Propane

5.
Designing & Installing Dispenser Transfer Systems
PRC 004225
All rights reserved. No part of this text may be reproduced or utilized in any form without permission in writing. 2008 Propane Education and Research Council
NOTICE AND DISCLAIMER CONCERNING LIABILITY

The Propane Education and Research Council (PERC) is a non-profit 501 (c) 6 trade organization authorized by the Propane Education and Research Act of 1996 (PERA), Public Law 104-284. PERC was created to enhance consumer and employee safety and training, to provide for research and development of clean and efficient propane utilization equipment, and to inform and educate the public about safety and other issues associated with the use of propane. PERC is governed by a twenty-one member Board of Directors appointed by the National Propane Gas Association (NPGA) and the Gas Processors Association (GPA). PERC program beneficiaries include propane retail marketers, producers, transporters and agricultural cooperatives, as well as representatives of allied service and supply industries (industry members). The recommendations, standards, or recommended practices, as reflected in this document, were developed by independent consultants retained by PERC. While PERC administers the process of obtaining the information, it does not independently test or verify the accuracy of the information or methods used to collect the data that supports the conclusions or recommendations reflected in this document. PERC, NPGA, GPA and the industry members disclaim any liability for any personal injury, property damage, business losses or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use, or reliance on this document, or any information, apparatus, method, process, or similar item disclosed in this document. This disclaimer of liability shall apply even if such loss or damage results, in whole or in part, from any acts or omissions of or by any negligence on the part of PERC, NPGA, GPA or industry members or any persons who contributed to the development of the information contained in this document. PERC, NPGA, GPA and industry members make no warranty or guaranty as to the accuracy or completeness of any information published in this document. By disseminating or publishing this document, PERC is not undertaking to render any professional or other service to or on behalf of any person or entity. PERC, NPGA, GPA and the industry members are not undertaking to perform any duty owed by any person or entity to any third party. Anyone reading or using this document should rely on his other own judgment or, as appropriate, should seek the advice of a competent professional in determining the exercise of reasonable care in any and all circumstances. PERC, NPGA, GPA and the industry members have no authority or power, and do not voluntarily undertake any authority, to supervise or enforce compliance with any
of the suggestions or recommendations contained in this document. Any certification or other statement of compliance with this document shall not be attributable to PERC, NPGA, GPA or the industry members and is solely the responsibility of the maker of any such statement. PERC, NPGA, GPA and the industry members, including any consultant, subcontractor, or any other party acting on behalf of either of them, do not make any warranty or representation whatsoever, express or implied, i. With respect to the use of any information, apparatus, method, process, or similar item disclosed in this document, including merchantability and fitness for a particular purpose, or ii. That such use does not infringe on or interfere with privately owned rights, including any partys intellectual property, or iii. That this document is suitable to any particular users circumstances. The material and other information included in this document are intended to provide general guidance only on the subject matter addressed by the document. It is not intended to be a substitute for the personal instruction, guidance and advice of a professional with training and experience in the safe and proper use of propane. Users of this document should consult the law of their individual jurisdictions for codes, standards and legal requirements applicable to them. This document is not intended nor should it be construed to (1) set forth policies or procedures which are the general custom or practice in the propane industry; (2) to establish the legal standards of care owed by propane distributors to their customers; or (3) to prevent the user from using different methods to implement applicable codes, standards or legal requirements.
Propane Education & Research Council 1140 Connecticut Avenue N.W., Suite 1075 Washington, DC 20036 202-452-8975 www.propanesafety.com
LEARNING AIDSThese margin notes are provided to help you identify sources, take precautions, or give guidance on your job. Warning: Important precaution that you should always remember when performing the identified task.
Symbols
Tools: This task requires special tools or procedures.
PPE: This is a task that requires personal protection equipment.
Lockout/Tagout: Lockout and Tagout procedures must be followed when performing this task.
TA
UT G! NIN AR T W NO E DO AT ER OP GO
Safety Procedure: For your safety special precautions and safety guidelines apply to this task or operation of equipment. Electrical Hazard: This task involves an electrical hazard. Lockout and Tagout procedures must be followed. Explosive/Fire Hazard: This task involves a pressurized gas, fire or explosion hazard. Use appropriate precautions. Lockout and Tagout procedures may apply.
Technical
Technical Tips: This technique may be very useful as you do a task.
Tip
The National Fire Protection Association: References to sections of the LP-Gas Codes and Standards. Refer to your companys Plant Operating & Maintenance Procedures Manual Paper Work or Forms: This task should be documented on your companys forms for compliance or legal reasons.
NFPA 54
Or
NFPA 58
O&M Procedures Manual
5.1
Designing & Installing Dispenser Transfer Systems

Page
5.1.1
Determining Dispenser Application, Operating Requirements and Proper Location Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping Identifying Dispenser Electrical System Requirements Applying Propane Pump Operating Characteristics and Selecting the Dispenser Pump Identifying Dispenser Emergency Shutdown Systems and Fire Extinguisher Requirements Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, and Adapters Identifying Auxiliary Equipment Used With Propane Dispensers Identifying Metering Systems and Maintenance Procedures For Service Station Dispensers Installing Propane Dispensers
5.1.2
17
5.1.3 5.1.4
37 47
5.1.5
59
5.1.6
67
5.1.7 5.1.8
79 91
5.1.9
125 137
5.1.10 Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons 5.1.11 Identifying Startup Procedures for New and Expanding LP-Gas Storage Facilities
145
5.1.1
Determining Dispenser Application, Operating Requirements & Proper Location
Table of Contents
Table of Contents....................................................................................................... 1 Learning Activities...................................................................................................... 2
Determining Dispenser Application Operating Requirements & Proper Location ...... 3 Identifying the Types of Containers To Be Filled at the Dispenser............................. 3 Determining the Dispenser Tank Size and Orientation .............................................. 5 Determining the Location for the Dispenser and Other Factors Affecting Dispenser Component Selection................................................................................ 7 Identifying NFPA 58 Code Separation Distances Provisions and Other Installation Requirements................................................................................. 7 Provisions for Vertical Tanks.. 9 Identifying Available Site Electrical Supply Specifications ....................................... 11 Review ..................................................................................................................... 13 Performance Criteria Self-Check ............................................................................. 15
Learning Activities Performance Objectives

