASME tanks would you establish a proper base to ensure that the tank is set
on a level surface? a. Step 2. Determine the size of the hole b. Step 3. Digging the hole c. Step 4. Prepare the excavation base d. Step 5. Install the anodes
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7. In order to place the tank into service, all of the following must be completed EXCEPT:
a. Verifying the anode wires are properly connected and secure b. Installing the pigtail, first-stage regulator, and regulator vent pipe-away as necessary c. Connecting the buried distribution line to the regulator outlet d. Verifying that the regulators vent or vent extension terminates below the anticipated water line
8. Underground tanks must be manifolded before they are prepared for service.
a. True b. False
9. Testing the cathodic protection system can be done by checking the _____________.
a. Soil content b. Tank-to-soil potential c. Anode reading d. None of the above
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Objective
After completing this module, you will be able to:
Identify code requirements and common practices followed when working with pipe and tubing. Explain techniques and procedures used for installing pipe and tubing between a container and the second-stage regulator.
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Introduction
After installing an aboveground or underground container, you will install the exterior lines of the vapor distribution system. This lesson provides guidance for installing the exterior lines of a 2-stage regulated vapor distribution system. After completing this lesson, you will be able to:
Identify code requirements and common practices followed when working with pipe and tubing. Explain techniques and procedures used for installing pipe and tubing between a container and the secondstage regulator.
2-stage regulated systems refer to those with two separate regulators as well as those with an integral type regulator.
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Piping must be run as directly as possible from one point to another, with as few fittings as practical. Piping systems, including the interconnection of permanently installed containers, must compensate for expansion, contraction, jarring, vibration, and settling. Where condensation of propane vapor can occur, piping must be sloped back to the container. If that cannot be done, some other means for re-vaporizing the condensate must be provided. Although flexible metallic connectors are permitted in vapor distribution systems, nonmetallic pipe, tubing, or hose are never permitted for permanently interconnecting containers. Vapor distribution system piping can never be used as a grounding electrode.
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Aboveground Lines
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Vapor delivery lines that run from a container to a building are normally installed underground. However, there may be instances where you are not required to bury a line. For example, you may use an exterior aboveground line when a cylinder is installed right next to a building. In these situations, you can use steel pipe, copper tubing, or approved Corrugated Stainless Steel Tubing (CSST) for aboveground vapor distribution lines. The steps for assembling aboveground sections of exterior piping are similar to those for assembling similar types of underground pipe and tubing. These steps are discussed in detail later in this lesson.
Steel pipe, copper tubing, or approved CSST can be used for aboveground vapor distribution lines.
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You cannot use polyethylene (PE) pipe, tubing, and fittings in aboveground line installations. Aboveground piping must be supported and protected against physical damage from vehicles. You should install piping so there are no sags. If the pipe is not supported properly, it could fail. Salts and other substances in the ground and in concrete can corrode piping. Make sure the portion of aboveground piping in contact with a support structure or corrosion-causing substance is protected against corrosion.
NOTE: NFPA 58 does not specify how aboveground lines should be supported or protected, so check your company policy or with your supervisor for company-specific requirements.
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1. Dig a trench. 2. Insert pipe or tubing in the trench. 3. Plug or cap lines. 4. Test for leakage in the exterior installed line and document results. 5. Backfill the trench.
Specific installation instructions for different types of pipe and tubing are addressed in detail later in this course.
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If at least 12 of cover is not possible, the pipe or tubing must be installed in conduit or be bridged or shielded.
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Steps 2 and 3. Insert Pipe or Tubing in the Trench and Plug or Cap Lines
Step 2. Insert Pipe or Tubing in the Trench
Piping assembly techniques vary depending upon the type of pipe or tubing used. We will discuss the specific procedures for each later in this course. Make sure the pipe lies flat in the trench and is supported by well-compacted soil, with no rocks or other materials under it. The piping must be long enough to connect the first-stage regulator to the second-stage regulator.
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You must conduct this test at pressures no less than the operating pressure. You must not use an open flame.
The underground distribution line typically operates at 10 pounds per square inch gauge (psig). A test pressure must be equal to at least the normal operating pressure of the line. Local codes or company procedures may require test criteria in excess of these values. NOTE: This course describes one method to perform a test for leakage. Other methods include utilizing leak detection solution, using a combustible gas detector, or using a combustible gas indicator. Check state and local codes for other test for leakage requirements.
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There are many ways to test for leakage. Heres one example.
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Note that the service valve must be repaired or replaced according to this test for leakage method. You can still conduct a test for leakage using other methods, but dont forget to repair or replace the defective valve.
If the pressure increases, propane may be leaking into the system from a container service valve. Verify that the service valve is fully closed and restart the test for leakage. If you observe another pressure increase, the container service valve must be repaired or replaced to complete a valid test for leakage. Do not repair or replace a service valve unless you have been trained to do so. If the pressure decreases, there is a leak in the piping. After the source of the leak is located and repaired, the test for leakage must be restarted and continued until no change in pressure is observed. You must determine that the vapor distribution system is gastight in accordance with your company policy.
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You should use a shovel to carefully hand backfill the area around the distribution line.
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Which of the following is not true of aboveground pipe and tubing installation?
PE pipe, tubing, and fittings can be used in aboveground line installations
Aboveground piping must be protected against physical damage by vehicles The portion of aboveground piping in contact with a support or corrosion-causing substance must be protected against corrosion Aboveground piping should be installed so there are no sags
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Introduction
The previous lesson addressed the basic steps for installing exterior lines. This lesson provides guidance for installing PE piping for a two-stage regulated vapor distribution system. After completing this lesson, you will be able to:
Identify code requirements and common practices when working with PE pipe and tubing. Explain techniques and procedures to install pipe and tubing between the container and the second-stage regulator.
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D 2513 is an ASTM code that refers to the standard specification for thermoplastic gas pressure pipe, tubing, and fittings.
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MECHANICAL FITTING
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Mechanical Fittings
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Two common mechanical fittings are the stab and the barbed types. Always follow manufacturer-specific instructions when connecting these fittings.
Stab-Type Fitting
A stab-type fitting is a specially designed mechanical fitting that:
Uses specially designed components including an elastomer seal (such as an O-ring) and a gripping device to create pressure sealing and provide pull-out resistance. And is designed so that the greater the pull, the firmer the lock and tighter the seal in the joint.
These fittings are available in sizes from " Copper Tube Sizing (CTS) through 2" Iron Pipe Size (IPS) and must also comply with ASTM D2513, which specifies sealing and full restraint against pull-out requirements.
D 2513 is an ASTM code that refers to the standard specification for thermoplastic gas pressure pipe, tubing, and fittings.
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Barbed Fitting
A barbed fitting is another method for mechanically joining PE pipe and tubing and is used in combination with pressed-on exterior compression sleeves. You insert the barbed fitting into the ends of the sections of pipe or tubing to be joined.
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Use the correct barbed insert or spigot and compression sleeves for the pipe and tubing sizes. Use the appropriate installation tools according to the size of the pipe or tubing.
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Special Tools
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Two special tools are required when working with PE piping: a plastic pipe cutting shear and a chamfering tool.
Cutting Shear
There are different types of shears used, but they all basically involve opening the jaws of the shear around the pipe and then squeezing the handles to cut. Be sure you use the appropriate size cutter for the pipe you are cutting. Be careful to cut the pipe and not flatten it.
Chamfering Tool
A chamfering tool is used to bevel the end of PE pipe in preparation for attaching it to a service head adapter or fitting. Follow the manufacturers instructions when using this tool. Make sure you use a chamfering tool that matches the fitting. Some fittings require chamfering on the outside of the tubing, and some on the inside. Some require no chamfering at all.
Note: Cut the pipe square and remove all burrs and cuttings. You may remove burrs with a chamfering tool, reamer, sharp knife, or fine tooth file. A miter box or a cold ring clamp can help ensure square cut ends.
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Laying PE Pipe
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PE pipe has specific installation requirements. These requirements are based on the physical properties of plastic and the effect of environmental conditions during and after installation.
If PE pipe is not encased in a gastight metal pipe, it must be traced with a continuous electricallyconductive tracer wire or metallic tape. Where PE pipe is not buried at either the container or the second-stage regulator, it must be encased in an approved anodeless riser because PE cannot be exposed to sunlight for extended periods of time. PE piping must be joined so that all connections are covered with soil; PE pipe and fittings cannot be exposed in the dome of an underground tank. If PE pipe is not encased in a gastight metal pipe, it must be traced with a continuous electrically-conductive tracer wire or metallic tape.
PE pipe needs to be continuously supported. Ensure that the trench is relatively level and free of rocks and other materials that may damage the pipe or tubing. When you install PE pipe, carefully lower the required length into the trench. Do not subject it to undue stress. Do not drag it over rocks or other abrasive material. Changes in temperature will cause PE pipe to expand and contract, which is normal. Allow for these changes by snaking the piping from one side of the trench to the other.
Snake PE piping to allow for changes in temperature, which causes the pipe to expand and contract.
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Emerges from the ground. Connects to a container. Connects to a second-stage regulator at the service entrance to a building. Connects to an outdoor appliance.
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Within 1/8" of moisture seal on 1/2" CTS and 1" CTS sizes. Within 1/4" on all other sizes through 1 " CTS. Approximately 3/8" on 1-1/4" IPS and 2" IPS sizes.
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False
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Introduction
You have already learned the basic steps to installing exterior lines. This lesson provides guidance for installing copper piping for a two-stage regulated vapor distribution system. After completing this lesson, you will be able to:
Explain techniques and procedures used for installing copper pipe and tubing.
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Copper Tubing
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There are two types of soft seamless copper tubing commonly used for vapor distribution system installations: water tubing and refrigeration tubing.
Water tubing is sized by inside diameter (ID) and is commonly available in two types:
Type L is the most common and is approved for both liquid and vapor lines. Type K has greater wall thickness than Type L and is often used for liquid and high-pressure vapor lines.
COPPER TUBING
Refrigeration tubing, also known as Air Conditioning and Refrigeration (ACR) tubing, is sized by outside diameter (OD). Refrigeration tubing is approved for both liquid and vapor lines. Refrigeration tubing is usually charged with nitrogen gas to keep it clean and dry until it is used.
Copper tubing is flexible, but when installed aboveground it must be properly supported by clamps and suitable brackets. Copper tubing should be plugged or capped after cutting to help maintain its dryness and cleanliness.
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Brazing is a process of heating filler material to join two pieces of metal. Copper tubing may be brazed using filler material that has a melting point exceeding 1,000 F.
Tools
You will use a tubing cutter and a flaring tool to join soft copper tubing.
Tubing Cutter: A wheel-type tubing cutter is typically used. This cutter usually has built-in reamer blades that remove burrs and bevel the leading edge of a flare.
Flaring Tool: A flaring tool consists of a die block and a flaring cone. A flare is formed by clamping the tubing into the correctly-sized hole in the die block and driving the cone into the end of the tubing with a screw mechanism.
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Forged flare nuts attach the end of tubing to any external flare fitting.
Flare elbows connect two sections of flared tubing at right angles and are useful when tubing cannot be bent to fit the installation.
Flare by male pipe thread connectors connect flared tubing to a female pipe fitting.
Flare by female pipe thread connectors connect flared tubing to a male pipe fitting.
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Explain techniques and procedures used for installing metal pipe and tubing. Explain techniques and procedures used for installing CSST pipe and tubing.
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Lesson 4. Installing Vapor Delivery Lines: Metal and CSST LESSON 4. INSTALLING VAPOR DELIVERY LINES: METAL AND CSST
Cast iron cannot be used in vapor distribution system piping. The mechanical properties of cast iron is not compatible for use with propane distribution systems.
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Nipple - A nipple is a short piece of pipe used between other fittings that are closely spaced. It eliminates the difficulty of using a vise to thread short pieces of pipe.
Pipe Elbow - A pipe elbow typically provides a 45 or 90 turn in the piping, and thus has two openings; some have female threads at each opening while others have male and female openings called street elbows.
Street Elbow - A street elbow is designed to connect two separate pieces of pipe or tubing and allows for a decrease or increase in size while making a 90 turn.
Pipe Tee - A pipe tee provides a branch connection in the piping, and has three openings, each with a female thread.
Pipe Cap - A pipe cap is used to close the end of a pipe and connects to a male thread.
Straight Coupling - A straight coupling has two openings, each with a female thread, and joins two pipes of the same size. A thread protector must not be used to join pipe as the female threads are continuous with no separation in the center.
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Reducing Coupling - A reducing coupling has two openings, each with a female thread, and joins two pipes of different sizes.
Pipe Plug - A pipe plug is a solid fitting with male threads used to close a female threaded opening in another fitting.
