© commonwealth of australia 2 -...
TRANSCRIPT
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
CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL
© 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.
CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL
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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
CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL
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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
CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL
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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 8KL
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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
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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
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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
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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
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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.
CPCPGS3060A - INSTALL LPG STORAGE OF AGGREGATE STORAGE CAPACITY EXCEEDING 500 LITRES AND LESS THAN 8KL
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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)
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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
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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.
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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
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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.
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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.
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First stage regulator
First stage regulator
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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)
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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:…………………………….
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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
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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:…………………………………
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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:………………………….