1. Determining Dispenser Application, Operating Requirements & Proper Location
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning dispenser applications, operating requirements & proper location and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to dispenser applications, operating requirements & proper location. (Skills Assessment)
Read Performance Objective 1: Determining Disperser Application, Operating Requirements & Proper Location
Check your knowledge by completing the Review.
To prepare for the Certification Exam complete the Performance Criteria SelfCheck found at the end of this module.
5.1.1
To successfully plan the installation of a propane dispenser, select appropriate dispenser configuration and associated equipment, and to determine the proper location for the dispenser, it is necessary to examine the installation site and to fully understand how the dispenser will be used and operated. In this module you will learn to properly select the dispenser for a customer application by: (1) (2) (3) Identifying the types of containers to be filled at the dispenser Determining the dispenser tank size and orientation Determining the location for the dispenser and other factors affecting dispenser component selection Identifying the types of containers to be filled at the dispenser. Designing and installing a propane dispenser requires a clear determination of the functions the installation will serve. If the dispenser is installed at a marketers bulk plant it will need to be designed and equipped to fill a wide range of propane cylinders and mobile or motor fuel ASME tanks. Likewise, a dispenser installed for a customer at a recreational vehicle dealership or park may be used to fill the same range of propane containers. Single-function dispensers may be required for: an industrial truck customer filling only motor fuel cylinders, or a service station operator who needs specialized motor fuel service equipment such as motor fuel cabinet dispensers with integral meters, price and gallon sales displays and electronic metering remote sales and transaction recording equipment.
(1)
Figure 1. Vapor Cylinder & Motor Fuel Cylinders
A dispenser installation site inspection and discussion with the dispenser operator is the first step in designing and installing the dispenser.
Determining the types of propane containers that will be serviced and a good estimate of the volume of propane usage on a weekly basis will lead to a better dispenser design and installation while avoiding wasted time and expense that can arise out of poor pre-installation planning. A dispensing installation form can be used to collect and organize the required information. (Figure 2.)
Figure 2. Sample Dispensing Installation Planning Form (Front)
(2)
Determining the dispenser tank size and orientation. Propane dispensers typically use one ASME stationary tank, although more that one tank may be needed for a specific dispenser installation on a site that presents unusual tank separation distance requirements. Dispenser supply tanks may be vertical or horizontal types.
Figure 3a. Vertical Motor Fuel Dispenser With Pump & Meter Cabinet
Figure 3b. Horizontal Dispenser With Pump & Meter Cabinet Most propane dispensers operated by commercial or industrial customers typically use a 500 or 1,000-gallon water capacity tank. Selecting the proper sized tank(s) for the dispenser installation for high volume installations is crucial for cost-efficient delivery routing and reliable service. Installing the appropriate sized tank(s) is also important where local jurisdictional authority approval or Fire Safety Analysis, O& M Manual procedures and/or installation permits are required and replacing tanks later might jeopardize the installation. Selecting the appropriate sized tank(s) to supply the dispenser should be based on a thorough examination of the functions of the dispenser and the customers operations. The back page of the sample dispenser installation form shows methods for estimating propane usage. (Figure 4.)
Figure 4. Sample Dispersing Installation Planning Form (Back) (3) Determining the location for the dispenser and other factors affecting dispenser component selection. (a) Identifying NFPA 58 Code separation distances provisions and other installation requirements. ASME stationary tank separation distance requirements are listed in Table 6.3.1
NFPA 58
2008
Table 6.3.1 Separation Distances Between Containers, Important Buildings, and Other Properties
Footnote f for 501-2,000 water capacity gallon aboveground tanks refers to 6.3.3, which says: The 25-foot distance from aboveground ASME containers of 501 gallons to 2,000 gallons water capacity to buildings, a group of buildings, or the line of adjoining property that can be built upon shall be reduced to 10 feet for a single ASME container of 1200 gallons or less water capacity where such container is at least 25 feet from any other LP-Gas container of more than 125 gal water capacity. NFPA 58 limits the maximum aggregate water capacity for tanks supplying dispensing stations not located in a bulk plant or industrial plant to no more than 30,000 gallons.
Provisions for Vertical Tanks.
NFPA 58
2008
5.2.4.3 In addition to the applicable provisions for horizontal ASME containers, vertical ASME containers over 125 gallons water capacity shall comply with 5.2.4.3(A) through 5.2.4.3(E). (A) Containers shall be designed to be self-supporting without the use of guy wires and shall be designed to withstand the wind, seismic (earthquake) forces, and hydrostatic test loads anticipated at the site. (B) Maximum allowable working pressure (see Table 5.2.4.2) shall be the pressure at the top head with allowance made for increased pressure on lower shell sections and bottom head due to the static pressure of the product. (C) Wind loading on containers shall be based on wind pressures on the projected area at various height zones above ground in accordance with ASCE 7, Minimum Design Loads for Buildings and Other Structures. Wind speeds shall be based on a mean occurrence interval of 100 years. (D) Seismic loading on containers shall be in accordance with ASCE 7, Minimum Design Loads for Buildings and Other Structures. A seismic analysis of the proposed installation shall be made that meets the approval of the authority having jurisdiction. 6.6.4.1 Vertical ASME containers over 125 gallons water capacity designed for permanent installation in stationary service aboveground shall be installed on reinforced concrete or steel structural supports on reinforced concrete foundations that are designed to meet the loading provisions established in 5.2.4.3. 6.6.4.3 Steel supports shall be protected against fire exposure with a material that has a fire resistance rating of at least 2 hours, except that continuous steel skirts that have only one opening that is 18 inches or less in diameter shall have fire protection applied to the outside of the skirts.
Compliance with NFPA 58 vertical tank installation provisions generally requires: Consultation with the tank manufacturer and strictly following their prescribed installation instructions Knowing the prevailing local conditions with respect to earthquake potential and the effects of high winds Communicating these actions to the local authority having jurisdiction during pre-installation planning
The potential for seismic (earthquake) forces in a given location may be evaluated by consulting maps produced by the United States Geological Survey (USGS). (Figure 5.)
Figure 5. Probabilistic Seismic Hazard Maps, U.S. Geological Survey http://earthquake.usgs.gov/research/hazmaps/products_data/images/nshm_us02.gif
Vertical propane tank manufacturers typically provide installation instructions for their products addressing wind loads and seismic forces. If a vertical tank is used in a dispenser operation obtaining tank dimensions, including support locations and anchoring details and a foundation plan from the manufacturer is crucial for a successful installation. (Figure 5.)
10
(Support I-Beams)
Figure 6. Vertical Tank Specification Drawings & Foundation Partial Detail Warning: The foundation partial detail drawing shown in Figure 6 is not the manufacturers actual foundation plan. Obtain and use the actual foundation plan provided in the manufacturers installation instructions for the specific tank you plan to install. (c) Identifying available site electrical supply specifications. The planning and installation of electrical service to a propane dispenser should be coordinated with the installation site owner or operator and a licensed electrical contractor. The cost of the electrical system installation to serve the dispenser will depend on the following factors: 1. Is the available power supply single-phase or three-phase? Single-phase electrical systems require larger wire sizes, and generally cost more in terms of electricity monthly charges. The dispenser pump motor must be matched to the available power supply. 2. Where is the connection point to the existing power supply and are there open breaker panel slots to accommodate the dispenser? What is the distance to the dispenser pump motor and to any remote emergency shutdown switches?
11
3. Will existing electrical connections near the planned dispenser location need to be modified to meet NFPA 58 requirements for ignition source control? 4. Does the location have a history of electrical service problems due to low-voltage, brown-outs or other factors such as extremely high summer temperatures that must be considered and addressed? Information gathered to answer those questions should be recorded on the dispenser installation form for use in selecting the pump motor and electrical controls selected for the installation. As the dispenser installation planning nears completion, attention should be given to other equipment and accessories needed for dispenser operating requirements, including: Cylinder scales Liquid metering if applicable Protection from vehicular traffic Security fencing or other appropriate security measures Fire extinguisher location and emergency shutdown features Signs and tank labels Filling hose-end valves and adapters for the tanks and cylinders the dispenser will service Lighting for nighttime operations if appropriate Tank and cabinet foundations Buried piping, piping corrosion control, and remote dispensing island for service station or fleet motor fuel facilities Transfer bulkhead and ESVs for large supply tank installations
12
REVIEW:

Directions: Select from the list below the response that most correctly completes each of the following statements, writing the letter of your choice in the space provided; or complete the statement by filling in the blanks.
A. B. C. D. E.
30,000 wind, seismic (earthquake) forces, and hydrostatic test loads 2,000 types of propane containers that will be serviced 4,000 1. Determining the _____ and a good estimate of the volume of propane usage on a weekly basis will lead to a better dispenser design and installation while avoiding wasted time and expense that can arise out of poor pre-installation planning.
2.
Selecting the proper sized tank(s) for the dispenser installation for high volume installations is crucial for: a. b. c. d.
3.
NFPA 58 limits the maximum aggregate water capacity for tanks supplying dispensing stations not located in a bulk plant or industrial plant to no more than ____ gallons. According to NFPA 58, vertical tanks shall be designed to be selfsupporting without the use of guy wires and shall be designed to withstand the ____ anticipated at the site.
4.
13
Complete the statements in items 5 and 6 by filling in the blanks provided. 5. Compliance with NFPA 58 vertical tank installation provisions generally requires: a. b. c.
6.
The planning and installation of electrical service to a propane dispenser should be coordinated with the installation site owner or operator and a
14
Performance Criteria Self-Check: 5.1.1