Union - A union permits quick connection and disconnection of a vapor distribution line. It provides a way to readily open a piping system to replace fittings and other devices that control the flow of propane vapor.
You should store and handle pipe and fittings in a way that prevents rust and thread damage. Do not use pipe and fittings with stripped, chipped, corroded, or defective threads.
NOTE: Check your state and local codes regarding the use of certain fittings, such as bushings or close nipples.
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Lesson 4. Installing Vapor Delivery Lines: Metal and CSST LINES: METAL AND CSST LESSON 4. INSTALLING VAPOR DELIVERY
Pipe vise - A pipe vise holds pipe during cutting and threading.
Pipe cutter - A pipe cutter cuts steel pipe and is identified by the number of cutting wheels. The two typical types of pipe cutters are single wheel cutters and four wheel cutters.
Pipe reamer - A pipe reamer removes metal burrs from the inside pipe wall.
Pipe threading tool - A pipe threading tool consists of two parts: a die and a stock. The die cuts the male threads. The stock holds the die in position and provides a guide opening, through which the pipe must pass before it reaches the die, keeping the stock and die aligned with the pipe so the threads are cut straight.
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Some pipe fittings are standardized; you only need to measure to the center of the fitting when using fittings with standardized allowances. Valves and fittings, such as unions and couplings, are not standardized; when using these fittings, the correct fitting allowance is determined by subtracting the length of the pipe threads screwed into the fitting from the actual length of the fitting.
Make-Up: The distance a standard male pipe thread will screw into the female pipe thread. Average Distances for Make-Up and Fitting Allowance: The average distances for the make-up and fitting allowance of most common sizes of pipe fittings are shown in the corresponding table. End-to-End Measurement: The length of a piece of pipe with no fittings. End-to-Center Measurement: The distance between one end of the pipe and the center of the opening of the fitting attached to the other end. Center-to-Center Measurement: The distance between the centers of the openings of two fittings connected to opposite ends of a piece of pipe.
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You should apply paint or a coating, including wrapping, to protect aboveground steel piping against corrosion from the atmosphere and the surrounding environment.
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Lesson 4. Installing Vapor Delivery Lines: Metal and CSST LINES: METAL AND CSST LESSON 4. INSTALLING VAPOR DELIVERY
The fitting allowance is the distance from the end of the pipe to the center opening of the fitting.
True
False
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Lesson 4. Installing Vapor Delivery Lines: Metal and CSST LINES: METAL AND CSST LESSON 4. INSTALLING VAPOR DELIVERY
Ensure any exposed CSST is not damaged during installation. Store all tubing, fittings, and hardware in a clean, dry location prior to installation. Temporarily plug or tape the open ends of tubing closed before installation to keep dust, dirt, and other foreign material out. Protect tubing from contact with sharp objects. Avoid tight bends, kinks, twists, or excessive stretching, as these can stress the tubing and fittings and could cause leakage. When connecting CSST, use wrenches that are properly sized for the CSST nut and terminating fitting flats. This will help ensure gastight seals, protect the tubing from twisting, and avoid rounding off fitting wrench flats. Properly support tubing with pipe straps, bands, or hangers suitable for the tubing size and weight and in accordance with manufacturers recommendations. Avoid using components from flexible piping systems, other than those specified as part of the CSST manufacturers system as this could cause poor system performance, bodily injury, or property damage.
For outdoor installations, the external plastic jacketing of CSST should remain intact as much as possible. Use a pipe wrap tape to cover exposed portions of the stainless steel tubing. This will help prevent corrosion. If any corrosive material, such as a masonry cleaning solution, makes contact with the plastic covering during installation, it should be thoroughly rinsed as prescribed by the CSST manufacturer. For installing CSST underground, under concrete, or encased in concrete, enclose the tubing in a non-metallic conduit at least " larger than the tubing. Seal the ends to keep out water. Keep the protective plastic jacketing in place to protect the tubing from corrosive threats. Note: Always follow the manufacturers instructions when installing CSST.
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Module Summary
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Some important points to remember from this module are:
There are five basic steps for installing underground lines: dig a trench; insert pipe or tubing in the trench; plug or cap lines; test for leakage in the exterior installed line and document results; and backfill the trench. This module described four types of exterior vapor distribution lines: polyethylene (PE); copper; metal (including black iron, galvanized steel, and wrought iron); and corrugated stainless steel tubing (CSST). Different types of lines are used in different environments. Ultraviolet light in sunlight damages PE pipe and tubing. Therefore, PE can only be used for underground vapor service or must be encased in an approved flexible conduit. PE pipe and tubing are non-conductive and cannot be found by pipe-locating devices. PE pipe and tubing must be installed with tracer wire. Copper tubing is flexible, but when installed aboveground it must be properly supported by clamps and suitable brackets. Copper tubing should be plugged or capped after cutting to help keep it clean and dry. Steel piping should be protected against corrosion. Paints, coatings, and wrappings help protect aboveground steel piping against corrosion from the atmosphere and the surrounding environment. Cathodic protection systems help protect underground steel piping. Technicians who install CSST must be trained and qualified by the CSST manufacturer, supplier, or a trainer qualified by the manufacturer.
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Module 6 Quiz
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Module 6 Quiz
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Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
1. According to NFPA 58 requirements, which of the following is a requirement for piping installation?
a. Vapor distribution system piping can never be used as a grounding electrode b. Flexible metallic connectors are not permitted in vapor distribution systems c. Piping must be run as directly as possible from one point to another, with as many fittings as practical d. Where condensation of water vapor can occur, piping must be sloped away from the container
2. According to NFPA 58 requirements for aboveground lines, you can use polyethylene (PE) pipe, tubing, and fittings in
aboveground line installations. a. True b. False
3. Mechanical fittings are used to join PE pipes in most residential and small commercial installations. PE can also be
joined using ____. a. Stab-type fittings b. Barbed fittings c. Heat fusion d. Electro-fusion
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5. There are two types of soft seamless copper tubing commonly used for vapor distribution system installations: water
tubing and refrigeration tubing. Water tubing is sized by inside diameter (ID) and is commonly available in which type? a. Type L b. Type K c. Type M d. Both a and b
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6. Should you use pipe thread-sealing compounds on the seats of brass flare fittings?
a. No. Flared copper connections are highly corrosive and need to be sealed frequently; therefore pipe thread-sealing compounds would not work properly on the seats of brass flare fittings b. No. Flared copper connections are metal-to-metal seals that may not seat and seal properly if you use thread-sealing compounds c. Yes. Pipe thread-sealing compounds are always used on the seats of brass flare fittings d. None of the above
7. NFPA 58 specifies that the following types of steel piping can be used for propane vapor distribution systems:
a. Cast iron, black iron, or wrought iron b. Black iron, galvanized steel, or cast iron c. Red iron, galvanized steel, or wrought iron d. Black iron, galvanized steel, or wrought iron
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Objectives
After completing this module, you will be able to:
Identify the procedures and precautions for installing regulators and vapor meters. Identify and explain the role of accessories required for regulator installation. Explain methods for storing and handling vapor meters. Identify locations for vapor meter installation.
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Introduction
This lesson provides typical installation guidelines for exterior regulators in residential and small commercial systems. When installing a regulator, always make sure you:
Understand the requirements of National Fire Protection Association (NFPA) 58. Have read, understand, and are able to follow the manufacturers instructions.
Identify code requirements for installing regulators. Identify and explain the role of accessories required for regulator installation. List the steps to install regulators up to the service entrance of a structure in the vapor distribution system. Identify components needing inspection and protection during and after regulator installation.
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Code Requirements
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Personnel who install exterior propane vapor distribution system components must be familiar with NFPA 58 requirements related to regulator installations. Check with your supervisor to determine the edition (published year) that applies to your location, as these requirements can vary among different editions.
Single- and 2-stage systems. First-stage and high-pressure regulators. Installation and location.
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If a single-stage regulator no longer functions properly, then the existing system must be converted to a 2-stage regulator system, an integral 2-stage regulator system, or 2-psi regulator system.
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Location
The point of discharge from the pressure relief valve on a regulator must be:
No less than 3 ft horizontally from any building opening below the point of discharge. No less than 5 ft in any direction away from any source of ignition, opening into direct vented appliances, or mechanical ventilation air intakes.
Remote Venting
If you are unable to meet these requirements, vent piping can be attached to the regulator so that the vent can discharge the required distances from building openings or sources of ignition. This is called remote venting. Remote vent piping is usually plastic, but can be metal. Vent piping must meet UL standards. A vent extension cannot be narrower than a regulator vent. The circumference of the piping and termination point must be at least as large as the regulator vent to carry the discharge of the regulator vent. You will need to install the correct vent fitting at the end of the extension. There are different techniques for installing remote venting. Consult your company policy or your supervisor for specific guidance.
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False
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Pigtail Connector
A pigtail is a flexible metallic connector often used to connect a regulator to the service valve on a container. Pigtail connectors are used with first-stage, integral 2-stage, and high-pressure regulators. The preferred installation of the pigtail is a loop configuration. Without the pigtail loop, the vapor distribution piping would be too rigid and therefore more susceptible to leaks in the event of a gradual or sudden shifting of the ground, piping, container, or service line. When installing a pigtail, make sure that the pigtail loop and regulator inlet is higher than the service valve. This limits the flow of moisture that might be present in the propane in the regulator and allows it to drain back into the container.
When installing a pigtail, make sure that the pigtail loop and regulator inlet is higher than the service valve.
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Underground first-stage regulators. Underground high-pressure regulators. Second-stage regulators installed inside buildings. Second-stage regulators installed outside of buildings that do not meet specific code requirements to openings into a building, to a source of ignition and the potential for vent being obstructed by snow or ice.
NOTE: Before installing a regulator and possible vent extension, you should always read and follow the manufacturers instructions.
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On an underground tank, install the regulator after the tank is in the ground to avoid damage during the container installation. If a vent extension has been installed, ensure it is positioned so that it is above-grade and at the highest point available at the installation site.
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When installing a pigtail, make sure that the pigtail loop and regulator inlet is higher than the service valve.
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1. Prepare and install the necessary fittings, and insert them into the inlets of
the regulator. Use a thread sealing compound, but do not apply it to the two leading threads of pipe nipples. You should wipe any excess compound off the threads.
2. Ensure the regulators vent screen is in place, and that the bonnet cap is
properly tightened.
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4. Attach the regulator to the top of the riser or other piping materials. When
connecting the piping, it is important to ensure the pipe is cleaned of thread burrs and that thread-sealing compound material is not introduced into the regulator body.
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5. Make sure the vent is pointing downward to keep debris and moisture from
entering the regulator.
NOTE: Some propane marketers install a shutoff valve immediately upstream of the second-stage regulator inlet. This is not required by NFPA 58. Check with the local Authority Having Jurisdiction (AHJ) or building codes to determine if a shutoff valve should be installed at the second-stage or integral regulator. Also, make sure you understand your companys policy for installing shut-off valves.
Remember this course describes how to install a vapor distribution system up to the outlet of the regulator. You will learn how to install piping downstream and connecting to the regulator in the course on Placing Vapor Distribution Systems and Appliances into Operation.
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Regulator Vent: A screen protects the vent and helps keep out spiders, wasps and other pests. However, you or your customer should periodically check the vent and clear blockages as needed. The vent must also be protected against accumulation of sleet, snow, ice, mud, or ground water.
Regulator Bonnet Cap: The bonnet cap must be in place and tight to keep out water.
Protection from the Environment: If a regulator installed outdoors could be affected by weather, the regulator must be protected. Follow your company policy for protecting regulators.
Heat Sources: Regulators should not be installed near intense heat sources. Internal components, such as the diaphragm, can be damaged by exposure to high temperatures.
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INTRODUCTION
Vapor meters are precision measuring devices that require special care before and during installation. In this lesson, you will learn about selecting appropriate installation locations for vapor meters and the procedures and precautions involved when installing them.
Explain methods for storing and handling vapor meters. Identify locations for vapor meter installation. Explain procedures and precautions to follow when installing vapor meters.
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Where they are not subjected to damage, such as adjacent to a driveway, under a fire escape, in public passages, in coal bins, or where they will be subject to excessive corrosion or vibration. Where they are not subjected to extreme temperatures, sudden extreme temperature changes, or temperatures beyond those recommended by the manufacturer. In ventilated spaces readily accessible for examination, reading, replacement, or maintenance.
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In some instances, you can install the vapor meter near the ASME tank or DOT cylinder. The meter must be immediately downstream from the outlet of the integral 2-stage or 2 psi service regulator. The meter is typically installed on a post adjacent to the tank or cylinder. NOTE: Installation and testing of vapor distribution lines downstream of the meter will be covered in the CETP course Placing Vapor Distribution Systems and Appliances into Operation.
