© Commonwealth of Australia 2 - NPSTAGnpstag.com/wp-content/uploads/2016/05/CPCPGS3060A-Install-LPG... · iv © Commonwealth of Australia 2015 ... locate, install and test liquefied

© Commonwealth of Australia 2

CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL

© Commonwealth of Australia 2015 ii

CONSTRUCTION, PLUMBING AND SERVICE

INTEGRATED FRAMEWORK

TRAINING PACKAGE

CPC08

CPCPGS3060A

INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL

LEARNING GUIDE


© Commonwealth of Australia 2015 iii

ACKNOWLEDGEMENTS

National Plumbing Services Training Advisory Group

Plumbing Industry Commission Victoria

© Commonwealth of Australia 2015

Construction and Property Services Industry Skills Council PO Box 151 Belconnen ACT 2616 Tel: 02 6253 0002 www.cpsisc.com.au This work is copyright, but permission is given to trainers and teachers to make copies and contextualise the resources for use within their own training organisation or in a workplace where training is being conducted. This permission does not extend to making copies for use outside the immediate training environment for which they are made, or the making of copies for hire or resale to third parties.

This work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The 2015 publication has been updated to reflect changes to the national units of competency.

The views expressed in this work do not necessarily represent the views of the Commonwealth of Australia or CPSISC. In addition, the Commonwealth of Australia and CPSISC do not give warranty or accept any legal liability in relation to the content of this work.

The website addresses and other contact information provided in this publication were compiled in good faith and were correct at the time of printing. The updating of these resources was completed by:

National Plumbing and Services Training Advisory Group, with funding and support provided by the Construction and Property Services Industry Skills Council (CPSISC):

This guide was developed in consultation with representatives of the Plumbing Industry by NPSTAG and CPSISC to support the implementation of the CPC08 Construction, Plumbing and Services Training Package.


© Commonwealth of Australia 2015 iv

Contents

What is this resource about? ................................................................................................ 1

How do I use this resource? ................................................................................................. 1

Flexible Delivery ................................................................................................................. 1

What do I have to do? .......................................................................................................... 1

Unit Descriptor .................................................................................................................... 2

Element ................................................................................................................................ 2

Performance Criteria ........................................................................................................... 2

Required knowledge ............................................................................................................ 5

Are there any pre-requisites? ............................................................................................... 5

What other resources will I need? ....................................................................................... 5

Texts .................................................................................................................................... 5

Web sites ............................................................................................................................. 5

Video or audio cassettes ...................................................................................................... 5

Safety ................................................................................................................................... 6

Workplace environment and safety ..................................................................................... 6

Introduction ......................................................................................................................... 7

Properties of LP gas ............................................................................................................. 7

Physical data ........................................................................................................................ 8

Health data ........................................................................................................................... 8

Reactivity data ..................................................................................................................... 9

Combustion principles ......................................................................................................... 9

The fire triangle ................................................................................................................. 10

Complete combustion ........................................................................................................ 10

Pressure and flow rates ...................................................................................................... 11

Liquid temperature and wetted surface ............................................................................. 11

The type and size of regulator selected ............................................................................. 11

Gas delivery systems ......................................................................................................... 11

The size of consumer piping .............................................................................................. 14

LP gas sizing tables ........................................................................................................... 16

Electrical safety ................................................................................................................. 17

Electrical testing equipment .............................................................................................. 18

Safety action ...................................................................................................................... 18


© Commonwealth of Australia 2015 v

Care of the neon tester ....................................................................................................... 19

Bonding straps ................................................................................................................... 19

Power point safety tester ................................................................................................... 20

Procedure for using either power point safety tester ......................................................... 21

Safety action ...................................................................................................................... 21

Reverse polarity ................................................................................................................ 21

Gas safety .......................................................................................................................... 22

Regulations ........................................................................................................................ 22

Minor storage and usage ................................................................................................... 23

Components for tank systems ........................................................................................... 23

Tank system installation .................................................................................................... 23

Underground tank installations ......................................................................................... 23

Cylinder and cylinder systems .......................................................................................... 23

Automotive filling installations ......................................................................................... 24

Quality assurance .............................................................................................................. 25

Plan work activities ........................................................................................................... 26

Workplace health and safety ............................................................................................. 27

Tools and equipment ......................................................................................................... 28

Determine installation requirements ................................................................................. 30

Determining gas load ........................................................................................................ 30

Calculating storage capacity.............................................................................................. 30

Calculating regulator size and connections ....................................................................... 31

Checking the location ........................................................................................................ 33

Install and test the storage system ..................................................................................... 35

Installing the regulator and pipework ................................................................................ 35

Testing the installation and reporting ................................................................................ 36

Clean up ............................................................................................................................ 38

Worksheet ......................................................................................................................... 39

Practical application .......................................................................................................... 42

Assessment checklist ......................................................................................................... 44


© Commonwealth of Australia 2015 1

What is this resource about?

Welcome to CPCPGS3060A – Install LPG storage of aggregate storage capacity exceeding 500 litres

and less than 8 KL. This resource will help you gain the skills and knowledge necessary to

demonstrate competence in this unit.

How do I use this resource?

This resource is divided into four main sections:

• A learning unit, which contains background information on CPCPGS3060A Install LPG

storage of aggregate storage capacity exceeding 500 litres and less than 8 KL

• Worksheets, which prepare you for the practical application

• Practical application, which allows you to experience install LP gas cylinders – aggregate

storage capacity exceeding 500 litres and less than 8 KL

• Assessment materials, which help you demonstrate competency.

To complete this unit of competence you will need to:

• read the information contained in the learning unit

• complete the worksheets as instructed

• have your answers checked by your trainer or supervisor

• work with your trainer or supervisor to practise install LP gas cylinders – aggregate storage

capacity exceeding 500 litres and less than 8 KL

• read the assessment checklist together with the assessment sheets

• complete the assessment.

Learning Resources are not intended to be the only source of information nor are they intended to be

an exhaustive form of instruction.