Directions:

Use the following performance criteria statements as a self-evaluation in preparation for the final exam.
I can identify: 1. The first step in designing and installing the dispenser to avoid wasting time and the expense that can arise out of poor pre-installation planning Reasons why selecting the proper sized tank(s) for the dispenser installation is important. The basis for correctly determining the correct minimum separation distances required by NFPA 58 for dispenser installations that use more than one supply tank. The maximum aggregate water capacity limitation specified by NFPA 58 for propane dispenser supply containers not located in LP-gas bulk plants, industrial plants, or industrial applications. Design factors that must be considered for vertical tank installations according to NFPA 58. Actions generally required to comply with NFPA 58 provisions for vertical tank installations. Who should be involved in the determination of electrical power supply requirements for a dispenser installation?
2.
3.
4.
5.
6.
7.
15
16
5.1.2
Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping
Table of Contents
Table of Contents..................................................................................................... 17 Learning Activities.................................................................................................... 18 Identifying Required Dispenser Tank Valves and Fittings........................................ 19 Identifying NFPA 58 Code Requirements for ASME Tank Valves ........................... 19 Verifying Proper Specification and Protection Measures for Tank Relief Valves ..... 25 Verifying That Proper Components for the Dispenser Installation Are Provided...... 28 Filler Valve or Other Filling Systems ........................................................................ 28 Internal Valves and Excess Flow Requirements ...................................................... 29 Emergency Shutdown Systems ............................................................................... 30 Manual Valves ......................................................................................................... 31 Tank Fittings ............................................................................................................ 32 Liquid Level Gauges ................................................................................................ 32 Optional Pressure Gauge ........................................................................................ 33 Thermometer and Pressure Gauge Requirements for Larger Tanks ....................... 33 Review ..................................................................................................................... 34 Performance Criteria Self-Check ............................................................................. 36
17