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On a Building Wall
Mount the vapor meter and regulator on a building wall by attaching the meter to a bracket on the wall immediately downstream from the regulator outlet. To provide solid support for the meter, use suitable fasteners such as lag screws, masonry anchors, and inserts, or molly bolts, to attach the meter bracket to a structures exterior wall.
Freestanding
If a regulator is at the end of a riser, you can install the meter without a bracket. In this type of freestanding installation, a standard or utility-style meter is connected to and supported by the distribution lines. NOTE: Use a freestanding installation only if the distribution line is assembled from rigid pipe. If an installation uses tubing for the distribution lines, the weight of a freestanding meter will cause the lines to sag which could damage the tubing or meter, and cause a leak.
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Post-mounted and wall-mounted meters should be approximately 12" off the ground for ease of reading and maintenance. Freestanding meters should be installed on the riser so that the bottom of the meter is completely off the ground to help prevent corrosion. Do not install meters where they will be subjected to water or ice damage, such as in locations where snowfall occurs; snow and ice could slide off the roof and strike the meter. You can protect the meter by building a protective hood around it, but there must be a way to read it. For meter accuracy, avoid locations near heat sources. such as a heat pump, air conditioner, appliance vent termination, or clothes dryer exhaust. Constant inlet pressure is important for meter accuracy. Existing systems that use a single-stage regulator cannot provide a constant pressure to the meter. When installing a vapor meter, it is important to install a 2-stage regulator to be sure the meter can receive a constant inlet pressure. Ensure that the meter has a vapor measuring capacity that exceeds total gas appliance demand. State and local codes may require that the meter have a temperature compensated meter. Contact your supervisor or check your company policy to determine if a temperature compensated meter needs to be installed.
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It is appropriate to install a vapor meter right below a dryer exhaust on a building wall.
True
False
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Use an appropriate thread-sealing compound on male pipe threads after the two leading threads. Use a rag to remove excess compound before making the connection handtight. Always turn fittings and nipples into the meter; do not hold the fitting and turn the meter. Turning the meter could damage the threads in the meter inlet or outlet, and could affect the accuracy of the meter. When installing a steel pipe nipple, use a properly-sized wrench on the meter boss to prevent warping or distorting the case.
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The meter is now ready to be connected to the piping downstream of the meter.
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You must consider the safe and leak-free operation of the total system and make certain:
No obvious code violations are present with the interior vapor distribution system installation. No visible gas lines are damaged. Exposed venting is installed per code. Sufficient combustion air is provided where appliances are located in a closet or in an enclosed area. Any other deficiency that would prevent the proper operation of the system has been repaired.
The CETP course Placing Vapor Distribution Systems and Appliances into Operation provides specific requirements and methods for connecting the interior system to the meter or regulator and conducting the interior site assessment, including testing and verification procedures. Refer to your company policy for specific guidance regarding the interior site assessment and any required documentation.
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Have I installed the proper size, type, and pressure rating container? Is the container installed at the proper distance from buildings, property lines, sources of ignition, and other containers? Is the container level and installed on a solid and noncombustible foundation? Have I adequately secured the container against high water, wind, earthquake, and other potential hazards as required by the local jurisdiction? Is the container properly protected from weather, snow, power lines, traffic, and other structures? Is the container properly labeled per local, OSHA, and DOT requirements, including company name and vitals? Is the data plate attached and readable? Is the container in good condition, free of corrosion and leaks? Are DOT specification containers re-qualified and marked? Have I installed the correct piping with the proper material and working pressure? Is the piping installed at the minimum depth or deeper? Is the piping protected, including corrosion protection, tracer wire, and dielectric union as needed? Does the piping have the proper connections? Have I capped open ends of the piping for incomplete systems? Does the piping go under a right of way? Did I install the correct regulator in accordance with code requirements?
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Is the regulator mounted properly and in the correct position? Is the regulator vent at least 5 ft from sources of ignition? Did I plug the regulator if the system is incomplete? Did I install the correct meter in accordance with code requirements? Did I test the system for leakage? Did I comply with all company policies and federal, state, and local codes? If the system will not be immediately placed in operation, did I shut off the gas supply? Did I clear my tools and personal belongings? Did I clear away materials and fulfilled any landscape requirements? Have I provided all the required paperwork to the customer per your company policy? Have I trained the customer on how to recognize gas leaks and what to do if one exists? Have I demonstrated what actions to take in the event of a gas leak, including turning off the gas supply at the tank, getting everyone out of the house and instructed them to stay out until the service company or local authority allows them to go back inside? Have I allowed the customer to smell propane? Have I provided the customer with warning materials? Have I obtained the proper signatures required by your company policy?
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Module Summary
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Some important points to remember from this module are:
2-stage regulation is now required for all fixed piping systems that serve psig appliance systems. High-pressure and first-stage regulators used in residential and small commercial settings must be installed outside of buildings. Vapor meters are precision measuring devices that require special care before and during installation. Handling and installing them with care will help ensure their accuracy and long service life. Select a location to install a vapor meter that will allow for its safe and reliable operation and service.
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Module 7 Quiz
Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
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3. All piping layouts for vapor distribution systems require more than one second-stage regulator.
a. True b. False
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Module 7 Quiz
5. When installing meters at service entrances, two meter-mounting methods are typically used in distribution lines that
use independent 2-stage regulation. How can these meters be mounted? a. On a building wall or post-mounted b. On a building wall or freestanding c. Post-mounted or freestanding d. None of the above
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6. After the interior distribution system is installed, inspected for NFPA 54 code requirements, and is ready to be placed into
operation, the meter or regulator will have to be connected to the interior system. This assessment will be conducted after the connections are made between the exterior and interior portions of the system, subsequent to the installation of the container, piping, and regulators. a. True b. False
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Identify examples and safety factors to consider when performing a special installation. Identify procedures for transferring liquid propane between stationary containers using a portable compressor or a portable liquid pump. Identify evacuation safety precautions when conducting a container-to-container transfer.
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Introduction
So far, this course has addressed the factors you should consider when designing typical vapor delivery systems in residential and small commercial installations. Now, lets look at what to consider when designing special installations. This lesson provides examples of special installations and important safety issues and factors to consider before, during, and after a special installation.
Identify examples of special installations. Identify factors to consider for special installations. Explain safety considerations for special installations.
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Overview
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Special installations may serve recreational, residential, commercial, agricultural, or other applications. They may be indoor or outdoor, seasonal or year-round, and could involve total demand that is larger or smaller than a typical residential or small commercial installation. Special installations often have unique requirements, so you should thoroughly understand the demands and limitations of each type of equipment. Take the time to read and understand manufacturers instructions and follow any unique type of safety procedures that may apply to a special installation you ae designing. Because special installations can have large propane demands, you need to be aware of proper pipe sizing and pressure requirements. NFPA 54 & 58 codes apply to piping, hoses, fittings, distance, and location requirements. Also, installation and testing requirements must conform to NFPA, state, and local codes.
Consult your supervisor or company policy to determine if your company supports special installations, and if so, for specific guidance before you proceed.
The next page provides examples of just some of the many types of special installations. Understand that this list is not complete, and some installations may require special equipment, tools, and additional training. Never attempt an installation that you are not trained to perform.
LEARNING ACTIVITY
The maximum length of time for most temporary installations is 12 months. Contact AHJ for any questions concerning the project and its schedule. Installations exceeding 4,000 gallons require AHJ approval which could include a fire safety analysis and other requirements.
Seasonal Camps
Some installations, such as campsites and vacation properties, are used seasonally instead of year round. These installations are sometimes in rural locations, where propane may be the only practical or available source of energy. In these instances, propane can be used to provide heat for cooking and warmth, and to provide power and light. All common propane safety practices must be followed.
LEARNING ACTIVITY
Kilns
A kiln can be used to fire or cook pottery or other clay objects. Kiln installations, like temp heat installations, must conform to local building codes. Any unlisted equipment not equipped with 100% safety shutoff valves must be approved by the AHJ.
Generators
Propane can be used to fuel certain types of generators that provide electricity. They are most often used during an emergency, such as a hurricane, tornado, or other situation where electricity may be unavailable for an extended period. The design and installation of a propane-fueled generator is similar to a typical residential installation; however, the National Electric Code (NEC) has additional rules that apply to this type of generator.
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Containers of 125 500 gallon water capacity may be transported over public roads from a customer location to the propane marketers bulk storage location. Check your company policy.
Therefore, if such a container is to be relocated, the excess liquid propane must be removed using the container-to-container or container-to-cargo tank, liquid transfer process. Liquid transfer between containers may also be necessary when exchanging containers for maintenance or other reasons. Always check local codes and regulations before transferring liquid between containers. Container-to-container liquid transfer is a complicated and potentially hazardous process and you must understand how to perform it safely. This lesson will explain step-by-step how to safely perform container-to-container liquid transfer between stationary containers using either a portable compressor or a portable liquid pump. Evacuating DOT containers involves different procedures than evacuating ASME containers and will be addressed later in this lesson.
Identify procedures for transferring liquid propane between stationary containers using a portable compressor or a portable liquid pump. Identify evacuation safety precautions when conducting a container-to-container transfer.
Portable compressors create a differential vapor pressure between two containers which allows propane liquid to flow from one container to another. Portable liquid pumps use mechanical means to move propane liquid from one container to another.
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Pre-Transfer Review
MODULE 8
As an example, we will demonstrate a container-to-container liquid transfer using a 500 gallon ASME container starting at a level of 50% and a stationary ASME 1,000 gallon container starting at a level of 5%.
Before transferring any propane from one container to another, always make sure that:
Liquid will be evacuated from stationary containers (aboveground or underground). A liquid transfer valve and its adapter are installed so that propane will be withdrawn through a liquid withdrawal valve installed in the container. The receiving containers have adequate capacity to receive the liquid from the container being evacuated.
In this lesson the word evacuated refers to the removal of liquid from an ASME aboveground or underground container, so that it can be properly transferred.
NOTE: These procedures are based on NFPA 58 provisions and common industry practice. Check state and local regulations and your company policies, for any additional guidelines, methods, or equipment requirements. There are a number of companies that manufacture liquid withdrawal valves, so be sure to follow the manufacturers operating and maintenance instructions for the specific evacuation equipment you use. NOTE: Be sure to wear personal protective equipment (PPE), including hand and eye protection, while performing these procedures.
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Wear appropriate PPE and use proper transfer procedures according to the equipment manufacturers instructions and your company policy. Be thoroughly familiar with ASME container construction, valves, and all other evacuation equipment used. Verify all hoses are designed and listed for use with liquid propane. They must be marked 1,750 psig bursting pressure, and to the maximum psig working pressure. Follow your company procedures to inspect all hoses to be used during the transfer process. Do not use any hoses if they are found to be defective. Remove sources of ignition within 25 ft of the point of transfer, which is where hoses connect to the container filler valve and the liquid withdrawal valve. Keep at least one recently inspected fire extinguisher with a minimum capacity of 18 lb dry chemical and B:C rating within easy reach during the entire operation.
Refer to NFPA 58 for other requirements related to liquid transfer. NOTE: An individual qualified by his or her employer to perform this operation must be present during the entire evacuation procedure.
Sources of ignition like smoking, open flame, portable electrical tools, and extension lights capable of igniting propane must be at least 25 ft (7.6 m) away from a point of transfer while transfer operations are in progress. Metal cutting, grinding, oxygenfuel gas cutting, brazing, soldering, or welding must not be performed within 35 ft (10.7 m) of a point of transfer while transfer operations are in progress.
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1. Determine the amount of propane to transfer. 2. Prepare the evacuation site. 3. Inspect and connect pressurized hoses and assemblies. 4. Evacuate liquid propane. 5. Bleed down and disconnect hoses.
Now, lets learn each step in detail.
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4. Carefully and slowly loosen the plug or cap from the liquid
withdrawal valve. Be extremely cautious when loosening the cap. Take extreme care to loosen and remove just the plug or cap, not the entire withdrawal valve. Never loosen the plug or cap more than one turn. WARNING: Extreme care should be taken to ensure the plug or cap does not come out of the liquid withdrawal valve or that the entire liquid withdrawal valve does not come out of the container. If it does, contact your supervisor immediately for instructions on how to proceed and follow your company policy for taking emergency actions such as evacuating the area and calling emergency responders.
If propane liquid stops escaping from the weep hole, it is safe to continue removing the plug or cap. Remember that there are different manufacturers of liquid withdrawal valves, so please follow their instructions as well as your company policy. WARNING: If the valve is NOT working properly, propane will continue to spray out after loosening the plug or cap. If propane continues to escape, STOP! Immediately retighten the plug or cap.
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NOTE: Contact with liquid propane will result in serious freeze burns. Direct the valve outlet away from yourself.