Flexible Delivery

The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse

backgrounds to meet equity principles and conform to Legislative policies.

What do I have to do?

To demonstrate competence in this unit you will be required to show the level of skills and knowledge

for each of the elements involved in CPCPGS3060A – Install LPG storage of aggregate storage

capacity exceeding 500 litres and less than 8 KL:

• Identify installation requirements

• Prepare for installation

• Install and test storage system

• Clean up.

If you are unsure of the meaning of these elements you should read the performance criteria on the

following page.



CPCPGS3060A Install LPG storage of aggregate storage capacity exceeding 500 litres and less than 8 KL

Unit Descriptor This unit of competency specifies the outcomes required to select,

locate, install and test liquefied petroleum gas (LPG) storage

facilities with a storage capacity of more than 500 litres but less

than 8KL.

The storage is connected to consumer piping systems with

an operating pressure not exceeding 140kPa.

Element Performance Criteria Elements describe the

essential outcomes of a

unit of competency.

Performance criteria describe the performance needed to

demonstrate achievement of the element. Where bold

italicised text is used, further information is detailed in the

required skills and knowledge section and the range

statement. Assessment of performance is to be consistent

with the evidence guide.

1 Identify installation

requirements

1.1 Building plans and specifications and any special

instructions are obtained

1.2 Work health and safety (WHS) and environmental

requirements associated with installing LPG storage

facilities are adhered to throughout the work

1.3 Quality assurance requirements for company operations

are identified and adhered to

1.4 Gas load and design requirements are determined from

plans, specifications, and job drawing or workplace

instructions

1.5 Storage capacity is checked for compliance with regulatory

authorities’ and installation requirements

1.6 Appropriate regulators are determined to meet capacity and

load of the system according to installation requirements

1.7 Appropriateness of selected location to provide required

service is established in compliance with standards and

installation requirements

1.8 Quantity of required materials is calculated from design,

drawings and specifications in compliance with installation

requirements



2 Prepare for installation 2.1 Materials and equipment are ordered and checked for

compliance with docket and order form, and for acceptable

condition

2.2 Appropriate tools and equipment for installation of storage

facility, including personal protective equipment, are

identified, selected and checked for serviceability

2.3 Appropriate testing apparatus is selected

2.4 Work is planned in conjunction with others involved in or

affected by the work

2.5 Work area and materials are prepared to support efficient

installation of system

3 Install and test LPG

storage system

3.1 LPG containers, piping, fittings and components are

installed in compliance with standards and installation

requirements

3.2 Regulators and associated pipework are installed in

compliance with standards and installation requirements

3.3 Regulators are adjusted to provide working pressure in

compliance with standards and installation requirements

3.4 System is purged according to standards

3.5 System is tested in compliance with standards and

installation requirements

3.6 Test equipment is removed and test data recorded in format

required by regulatory authority and installation

requirements

3.7 Sustainability principles and concepts are applied

throughout the installation process

4 Clean up 4.1 Work area is cleared and materials disposed of, reused or

recycled according to legislation, regulations, codes of

practice and job specification

4.2 Tools and equipment are cleaned, checked, maintained and

stored according to manufacturer recommendations and

workplace procedures

4.3 Information is accessed and documentation completed

according to installation requirements

4.4 Relevant authorities and supervisors are advised of job

completion in compliance with regulatory and installation

requirements



Required knowledge Required knowledge for this unit is:

• electrical safety and requisite precautions

• how to access relevant information, including codes and

technical standards

• job safety analysis (JSA) and safe work method statements

(SWMS)

• material requirements determination process

• procedures for installing and testing gas storage facilities

• properties of gas, gas safety, combustion principles, pressure

and flow rates

• relevant statutory and authority requirements related to

installing and testing gas storage facilities

• SI system of measurements

• workplace and equipment safety requirements

An up to date version of the ‘Unit Descriptor’ may be located on the Australian Government web site

training.gov.au

http://training.gov.au/Search/Training?searchTitleOrCode=&nrtSearchSubmit=Search&includ

eSupersededData=true&includeSupersededData=false&homePage=true&javaScriptEnabled=tr

ue&typeAllTrainingComponents=true



How will I be assessed?

Your trainer or supervisor will decide with you how you will be assessed. Your assessment activity

may include completion of the student worksheet and practical task selected by your trainer or

supervisor. Your assessment should allow you to demonstrate all the skills and knowledge required to

install LP gas cylinders.

This unit may be assessed in conjunction with other units of competence. Your trainer or supervisor

will tell you if you are to be assessed this way.

Are there any pre-requisites?

Prior to commencing CPCPGS3060A – Install LPG storage of aggregate storage capacity exceeding

500 litres and less than 8 KL you must have successfully completed the following pre-requisite:

• CPCPCM2043A – Carry out WHS requirements

It is also recommended that prior to commencing CPCPGS3060A – Install LPG storage of aggregate

storage capacity exceeding 500 litres and less than 8 KL you should have successfully completed the

following competencies:

• Nil.

Project work may also group pre-requisite and or co-requisite competencies together to carry out such

projects. It is recommended that the following competencies are grouped with this unit of competency:

• CPCPGS3056A – Install gas piping systems

• CPCPGS3048A – Install gas pressure control equipment

• CPCPGS3051A – Purge consumer piping.

What other resources will I need?

To assist you the following resources have been suggested and should be available to you to do this

competency:

Texts

• Australian Standard AS/NZS1596 – LP Gas Storage and handling

• Australian Standard AS/NZS5601 – Gas Installations Relevant Version

• State or Territory regulations may override this learning guide.

Web sites

Video or audio cassettes



Safety

Workplace health and safety (WHS) requirements need to be observed in accordance with legislation.

You need to know the WHS laws governing your job. Revision of CPCPCM2043A – Carry out WHS

requirements, before commencing this unit is advisable.