1. Identifying Required Dispenser Tank Valves and Fittings
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning required dispenser tank valves and fittings and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to required dispenser tank valves and fittings. (Skills Assessment)
Read Performance Objective 1: Identifying Required Dispenser Tank Valves and Fittings
18
5.1.2
Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping
NFPA 58, LP-Gas Code, sets out the minimum valve and fitting requirements for propane tanks used to supply dispensers. In addition to the code requirements, selecting or verifying that dispenser tank valves and fittings are proper for a certain installation requires that installers also examine the application and operating requirements for the dispenser, and company operating procedures. In this module you will learn to verify that a dispenser tank is properly equipped by: (1) (2) (3) Identifying NFPA 58 code requirements for ASME tank valves & fittings Verifying proper specifications and protection measures for tank relief valves Verifying that proper components for the dispenser installation are provided, including: Filler valve or other filling systems Internal valves and excess flow requirements Emergency shutdown systems Manual valves Tank Fittings Dispenser Piping Identifying NFPA 58 code requirements for ASME tank valves and fittings.
(1)
NFPA 58
2008
1.3.2 (11) Propane dispensers located at multiple fuel refueling stations shall comply with NFPA 30A, Code for Motor Fuel Dispensing Facilities and Repair Garages. NFPA 58 definitions of propane dispensers. 3.3.20 Dispensing Station. Fixed equipment in which LP-Gas is stored and dispensed into portable containers. 3.3.77 Vehicle Fuel Dispenser. A device or system designed to transfer and measure LP-Gas into engine fuel and mobile containers on vehicles.
In most cases propane dispensers not installed at bulk plants use a 500, 1000, or up to a 1600 water gallon horizontal or vertical supply tank, and are used as both a dispensing station and a vehicle fuel dispenser.
19
NFPA 58
2008
5.7.4 Container Valves and Other Appurtenances 5.7.4.1 Containers of 2000 gal (7.6 m3) water capacity or less shall be fitted with valves and other appurtenances in accordance with Table 5.7.4.1. Shutoff, filler, check, and excess-flow valves shall comply with ANSI/UL 125, Standard for Valves for Anhydrous Ammonia and LP-Gas (Other than Safety Relief), except that shutoff valves used on DOT cylinders shall comply with UL1769, Cylinder Valves. Containers of 2001 gal through 4000 gal (7.6 m3 through 15.1 m3) water capacity in bulk plant and industrial plant service shall be fitted with valves and other appurtenances in accordance with Table 5.7.4.2. Containers of 2001 gal through 4000 gal (7.6 m3 through 15.1 m3) water capacity in other than bulk plant and industrial plant service shall be in accordance with Table 5.7.4.1. (A) The requirement for internal spring-type pressure relief valves that are shown in Table 5.7.4.1 for stationary ASME containers up to and including 4000 gal (15.2 m3) water capacity shall not apply to underground containers where external pressure relief valves are permitted or to containers that were originally equipped with external pressure relief valves. (B) Containers of 125 gal through 4000 gal (0.5 mS through 15.2 mS) water capacity shall be provided with an actuated liquid withdrawal excess-flow valve with a connection not smaller than % in. national pipe thread. (C) An actuated liquid withdrawal excess-flow valve shall not be required on container connections equipped for liquid withdrawal with a positive shutoff valve that is located as close to the container as practical in combination with an excess flow valve installed in the container connection. (D) The actuated liquid withdrawal excess-flow valve shall not be connected for continuous use unless the valve is recommended by the manufacturer for such service. (E) An overfilling prevention device shall not be required for engine fuel cylinders used on industrial (and forklift) trucks powered by LP-Gas or for engine fuel cylinders used on vehicles (including floor maintenance machines) having LPGas-powered engines mounted on them.
20
(F) Excess-flow protection shall not be required for manual shutoff valves for vapor service where an approved regulator is directly attached or attached with a flexible connector to the outlet of the manual shutoff valve for vapor service and the controlling orifice between the container contents and the shutoff valve outlet does not exceed 0/16 in. (8 mm) in diameter. (G) Overfilling prevention devices shall be required on cylinders having 4lb through 40 lb (1.8 kg through 18 kg) propane capacity for vapor service. (See 5. 7.3.) (H) Cylinders greater than 40 lb through 100 lb (18 kg through 45 kg) propane capacity filled by volume shall have a fixed maximum liquid level gauge.
Table 5.7.4.1 Container Connection and Appurtenance Requirements for Containers Used in Other Than Bulk Plants and Industrial Plants
1 Cylinders 2 Through 420 Ib Propane Capacity R (CGA 555 outlet prohibited) B Liquid shutoff valve I R with CGA 555 outlet and internal excess flow shutoff R (see 5.7.2.2) R (filled by volume) R (filled by weight, 40 Ib and > 100 lb) [see 5.7.4.1 (H)] R (4 thru 40 lb) (see 5.7.3) NR R with internal excess flow shutoff R2 [see 5.7.4.1(A)] R 2 Stationary ASME Containers 4000 gal Water Capacity R 3 DOT and ASME Engine Fuel and Mobile Containers R with internal excess-flow valve R with internal excess-flow valve R (full internal or flush-type full internal pressure relief valve) R
Part A
Appurtenance Vapor shutoff valve I
Pressure relief valve
Fixed maximum liquid level gauge
Overfilling prevention device
NR
R (ASME only) (see 5.7.4.1 (E)) NR
Actuated liquid withdrawal excess flow valve
R ( 125 gal) [see 5.7.4.1(B) through 5.7.4.1 (D)]
H I
Float gauge Double backflow check filler valve
NR R ( 100 Ib filled on site)
R (> 124 gal only) R
NR R (ASME only)
R: Required. NR: Not required. 1 Where installed. 2 Aboveground ASME containers, internal spring-type pressure relief valves only. 3All ASME container capacities are water capacity.
21
Dispenser tank valves and fittings that are optional or not specifically required by Table 5.7.4.1 but may be required by local or state jurisdictional authorities generally include: 1. 2. Backflow check and excess-flow vapor return valve(s) Manual shutoff liquid valve with internal excess-flow check valve 3. Pressure gauge
Figure 1 illustrates the valves and fittings used with typical propane dispenser supply tanks. The optional valve shown below is not provided on typical ASME stationary tanks designed for vapor service. It can be ordered from the tank manufacturer as an add-on fitting at relatively low cost. The additional top-mounted coupling provides a separate connection for the dispenser pump by-pass, greatly increasing the reliability and operating capacity and performance of the dispenser at little additional cost. (See Figure 2.)
Figure 1. Required and Optional Dispenser Supply Tank Valves & Fittings
22
*NOTE: Because the multi-valve in Figure 1 provides the vapor equalizing and maximum fixed liquid level functions, one of three options must be used for a dispenser installation: 1. The POL vapor outlet must be plugged if not used 2. An in-line excess flow installed at the POL opening must be provided if the vapor opening is used as a meter balance line connection. 3. A first-stage or integral 2-stage regulator must be installed if the tank is used for a vapor supply as well as a dispenser supply tank.
Figure 2. Dispensing Station/Vehicle Fuel Dispenser Component Diagram
NFPA 58
2008
5.7.4.2 ASME containers over 4000 gal (15.2 m3) water capacity shall be equipped in accordance with 5.7.4.2(A) through 5.7.4.2(G) and Table 5.7.4.2.
(A) Vapor withdrawal openings shall be equipped with either of the following: (1) A positive shutoff valve located as close to the container as practical in combination with an excess-flow valve installed in the container (2) An internal valve (B) Liquid withdrawal openings in new installations shall be equipped with an internal valve that is fitted for remote closure and automatic shutoff using thermal (fire) actuation where the thermal element is located within 5 ft (1.5 m) of the internal valve. (C) Liquid withdrawal openings in existing installations where the container is equipped with an internal valve that is not fitted for remote closure and automatic shutoff using thermal (fire) actuation shall be equipped for remote and thermal closure by July 1, 2003.
23
(D) Liquid withdrawal openings in existing installations shall be equipped with either of the following by July 1, 2011: (1) An internal valve that is fitted for remote closure and automatic shutoff using thermal (fire) actuation where the thermal element is located within 5 ft (1.5 m) of the internal valve (2) An emergency shutoff valve that is installed in the line downstream as close as practical to a positive shutoff valve in combination with an excess-flow valve installed in the container (E) Vapor inlet openings shall be equipped with either of the following: (1) A positive shutoff valve that is located as close to the container as practical in combination with either a backflow check valve or excessflow valve installed in the container (2) An internal valve (F) Liquid inlet openings in new installations shall be equipped with either of the following: (1) An internal valve that is fitted for remote closure and automatic shutoff using thermal (fire) actuation where the thermal element is located within 5 ft (1.5 m) of the internal valve (2) A positive shutoff valve that is located as close to the container as practical in combination with a backflow check valve that is designed for the intended application and is installed in the container (G) Liquid inlet openings in existing installations where the container is equipped with an internal valve that is not fitted for remote closure and automatic shutoff using thermal (fire) actuation shall be equipped for remote and thermal closure by July 1, 2003.
Dispenser supply tanks with water capacities up to and including 4,000 gallons must be outfitted with valves and other required fittings as set out in Column 2 of Table 5.7.4.1 (NFPA 58, 2008) for stationary ASME tanks not installed at a bulk storage or industrial plant. Tanks with water capacities of 2001 through 4000 gallons in bulk plant and industrial plant service must conform to the requirements of Table 5.7.4.2.
24
(2) Verifying proper specifications and protection measures for tank relief valves Tank relief valves must conform to the requirements of NFPA 58 and Underwriter Laboratories Standard 132. Minimum vapor discharge capacity in standard cubic feet per minute is determined according to the number of square feet of tank surface area. For propane, the relief valves start to discharge pressure is 250 psig.
25
The relief valve(s) for dispenser supply tanks must meet the requirements set out in 5.7.2.4 of NFPA 58, 2008 edition, with minimum relief discharge capacity conforming to those given in Table 5.7.2.5, Pressure Relief Valve Flow Capacity as a Function of Container Surface Area. Additional guidance information is found in Annex E. Tank container surface area is a required marking for the ASME tank data plate. (Figure 4.)
Figure 3. Internal Type Relief Valve
Figure 4. Container Surface Area (97.5 SQ. FT.) On ASME Data Plate
Relief valve installation provisions are given in section 6.7.2 of NFPA 58, 2008 edition. Important relief valve protection provisions include:
NFPA 58
2008
6.7.2.4 Rain caps or other means shall be provided to minimize the possibility of the entrance of water or other extraneous matter into the relief device or any discharge piping. Provision shall be made for drainage where the accumulation of water is anticipated. 6.7.2.5 The rain cap or other protector shall be designed to remain in place, except during pressure relief device operation, and shall not restrict pressure relief device flow.
26
NFPA 58
2008
6.7.2.7 The pressure relief valve discharge on each aboveground container of more than 2000 gallon water capacity shall be piped vertically upward to a point at least 7 feet above the top of the container, and the discharge opening shall be unobstructed to the open air. 6.7.2.8 Shutoff valves shall not be installed between pressure relief devices and the container unless a listed pressure relief valve manifold meeting the requirements of 6.7.2.9 is used. [6.7.2.9 gives requirements for manifold relief valve assemblies.] 6.7.2.10 Shutoff valves shall not be installed between a pressure relief device and the pressure relief device discharge piping. 6.7.2.11 The pressure relief valve discharge piping from underground containers of 2000 gallons or less water capacity shall extend beyond the manhole or housing or shall discharge into the manhole or housing, where the manhole or housing is equipped with ventilated louvers or their equivalent, in accordance with 5.7.11.1(H). 6.7.2.12 Pressure relief valve discharge on underground containers of more than 2000 gallons water capacity shall be piped vertically and directly upward to a point at least 7 feet above the ground. 6.7.2.13 Pressure relief devices installed in underground containers in dispensing stations shall be piped vertically upward to a point at least 10 feet above the ground. 6.7.2.14 Discharge piping shall be supported and protected against physical damage. 6.7.2.15 The discharge piping shall comply with the following: (1) Piping from aboveground containers shall be sized to provide the rate of flow specified in 5.7.2.5. Piping from underground containers shall be sized to provide the rate of flow specified in 5.7.2.7. (2) Piping shall be metallic and have a melting point over 1500F. (3) Discharge piping shall be designed so that excessive force applied to the discharge piping will result in breakage on the discharge side of the valve rather than on the inlet side without impairing the function of the valve. (4) Return bends and restrictive pipe or tubing fittings shall not be used.
27
(3) Verifying that proper components for the dispenser installation are provided. (a) Filler valve or other filling systems. Most dispenser supply tanks are filled through a double backflow check filler valve. (Figure 5.)
Figure 5. Double Backflow Check Filler Valve for Tanks with Filling Opening Less Than 1 Inch Dispenser supply tanks over 4,000 gallons water capacity or having a filling opening diameter 1-inch or larger require a transfer bulkhead equipped with an emergency shutdown valve (ESV) for the vapor equalizing connection (if 1-inch or larger), and an ESV for the liquid fill connection. A backflow check valve may be used for the liquid line if flow of liquid is limited to one direction (into the dispenser supply tank). (Figure 6.)
Figure 6. Transfer Bulkhead and Emergency Shutdown Valves for Supply Tank with Filling Opening 1 Inch (Liquid) or Larger
28
(b)
Internal valves and excess flow requirements.
The dispenser supply tank liquid opening that connects to the propane transfer pump must be fitted with an internal excess-flow valve. For supply tanks not located in a bulk or industrial plant having water capacities of 4,000 gallons or less a positive shutoff valve must be provided in conjunction with the internal excess-flow in one of the two methods listed below: 1. A manual valve located in the piping immediately downstream of the excess-flow, (Figure 7.) or, 2. An internal valve which incorporates the excess-flow and a positive shutoff (Figure 8.)
EXCESS FLOW VALVE 1/4 TURN MANUAL VALVE
VALVE DISC
LIQUID FLOW
Figure 7. Excess Flow Valve and Manual Valve for Liquid Withdrawal Beginning with the 2001 edition of NFPA 58, new installations having supply tank water gallon capacities in excess of 4000 gallons aggregate, were required to have either an internal valve or a nearby downstream emergency shutdown valve (ESV) with automatic and remote shutdown capability in the event of fire or emergency. These requirements are covered in more detail in module 5.1.10 of this training guide. Existing installations (installed prior to adoption of NFPA 58, 2001 edition) with aggregate supply tank capacity in excess of 4,000 water gallons must be retrofitted to comply with the emergency shutdown requirements no later than July 1, 2011.
29
Figure 8. Internal Valve for Liquid Withdrawal (Shown in a Vertical Tank) (c) Emergency shutdown systems. Internal valves as illustrated in Figures 8 and 9 can be fitted with cable or pneumatic actuators as part of an emergency shutdown system.
Figure 9a. Cable Actuated Liquid Withdrawal Valve
Figure 9b. Pneumatic Actuated Liquid Withdrawal Valve
30
(d)
Manual valves. Multi-valves on horizontal dispenser supply tanks include a manual vapor valve. The vapor opening of the multi-valve may be used as a liquid meter sensing line connection if the dispenser is equipped with a liquid meter. If not used in this manner, the lefthand thread POL opening should be sealed with a POL brass plug. When an optional vapor return opening is provided on the supply tank (labeled V3 in a circle in Figures 1 and 2 on page 3) for the pump by-pass return connection, the tank coupling should be fitted with a manual liquid transfer shutoff valve with an internal excess-flow. (Figure 11.) The transfer valve illustrated is an angle globe valve fitted with: a -inch plugged opening that can accept a pressure gauge to check pump and by-pass valve performance or a hydrostatic relief valve an excess-flow Ball valves are often used in dispenser piping circuits to control liquid flow to cylinder filling equipment or a liquid meter and equipment used to fill mobile or motor fuel tanks. These quarter turn manual valves produce less restriction to flow compared to globe valves, resulting in lower differential pressures that lessen pump performance. (Figure 12.) Figure 12. Ball Valve
Figure 10. Multi-valve
Figure 11. Manual Valve with Excess-Flow
31
(e)
Tank Fittings. Liquid level gauges. Horizontal dispenser tanks are typically fitted with a single top-mounted float gauge. (Figure 13.) Vertical tanks may have as many as four float gauges mounted at equal intervals up the tank to indicate the approximate liquid level in each vertical section.
13. Float Gauge
14a. Fixed Maximum Liquid Level Gauge with Dip Tube 14b. Multi-valve with Fixed Maximum Liquid Level Gauge
A fixed maximum liquid level gauge, which may be a separate fitting as shown in Figure 14a or a component fitting of a multivalve as shown in Figure 14b, is required for each dispenser supply tank.
32
Optional pressure gauge. (Fig 15) Although some state and local jurisdictional authorities may require a dispenser tank pressure gauge on ASME tanks having water gallon capacities of 1,200 or less, NFPA 58 does not require the installation of a pressure gauge unless the tank is over 1,200 water gallons capacity.
Figure 15. 0-300 PSI Pressure Gauge Thermometer and pressure gauge requirements for larger tanks. ASME tanks larger than 1,200 water gallons capacity must be fitted with a pressure gauge and a temperature gauge (thermometer).
Figure 16a. Tank Thermometer Well
Figure 16b. Dial Indicating Thermometer
NFPA 58 Identifying 58 Code Requirements for Dispenser Piping