As you tighten the adapter into the liquid evacuation valve, it will begin to open the liquid withdrawal valve and liquid propane will begin to leak out. Act swiftly to screw the valve and adapter assembly all the way in, tighten it, and immediately close it. The excess flow valve should shut which should stop the flow of liquid propane from escaping as the valve is being screwed in. Be sure to follow all manufacturers instructions when installing the transfer valve.
Using a full port ball valve attached to the machined adapter will direct the spray of liquid vertically and may assist in slugging the internal excess flow valve when removing the transfer valve and machined adapter from the liquid withdrawal valve.
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6. Make sure all valves in the liquid transfer line are closed.
Listen for an audible click to signal that the liquid withdrawal valve has opened and is ready for liquid withdrawal.
MODULE 8
NOTE: Liquid transfer hoses should be equipped with shutoff valves at each end. If two valves are used, a hydrostatic relief valve must be installed in one of the valves.
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Some marketers use a sight flow glass in the liquid transfer hose to determine if liquid is flowing. Some marketers install a 0-300 psi gauge in each container service valve. These gauges can be used to monitor the vapor pressure in each of the containers during the transfer process.
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If Using a Portable Compressor: 1. Connect one end of the liquid transfer hose to the
outlet of the transfer valve and the other end to the fill connection on the receiving container.
If Using a Portable Liquid Pump: 1. Connect one liquid transfer hose to the outlet of
the transfer valve and the other end to the liquid pump inlet. For best pump operation, the liquid inlet to the pump should come from the bottom of the container if possible. Connect the other liquid transfer hose between the pump outlet and the filler valve of the receiving container.
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Portable compressors create a pressure differential causing product to move between the two containers. When running the portable compressor, be sure to monitor the pressure in the ASME container being evacuated to avoid over-pressurization. For example, if the excess flow valve in the liquid evacuation valve closes and stops the flow of liquid during the procedure, the compressor must be shut down or excess pressure will build in the stationary container which could cause the relief valve to open. Liquid pumps operate by drawing liquid from the container to be evacuated and pushing it into the receiving container. Vapor lock and cavitation may occur, particularly in warm weather or when liquid withdrawal valves are located on top of the evacuating container . These conditions will result in slow transfer of liquid and excessive pump noise. If you experience these conditions, consult your supervisor.
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Quickly open the transfer valve and allow propane to flow through until the internal excess flow check valve in the liquid evacuation valve slugs. You must leave the transfer valve in the open position to prevent the excess flow valve from reopening. If the internal excess flow valve fails to close (and the liquid continues to escape), you must fully close the transfer valve and must not remove it until the system is depressurized and the problem is resolved. Contact your supervisor for instructions on what actions to take. Removing the transfer valve when the excess flow valve fails to slug will result in an uncontrolled release of propane.
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CERTIFIED EMPLOYEE TRAINING PROGRAM
Once the excess flow valve closes, do not close the transfer valve until it has been removed from the liquid withdrawal valve. If the valve is closed after it has slugged, the excess flow valve may re-open allowing full product flow through the valve. NOTE: The excess flow valve may not close when the container pressure is 35 psig or less.
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4. Bleed down and disconnect the vapor hose from the ASME
container either at the vapor equalizing valve or the transfer adapter.
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6. Bleed down and disconnect the vapor hose from the receiving
container. Install any dust caps on the hose or the vapor connection on the receiving container.
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There are some differences between DOT containers and ASME tanks that impact evacuation procedures, such as:
DOT containers may be transported filled to their legal limit. DOT containers are not usually equipped with liquid evacuation valves. Not all DOT containers are equipped with vapor return fittings. Not all DOT containers are equipped with float gauges.
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Before installing the transfer valve, you should carefully and slowly loosen the plug or cap from the liquid withdrawal valve. Never loosen the plug or cap more than one turn. If you see that propane continues to spew from the weep hole in the side of the cap or plug, the first thing you should do is:
Spin the plug or cap off and allow the excess flow valve to slug
Immediately tighten the plug or cap securely and inform your supervisor of the problem
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Module Summary
MODULE 8
Here are some key points to remember:
In addition to residential and small commercial vapor distribution systems, there are different types of special installations. Special installations may serve recreational, residential, commercial, agricultural, or other applications. They may be indoors or outdoors, seasonal or year-round, and could involve total demand that is larger or smaller than a typical residential or small commercial installation. Special installations often have unique requirements. You must thoroughly understand the demands and limitations of each type of equipment before conducting a special installation. Container-to-container liquid propane transfer is complicated and potentially hazardous.
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Module 8 Quiz
MODULE 8
Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
1. The maximum length of time for most temporary heat/construction installations is ____ months.
a. 6 b. 8 c. 12 d. 18
2. Propane grills, fire pits, mosquito traps, illuminating appliances, and patio heaters are all examples of _________.
a. Outdoor living equipment b. Indoor appliances c. Temporary heat d. Both a and b
3. When transferring liquid propane from container-to-container; be sure to remove sources of ignition within ___ ft of the
point of transfer, which is the location where hoses connect to the container filler valve and the liquid withdrawal valve. a. 15 b. 20 c. 10 d. None of the above
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5. There are some differences between DOT containers and ASME tanks that impact evacuation procedures. Which one
does NOT belong? a. DOT containers may be transported filled to their legal limit b. DOT containers are usually equipped with liquid evacuation valves c. Not all DOT containers are equipped with vapor return fittings d. Not all DOT containers are equipped with float gauges
MODULE 8
6. The same basic procedures and safety warnings that apply to container-to-container evacuation of ASME tanks apply to
DOT containers. a. True b. False
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MODULE 9
Objectives
After completing this module, you will be able to:
Recognize the different system tests. State when each check or test should be performed.
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Introduction
As a propane professional, one of the most important things you do is help keep customers safe.
One way to do this is by making sure a customers piping system is leak free and operating effectively. You have learned how to install the exterior components of a vapor distribution system. However, once installation is completed, the system is still not ready to be placed into service. A series of checks and tests must be performed by a trained technician before the system can be safely started. Consult your company policy for guidance whenever you perform any test or check of the vapor distribution system. Earlier in this course, you learned how to perform the test for leakage on newly installed exterior piping according to NFPA 58. This lesson provides an overview of the checks and tests required when installing a complete vapor distribution system (exterior and interior) or when restoring operation to existing systems. The CETP course Placing Vapor Distribution Systems and Appliances into Operation provides the training for each test, including specific steps for each procedure.
Recognize the different system tests. State when each check or test should be performed.
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System Tests
MODULE 9
In this lesson we will discuss:
Test for leakage Pressure test Leak check Leak test Flow test Lock-up test
Note: These terms are often confused and misused. There are many reasons for this, including code changes and jargon used in different geographic areas. This course uses industrystandard terminology to describe the various vapor distribution tests. It aligns with federal codes and regulations, and strives to standardize these terms within the propane industry. The plumbing codes in many local jurisdictions may require different test pressures and durations. Local codes may also have licensing requirements for the person performing the installation and testing. You must always be aware of the local jurisdiction requirements when you are installing.
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Pressure Test
A pressure test is similar to a test for leakage. However, a pressure test checks for leaks in the interior lines of a vapor distribution system governed by NFPA 54. This covers the lines downstream of the outlet of an integral 2-stage regulator, second-stage regulator, or meter. This test applies pressure of not less than 1 times the proposed maximum working pressure of the interior piping, but not less than 3 psig. The test medium shall be air, nitrogen, carbon dioxide, or an inert gas. It is performed only on newly-installed interior piping systems or on systems repaired or modified as specified by NFPA 54.
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Leak Test
A leak test is performed after the test for leakage, pressure test, or leak check if a leak in the system has been identified. A leak test uses a fluid leak detector or an instrument that can detect propane to determine the specific location of a leak. Once located, the leak must be repaired. The system must be checked again after the repair to determine that it is leak free.
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Flow Test
A flow test measures the pressure downstream of the firststage and final-stage regulators when the appliances are operating. It determines if the regulators are supplying the amount of gas the system requires. This test is conducted by temporarily installing a water manometer or pressure gauge in the outlet pressure tap of the first-stage regulator and in the distribution line close to the appliance that is furthest away from the final-stage regulator. The manometer or pressure gauge is used to monitor the delivery pressure at the test location when all appliances are turned on. Refer to your company policy for specific procedures.
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Lock-up Test
Lock up is the amount of pressure necessary to completely stop the flow of vapor through the first-stage and final-stage regulator inlet orifices, when there is no gas demand. A lock-up test measures the pressure in the lines downstream of the final-stage regulator to ensure that the regulator will shut off the flow of propane when the appliances are not calling for gas. The lockup test is conducted by opening the container service valve and closing all appliance shutoff valves or gas controls. Then the manometer, or pressure gauge, is monitored for any increase in pressure. This continues until the pressure stops rising at or below an acceptable limit. These limits are established by the appliance manufacturer or your company policy. You can tell the regulator has shut off the flow of propane when the pressure stops increasing.
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Module Summary
MODULE 9
You should remember this important point:
After installation of a vapor distribution system is completed and before the system is placed into service, a series of checks and tests must be performed. These must be performed by a trained technician. System tests include test for leakage, pressure test, leak check, leak test, flow test, and lock-up test.
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Module 9 Quiz
MODULE 9
Directions: Lets take moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
1. A pressure test applies pressure of not less than ___ times the proposed maximum working pressure of the interior
piping, but in no case less than ___ psig. a. 2/3 b. 1/2 c. 1/3 d. None of the above
2. The requirement for performing a leak check only applies to the portion of the piping covered by NFPA 54.
a. True b. False
3. A leak test is performed after a leak is identified in a system, and it is performed _____ the test for leakage, pressure
test, or leak check. a. After b. Before c. A leak test is not a kind of system test d. None of the above
4. Flow tests and lock-up tests are typically performed on vapor distribution systems ________ to determine if the piping
system and regulator(s) are sized correctly for the estimated load and are functioning properly. a. During shut down b. Flow tests and lock-up tests are never performed on vapor distribution systems c. During start up d. Both a and c
5. A lock-up test measures the pressure in the lines downstream of the first-stage regulator to ensure that the regulator
will shut off the flow of propane when the appliances are not calling for gas. a. True b. False
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MODULE 10
Identify the content in some of the PERC consumer safety materials. Identify what to do if there is an uncontrolled release of propane from stating evacuation procedures to providing appropriate information to 911.
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MODULE 10
Introduction
Safety brochures and decals can communicate specific warnings about propane and actions that your customer can take, or should avoid, in an actual or suspected propane emergency. Make sure you understand and follow your companys policies regarding communication with your customer or distribution of any safety materials and the application of any decals.
Identify the safety warnings provided in the Propane Education & Research Council consumer safety materials.
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LEARNING ACTIVITY
LEARNING ACTIVITY
LEARNING ACTIVITY
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Decals
MODULE 10
In addition to the decals and labels that local, state, and federal regulations require, you can place decals on a customers container that provide safety information. One such safetyrelated decal is a container shutoff valve label that warns the customer not to open a service valve that has been turned off for any reason. If your company places a decal on its containers with a 24hour emergency number, point it out to your new customer and encourage them to keep the number inside where they can easily refer to it in a suspected propane emergency.
A container shutoff valve label warns the customer not to open a service valve that has been turned off for any reason.
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Tell your new customer to close all valves, if it is safe to do so, when:
They smell odorant or suspect a leak in or around the building. Flooding is predicted for their area. They should turn off the gas valve at the cylinder or tank before the water rises. Something doesnt look right after a storm. If their tank has shifted position, gas lines are bent, broken or damaged, or they see something else unusual about their system or appliance.
Turning off the gas at the container will stop the flow of propane immediately and greatly reduce the potential for fire or explosion.
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Emergency Numbers
MODULE 10
If your new customer suspects a propane leak, the presence of carbon monoxide, or another propane emergency, they should evacuate their home or office. They should call your companys 24-hour emergency telephone number or 911 from another safe location. If a company decal with a 24-hour emergency telephone number is placed on a customer-owned or leased container, point that number out to your new customer as well. If your companys 24-hour emergency telephone number is not on a decal, provide that number when you are reviewing safety precautions with your new customer before you leave.
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Which of the following consumer safety recommendations is included in the PERC consumer safety material if the customer smells gas?
Turn on all light switches.
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Introduction
Propane is a safe, economical, clean-burning, and versatile fuel when properly used. Its safety record is due in part to the codes and regulations developed by the propane industry and the NFPA. Being properly trained and adhering to your companys policies greatly help prevent propane emergencies. However, you should be prepared for emergency situations that may arise. This lesson identifies steps to take in an uncontrolled propane release. In addition to the information in this lesson, make sure you understand your companys policies regarding emergency response to a propane incident. The PERC publication Propane Emergencies, 3rd Edition was written for emergency responders and has valuable information for propane marketers on coordinating with emergency responders prior to an emergency.