In any work situation you can reduce the risk of injury to yourself and others by using appropriate

personal protective equipment (PPE). The types of PPE that you will need include:

• overalls – used for the protection of the installer when working in different conditions

• boots – it is recommended that soft soled footwear is worn while working on roofs, as deep

grooved footwear pick up small stones and debris that might damage or scratch the roof sheets

• safety glasses or goggles to protect the eyes from injury when cutting the sheets with a power

saw

• ear plugs or muffs to protect the installer’s hearing from excessive noise

• dust masks or respirators to protect the user from breathing in dust or fine particles when

cutting the sheets with a power saw

• gloves, for the protection of the installer’s hands when working with different types of pipes,

tools and equipment.

Workplace environment and safety

Handling of materials Manual lifting and handling techniques must always be followed

according to WHS requirements. You should move materials into

position by hand where possible. Excessive manual handling should be

avoided and cranes and other mechanical lifting devices should be

employed when necessary.

Limited height scaffolds

and elevating work

platforms (EWP)

Operators must ensure they are familiar with all operating procedures

detailed by manufacturers in the elevated working platforms operators’

manual. Personal protective equipment must be worn at all times by the

person working in the basket of the EWP. This consists of safety

harnesses, safety helmets, rubber soled shoes, safety vests and suitable

clothing.



Introduction

In this unit you will look at installing LP gas cylinders with a capacity exceeding 500 litres and less

than 8 KL.

An installation may consist of a single 1 kilolitre tank supplying a villa or small industrial situation to

an 8 kilolitre tank installed in a large industrial complex and supplying gas in the gaseous or liquid

state to the appliances.

A tank may also be used to store LP gas for reticulation in areas that have no access to natural gas.

On successful completion of this unit and using the Australian Standards, AS/NZS1596 and (relevant

version) AS/NZS5601 you should be able to install bulk LP gas systems with a capacity up to 8

kilolitres and select the correct regulator to provide the required pressures and flow.

Before you can plan and install LP gas cylinders there are a number of issues that you must know

about. These include:

• properties of LP gas

• combustion principles

• pressure and flow rates

• electrical safety

• gas safety.

Properties of LP gas

Product name: Commercial propane or butane

Hazchem code: 2WE UN No 1978

Dangerous goods class: 2.1 (Flammable gas)



Physical data

Appearance Colourless, odourless, hydrocarbon gas, stored liquefied

under pressure, to which a distinctive odour, ethyl

mercaptan, is added

Heat value 96 megaJoules (mJ) per cubic metre of gas vapour

mJ per litre 25 mJ per litre of liquid gas

Boiling point Propane – 42° C

Butane – 0°C

Vapour pressure Dependant on ambient temperature.

740 kPa @ 15°C to < 1530 kPa @ 40°C

Expansion rate Propane = 0.00300% per degree temperature rise

Water = 0.00015% per degree temperature rise

Liquid to vapour Propane: 1 litre of liquid = 275 litres of vapour

Butane: 1 Litre of liquid = 235 litres of vapour

Ingredients Propane or butane and both may contain propylene and

ethane

Vapour density Weight of propane / Weight of air = 1.5 to 1

Weight of butane / Weight of air = 2 to 1

Specific gravity Weight of propane / Weight of water = 0.51 to 1

Weight of butane / Weight of water = 0.57 to 1

Health data

Threshold limit value 1000 ppm (TWA)

1250 ppm (STEL)

Eye contact Causes frostbite or burn

Inhalation Causes dizziness, drowsiness, suffocation

Ingestion N/A

Skin contact Liquid causes frostbite or burns



Reactivity data

Stability Keep in cool area, not exposed to high temperature

Incompatibility Avoid ignition sources, oxidising agents

From all of this the following characteristics of LP gas are evident.

• LP gas is flammable, heavier than air and colourless.

• Sufficient odorising agent is added to ensure that it can be detected by smell at a concentration

in air of one fifth of the LEL (lower explosive limit).

• LP gas is considered to be non toxic, but may have some anaesthetic effect if inhaled in large

concentrations. Where high concentrations of gas exist there is likely to be a deficiency of

oxygen, with a high risk of asphyxiation.

• Although LP gas exists in the vapour state under normal atmospheric temperature and pressure

conditions, it can be readily liquefied by:

− reducing the temperature

− applying pressure

− both reducing temperature and applying pressure.

• It is distributed and stored largely in a liquid state. When released from a container at any

temperature above its boiling point it will change from a liquid to a gas.

• If vapour is withdrawn rapidly from a container, the container will chill and the pressure will

drop because of the lower temperature of the remaining liquid.

Combustion principles

Combustion is the technical term for the action or the process of burning. Combustion takes place

when any oxidisable substance in sufficient oxygen, is heated to a point known as ignition

temperature. Once the ignition temperature is reached, heat from the resultant chemical reaction is

enough to maintain combustion. Various substances have different ignition temperatures. Propane has

an ignition temperature between 510°C – 580°C.



The fire triangle

Combustion requires three different products to survive.

Fuel triangle

Remove one side of the triangle and combustion ceases.

Complete combustion

Substances can be completely or partially burnt. Fuel gas is safely and most economically used when

complete combustion takes place.

To achieve complete combustion the gas requires a plentiful supply of uncontaminated air. To support

complete combustion of 1 m3 of propane, 24 m3 of air is required. When gases are burned the products

of complete combustion contain:

• carbon dioxide

• water vapour

• nitrogen

• heat

• oxides of nitrogen

• traces of aldehydes.

Example

Propane C3H8

To burn one cubic metre of LP gas, the ratio required is:

• oxygen – 5.00 cubic metres

• air – 23.80 cubic metres

Products of combustion per kilogram

• CO2 – 3 m3

• H2O – 4 m3



Pressure and flow rates

As previously indicated the vapour pressure for LP gas in tanks varies between

0 kPa at –42°C and 1530 kPa at 40°C.

The wide pressure range creates some problems when supplying LP gas to appliances that require set

pressures and flow rates to achieve designed outputs.

The gas stored under pressure in a liquid state is prevented from boiling off the surface of the liquid by

the pressure in the tank. To achieve a gas flow all that is required is to open a gas control tap and the

resultant drop in vapour pressure will allow the gas to boil off the surface of the liquid.