2008 Table 5.9.4.1 Service Pressure Rating of Pipe, Tubing Fittings, and Valves
Service Higher than container pressure Minimum Pressure 350 psig (2.4 MPag), or the MAWP, whichever is higher, or 400 psig (2.8 MPag) WOG rating
LP-Gas liquid, or vapor at operating pressure over 250 psig (1.7 MPag) 125 psig and at or below container pressure LP-Gas vapor at operating pressure of 125 psig (0.9 MPag) or less 125 psig (0.9 MPag)
33
REVIEW:
Identifying Required Dispenser Tank Valves and Fittings

Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. G. H. I. J. K. L. rain caps NFPA 30A inside diameter temperature gauge water gallon capacity at least 7 feet
A. B. C. D. E. F.
pressure gauge 1 -inch surface area in square feet NFPA 51 an aggregate water capacity float gauge
1.
The NFPA code that applies to propane dispensers located at multiple fuel refueling stations is _____. The valves and fittings required by NFPA 58 for ASME tanks typically used to supply propane dispensers include a double backflow check filler valve, a spring-type relief valve, a fixed maximum liquid level gauge, and a ____. Two additional ASME tank fittings (devices) required for ASME tanks over 4,000 gallons water capacity that are not required by NFPA 58 for ASME tanks typically used to supply propane dispensers are a ____, and ____. a
b
2.
3.
a
4.
An ASME tanks ____ is used to determine the discharge capacity requirements for its relief valve(s); this information must appear on the tanks ASME data plate. Means such as ____ (designed to remain in place, except during pressure relief device operation, and not restrict pressure relief device flow) shall be provided to minimize the possibility of the entrance of water or other extraneous matter into the tanks relief device or any discharge piping.
5.
34
A. B. C. D. E. F.
pressure gauge 1 -inch surface area in square feet NFPA 51 an aggregate water capacity float gauge
G. H. I. J. K. L. M.
rain caps NFPA 30A inside diameter temperature gauge water gallon capacity at least 7 feet plastic piping
6.
NFPA 58 requires the pressure relief valve discharge on each aboveground container of more than 2,000-gallon water capacity to be piped vertically upward to a point ____above the top of the container, and the discharge opening shall be unobstructed to the open air. Dispenser supply tanks over 4,000 gallons water capacity or having a filling opening ____ diameter or larger require a transfer bulkhead equipped with an emergency shutdown valve (ESV) for the vapor equalizing connection (if 1-inch or larger), and an ESV for the liquid fill connection. A backflow check valve may be used for the liquid line if flow of liquid is limited to one direction (into the dispenser supply tank). NFPA 58 allows for various materials and piping joints (threaded and welded) to be used in respect to liquid piping in dispenser stations, one type of piping that cannot be used for liquid piping is _________.
7.
_____8.
Write in your answers using the blank lines provided. 9. The dispenser supply tank liquid opening that connects to the propane transfer pump must be fitted with an internal excess-flow valve. For supply tanks not located in a bulk or industrial plant having water capacities of 4,000 gallons or less a positive shutoff valve must be provided in conjunction with the internal excess-flow in one of the two methods listed below: a. b.
35
5.1.2
Performance Criteria Self-Check: Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping
Directions: I can identify: 1.
The NFPA code that applies to propane dispensers located at multiple fuel refueling stations. The valves and fittings required by NFPA 58 for ASME tanks typically used to supply propane dispensers. The two additional ASME tank fittings (devices) that are required for ASME tanks over 4,000 gallons water capacity that are not required by NFPA 58 for ASME tanks typically used to supply propane dispensers. The ASME tank physical marking required on its data plate that is used to determine the minimum relief discharge capacity for the relief valve(s) for the dispenser supply tank(s). The relief valve protection measure required for any dispenser supply tank, without regard to the tanks water gallon capacity. The maximum aboveground ASME tank water gallon capacity for which vertical piping to at least 7 feet above the top of the tank is not required by NFPA 58. The filling system requirements for a dispenser supply tank over 4,000 gallons water capacity or having a filling opening diameter 1 inches or larger or a vapor equalizing connection 1-inch or larger. The two methods for providing excess-flow protection and positive shut off of liquid at the withdrawal opening of ASME tanks typically used to supply propane dispensers. The different types of materials that can be used according to NFPA 58 for the liquid piping system in dispenser stations.
2.
3.
4.
5.
6.
7.
8.
9.
36
5.1.3
Identifying Dispenser Electrical System Requirements
Table of Contents
Table of Contents..................................................................................................... 37 Learning Activities.................................................................................................... 38
Identifying Dispenser Electrical System Requirements............................................ 39
Applying NFPA 58 Electrical System Location Classification Criteria for Classified and Unclassified Areas............................................................................ 39 Identifying Electrical Component Requirements for Classified Areas ...................... 42
Review ..................................................................................................................... 45 Performance Criteria Self-Check ............................................................................. 46
37