Identify what to do if there is an uncontrolled release of propane. Identify how to encourage people to safely evacuate the scene of an emergency. Identify information that must be provided to 911 or other emergency response operators in the event of an emergency.
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Evacuate the area immediately. Be aware of your surroundings. Call for help.
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Leave the area immediately. Evacuate to a safe distance from a spill or leak. You should be at least 330 ft away in all directions, and for larger spills 1 mile in all directions. Evacuees should stay upwind of the emergency. Remain calm.
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Identify the source of the leak. Check for sources of ignition and shut them off if you can do so without placing yourself or anyone in danger. Note the wind direction.
This information may be helpful to emergency responders, so safely gather whatever information you can. Also, if you can do so safely, try to collect other technical information, such as the location and type of container involved, the amount of material present, and the location of shutoff valves. Follow your company policy regarding evacuations.
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Your name. Your companys name. The address of the emergency location. Your contact information, such as a cell phone number or a phone number nearby, and any obvious injuries needing immediate attention. A brief summary of the emergency. For example: Is there a leak, and if so where? What kind of container is on site, and what size is it? Is the area densely populated or rural? Has anyone been injured, and if so how many and to what extent?
Do not endanger yourself or others. Assign someone to meet and direct emergency response units to the scene. Call back from a safe distance if the situation changes before emergency responders arrive. Stay away from any unknown materials, such as unknown chemicals at industrial plants.
NOTE: Remember, any uncontrolled release of propane can be extremely dangerous. If you suspect an emergency, immediately evacuate the area and call for help.
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Module Summary
MODULE 10
Here are some important points for you to remember:
Make sure you understand your companys policies on providing and explaining safety information to your customers and be familiar with any safety warning materials your company provides. Make sure your customer is familiar with the odor of propane. Show your customers how to shut off the flow of propane. Customers should also be instructed to evacuate if they suspect a leak and not to enter any structure until the gas company or emergency personnel say it is safe to do so. Propane is a safe, economical, clean-burning, and versatile fuel. However, because it is flammable, emergency situations can and do arise. You should never attempt to respond to any emergency unless you have been properly trained to do so. In the event of an emergency, you should evacuate the area, be aware of your surroundings, and call for help. You should also notify your supervisor as soon as it is safe to do so.
Module 10 Quiz
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Module 10 Quiz
Directions: Lets take a moment to check how well you understand the information presented. Select the appropriate answer for each of the following questions.
MODULE 10
1. PERC provides customer information and safety warning materials that may be widely used by propane marketers.
Which of the following items are provided by PERC in the customer safety brochure? a. Scratch-and-sniff feature b. Facts about carbon monoxide c. Safety information regarding lighting warning labels, warning tags, and safety tips for using propane grills d. All of the above
2. In addition to the decals and labels that local, state, and federal regulations require, you can place decals on a
customers container that provide safety information. Out of the four decals listed, which safety-related decal is NOT available through PERC? a. ASME container label b. Consumer safety cylinder requalification decal c. Meter re-location and distribution label d. Container shutoff valve label
3. It is important to demonstrate to the customer how to shut off propane flow. When should customers shut off the flow of
propane? a. When they smell odorant or suspect a leak in or around the building b. When flooding is predicted for their area. They should turn off the gas valve at the cylinder or tank before the water rises c. When something doesnt look right after a storm. If their tank has shifted position; gas lines are bent, broken or damaged; or they see something else unusual about their system or appliance d. All of the above
4. You can respond to certain emergencies without training if and only if permission is granted by your supervisor.
a. True b. False
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6. If you have an uncontrolled release, NEVER enter or re-enter a hazardous environment. When you are evacuating, which
task below should you try to do? a. Identify the source of the leak b. Check for sources of ignition and shut them off c. Note the wind direction d. All of the above
7. Many marketers designate spokespersons that are authorized to address the news media. If there has been an
uncontrolled release of propane and you are not authorized to speak to the news media on behalf of your company, how should you interact with the news media? a. Speak if other members of your company are present b. Refer all media inquires to your company management c. Speak anyway, if it is an extremely relevant issue d. None of the above
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2. Frost penetration depth in the soil is important to consider when selecting aboveground tanks.
a. True b. False
3. The two deciding factors for sizing underground tanks are the effective demand of all existing and anticipated future gas
appliances and ______. a. The maximum anticipated soil frost penetration depth. b. The maximum average annual rainfall in the surrounding area. c. The maximum anticipated temperature in the surrounding area. d. The minimum anticipated temperature in the surrounding area.
4. Aboveground tanks with less than ___ gallons water capacity may be placed next to a building and must be at least __
ft horizontally from any building opening that is below the level of discharge. a. 125/ 3 b. 125/ 5 c. 125/ 10 d. None of the above
5. The primary factors affecting the rate or extent of corrosion for propane storage containers and vapor distribution piping
are __________. a. Type of metal and type of paints and protective coatings b. Type of metal and environment in which metal is exposed c. Type of metal and type of electrically insulated fittings d. Water content and aeration/ atmospheric corrosion
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8. To prevent regulator freeze-up due to vent blockage caused by ice formation or condensation, the regulator should be
mounted so that the ________ to allow drainage of moisture that forms above the diaphragm. a. vent points upward b. diaphragm points upward c. vent points downward d. regulator points downward
9. For a residential vapor distribution system involving a first- and second-stage regulator, the highest Btu/hr output
capacity for a single first-stage regulator is not sufficient to meet total gas demand of the system. What is the best solution? a. Install a commercial high-pressure regulator b. Install two first-stage regulators in a parallel installation c. Install two second-stage regulators in a parallel installation d. Install two first-stage regulators in series
10. When sizing vapor meters for lb systems, select the meter according to its capacity at 2 w.c. pressure drop.
a. True b. False
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11. A circular meter index commonly has four dials that record the volume of gas used. When reading the dials of a circular
index, start with the dial ____________. a. furthest to the left and proceed right b. furthest to the right and proceed left c. in the center and proceed outward d. anywhere, because it doesnt matter
12. All of the following are examples of physical defects that would disallow a container to be refilled EXCEPT:
a. Bulging b. Discoloration along the container wall c. Cracks d. Damage to the cylinder foot rings
13. ASME tanks used for LP-gas storage that have a water capacity of 125 gallons or greater cannot be transported over a
public roadway when filled to more than ______ of their water capacity. a. 20% b. 15% c. 10% d. 5%
14. The steps to performing a leak test are as follows: Step 1: Select a leak checking device; Step 2: Choose an appropriate
place in the plant to perform the inspection; Step 3: ________; Step 4: Use a leak detector to test for leaks. What is step 3? a. Pressurize the container b. Notify supervisor of potentially unsafe containers c. Connect a vapor hose to the container d. Spray fluid on valve and look for bubbles
15. If you are transporting cylinders or tanks containing propane, you must carry _______.
a. Shipping papers, placard holders, and emergency response information b. Shipping papers, a hazmat certificate of registration, and emergency response information c. Shipping papers, a hazmat certificate of registration, and a cylinder dolly d. Towing hitch, a hazmat certificate of registration, and emergency response information
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16. Which of the following procedures for loading and securing propane cylinders on a vehicle is NOT correct?
a. Park your vehicle at the dock or on the level ground before moving the dolly and cylinder onto the lift gate b. Take precautions before operating the lift gate, including centering the load on the lift gate to help prevent it from tilting or falling c. Use the lift gate to load cylinders on the service vehicle so most of the weight is on the front axle with side-to-side distribution d. Load and position the cylinders on the vehicle so that each cylinders pressure relief valve is in direct communication with the vapor space at all times and secure them in this position
17. Not all materials and supplies needed for installation at the customer site are considered cargo; only non-perishable
materials must be secured under DOT regulations. a. True b. False
18. Which of the following must be performed before excavating underground tanks and piping?
a. Confirm the locations of underground utilities b. Confirm the locations of customer-owned underground systems c. Ensure that the buried tank or piping will not interfere with pre-installed utilities or systems d. All of the above
19. The most important factor affecting the choice of T-blocks is whether the cylinder changeover system is manual or
automatic. a. True b. False
20. When determining a tank location, ensure that it meets the code requirements for:
a. Distance from property lines and distance from building and ignition sources b. Distance from property lines and distance from fire hydrants c. Distance from municipal lines and distance from building and ignition sources d. Distance from property lines and distance from water sources
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21. In order to place the tank into service, all of the following must be completed EXCEPT:
a. Verifying the anode wires are properly connected and secure b. Installing the pigtail, first-stage regulator, and regulator vent pipe-away as necessary c. Connecting the buried distribution line to the regulator outlet d. Verifying that the regulators vent or vent extension terminates below the anticipated water line
22. Testing the cathodic protection system can be done by checking the _____________.
a. Soil content b. Tank-to-soil potential c. Anode reading d. None of the above
24. According to NFPA 58 requirements for aboveground lines, you can use polyethylene (PE) pipe, tubing, and fittings in
aboveground line installations. a. True b. False
25. Mechanical fittings are used to join PE pipes in most residential and small commercial installations. PE can also be
joined using ____. a. Stab-type fittings b. Barbed fittings c. Heat fusion d. Electro-fusion
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26. Do you need to install tracer wire with PE pipe and tubing?
a. No. Even though PE pipe and tubing are non-conductive and cannot be found by pipe-locating devices, if you were to install tracer wire it would have to contact the PE piping in some way, which could damage the piping and possibly cause a leak b. No. PE pipe and tubing are conductive and can be found by pipe-locating devices c. Yes, because PE pipe and tubing are non-conductive and cannot be found by pipe-locating devices d. Yes. PE pipe and tubing are non-conductive and cannot be found by pipe-locating devices; therefore you must never install a tracer wire
27. Should you use pipe thread-sealing compounds on the seats of brass flare fittings?
a. No. Flared copper connections are highly corrosive and need to be sealed frequently; therefore pipe thread-sealing compounds would not work properly on the seats of brass flare fittings b. No. Flared copper connections are metal-to-metal seals that may not seat and seal properly if you use thread-sealing compounds c. Yes. Pipe thread-sealing compounds are always used on the seats of brass flare fittings d. None of the above
28. NFPA 58 specifies that the following types of steel piping can be used for propane vapor distribution systems:
a. Cast iron, black iron, or wrought iron b. Black iron, galvanized steel, or cast iron c. Red iron, galvanized steel, or wrought iron d. Black iron, galvanized steel, or wrought iron
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31. All piping layouts for vapor distribution systems require more than one second-stage regulator.
a. True b. False
32. Which of these statements about selecting a meter location is NOT correct?
a. NFPA 54 requires that meters be located in ventilated spaces readily accessible for examination, reading, replacement, or maintenance. b. NFPA 54 requires that meters be located where they are not subjected to extreme temperatures, sudden extreme temperature changes, or temperatures beyond those recommended by the manufacturer. c. NFPA 54 requires that meters be located at least 3 ft from sources of ignition, not including air conditioning compressors, heat pumps, and electric meters. d. NFPA 54 requires that meters be located where they are not subjected to damage, such as adjacent to a driveway, under a fire escape, in public passages, in coal bins, or where they will be subject to excessive corrosion or vibration.