Remember, this can only take place when the ambient temperature is above –42°C.

The flow of gas and the available pressure is controlled by several important factors.

Liquid temperature and wetted surface

To vapourise a gas load of 1000 mJ at 5°C, a tank with a minimum wetted surface area of 1.56 m2

would be required (calculated using Kleenheat Gas Sizing Calculator).

The number of 45 kg cylinders needed to vapourise a gas load of 500 mJ at various temperatures is

shown on the chart below.

• 0 degrees – seven cylinders

• 5 degrees – six cylinders

• 10 degrees – five cylinders.

In situations where demand is very high, the LP gas may be supplied from the storage tank to the

burner in its liquid state.

The type and size of regulator selected

The regulator is truly the heart of an LP gas installation. As such it must compensate for pressures

from as low as 50 kPa up to 1600 kPa and still deliver a steady flow of gas at the required pressure

under varying temperature conditions. It also needs to cope with intermittent and continuous appliance

usage.

Gas delivery systems

Gas delivery systems are divided into two types, single stage and two stage.

Single stage

Using one regulator may perform adequately under most domestic installation requirements, but is

restricted to supplying gas at one pressure only, usually

2.75 kPa, and can be subject to pressure fluctuations of up to 1 kPa.



Second stage regulators

Note

A single stage regulator cannot be used as a second stage

regulator in a two stage system.

Two stage

A first stage high pressure regulator at the tank compensates for varied inlet pressures. A second stage

regulator located at the building or at the appliance delivers low and constant pressure to the

appliances.

The pipe from the first stage regulator to the second stage regulator is much smaller in size due to the

higher operating pressure.



First stage regulator

First stage regulator



Second stage regulator

The size of consumer piping

Safety, economy and ease of installation should be considered when selecting the materials for

consumer piping. Planning should ensure long lengths of piping are avoided to reduce pressure loss in

the system. The allowable pressure loss in a single stage LP gas system is a maximum of 0.25 kPa.

Copper consumer piping between the tank control valve and the first stage regulator is:

• copper tube to AS 1572, alloy designation 122 to AS2783 with a minimum wall thickness of

1.22 mm and a nominal size of 6 mm

OR

• non-metallic hose assembly with an excess flow valve fitted immediately upstream of the

hose.

The size of consumer piping is selected taking into account:

• the design gas load

• pipe materials

• pipe length

• operating pressure

• an allowance for future additions to the system.



First stage consumer piping operating at pressures between 35 and 140 kPa generally have a smaller

diameter. Pressure losses in this section are only restricted by noise generated by the gas flow in the

pipe.

The higher the pressure the greater the pressure loss and greater the noise generated.

A typical chart for sizing LP gas systems operating at 140 kPa is provided below. For a full listing of

tables refer to (relevant version) AS/NZS5601.

Note

For low pressure pipe sizing tables refer to (relevant version)

AS/NZS5601: Appendix F.



LP gas sizing tables

Flow of LP gas (140 kPa) in mJ/hr through copper pipe

Pressure drop in kPa

14 14 14 14 14 14 14

Nominal pipe size (mm) 10 15 20 25 32 40 50

Length of pipe (m)

mJ/hr

10 548 1328 3786 8255 15506 25642 55771

12 500 1212 3456 7536 14155 23406 50912

14 483 1122 3200 6977 13105 21672 47135

16 433 1050 2992 6525 12258 20272 44091

18 408 990 2822 6153 11557 19113 41569

20 387 939 2677 5837 10964 18132 39436

25 346 840 2395 5221 9807 16218 35273

30 316 767 2186 4766 8952 14805 32199

35 292 710 2023 4412 8228 13706 29811

40 274 664 1893 4127 7753 12821 27885

45 285 626 1785 3891 7309 12088 26291

50 245 584 1693 3692 6934 11468 24842

60 224 542 1546 3370 6330 10468 22768

70 207 502 1431 3120 5861 9692 21080

80 194 469 1339 2918 5482 9066 18718

90 183 443 1262 2752 5169 8547 18540

100 173 420 1197 2610 4903 8109 17636

120 158 383 1093 2383 4476 7402 16100



Electrical safety

Some work situations are more electrically hazardous than others, such as beneath floors or in ceilings,

or where moisture is present.

Avoid placing yourself in a position where you may become part of an electrical circuit. Confined

spaces increase the risk of electrocution.

Working beneath floor

When you lie on the ground you make a good electrical contact with earth. If possible touch only one

metal object at a time (after you have tested them).

Working beneath ceiling

Be wary when contacting any metal, particularly piping or electrical conduits – they may be

electrically live.

Wear good quality footwear and clothing and keep dry to limit current passing through you to

maintain a safe level of insulation.



Electrical testing equipment

An electrical test must be carried out before working on appliances, consumer piping, etc to determine

if stray electrical voltage is present and to ensure power is effectively isolated.

There is a range of equipment available for the testing of this stray current. Stray current is that which

has left the conductor that is supposed to be carrying it, instead using an alternative route, eg appliance

body, to return to its source.

With this range of test equipment comes a variety of features, accuracy and of course, costs. They

include neon test pencils, test lamps, solenoid operated testers, steinel volt sticks and multimeters.

No matter which one you choose, unless they are tested often, prior to and following the test procedure

they may not be giving you the correct reading.

The neon tester has been the instrument most used by plumbers, probably due to the low cost and

limited electrical knowledge required to use them. They do have limitations, although fortunately in a

fail-safe way.

Neon tester

Warning

On no account should a person fitted with a heart pacemaker

device use a neon tester.

When using the neon tester, it is essential to ensure the probe end of the tester makes a good contact

with a bare metal surface. If the neon tube glows when your finger is depressing the button or making

contact with the brass end, it indicates electrical voltage is present and precautions must be taken.

Safety action

If undesirable electrical current is detected, immediately prevent any person from coming into contact

with the hazard. Isolate the power if possible and inform the consumer. Contact the appropriate

authority and do not carry out the intended work until the fault is rectified.