1. Identifying Dispenser Electrical System Requirements
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning dispenser electrical system requirements and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to dispenser electrical system requirements. (Skills Assessment)
Read Performance Objective 1: Identifying Dispenser Electrical System Requirements
38
5.1.3
Propane dispenser electrical systems must conform to the provisions of NFPA 58, LP-Gas Code for ignition source control and those of NFPA 70, National Electrical Code (NEC) for hazardous locations. In this module you will learn to: (1) (2) (1) Apply NFPA 58 electrical system location classification criteria for classified and unclassified areas Identify electrical component requirements for classified areas Applying NFPA 58 electrical system location classification criteria for classified and unclassified areas. 6.22.2 Electrical Equipment.
NFPA 58
2008 6.22.2.1 Electrical equipment and wiring installed in unclassified areas shall be in accordance with NFPA 70, National Electrical Code, for non classified locations. 6.22.2.2* Fixed electrical equipment and wiring installed within a classified area specified in Table 6.22.2.2 shall be installed in accordance with NFPA 70, National Electrical Code. Because propane is highly flammable, ignition source control is important at any installation where propane transfer operations are done. The electricity that powers the dispenser pump is a potential ignition source. NFPA 58 and NEC specify that the electrical system within 15 feet of the dispenser pump (and cabinet if applicable) must meet the requirements of an explosion proof electrical system. The classification of electrical system requirements for propane installations is presented in Table 6.22.2.2, Electrical Area Classification of NFPA 58, 2008 edition. Parts of Table 6.22.2.2 that relate to propane dispensers are shown on the next page. The term classified area in NFPA 58 corresponds to hazardous locations in NEC (NFPA 70). The electrical equipment used within the classified area(s) of a propane installation must be approved for NEC Class I, Group D, Division 1 or 2. That means that, with the exception of conduit, the enclosed wires and motor operating switch, the electrical components must be marked or bear a rating plate indicating that they are Class I, Group D, Division a or 2 rated.
39
Parts of NFPA 58 Table 6.22.2.2 Electrical Area Classification Related to Propane Dispensers
Part Location Extent of the Classified Areaa
Equipment Shall be Approved for NEC a b Class I , Group D
Fc
Unrefrigerated containers other than cylinders and ASME vertical containers of less than 1000 pounds water capacity Pumps, vapor compressors, gasair mixers and vaporizers (other than direct-fired or indirect-fired with an attached or adjacent gas-fired heat Outdoors in open air at or above grade
Within 15 feet in all directions from connections, except connections otherwise covered in Table 6.22.2.2
Division 2
Vehicle fuel dispenser
Within 15 feet in all directions from this equipment and within the cylindrical volume between the horizontal equator of the sphere and grade Entire space within dispenser enclosure, and 18 inches horizontally from enclosure exterior up to an elevation 4 feet above dispenser base; entire pit or open space beneath dispenser Up to 18 inches above ground within 20 feet horizontally from any edge of enclosure (Note: For pits within this area, see part H of this table.)
Division 2
Division 1
Division 2
Pits or trenches containing or located beneath LP-Gas valves, pumps, vapor compressors, regulators, and similar equipment Without mechanical ventilation Cylinder fillingIndoors with ventilation Cylinder fillingOutdoors in open air
Entire pit or trench Within 5 feet in all directions from a point of transfer Beyond 5 feet and entire room Within 5 feet in all directions from a point of transfer Beyond 5 feet but within 15 feet in all directions from point of transfer and within the cylindrical volume between the horizontal equator of the sphere and grade
Division 1 Division 1 Division 2 Division 1 Division 2
Footnotes to Table 6.22.2.2 a The classified area shall not extend beyond an unpierced wall, roof, or solid vaportight partition. b See Article 500 Hazardous (Classified) Locations, in NFPA 70, National Electrical Code, for definitions of classes, groups and divisions. c See A.6.22.2.2 (Figure 1 on the next page)
40
Figure 1 illustrates the terms cylindrical volume horizontal equator of the sphere (radius of 5 feet and 15 feet grade (referring to ground level) used in the descriptions of classified areas.
Sphere with a radius of 15 feet--Division 2 Sphere with a radius of 5 feet--Division 1
Horizontal equator of the sphere
Point of connection or source of excessive release of liquid or vapor
Grade level Cylindrical volume Division 2 (includes the bottom half of 15 foot radius sphere)
Figure 1. Extent of Electrically Classified Area