33. When installing meters at service entrances, two meter-mounting methods are typically used in distribution lines that
use independent 2-stage regulation. How can these meters be mounted? a. On a building wall or post-mounted b. On a building wall or freestanding c. Post-mounted or freestanding d. None of the above
34. After the interior distribution system is installed, inspected for NFPA 54 code requirements, and is ready to be placed into
operation, the meter or regulator will have to be connected to the interior system. This assessment will be conducted after the connections are made between the exterior and interior portions of the system, subsequent to the installation of the container, piping, and regulators. a. True b. False
35. The maximum length of time for most temporary heat/construction installations is ____ months.
a. 6 b. 8 c. 12 d. 18
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36. Propane grills, fire pits, mosquito traps, illuminating appliances, and patio heaters are all examples of _________.
a. Outdoor living equipment b. Indoor appliances c. Temporary heat d. Both a and b
37. When transferring liquid propane from container-to-container; be sure to remove sources of ignition within ___ ft of the
point of transfer, which is the location where hoses connect to the container filler valve and the liquid withdrawal valve. a. 15 b. 20 c. 10 d. None of the above
39. There are some differences between DOT containers and ASME tanks that impact evacuation procedures. Which one
does NOT belong? a. DOT containers may be transported filled to their legal limit b. DOT containers are usually equipped with liquid evacuation valves c. Not all DOT containers are equipped with vapor return fittings d. Not all DOT containers are equipped with float gauges
40. A pressure test applies pressure of not less than ___ times the proposed maximum working pressure of the interior
piping, but in no case less than ___ psig. a. 2/3 b. 1/2 c. 1/3 d. None of the above
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41. The requirement for performing a leak check only applies to the portion of the piping covered by NFPA 54.
a. True b. False
42. A leak test is performed after a leak is identified in a system, and it is performed _____ the test for leakage, pressure
test, or leak check. a. After b. Before c. A leak test is not a kind of system test d. None of the above
43. Flow tests and lock-up tests are typically performed on vapor distribution systems ________ to determine if the piping
system and regulator(s) are sized correctly for the estimated load and are functioning properly. a. During shut down b. Flow tests and lock-up tests are never performed on vapor distribution systems c. During start up d. Both a and c
44. A lock-up test measures the pressure in the lines downstream of the first-stage regulator to ensure that the regulator
will shut off the flow of propane when the appliances are not calling for gas. a. True b. False
45. In addition to the decals and labels that local, state, and federal regulations require, you can place decals on a
customers container that provide safety information. Out of the four decals listed, which safety-related decal is NOT available through PERC? a. ASME container label b. Consumer safety cylinder requalification decal c. Meter re-location and distribution label d. Container shutoff valve label
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46. The PERC consumer safety material includes all of the following except:
a. A scratch-and-sniff to help demonstrate propane odorant b. How to turn of the propane supply valve(s) c. The physical properties of propane d. None of the above
47. You can respond to certain emergencies without training if and only if permission is granted by your supervisor.
a. True b. False
49. If you have an uncontrolled release, NEVER enter or re-enter a hazardous environment. When you are evacuating, which
task below should you try to do? a. Identify the source of the leak b. Check for sources of ignition and shut them off c. Note the wind direction d. All of the above
50. The most common method for joining steel and wrought iron pipes in residential and small commercial installations is:
a. Threaded fittings b. Welding c. Brazing d. Flaring
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A. True. Total gas demand is calculated to ensure the proper sizing of regulators and distribution lines and that the
container is sized properly.
C. Container manufacturer/brand. The container manufacturer/brand does not affect its sizing. All other factors do
affect the sizing of the container.
B. Underground ASME tank(s). An underground container would not be impacted as much by ambient temperature.
Learning Activity: Select the Appropriate Container
Residence A: 1,000 gallon aboveground ASME tank Residence B: 200 lb DOT Cylinder Residence C: 1,000 gallon underground ASME tank
Lesson 4: Learning Activity: Container Distance Requirements
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B. False. Soils with high moisture content and high levels of dissolved salts tend to be more corrosive than soils with a high proportion of sand and limited water retention capacity. This is because soils with a high proportion of sand and limited water retention capacity are more resistive and have lower electrical conductivity.
Learning Activity: Corrosion Analysis and Prevention
Answer: Propane Tank Coating, High Potential Magnesium Anodes, Dielectric Unions MODULE 3
Learning Activity: Identify Regulator Components
From left to right: 1. Diaphragm (d) 2. Internal Relief Valve (b) 3. Orifice & Disk Assembly (c) 4. Vent (a) 5. Upper Spring Case (e) 6. Lower Body (f) 7. Regulator Main Spring (g) 8. Seat Disk (h)
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Description 1: Line-Pressure Regulator Description 2: Automatic Changeover Regulator Description 3: Integral Two-Stage Regulator Description 4: High-Pressure Regulator Description 5: Integral 2-PSI Service Regulator Description 6: First-Stage Regulator Description 7: 2-PSI Service Regulator Description 8: Second-Stage Regulator Description 9: Single-Stage Regulator
Lesson 1: Check for Understanding 1
B. Regulator spring, diaphragm, orifice. When the service valve on the regulator is closed and there is no gas pressure on the system, the regulator spring has forced the diaphragm down, fully opening the regulator orifice.
Learning Activity: Select the Number of Second-Stage Regulators
House A: (1) Regulator B (2) Regulator A House B: (1) Regulator A (2) Regulator A While regulator C will work, there may be a cost factor to consider when selecting a larger, more expensive regulator. Refer to your company policy.
Lesson 1: Check for Understanding 2
C. Customer preferences. Although customer preferences are important, they cannot overrule the other important
requirements such as pressure and total gas demand.
D. 300 CFH. You have determined that the total gas demand for a customer residence is 450,000 Btu/hr and you need to
select a vapor meter for installation. Your company has a variety of vapor meters available, but they are all rated based on the specific gravity of natural gas. The appropriate meter for this installation is 300 CFH.
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MODULE 4
Learning Activity: Inspecting DOT Cylinders
Top row, left to right: Reject, Reject, Reject Bottom row, left to right: Accept, Reject, Reject
Lesson 1: Check for Understanding
B. False. Since ASME tanks have many welds and openings for valves and gauges, you should select every weld and connection for leaks, verifying that the tank is leak free.
Lesson 2: Check for Understanding
C. A 1,000 gallon ASME tank containing 100 gallons of liquid propane. According to DOT requirements, A
1,000 gallon ASME tank containing 100 gallons of liquid propane containers cannot be transported on public roadways to the customer site.
Correct: Boom angle of crane. Incorrect: Slings not attached per regulations DOT infraction on tank being filled more than 5% Outriggers not extended Service tech standing beneath the lifted tank Service tech not wearing hard hat/PPE
Learning Activity: Safely Loading CDVS
DOT violations: Accessories, such as vehicle chocks, should be secured to prevent movement during transport. Cylinder dollies must be secured to prevent sudden movement and potential damage during transport.
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Containers should not be loaded to one side but evenly distributed along the width of the truck bed. An unbalanced load, as seen here, is extremely dangerous; it could cause poor handling due to insufficient ground contact. It could even cause the truck to overturn. Materials of trade, such as paint or insect repellent, should be stowed in a secure compartment during transport. Fire extinguishers need to be fully secured in their mounts to prevent sudden movement and damage during transport. The DOT Hazard Class Placard is displaying the wrong identification number for LP Gas. The correct Hazard Class number is 1075.
MODULE 5
Lesson 1: Check for Understanding
B. Low water level in the ground. Low water level in the ground is not a factor in the pre-installation activities for an
aboveground container.
C. Regulator. In an automatic changeover system, the regulator automatically switches the supply of propane vapor from
the supply cylinder to the reserve cylinder when the pressure in the supply cylinder drops to a low level.
This installation has the following errors: Pigtails not properly looped. Cylinder not sitting on foundation properly. Foundation not level. Cylinder too close to air conditioner intake. Combustible materials within 10 ft of the cylinder.
Lesson 2: Check for Understanding 2
B. False. For both single and multi-tank installations, the foundations must be level and at the same height or elevation relative to each other so the tank will be level when installed.
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C. 18. According to NFPA 58, if vehicle traffic is expected to cross the location of an underground tank, then the tank must
be at least 18 below grade, or the container must be protected from damage due to vehicle traffic.
MODULE 6
Lesson 1: Check for Understanding
A. PE pipe, tubing, and fittings can be used in aboveground line installations. PE pipe, tubing, and fittings
can not be used in aboveground line installations.
A. True. Tracer wire should not be installed in contact with PE piping to avoid damage from stray electrical currents or
lightning strikes. When installing tracer wire, first backfill a layer of earth about 6 deep above the PE piping, then install the tracer wire.
Top left: Reject Top right: Accept Bottom left: Reject Bottom right: Reject
Lesson 4: Check for Understanding
A. True. The fitting allowance is the distance from the end of the pipe to the center opening of the fitting. MODULE 7
Lesson 1: Check for Understanding
A. True. The 1995 and later editions of NFPA 58 require 2-stage regulation for all fixed piping systems that serve psig
appliance systems. Single-stage systems installed prior to June 30, 1997 can remain in service. However, if the single-stage regulator no longer functions properly, then the existing system must be converted to a 2-stage regulated system.
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Incorrect Scene Details: Second-stage regulator should have a regulator protector installed so that it is not damaged from falling ice or snow.
There should be a dielectric union installed to electrically isolate the underground container and prevent the anode from having to supply current to protect everything metal located underground near the building, which would drain the anode too quickly. The pigtail at the first-stage regulator should have an upward loop configuration to prevent water from collecting at the bottom of the loop and freezing.
Second-stage regulators should not be installed within 5 ft of a source of ignition, such as this A/C unit.
The second-stage regulator is installed improperly; the vent should point down so that it is protected from debris.
B. False. For meter accuracy, avoid locations where there is a source of heat. Do not install meters close to sources of heat
such as heat pumps, air conditioners, appliance vent terminations, and dryer exhausts.
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MODULE 8
Lesson 2: Check for Understanding
D. Immediately tighten the plug or cap securely and inform your supervisor of the problem. By
immediately screwing the plug or cap back on, tightening it securely, and informing your supervisor of the problem you will not only stop the excess flow of propane, you will also prevent a potentially dangerous situation from occurring.
MODULE 10
Lesson 1: Check for Understanding
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Glossary
2-PSI SERVICE REGULATOR AUTOMATIC CHANGEOVER REGULATOR
This type of regulator has an internal relief valve, and is designed to serve as an intermediate regulator. These regulators supply propane to a manifold (located inside the structure) where piping such as corrugated stainless steel tubing (CSST) is routed to a line regulator supplying approximately 11" water column (w.c.) to appliances throughout the structure.
AMERICA SOCIETY FOR TESTING AND MATERIALS (ASTM)
A regulator designed to connect two cylinders or groups of cylinders, so that one cylinder (or group) is in use at any one time. When the pressure in the cylinder(s) in service drops below a pre-determined limit, the reserve cylinder(s) will deliver vapor to the system.
BELLOWS
American Society for Testing and Materials (ASTM) is an international standards developing organization that develops and publishes voluntary technical standards for a wide range of materials, products, systems, and services.
ANODE
Any structure or portion of a structure located underground or below the surface grade of the surrounding land.
BLOCK GAUGE
Metal that is oxidized and consumed as it corrodes while giving up its electrons to a cathode.
ANODELESS RISER
A transition assembly where polyethylene (PE) pipe or tubing is installed underground and terminated aboveground outside of a building.
APPLICABLE HUMIDITY SECTION
The column on a container vaporization chart listing the relative humidity expected during a season's maximum vaporization. For example, a high relative humidity would result in frost on a container thereby reducing vaporization capacity.
A way of protecting piping from the elements. The method used depends on the type of pipe you are installing and the elements you are protecting it from. For example, in a residential situation, you might insert the underground pipe or line into a heavily-walled Polyvinyl Chloride (PVC) pipe that is subsequently sealed at both ends.
BRITISH THERMAL UNIT PER HOUR (BTU/HR)
Large propane storage tanks installed at the bulk plant that typically range in size from 6,000 to 60,000 gallons.
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GLOSSARYBushing
BUSHING
COMBUSTION AIR
The amount of air required for propane to burn within its lower and upper flammability limits. Also known as "air for combustion."
CONTINUOUS DEMAND
A type of exothermic weld that uses a brazing process to connect anode wires to tanks or pipes. The weld metal consists of copper oxide flakes and finely ground aluminum starting powder. Anode wires must always be welded to a special welding pad or other non-pressure surface of an ASME tank.
CATHODIC PROTECTION SYSTEM
A system that controls the corrosion of a metal surface by making the metal act as a "cathode" of an electrochemical cell. This is achieved by placing another more easily corrosive metal (an anode) in contact with the metal to be protected. In propane vapor distribution systems, steel is the metal typically protected by this corrosion-control method.
CAVITATION
The component of a crane that lifts and lowers materials both horizontally and vertically. The maximum capacity of a boom is greatest when the boom is nearest to vertical; least when it is nearest to horizontal.
CRANE TRUCKS
The formation of vapor bubbles that occurs in an area where flowing liquid falls below its vapor pressure. This occurs in bobtail pumps when the turbulent flow of LP-gas forms bubbles. As the pump spins and moves the liquid propane out of the cargo tank, vapor bubbles are produced. As these vapor bubbles continue to form and collapse, the pump is subjected to pressure changes which cause a hammering effect on internal pump parts and the rotor bearings.
CHAMFERING
Corrosion that occurs in gaps where fluid does not flow in a working environment.
CUSTOMER GAS APPLIANCE USE PROFILE
A form used to list the appliances of a customer in order to determine their total gas demand.
DIAPHRAGM
A flat, flexible, rounded piece of material that responds to fluctuations in regulator outlet pressure.
DIELECTRIC UNION
The process of connecting two surfaces. If the surfaces are at right angles, the chamfer will typically be symmetrical at 45 degrees.
CLOSE NIPPLE
A pipe fitting used to connect two pieces of pipe. It contains a synthetic plastic gasket that stops the flow of an electrical current between the two pieces of pipe.