Care of the neon tester

The neon tester is a testing instrument not a tool. Care must be taken with the neon tester if it is to be

relied upon to warn of potential electrical hazards.

• Test it regularly at a reliable 240 V source.

• Check it for visual damage or cracks.

• Keep it dry and clean at all times.

• Do not use it as a screwdriver.

• Carry or store it where it will not be damaged.

Note

Care should be taken to see that the neon tester is of the correct

voltage range for the application, eg 12 Volt or

110 V – 500 V.

Note

When using outdoors or in a well lit area, extra care with

shading the handle may be necessary to see the glow of the

neon.

Bonding straps

Bonding straps provide a temporary electrical path and must be attached before work commences.

Bonding straps must be fitted whenever any of the following work is done:

• cutting or disconnecting consumer piping

• disconnecting appliances or changing gas controls

• cutting or disconnecting water service lines

• connecting or disconnecting gas or water meters.

Before cutting or disconnecting any piping or fixtures, a testing device (neon tester, voltstick, steinel

etc) should always be used in conjunction with bonding straps.



If the testing device indicates that there is no electrical current present, bonding straps should be

connected across the site of the intended break.

Typical bonding straps

Make sure that rust or paint is removed first to enable good electrical contact to be made by both the

tester and the straps. Once the break is made, each end of the bonding strap should be removed

carefully (one at a time) and tested for being live and replaced.

Remember that bonding straps could be carrying an electrical current when attached to an installation.

No exposed part of the clamps should be touched and the bonding strap should be given the same

respect as a live cable. Special care must be taken if using car jumper leads as bonding straps because

the jaws are not insulated.

Never attach or remove bonding straps where gas may be present, as electrical sparking may occur and

ignite the gas with explosive results! Always ensure that meters are capped and that the area is well

ventilated.

Power point safety tester

Electrically connected gas appliances may become hazardous when connected to faulty power points.

The use of a power point safety tester will detect the most commonly encountered faults in power

points and must be used:

• whenever an appliance safety check is carried out

• prior to commencing any work where a power point is being used.

Some modern appliances using electronic components may be either damaged or will not function if

the polarity of the power supply is incorrect, ie active and neutral swapped around.

The two common types of power point testers are:

• a fully moulded and sealed 3 pin plug with green and orange neons

• a plastic, two piece 3 pin tester with red, amber and green neons.



Fully moulded tester Two piece tester

Procedure for using either power point safety tester

• Turn the power point off.

• Plug the Tester in.

• Observe the light in both the switched off and the switched on positions.

• Compare the lights to the power point safety tester manufacturer’s reference.

Note

If any lights illuminate in the off position the power point safety

tester is unsafe and must be checked by a licensed electrician.

Each of the testers mentioned will indicate the condition of the power supply as being available,

having the correct polarity and that it has an earth.

The two piece tester uses the combination of three lights to do this and more. The moulded one uses a

green light to indicate the presence of power and a fast or slow flashing orange neon indicating

missing earth or incorrect polarity.

The tester will not detect the following:

• high resistance earth faults

• combination of faults.

Safety action

If the power point is defective, do not carry out the intended work unless an alternative and safe power

point can be used. Inform the consumer of the hazard and contact the appropriate authority of the fault.

Reverse polarity

As mentioned earlier, reverse polarity occurs when the active and neutral wires are reversed. This

means that when the switch at the general power outlet is turned off, the cables to and from the

appliance, including the appliance itself, are still live. Any attempt to service the appliance could

prove fatal. By using neon testers, bonding straps and power point tester you will greatly reduce the

likelihood of becoming a statistic.



Gas safety

The installation of LP gas storage and distribution systems has inherent dangers that must be provided

to protect personnel and property. Personal safety should be a priority for every person involved in the

LP gas industry.

Protection for individuals requires the use of the correct personnel protective equipment (PPE).

Examples of PPE are:

• ASA approved safety glasses

• gloves to protect from cold burns (i.e. frostbite)

• overalls in good condition

• safety boots.

Note

Due to the low LEL of LP gas, and its tendency to gravitate to

low lying areas, any source of ignition must be kept a safe

distance from any potential source of gas. The requirements of

(relevant version) AS/NZS5601 must be strictly adhered to.

Regulations

When installing gas cylinders you must observe the regulatory as well as any WHS requirements.

Your trainer or supervisor will provide you with a copy of (relevant version) AS/NZS5601 and

AS/NZS1596 which govern the installation and operation of LP gas cylinders.

The Australian Standard for gas installations is (relevant version) AS/NZS5601. In relation to this unit

it covers the areas of:

• general work and safety requirements

• approved materials and components

• installation of consumer piping

• LP gas systems (refers the cylinder or tank installation to (relevant version) AS/NZS5601)

• purging of consumer piping

• testing of consumer piping.

The Australian Standard for storage and handling of LP gas, AS/NZS1596, provides the minimum

requirements for the following.



Minor storage and usage

• precautions for minor storage

• additional requirements for cylinders in restaurants

• requirements for LP gas cylinders on trolleys, with oxygen cylinders

• total capacity of non-refillable containers stored indoors

• cylinder use.

Components for tank systems

Deals with tank design and construction, control of gas outflow, approved safety valves and other

valves, accessories, piping and vapourisers.

Tank system installation

Covers location of tanks and all installation requirements including foundations, supports, tank

separation, fire protection, filling and emergency shutdown. Also covered in this area are components

of the system, and safety relief discharges.

WHS requirements for lighting, access, hazard identification (marking and notices) and the

requirements for security, ladders, steps and platforms are also included in this section.

Underground tank installations

Covering corrosion control, location and installation, access, protection, fittings, accessories and

safety relief discharges.

Cylinder and cylinder systems

Provides for the design and construction of cylinder installations and for their use to supply LP gas

either directly from a cylinder to an appliance or from single or multiple cylinders through a piping

system for use away from the cylinders.