Figure A.6.22.2.3 in Annex A of NFPA 58, 2008
Divisions in electrical area classifications are based upon the likelihood of the presence of a flammable mixture of materials located in the area. The likelihood of a flammable mixture being present varies from continuously to not at all. The NEC defines Class I, Division 1 hazardous locations as locations in which: 1. Ignitable concentrations of flammable gases or vapors can exist under normal operating conditions; or 2. Ignitable concentrations of such gases or vapors may exist frequently because of repair or maintenance operations or because of leakage; or 3. breakdown or faulty operation of equipment or processes might release ignitable concentrations of flammable gases or vapors, and might also cause simultaneous failure of electric equipment. The NEC defines Class I, Division 2 locations as those locations: 1. in which volatile flammable liquids or flammable gases are handled, processed, or used, but in which the liquids, vapors, or gases will normally be confined within closed containers or closed systems from which they can escape only in case of abnormal operation of equipment; or 2. in which ignitable concentrations of gases or vapors are normally prevented by positive mechanical ventilating equipment, and which might become hazardous through failure or abnormal operation of the ventilating equipment; or 3. that are adjacent to a Class I, Division 1 location, and to which ignitable concentrations of gases or vapors might occasionally be communicated unless such communication is prevented by adequate positive-pressure ventilation for a source of clean air, and effective safeguards against ventilation failure are provided.
41
(2)
Identifying electrical component requirements for classified areas. An electrical system made up of Class I, Group D electrical fixtures and components is generally called explosion-proof. In reality the individual parts of the system are not explosion proof; rather, they are designed and built to momentarily retain the rapidly expanding hot gases produced inside them if a combustible mixture inside the electrical system is ignited by electrical spark or mechanical actionthen control the spread of hot gases to the outside environment. (Figure 2.)
Figure 2. How Explosion Proof Enclosures Limit the Spread of Hot Gases
These actions remove the potential ignition source for any flammable mixtures outside the electrical system. Primary components of a dispenser electrical system are: An explosion-proof electrical motor for the pump Rigid metal conduit for routing the electrical wiring One or more electrical unions to facilitate motor or switch replacement One or more flexible connector sections to allow for normal pump and motor vibration, and to relieve stress on other rigid system parts A switch enclosure Suitable wiring junction boxes for wire splices A sealing fitting within 18 inches of a spark producing device or entering/exiting a Hazardous Area; the lower portion of the fitting is filled with a suitable (putty-like) sealing compound that surrounds the wiring connected to the power source
Except for the conduit, electrical unions, wiring and switch (which must be installed in an approved enclosure), all the components of the system must be marked or labeled to certify that they are approved for Class I, Group D locations.
42
Electrical systems for propane dispensers are fairly simple. Most dispensers use a 5 horsepower explosion-proof motor driven pump. Magnetic starters used with larger motors are not generally required for dispenser electrical systems. (Figure 3.)
Motor a nd All Fixtures & Fittings Approved for Cla ss I, Group D

Explosion-Proof Electrical Pump Motor Flexible Section
Cla s I, Gro up D s
Switch Enclosure 3-Way Junction Enclosure
ON OFF
Electrical Union Heavy-Wall Conduit Sealing Fittings
To Electrical Power Supply
Figure 3. Simple Propane Dispenser Electrical System Common electrical system Class I, Group D components are illustrated in Figures 4 though 6.
Figure 4. Explosion-Proof Electrical Flexible Connector
Figure 5a. 2-Way Junction Box
Figure 5b. 4-Way Junction Box
43
Sealing Fitting Conduit Sealing Compound
Figure 6a. Sealing Fitting
Figure 6b. Sealing Fitting Cross Section
Although all components of the dispenser electrical system must be approved and properly installed, the sealing fitting with its sealing compound is a key component of the explosion-proof system. Located within 18 inches of a spark producing device and at the boundary between Division 1 (and/or Division 2) classified area(s) and the non-classified portions of the electrical power system, it prevents the transmission of the hot gas products of an internal explosion as a potential ignition source into the adjacent areas. If no sealing fitting is provided, or if the lower portion of the fitting is not properly sealed with sealing compound, the entire system cannot function as an explosion-proof system.
44
REVIEW:

Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided.
A. Divisions D. can function B. cannot function E. NEC Class I, Group D C. NFPA 70, National Electrical Code (NEC)
1.
Propane dispenser electrical systems must conform to the provisions of NFPA 58, LP-Gas Code for ignition source control and those of _____ for hazardous locations. The electrical equipment used within the classified area(s) of a propane installation must be approved for ____. ____ in electrical area classifications are based upon the likelihood of the presence of a flammable mixture of materials located in the area.
2.
3.
4.
Primary components of a dispenser electrical system are: a. b. c. d. e. f. g.
5.
If no sealing fitting is provided at the boundary between classified and non classified areas, or if the lower portion of the fitting is not properly sealed with sealing compound, the entire system ____ as an explosion-proof system.
45
5.1.3
Performance Criteria Self-Check: Identifying Dispenser Electrical System Requirements

Directions:
I can identify: 1. The NFPA codes that must be applied to the electrical system of a propane dispenser. The class and group approval required by the National Electrical Code (NEC) for the visible components of a dispenser electrical system which must be marked on the all visible components with the exception of the wiring conduit. The basis for determining the divisions within classified areas as defined by the NEC. The primary components of a propane dispenser electrical system. The key component of an explosion-proof electrical system that must be installed at the boundary between classified and non classified areas and a condition of its installation that is crucial to the functioning of the explosion-proof system.
2.
3.
4. 5.
46
5.1.4
Applying Propane Pump Operating Characteristics & Selecting the Dispenser Pump
Table of Contents
Applying Propane Pump Operating Characteristics & Selecting the Dispenser Pump................................................................................. 49 Identifying the operating characteristics of propane pumps ..................................... 49 Turbine pumps.................................................................................................... 49 Positive displacement pumps ............................................................................. 50 Selecting the Dispenser pump ................................................................................. 50 Dispenser application and operating requirements............................................. 50 Pump rating ........................................................................................................ 51 Motor Selection................................................................................................... 53 Pump protection devices..................................................................................... 53
47

1. Applying Propane Pump Operating Characteristics & Selecting the Dispenser Pump
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning applying propane pump operating characteristics & selecting the dispenser pump and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to applying propane pump operating characteristics & selecting the dispenser pump. (Skills Assessment)
Read Performance Objective 1: Applying Propane Pump Operating Characteristics & Selecting the Dispenser Pump
48
5.1.4
Selecting the pump for a propane dispenser should include a complete understanding of how the dispenser will be operated, and the functions that the dispenser must fulfill. In this module you will learn to: (1) (2) (1) Identify the operating characteristics of propane pumps Select the dispenser pump Identifying the operating characteristics of propane pumps. (a) Regenerative turbine pumps are suitable for typical dispenser installations and will provide adequate transfer volume for filling portable cylinders, motor fuel cylinders, and vehicle-mounted ASME mobile and motor fuel tanks under most operating conditions. They are less affected by cavitation (vapor bubbles in the liquid moving through the pump) compared to propane pumps classified as positive displacement types. Regenerative turbine pumps used with dispensers are frequently mounted directly to the totally enclosed, explosion-proof motor supplied as a single unit by the manufacturer. Depending on the model and operating conditions, these pumps will transfer propane at rates varying from 2 to 38 gallons per minute.
Figure 1. Regenerative Turbine Pump
49
(b)
Positive displacement pumps.
Figure 2a. Sliding Vane Pump
Figure 2b. Gear Pump