DRYER EXHAUST TERMINATION
A fitting, typically with male pipe threads at either end, used to join two other fittings.
GLOSSARYElectrical Isolation
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ELECTRICAL ISOLATION
GALVANIC
A means by which a physical device (gasket, washer, non-conductive material) prevents the flow of an electrical current.
FIRST-STAGE REGULATOR
Pertaining to the current resulting from the coupling of dissimilar electrodes in an electrolyte.
GROSS AGGREGATE WEIGHT
A regulator designed to reduce container pressure to between 5 and 10 pounds per square inch gauge (psig).
FIXED PIPING SYSTEM
The weight of the container empty plus the weight of the actual product in the container.
HARD-DRAWN TUBING
A system that is permanently installed and connected to an LP-gas source and the equipment using the gas. These parts can include the piping, valves, and fittings.
FIXED-VOLUME MEASUREMENT COMPARTMENTS
Rigid copper tubing used in fittings to change direction. Hard drawn tubing is used above ground and is typically joined by brazing.
HEAT FUSION
A component of a vapor meter used to measure a specific amount of propane vapor. Typical residential and small commercial meters have two compartments.
FLARE NUT THREADS
Used in commercial settings where gas demand is very high, and reduces pressure to a range of 12 to 15 psig.
HOLIDAY
Straight machine threads used inside flare nuts and on the flare seal end of male flare fittings. Flare nut threads are not compatible with, and must not be joined to pipe threads.
FLASH POINT
The lowest temperature at which a liquid gives off enough vapor to start burning at the surface of the liquid.
FLOW RATE
A type of test used for requalifying cylinders. A date without a letter indicates the cylinder was subjected to a complete water jacket hydrostatic test. The next cylinder requalification must be within 12 years.
IMPRESSED CURRENT SYSTEMS
The amount (volume) of vapor moving through a registar in a unit of time, typically measured in cubic feet per hour.
FLUXES
A cathodic protection system used in large structures where an anode is connected to a source of power, or rectifier, to distribute a current.
IN-SLAB INSTALLATIONS
Substances applied to surfaces that are to be joined by soldering or brazing. Fluxes promote the flow of solder and prevent the formation of contaminants.
FROST PENETRATION DEPTH
An installation in which a Corrugated Stainless Steel Tubing (CSST) line runs through a conduit that is embedded in a concrete slab, such as a patio.
INLET PRESSURE
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LOOP CONFIGURATION
Contains a non-adjustable first-stage regulator on the inlet. The second-stage provides 11" water column (w.c.) outlet pressure.
INTEGRAL 2-PSI SERVICE REGULATOR
A way of connecting two containers with a length of soft copper, or pigtail, in a loop shape to provide flexibility.
MANIFOLD
Combines a high-pressure regulator and a 2-psi service regulator into a single unit for vapor service.
INTERMITTENT DEMAND
A piping system that directs the flow of vapor from two or more containers to an appliance(s).
MATERIAL OF TRADE (MOT)
The Btu/hr requirements of a system that last only a short period of time.
K FACTOR
Hazardous materials, as defined by the Department of Transportation (DOT), that are carried on a motor vehicle to protect the driver or passengers, support the operation of the motor vehicle, or directly support the business.
METER BOSS
A factor that represents a constant minimum percent volume of liquid in a container. Used to calculate tank vaporization.
KITCHEN EXHAUST TERMINATION
A device located on the side or top of a vapor meter designed to stabilize the meter using one wrench while a second wrench is used to join the piping to the meter. Also called a "wrenching flat."
NATIONAL INSTITUTE OF SCIENCE AND TECHNOLOGY (NIST)
The outdoor termination of a duct from a vent hood used over a kitchen range or cook top.
LEAK CHECK
Leak Check is a test for gas leakage. Immediately after the gas is turned on into a new system or into a system that has been initially restored after an interruption of service, the piping system shall be tested for leakage. See also, the definition for Interruption of Service.
LEAK TEST
A bureau of the federal government that establishes standards for measurement devices for the propane and natural gas industries in its NIST Handbook 44. Formerly known as the National Bureau of Standards (NBS).
NFPA 30: FLAMMABLE AND COMBUSTIBLE LIQUIDS CODE
Test performed to determine where a leak is located in a vapor or liquid distribution system through the use of an approved leak-detector solution or gas-detection instrument.
LINE PRESSURE REGULATOR
A regulator designed to reduce 2 - 5 pounds per square inch gauge (psig) inlet pressure to appliance inlet pressure (typically 11" water column).
LOCKUP
Book of code adopted by most states and established by the National Fire Protection Association (NFPA) to provide guidance on the storage, handling, and use of flammable and combustible liquids. The NFPA is charged by OSHA to create and maintain minimum standards and requirements for fire prevention and suppression activities, training, and equipment, as well as other lifesafety codes and standards.
"ONE-CALL" SERVICE
The amount of pressure necessary to completely stop the flow of vapor through the first-stage and final-stage regulator inlet orifices, when there is no gas demand.
A nationwide, federally-mandated number, 811, that provides information on the location of underground utilities. Call this number before digging. For more information, visit their website at http://www.call811. com.
GLOSSARYOperating Pressure
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OPERATING PRESSURE
The pressure in the piping system under normal conditions while the appliances are not operating.
ORIFICE
A number assigned by the Department of Transportation (DOT) to locations that requalify cylinders. This number is placed on a cylinder along with the requalification date once a cylinder has been requalified and found to be fit for continued service.
RESISTIVITY
The pressure of a regulator expressed in pounds per square inch gauge (psig) or inch water column (w.c.).
PIGTAIL
A measure of how strongly a material opposes the flow of electric current. A low resistivity indicates a material that readily allows the movement of electrical charge.
"RULE OF THUMB"
A length of tubing that connects two or more devices and controls the flow of liquid or vapor. Usually is found between the container service valve and the regulator.
PITTING
A general guideline used to determine container vaporization capacity based on a container's dimensions and liquid percentage.
SECOND-STAGE REGULATOR
A form of extremely localized corrosion that leads to the creation of small holes in metal.
PRESSURE
The average force that vapor places on a piping system typically measured in pounds per square inch gauge (psig) and inch water column (w. c.).
REGULATOR MAIN SPRING
A regulator designed to reduce a regulated inlet pressure (typically 5 to 10 pounds per square inch (psig) to the interior piping system pressure (typically 11" water column (w.c.) or 2 psig).
SINGE-STAGE REGULATOR
The coil spring used to exert pressure on the regulator diaphragm. The tension of the spring determines the outlet pressure of the regulator.
REGULATOR ORIFICE
Reduces vapor pressure from the container to 1 psig or less, and is prohibited by NFPA 58 to be installed in any new or modified fixed piping systems.
SLUGGING
A fixed-sized opening in a regulator that helps control the flow rate of propane.
RELIQUEFACTION
Slugging means the valve will close when the valve flow rate has been exceeded. This may occur when there a significant drop in pressure from one side of the valve to the other as well"
SOFT SEAMLESS WATER TUBING
The changing of propane vapor back into a liquid in a vapor distribution system, usually due to a temperature or pressure change.
Copper tubing that is flexible and can be shaped to go around obstacles. Measured by outside diameter (O.D.).
TEMPERATURE COLUMN
The column on a container vaporization chart listing outdoor temperatures. Vaporization will decrease as temperatures decrease.
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VAPORIZATION CAPACITY
A test on the exterior portion of a piping system to determine if there are propane leaks. This includes the portion of the piping from the outlet of the tank vapor service valve to the outlet of the second-stage regulator and must be performed on all newly-installed piping.
TEST PRESSURE
The amount of vapor, expressed in Btu/hr, a container is capable of delivering at a given outside temperature and humidity.
VAPORIZATION CHARTS
The required pressure at which a piping system is tested to ensure proper piping integrity or to find leaks in the piping system.
THREAD BURRS
A chart that considers various factors, such as container size and atmospheric temperature, to determine how much propane vapor a container will produce without the vapor pressure going below a critical value (typically 10 pounds per square inch gauge (psig).
VAPORIZATION RATE
Small slivers of metal resulting from cutting threads into piping. These metal pieces can cause a host of installation problems, such as improper seals and regulator orifice blockage.
TIE DOWNS
Straps designed to restrict container movement. Tie downs can be metal, fabric straps, or chains. They attach to eye bolts or other anchoring mechanisms in the concrete foundation.
TRACER WIRE
The rate, expressed in volts, at which energy is drawn from a source that produces a flow of electricity in a circuit.
WATER CAPACITY
The maximum amount of water a propane container can hold when completely filled.
An electrically continuous and corrosion-resistant wire, minimum American Wire Gauge (AWG) 14, that is laid directly above underground piping, but not in direct contact with the piping. It is used as a conductor of an electrical signal when an underground pipe locator is used to locate the piping at a later date, preventing the need for excavation.
UNDERWRITERS LABORATORIES
An independent product safety certification organization that tests products and writing standards for safety.
VAPOR LOCK
When liquid propane turns to vapor within a piping system. This can cause overpressurization or excessive pump noise within a liquid pump.
VAPORIZATION
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Resources
APPROXIMATE GAS INPUT FOR TYPICAL APPLIANCES
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Step 4:
Apply a thin layer of flux to the silver alloy brazing rod. Hold the tip of the torch flame against the fitting until the flux begins to sizzle. Move the flame around to the other side of the fitting to ensure even heat. (When the flux begins to bubble, the connection should be hot enough for brazing.)
Step 5:
Touch the end of the brazing filler to the pipe just below the fitting. If it melts and is drawn into the joint, the pipe is sufficiently hot.
Step 6:
Quickly apply the brazing filler along both seams of the fitting, allowing it to be drawn into the fitting. When correctly brazed, the joint will show a thin bead of silver-colored brazing around each seam.
(Note: Brazing filler will harden in a minute or less if the joint has not been overheated.)
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Step 7:
Allow the joint to cool until the brazing material has a frosty appearance rather than a shiny silver color one. Wipe away any excess material with warm water, a wet cloth, and a brush.
After the joint is completed, do not disturb the tubing until the brazing filler and joint has cooled.
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RESOURCESK Factor
K FACTOR
40 30 20 10
80 70 60 45
D x L x 80 D x L x 70 D x L x 60 D x L x 45
These formulas allow for the temperature of the liquid to refrigerate to -20F (below zero), producing a temperature differential of 20F for the transfer of heat from the air to the tanks wetted surface and then into the liquid. The vapor space area of the vessel is not considered. Its effect is negligible. This K Factor is not the same as, and should not be confused with, the K-factor that is used for delivery scheduling and associated with degrees days (that is, a number used to indicate how fast a tank uses fuel.)
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100lbCylinders
Howmanyarerequired RuleofThumbGuideforInstalling100lbContainers
Forcontinuousdrawswheretemperaturesmayreach0F.Assume thevaporizationrateofa100lbcylinderasapproximately50,000 BTUperhour. TotalLoadinBTU Numberofcylindersperslide: 50,000 Example: Assumetotalload=200,000BTU/hr 200,000 Cylindersperside==4cylindersperside. 50,000
VaporizationRate
100lbPropaneCylinders
lbsPropanein Cylinder MaximumcontinuousdrawinBTUperhouratvarious temperaturesinDegreesF.
0F 20F 40F 60F70F
100 90 80 70 60 50 40 30 20 10
113,000 104,000 90,000 83,000 75,000 64,000 55,000 45,000 36,000 28,000
167,000 152,000 137,000 122,000 109,000 94,000 79,000 66,000 51,000 38,000
214,000 200,000 180,000 160,000 140,000 125,000 105,000 85,000 68,000 49,000
277,000 247,000 214,000 199,000 176,000 154,000 131,000 107,000 83,000 60,000
300,000 277,000 236,000 214,000 192,000 167,000 141,000 118,000 92,000 66,000
ASMEStorageContainers
DeterminingPropaneVaporizationCapacity RuleofThumbGuideforASMELP-Gas StorageContainers
CERTIFIED EMPLOYEE TRAINING PROGRAM
D-Outsidediameterininches
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105,000 79,000 55,000 40 85,000 66,000 45,000 30 68,000 51,000 36,000 20 of Thumb Guide 49,000 38,000 28,000 10 RESOURCESrule
ASMEStorageContainers
DeterminingPropaneVaporizationCapacity RuleofThumbGuideforASMELP-Gas StorageContainers
L D K
K
Percentageof ContainerFilled
PropaneVaporizationCapacityat0F(BTU/hr)
60 50 40 30 20 10
100 90 80 70 60 45
VaporizingCapacitiesforOtherAir Temperatures
Multiplytheresultsobtainedwiththeaboveformulae,byoneofthefollowing factorsfortheprevailingairtemperature.