Automotive filling installations

Specific requirements for a variety of types of installation for vehicle refuelling of LP gas for vehicles

of any type.

The other sections of the standard describe procedures for the filling of cylinders, operation and

upkeep of LP gas installations, fire risk assessment and general fire safety.

The following list of appendices need to be referred to and followed to facilitate completion of the

installation to the required standard.

• List of reference documents.

• Tank or cylinder fill level.

• Markings signs and notices.

• Discharge capacity of safety valves.

• Tank and cylinder location.

• Identification of liquid and vapour lines.

• Leakage testing of pipe work.

• Hazardous areas.

• Emergency plans.

• Motor vehicle refuelling.

• Fire exposure protection.

• Driver instruction signs.

• Scope of Australian/New Zealand Standard 1596.



Quality assurance

Most companies these days have a policy for assuring quality to the customer. This policy is designed

to control the processes used within the company, record keeping, quality of materials used and the

way the work is done, which includes handling procedures.

You need to be aware of your company’s particular quality assurance requirements. A number of

quality assurance issues are dealt with in the next section ‘Plan work activities’.

Worksheet

Now go to the Worksheet and answer Questions 3 – 7.



Plan work activities

Before you begin to plan installation of LP gas cylinders you need to obtain the plans or specifications

or design drawings for the job and information from the local authorities. Some of this may be

available from your job supervisor. Before beginning any work, you need to obtain work notices and

submit them to the relevant authorities.

To plan the installation of LP gas cylinders you need to gather together information from a number of

sources. The table below shows some information sources and the type of information each source can

provide.

Source of information

The information provided

Authorities Location of existing services

Plans or specification Location of installation

Design drawing Gas load or design requirements

Regulatory requirements Work notices

Manufacturers’

specifications

Details of tank installation requirements, general

specifications, flow rates, pressure limitations of

vapour and liquid regulators and associated equipment.

Site inspection Information required to plan the project

Site supervisor Controls the work schedule or progress

AS/NZS1596 Standards for LP gas storage and handling

Job specifications are developed during the planning stage of an installation and take into account:

• the type of work to be performed

• time frame

• when various phases of the works will be performed to complete the works

• where the installation fits into the overall project

• what is to be installed?

Specifications vary. Some may be detailed to the point of listing every component required and its

location within the project. Others may be general indicating only the location for the installation and

basic measurements.



Job specifications are usually prepared by designers and architects. They require close scrutiny by the

plumber to ensure all aspects of the work comply with the regulations before commencing work and

on completion, before issuing the certificate of compliance.

Note

The licensed plumber is ultimately responsible for compliance.

Workplace health and safety

You need to consider how the task you are about to do affects others. You should plan the task with

the others involved or affected by the work. Your company may have procedures regarding this, and

you will need to take these into account.

Large LP gas tank installations will require large vehicles to transport the tank on to the site and a

crane to unload and position the tank in place. Access for the equipment is vital and planning with

other trades will be required to eliminate problems and job delays.

Safety for personnel may require barricades and detours. Sources of ignition and any potential source

of ignition must be kept from clearly defined areas. Only qualified persons may operate some types of

machinery, eg cranes, excavators etc.

Some tanks already have LP gas in them when they are delivered on site or may contain gas vapour.

During this stage you will need to have and use various personal protective equipment (PPE) to

protect yourself, which may include the following:

Protective gloves Cold resistant gloves which are impervious to oil should

be worn when using this product. Gloves made of PVC

are preferred, although gloves made of nitrite and

chloroprene should also be satisfactory. Any such gloves

should comply with AS/NZS2161.

Safety glasses Eye protection is required (face shield, chemical safety

glasses or side shield glasses) where splashing is likely.

Eye protection should comply with AS/NZS1336/1337.

Boots, overalls Safety boots to AS1234 and overalls to protect the body

and feet.

Hard hat To AS1234 to protect the head from injury.

Dust protection Dust mask.



Respiratory protection If ventilation of the area is not sufficient, respiratory

protection complying with AS/NZS1715/1716 should be

provided.

Hearing protection Approved earmuffs or ear plugs complying with AS1234

should be worn to protect hearing.

Welding shields Correct shields for oxy and arc welding.

Note

PPE should be worn as a matter or course and not worn only

when safety audits are made.

Tools and equipment

To complete this stage you will need a range of hand and power tools and equipment. These could

include:

• general plumbers hand tool kit:

− pipe dies and pipe cutters for cutting and threading pipes

− power drill

− measuring tape

• shovel, pick, crowbar, sledge hammer

• oxy acetylene kit

• arc welder

• wheel barrow

• levelling equipment

• approved gas testing equipment

• ladder

• silver brazing equipment.



The following manual handling and lifting equipment may be required when installing LP gas storage

systems.

Mobile crane Chosen to suit the size and weight of the tank.

Forklift May be required to relocate the tank after delivery.

Jacks For lifting and final levelling of tank.

Rollers May assist in moving smaller tanks.

Hoists For safe lifting of materials, tools and personnel.

Chain blocks Lifting heavy equipment.

Low level scaffold For safe high level work platforms.

Hand trolleys To move light portable equipment.



Determine installation requirements

Before you can install LP gas cylinders – aggregate storage capacity exceeding

500 litres and less than 8 KL, you must be able to understand and state the gas or load requirements of

the system.

Determining gas load

The gas load requirements need to be determined from the design drawing and any other given or

available information. You can determine gas load requirements by adding together the mJ rate of

each appliance shown on the drawings. This will give you the total Mega Joule input per hour

Note

You may be required to provide for future extension to the

system.

Example

Appliances Input

Staff canteen / 3 appliances 134 mJ input

Boiler 900 mJ input

Furnaces 845 mJ input

Total Mega Joule input 1879 mJ

Calculating storage capacity

The storage capacity selected must be adequate for the load details given in the design instruction.

The storage capacity of the LP gas tank may be calculated using the information determined from the

gas load and the average burner on time for the installation.