PrevailingAir Temperature Multiplier PrevailingAir Temperature Multiplier
50 40 30 20 10
90 80 70 60 45
RESOURCESOdorization
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VaporizingCapacitiesforOtherAir Temperatures
Multiplytheresultsobtainedwiththeaboveformulae,byoneofthefollowing factorsfortheprevailingairtemperature.
PrevailingAir Temperature Multiplier PrevailingAir Temperature Multiplier
ODORIZATION
ODORIZATION:ALTERNATEMETHODSTOVERIFYPROPANEODORIZATION
ODOROMETERS
STAINTUBES
Staintubesprovideasimpletestforthepresenceofethylmercaptan.Someofthesetestsusecolortoindicatethepresenceofethylmercaptan. Besuretofollowmanufacturersinstructions.
450
451
452
453
SelectingandInspectingLiftingChainsandSlings
Theoperatormustexerciseintelligence,careandcommonsensewhenselectingandusingslings.[Slings
includeschain,wirerope(cables),andfabricweb(strap-type)slings.]
Wheninspectingwireropeslings,iftenrandomlydistributedwiresinonelay[twistedwirebundle;lay describesthedirectionthewiresandstrandsaretwistedduringtheconstructionofthewirerope]are broken,oriffi vewiresinonestrandofaropelayaredamaged,theslingmustnotbeused.Wireropeslings mustalsoberemovedfromserviceiftheinspectionrevealsanyofthefollowingconditions: 1.Damagedendfi ttings 2.Excessivecorrosion 3.Localizedwear 4.Aone-thirdreductioninouterwirediameter 5.Distortion,kinking,birdcaging,orotherstructuraldamagetothewirerope
Afterinspectingthesling(s),thecraneoperatormustdeterminehowthetankwillbelifted,howthesling(s)
willbearranged,andifadditionalslingsorotherequipmentisneededfortheload.Slingsusedshouldhave loadratingswellinexcessoftheweightofthetankanditscontents.Operatorsmustalwaysbearinmind
RESOURCESSelecting and Inspecting Lifting Chains and Slings 454 1.Damagedendfi ttings
2.Excessivecorrosion 3.Localizedwear 4.Aone-thirdreductioninouterwirediameter 5.Distortion,kinking,birdcaging,orotherstructuraldamagetothewirerope
Decreasing Sling Load Capacity as Angle Approaches Horizontal Additional Slings May Be Required
TheE ectofSlingAngleonSlingLiftingCapacity
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For the purpose of protecting the health and safety of the motor vehicle operator or passengers (such as insect repellant) For the purpose of supporting the operation or maintenance of a motor vehicle, including its auxiliary equipment (such as engine starting fluid) By a private motor carrier in direct support of a principal business that is other than transportation by motor vehicle (such as lawn care, plumbing, welding, painting).
REQUIREMENTS EXCEPTED FROM When you transport small amounts of these materials under the Materials of Trade exceptions, you are not subject to some of the regulations that apply to the transportation of hazardous materials. If you are only transporting classes and quantities of hazardous materials that qualify for the Materials of Trade exceptions, you do not need placards. These are the regulations you are excepted from. You are not required to have: Shipping papers Placarding Emergency response information Training for any hazardous materials carried as materials of trade Materials of trade may be transported on a motor vehicle with other fully regulated hazardous materials and still qualify for the above exceptions from the regulations. The driver should know which materials are fully regulated and which are materials of trade.
Note: If you are transporting propane, and at the same time carrying materials that qualify for the materials of trade exceptions, you are still responsible for complying with the full Hazardous Materials Regulations for the propane.
CLASSIFICATION REQUIREMENTS To be transported as a material of trade, the material must meet the materials of trade definition, hazard classification, and quantity guidelines.
CLASSIFICATIONS The material must belong to one of the following classifications: Division 2.1 - (Flammable Gas) Division 2.2 - (Non-flammable Gas) Class 3 - (Flammable Liquid) Division 4.1 - (Flammable Solid) Division 4.3, PG II or III - (Dangerous When Wet) Division 5.1 - (Oxidizer) Division 5.2 - (Organic Peroxide) Division 6.1 - (Poison) Class 8 - (Corrosive) Class 9 - (Miscellaneous) ORM-D - (Other Regulated Material)
QUANTITY REQUIREMENTS To be transported as a material of trade, the material must meet the materials of trade definition, hazard classification, and quantity guidelines. Note: Quantity limits for most of the classes/divisions (listed on the previous page) have not been included here, since the hazardous materials in these categories are not used in the propane industry.
QUANTITY LIMITS The following quantity limits apply to Classes 3 and 8. The limits are gross mass or capacity and include the weight of the packaging. Packing Group PG I PG II or III Package Quantity Limits for Classes 3 and 8 Not over 1 pound or 1 pint Not over 66 pounds or 8 gallons
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Class 3 - (Flammable Liquid) Division 4.1 - (Flammable Solid) Division 4.3, PG II or III - (Dangerous When Wet) Division 5.1 - (Oxidizer)
QUANTITY REQUIREMENTS To be transported as a material of trade, the material must meet the materials of trade definition, hazard classification, and quantity guidelines. Note: Quantity limits for most of the classes/divisions (listed on the previous page) have not been included here, since the hazardous materials in these categories are not used in the propane industry.
QUANTITY LIMITS The following quantity limits apply to Classes 3 and 8. The limits are gross mass or capacity and include the weight of the packaging. Packing Group PG I PG II or III Package Quantity Limits for Classes 3 and 8 Not over 1 pound or 1 pint Not over 66 pounds or 8 gallons
For Division 2.1 or 2.2, in a cylinder, the gross weight cannot be over 220 pounds. Note: If transporting propane is your principal business, propane cylinders are fully regulated - they would not qualify for the materials of trade exceptions.
PACKAGING REQUIREMENTS The following guidelines must be met for you to use the materials of trade exceptions.Hazardous Materials
liquids and gasesPackagings must be: Leak proof Securely closed Secured to prevent movement Protected against damage Cylinders or other pressure vessels used to transport Division 2.1 (Flammable Gas) or 2.2 (Non-flammable Gas) must conform to the packaging, qualification, maintenance, and use requirements as described in the HMR, except that outer packagings are not required. Manifolding of cylinders is authorized as long as all valves are tightly closed. gasoline must be in metal or plastic packaging and conform to the HMR or OSHA requirements.
PACKAGING
Materials must be packaged in the manufacturers original packaging, or one of equal strength and quality. An outer packaging is not required for cans and bottles that are secured in cages, carts, bins, boxes, or compartments to prevent movement. But, you cannot simply place a can inside a bin - it must be secured to prevent movement.
MARKING REQUIREMENTS
Non-bulk packagings (capacity of 119 gallons or less for liquids), other than cylinders, must be marked with the common name or proper shipping name of the material being carried. DOT specification cylinders must be marked and labeled as required by the HMR.
DRIVER REQUIREMENTS DOT requires that the operator of a motor vehicle containing materials of trade be informed:
Of the presence of the hazardous materials About the requirements of the Materials of Trade exceptions
TOTAL GROSS WEIGHT The total gross weight of all materials of trade carried on one motor vehicle cannot exceed 440 pounds. Because the amount that can be transported is critical - drivers need to know the capacity and weight of containers. This is extremely important, especially if several items are transported at once. EXAMPLES OF PRODUCTS ELIGIBLE FOR THE EXCEPTIONS The following are examples of products that are eligible for materials of trade exceptions if they are carried in the correct amount:Division 2.1 (Flammable gas) - 220 pounds or less and in a DOT-approved cylinder.
Acetylene Propane
Division 2.2 (Non-flammable gas) - 220 pounds or less and in a DOT-approved cylinder. Nitrogen Oxygen
MARKING REQUIREMENTS
Non-bulk packagings (capacity of 119 gallons or less for liquids), other than cylinders, must be marked with the common name or proper RESOURCESTransporting Flammable Liquids as Materials of Trade shipping name of the material being carried. DOT specification cylinders must be marked and labeled as required by the HMR.
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DRIVER REQUIREMENTS DOT requires that the operator of a motor vehicle containing materials of trade be informed:
Of the presence of the hazardous materials About the requirements of the Materials of Trade exceptions
TOTAL GROSS WEIGHT The total gross weight of all materials of trade carried on one motor vehicle cannot exceed 440 pounds. Because the amount that can be transported is critical - drivers need to know the capacity and weight of containers. This is extremely important, especially if several items are transported at once. EXAMPLES OF PRODUCTS ELIGIBLE FOR THE EXCEPTIONS The following are examples of products that are eligible for materials of trade exceptions if they are carried in the correct amount:Division 2.1 (Flammable gas) - 220 pounds or less and in a DOT-approved cylinder.
Acetylene Propane
Division 2.2 (Non-flammable gas) - 220 pounds or less and in a DOT-approved cylinder.
Nitrogen Oxygen
Gasoline PVC cleaner and glue Methanol Paint (lacquer, enamel, stain, shellac solutions, varnish, polish, liquid filler and liquid lacquer base)
Charcoal
Spray paint
Note: Materials that are self-reactive, poison by inhalation, or hazardous waste cannot qualify for these exceptions. Even though you are not likely to encounter these materials, you must be informed of these requirements.
FAILURE TO FOLLOW THE GUIDELINES If you fail to follow the guidelines for the materials of trade exceptions, you will be in violation of many requirements of the HMR and may be subject to significant fines and penalties.Currently the HMR allow for fines ranging from $250 to $50,000 per day, per violation. Criminal penalties can also be imposed on individuals directly involved with non-compliance.
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VAPOR METER SPECFIFICATION WORKSHEET Vapor Meter Speci cation Worksheet (4.1.1.i.4)
The following example illustrates a worksheet that can be used to record the selection and specications of a vapor meter.
Installation Address: ________________________________________________________ ________________________________________________________ ________________________________________________________ Customer Total System Demand _____________________ Btu/hr Manufacturer Fuel Gas CFH @ Btu/hr @ Accessories: _____________________ Model Number __________________ Propane System Pressure 2 PSI 11in. w.c. in. w.c. drop _______________ 2 in. w.c. drop ________________ in. w.c. drop _______________ 2 in. w.c. drop ________________ Index Circular (Clock Dial) Direct (Digital) Volume Pulser Index Units Vapor Cubic Feet Liquid Gallons Liters Support Meter Bar Wall Mounting Bracket ID Tag ________ Customer Tag Number _____________________ Install Date _______/_______/_______
Job No.
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Meter Size : 175 to 425 CFH Main Delivery Pressure: 5 to 20 psig Meter Inlet Pressure: 11 in. w.c. Material List No. Quantity Material 1 1 Meter 2 1 Service Riser Assembly 3 1 Shut-Off Valve 4 1 Service Line 5 1 Regulator with Internal Relief 6 1 Insulating Swivel Other General Pipe and Fittings
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2 1 Service Riser Assembly 3 1 Shut-Off Valve 4 1 Service Line 5 1 Regulator with Internal Relief RESOURCESVapor Meter Specfification Worksheet 6 1 Insulating Swivel Other General Pipe and Fittings
Typical Inside Meter Installation At any point were piping contacts or passes through concrete or masonry grout, the piping should be protected from abrasion and corrosion by the use of a sleeve of suitable material, such as PE pipe. You should check local codes to verify if an inside meter set installation is permitted.
Meter Size : 175 to 425 CFH Delivery Pressure: 0.25 to 2.0 psig Inlet Pressure: .5 to 60 psig Material List No. 1 2 3 4 5 6 Quantity 1 1 1 1 1 1 Material Meter Regulator with Internal Relief Vented Outside Shut-Off Valve Service Line Service Riser Assembly Insulating Swivel
Multiple Domestic Manifold Installation When installing one regulator on a multiple meter manifold, be sure to install a regulator properly sized for the load in order to maintain proper relief capacity. Some companies choose to install a service regulator for each CERTIFIED meter. EMPLOYEE TRAINING PROGRAM
1 2 3 4 5 6
1 1 1 1 1 1
Meter Regulator with Internal Relief Vented Outside Shut-Off Valve Service Line RESOURCESVapor Meter Specfification Worksheet Service Riser Assembly Insulating Swivel
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Multiple Domestic Manifold Installation When installing one regulator on a multiple meter manifold, be sure to install a regulator properly sized for the load in order to maintain proper relief capacity. Some companies choose to install a service regulator for each meter.
Meter Size : 175 to 425 CFH Delivery Pressure: 0.25 to 2.0 psig Inlet Pressure: .5 to 60 psig Material List No. 1 2 3 4 5 6 Quantity 1 1 1 Material Meter Regulator with Internal Relief Vented Outside Shut-Off Valve Service Line Service Riser Assembly Insulating Swivel
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