Example

Total input = 1879 mJ divide by 26.6 mJ per litre

= 70.6 litres of gas per hour

Litres per hour by burner on time (say 12 hours x 6 days weekly)

= 81.2 litres x 12 hours x 6 days

= 5086 litres per week

= 5.086 m3 of gas used per week

Therefore an 8 kilolitre tank would require filling on a weekly basis.

Tanks may also be sized using charts provided by manufacturers of LP gas equipment.

Calculating regulator size and connections

Manufacturers of LP gas equipment provide information by way of manuals and charts. These are

readily available to the plumber for use when selecting regulators for use in the domestic and

industrial or commercial arena.

Most of this information originates in America, so conversion from imperial to metric measurements

must be made by the plumber.

BTU = British Thermal Units

mJ = MegaJoules

Conversion from imperial to metric:

• 1000 BTUs = 1.055 mJ

Example

450,000 BTUs divide by 1055 = 426.54 mJ

1,000,000 BTUs divide by 1055 = 947.87 mJ

Note

Regulator selection charts are readily available from gas

equipment companies such as REGO, and CEM who distribute

FISHER, SHERWOOD and MARSHALL regulators.



An example of a selection chart from REGO is shown below

Type of system Maximum load mJ/hr

Suggested regulator

First stage in a two stage

system

474 mJ LV2302TR

2370 mJ LV4403SR Series

LV4403TR Series

Second stage in a two

stage system

886 mJ LV4403B Series

1516 mJ LV5503B4/B6/B9

2180 mJ LV5503B8

Integral twin stage 190 mJ LV404B23 Series

498 mJ LV404B4 Series

LV404B9 Series

Automatic changeover 171 mJ 7523B23 Series

474 mJ 7523B4 Series

Other information that must be available to allow selection from the above list of regulators is:

• the intended operating pressure of all regulators

• the operating pressure of each appliance burner

• tank pressure available relating to the lowest probable winter temperature

• two stage or single stage system

• manual (supplied by the manufacturer of the regulator) detailing the exact process for

selecting the appropriate regulator or regulators

• the total gas load imposed on the system in megajoules per hour.

Note

The chart from which the regulator is selected will provide you

with the inlet and outlet sizes for pipe connections.



Remember

You must still size the consumer piping as per (relevant

version) AS/NZS5601.

Checking the location

The selected location of the installation must be appropriate for the details given in the design

instruction, must comply with (relevant version) AS/NZS5601 - Gas Installations and AS/NZS1596.

The following table shows the points you need to take into account when determining the location for

LP gas tanks.

Location of above ground storage tanks

1 2 3 4

Capacity of

the tank

(KL)

Minimum distance to

an adjacent LP gas

tank (m)

Minimum distance from the

tank to a public place, or

railway line (m)

Minimum distance

from the tank to a

protected place (m)

Under 0.5 Nil* Nil*

0.5 1.5 1.5

1 Diameter of the

larger tank

2 3

2 4(3) 6(4.5)

5 5(3.5) 8(5)

8 6(4) 10(6)

Note

Distances in brackets are alternatives, which are permissible

only for a single tank used only for vapour withdrawal. A tank,

which has no other tank within 8 m of it, may be treated as a

single tank, subject to AS/NZS1596.



Tank locations

Determining materials, cylinders and components

Materials, cylinders and components must comply with (relevant version) AS/NZS5601 - Gas

Installations and AS/NZS1596. The quantity of materials will be determined from the design

instruction.

Once the major materials and components have been determined, all materials need to be ordered to

complete the installation.

Some companies use pre-prepared stationery to submit an order to their supplier. Others may fax or

phone in their orders and some drive in and collect the required materials. Whichever method you use

it can be costly to omit any materials needed and may lead to unwanted down time for workers.

Double check all material lists before placing your order.

On arrival you need to check the materials and components to ensure that they are of the amounts and

standard required, and have been delivered in acceptable condition.

Carefully checking each item delivered against a copy of the materials order ensures that the materials

delivered:

• comply with the relevant standards

• have not been damaged in transit

• are correct as per your order.



Install and test the storage system

Installing the regulator and pipework

Before installing the LP gas pressure regulator, it must meet the requirements of (relevant version)

AS/NZS5601.

The installation of the regulator must comply with the following:

• any first stage regulator shall be outdoors except where the regulator is attached to a cylinder

that is permitted to be used indoors

• single stage and second stage regulators shall be installed in accordance with (relevant

version) AS/NZS5601.

• a single stage regulator or the first stage of a multi-stage regulator shall be located so that the

length of piping which is subject to cylinder or tank pressure is as short as practicable.

• for exchange cylinder installations the piping subject to cylinder pressure is limited to 1 m

(relevant version) (AS/NZS5601)

• thread sealant or any other sealing material shall not be used on a union, flared compression

joint or POL connection to a cylinder valve (relevant version) (AS/NZS5601).

Typical installation layout

Note

Consumer piping must be installed to meet the requirements of

(relevant version) AS/NZS5601 – Installing consumer piping,

and the materials must comply with (relevant version)

AS/NZS5601 – Materials and components.

The (relevant version) AS/NZS5601 standard gives specific details as to the design and sizing of

single stage LP gas installations. Also covered is the required identification marking for LP gas pipe

work.



Marking of LP gas pipeline

Adjusting the regulator

Manufacturer’s instructions that accompany the selected regulator detail the method for adjusting the

required flow rates and pressure settings. You should use the approved equipment detailed in the

testing and reporting section of these notes.

Testing the installation and reporting

Following the completion of the installation you will need to test the installation.



Selecting test equipment

Test procedures for installations with appliances connected, and installations where appliances have

not yet been installed can be found along with approved test equipment in (relevant version)

AS/NZS5601. Where test pressure is to exceed 400kPa the technical regulator is to be contacted for

testing requirements.

You need to test downstream of a manual shut-off valve.

The piping, components, equipment and valve train down stream of an appliance manual shut-off

valve are to be gas tight when tested at operating pressure

Test LP gas upstream of a first stage regulator.

The pipe, fittings and joints between a LP gas tank not exceeding 8 KL (8 m3) or a cylinder and a first

stage regulator are to be checked for leakage at tank or cylinder pressure using a soap and water

solution or other suitable leakage detection method.

Note

Matches, candles and any other ignition source shall not be used

as per (relevant version) AS/NZS5601.

Note

Be extremely careful when testing gas lines that will operate at

high pressures. The test pressures used can be a serious health

risk due to sudden discharges. These discharges could inject an

air embolism under the skin or cause serious eye injury.

Recording

On completion of the required tests it is good practice to record the test pressures and test duration in a

diary or in the job file along with photos of the installation taken during construction and on

completion.

Worksheet

Now go to the Worksheet and answer Questions 8 – 11.



Clean up

Cleaning up the work site is not just a matter of appearance; it also concerns safety and health issues.

It is good work practice to clean up as you go. Building sites are always short of space and build up of

debris will only add to storage, health and safety issues. Most sites will have a site safety committee

policy on cleaning up the work site, however you should consider the following on any worksite.

• The work site must be cleared of debris. The disposal areas for site debris should be identified

at the site induction. If not, find out from your trainer or supervisor.

• Clean up as you go if possible, but at least on a daily and weekly basis and on completion of

an installation.

• Food and drink waste, wrappers and containers should be disposed of in the correct bin

immediately after use as build up attracts vermin and associated health risks.

• Packaging debris should not be allowed to become a tripping or other hazard. Dispose of it in

the correct bin as soon as practicable.

• Off cuts and surplus material that may be used later in the job should be held in a safe storage

area until required.

• Off cuts and surplus material that is not suitable for re-use should be disposed of in the correct

bin at the end of each days’ work or sooner if practicable.

• Do not use cupboards, empty rooms or corners to store rubbish and debris.

• On completion of an installation check the whole of the work area. Remove materials to the

store, tools and equipment to the correct location and rubbish and debris to the correct bins.

• Sweep the completed work area clean and correctly dispose of sweepings.



Name:……………………………………………………………

Worksheet

CPCPGS3060A – Install LPG storage of aggregate storage capacity exceeding 500 litres and less than 8 KL

The student should complete this worksheet before attempting the practical installation.

The worksheet may form part of the assessment and should be checked and signed off by your trainer

or supervisor.

1. Name the gas properties of propane/butane.

a) Appearance

b) Vapour pressure

c) Liquid to vapour

(i) Propane

(ii) Butane

2. Name three undesirable effects of incomplete combustion.



3. Name two types of regulators.

4. What is required to minimise electrical current passing through your body when working

beneath ceilings or floors?

5. Name two (2) types of electrical testing equipment.

6. List the procedure for using a power point safety tester.

7. State which section of AS/NZS1596 covers automotive installations and list three appendices

that need to be referred to.

(a)

(b)

(c)



8. List four sources of information and the type of information they provide.

Source of information Information provided

9. List three specific types of PPE you will need to use in installing LP gas cylinders.

(a)

(b)

(c)

10. Describe how you determine the gas load requirements of an installation.

11. State what must not be used for testing as an ignition source.

Trainer or Supervisor’s Signature:…………………………………….

Date of Completion:…………………………….



Name:……………………………………………………

Practical application

CPCPGS3060A – Install LPG storage of aggregate storage capacity exceeding 500 litres and less than 8 KL

Your trainer or supervisor will now work with you to demonstrate and explain how to install LP gas

cylinders – aggregate storage capacity exceeding 500 litres and less than 8 KL.

The following points will be covered.

Building plans or specifications and any special instructions are obtained

WHS requirements associated with the installation of LP gas storage facilities, and the

workplace environment, are adhered to throughout the work

Quality assurance requirements for company operations are identified and adhered to

Gas load or design requirements are determined from plans or specifications or job drawing

or workplace instructions

Storage capacity is calculated in compliance with regulatory authority and workplace

requirements, ensuring adequacy to meet load details

Regulator size and the size of connections to cylinders are determined to meet the capacity

and load of the system in accordance with workplace requirements

Appropriateness of the selected location to provide the required service is established in

conformance with standards, design instruction and workplace requirements

Quantity of cylinders and materials required is estimated from design instruction and selected

to comply with standards and authorities’ requirements

The required materials and equipment are ordered and checked for compliance with docker

or order form and for acceptable condition

Appropriate tools and equipment for the installation of the storage facility, including personal

protective equipment, are identified, selected and checked for serviceability

Appropriate testing apparatus is selected

Work is planned in conjunction with others involved in, or affected by, the work

Work area and materials are prepared to support the efficient installation of the system

LPG cylinders or tank, piping, fittings and components are installed in conformance with

standards and workplace requirements

Regulator and associated pipework is installed in compliance with standards and workplace

requirements

Regulator is adjusted to provide flow pressure in conformance with standards and workplace

requirements



System is purged in accordance with standards

System is tested in conformance with standards and workplace requirements

Test equipment is removed and test data is recorded in the format required by regulatory

authority and workplace requirements

Work area is cleared and materials disposed of or recycled in accordance with State or

Territory legislation and workplace procedures

Tools and equipment are cleaned, checked, maintained and stored in accordance with

manufacturers’ recommendations and workplace procedures

Documentation is completed in accordance with workplace requirements

Relevant authorities or supervisors are advised of job completion in conformance to

regulatory requirements and workplace requirements

On completion of this practical application you will be assessed. To prepare for your assessment make

sure you read the Assessment checklist, the Assessment task and Questions.

Trainer or Supervisor’s Signature:……………………………………………….

Date of Completion:…………………………………



Assessment checklist

CPCPGS3060A Install LPG storage of aggregate storage capacity exceeding 500 litres and less than 8 KL

Criteria Yes No

Have the worksheets been successfully completed?

Has the practical task been completed?

Are the job specification and local authorities or utilities requirements

available?

Trainer or Supervisor’s signature:………………………………………

Date of completion:………………………….

Documents

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