(Coupling Shield Removed for Illustration)
Propane pumps classified as positive displacement types are illustrated in Figure 2. Used in some dispenser applications, they are more commonly found in high-volume liquid transfer systems such as cargo tank loading and unloading. (2) Selecting the dispenser pump. (a) Dispenser application and operating requirements. When selecting the pump for a dispenser it is important to review the applications and operating conditions for the installation. A number of questions should be asked and answered, including: 1. What containers will be filled? If the dispenser will be primarily used to fill smaller cylinders, with larger containers filled only occasionally, a pump with minimal gallon per minute rating should be selected. The primary consideration in this case is minimizing the risk of over filling small cylinders. By contrast, if the installation is primarily used to fill larger, vehicle-mounted mobile or motor fuel tanks at one or more remote dispenser units, such as a filling station or fleet service center, a higher volume pump should be considered to reduce filling time and minimize operator waiting that could contribute to lack of attention during the filling operation. 2. What is the expected volume of daily usage? If the dispenser is to be located at a recreational vehicle dealership or park, and the number of filling operations per hour is typically 5 to 15 cylinders, a smaller volume pump should be satisfactory.
50
3. Does the installation location present particular limitations? If the power supply at the site will only support low-voltage, singlephase electric motors, the pump size and volume must be matched to the limitations of the power supply. If site requirements or jurisdictional authority approval mandates the use of a buried or mounded underground supply tank, the pump selection should be made after consulting the pump manufacturer or distributor. Buried underground tanks can be used, but the type of pump used and the piping arrangement must strictly follow manufacturer IOM instructions for satisfactory service. (b) Pump rating. Manufacturers propane pump ratings are generally shown in relation to differential pressure. Differential pressure is the difference between the pressure at the outlet side of the pump and the pressure at the inlet side of the pump. Differential pressure is the additional pressure the pump must produce and work against in order to move propane liquid out of the pump and into the receiving container. Under ideal conditions, there would be no buildup of pressure at the pump outlet and thus no difference between the inlet and outlet pressures. The pump would simply trap the liquid at the inlet and hurry it on its way through the pump chamber and into the outlet piping. In reality, there is always considerable resistance downstream from the pump. Resistance to the flow of propane is often due to a buildup of pressure in the receiving container. This is especially true of metered filling operations, where there is no vapor equalization hose to route the higher vapor pressure in the receiving container back to the supply tank. When this is the case, propane from the pump outlet must be discharged back into the tank through the bypass valve. This can cause the flow of liquid to slow and the pressure at the pump outlet to rise, sometimes causing cavitation (propane liquid boiling in the inlet piping and inside the pump, displacing liquid with vapor). Severe cavitation increases pump wear and can quickly damage the pump, especially positive displacement types. Even under ideal conditions, there will always be considerable resistance to flow of liquid in the outlet piping. As with resistance in the inlet piping, it comes in part from friction between moving liquid and the walls of the pipe and hose, and in part from restrictions in the line caused by the valves and pipe fittings. There will always be some differential between the inlet and the outlet pressures at the pump.
51
It is important to know and understand that differential pressure always works against pump efficiency. The greater the differential pressure of the pump, the lower will be the flow rate or capacity of the pump. The same pump that will deliver nearly 40 gallons per minute (GPM) at a differential pressure of 10 psi will deliver only as much propane liquid when the differential pressure rises to 100 psig. For this reason, it is always advantageous to keep the differential pressure as low as possible. Pump ratings for typical dispenser pumps are shown in the following tables. Table 1. Volume Compared to Differential Pressure for Typical Regenerative Turbine Dispenser Pumps
Regenerative Turbine Pump Approximate Capacities in Gallons per Minute at Various Pressures Differentials*
Model C-10 C-12 C-13 C-14
20 psid
50 psid
70 psid
75 psid
85 psid
100 psid
Electric Motor Reqd
12 gpm 19 gpm 28 gpm 38 gpm
7 gpm
12.5 gpm 26 gpm
3 gpm 16 gpm
10 gpm
11.5 gpm 20 gpm
hp 1 hp 2 hp 3 hp
Table 2. Approximate Container Filling Times for Typical Regenerative Turbine Dispenser Pumps
Regenerative Turbine Pump Approximate Cylinder Fill Times or Motor Fuel Transfer Rates Through a Meter*
Model C-10 C-12 C-13 C-14
20 lb Cylinder
30 sec. to 1 min. 15 to 30 seconds 10 to 20 seconds
100 lb Cylinder
2- to 3- minutes 2 to 3 minutes 1- minutes Less than 1 minute
Motor Fuel Through a Meter

7 gpm 15 gpm 23 gpm 30 gpm
Electric Motor Reqd
hp 1 hp 2 hp 3 hp
Table 3. Volume at Two Differential Pressures & Approximate Container Filling Times for Typical Sliding Vane Dispenser Pumps
Sliding Vane Pump Approximate Cylinder Fill Times & Capacities in Gallons per Minute at Various Pressures Differentials*
Model LGB1 LGB1P
50 psid
100 psid
20 lb Cylinder
minute minute
100 lb Cylinder
3 minutes 2 minutes
Electric Motor Reqd
7.5 gpm 12 gpm
4.4 gpm 8 gpm
1 hp 1 hp
*Times are estimates and will vary depending on conditions at the installation location, container type and design, dispenser design, and the type of container filler valve, especially if the valve is an OPD. Psid is pounds per square inch differential, or differential pressure.
52
(c)
Motor Selection. Usually dispenser pumps and motors are selected as a single unit supplied by the manufacturer or propane equipment distributor. Three factors must be known to verify that the explosion-proof motor is appropriate for the dispenser installation and pump: 1. The pumps horsepower and revolutions per minute (rpm) requirements 2. The installations available electrical power supply voltage and phase 3. The motor frame style required; the frame style refers to how the motor is mounted and how the pump is driven by the motor
(d)
Pump protection devices. In addition to meeting the pump manufacturers piping layout and size specifications, three pump protection devices are required. 1. Proper bypass valve and system. For the protection of the pump and its piping circuits, verify the following: The piping in the bypass circuit meets the minimum diameter requirements recommended by the manufacturer; this should be true of the piping between the pump and bypass valve, and the piping between the bypass valve and the supply tank. Dont use small diameter copper tubing where the manufacturer specifies the use of 1-inch or larger pipe diameter bypass return lines. Bypass piping terminates in the supply tank opening recommended by the pump manufacturer and all valves in the piping circuit and tank connection meet pump manufacturer recommendations. The external bypass valve is properly matched to the capacity of the pump. (Figure 3.)
Figure 3a. For Pumps Up to 40 GPM
Figure 3b. For Pumps Up to 80 GPM
53
Manufacturer instructions state that when a new or replacement bypass valve is installed, it must be adjusted to the proper differential pressure, following the manufacturers installation, operation and maintenance (IOM) instructions. Periodic checks of proper bypass valve setting will eliminate many pump problems and prolong equipment life. To adjust a bypass valve, install liquid-filled or snubber-equipped pressure gauges as given in the manufacturers instructions and follow the directions given. (Figure 4.) NOTE: For LP-gas installations, a maximum differential of 125 psig is allowed by Underwriters Laboratories, Inc. listing and NFPA 58. Never adjust a bypass valve to a higher pressure than the LP-Gas Code allows.
Figure 4. Automatic Bypass Valve & Adjustment Mechanism If the pump is equipped with an internal bypass (sometimes called a pump relief valve), check its pressure setting on the rating plate attached to the pump or in the manufacturers IOM instructions. The internal bypass valve pressure must be set according to manufacturer instructions, typically at least 10-25 psig higher than the external bypass valve setting.
2. Verify that a flexible connector (Figure 5) for piping stress relief is provided in the pump inlet piping, and if needed, in the pump outlet piping.
Figure 5. Stainless Steel Flexible Connector
54
Flexible connectors of the proper length must be selected, and should be installed so that they are as close as practical to a straight line. They should never be used in place of pipe fittings to make turns or bends. Improper installation may result in damage to the reinforcement braids and complete failure of the connector. (See Figure 6.)
Figure 6a. Improperly Installed Flex Connector
Figure 6b. Reverse Side Damage to Stainless Steel Reinforcement Webbing
3. The pump should be protected by the installation of an inline strainer upstream of the pump inlet. Pump manufacturer IOM instructions give strainer screen size specifications for protecting the pump from debris that could damage internal components.
Figure 7. Inline Strainer Body (Note Flow Direction Arrow, L to R)
55
REVIEW:
Directions: Select from the list below the response that most correctly completes the following statements by writing the letter of your choice in the space provided, or filling in the blank lines. F. G. H. I. J. over filling small cylinders maximum differential pressure strainer screen size specifications manufacturer instructions
A. B. C. D. E.
pump manufacturer or distributor limitations of the power supply minimum higher volume pump to make turns or bends 1.
The primary consideration in selecting a pump for a dispenser that will be primarily used to fill smaller cylinders is to select a pump with minimal gallon per minute to minimize the risk of _____ . If a dispenser installation is primarily used to fill larger, vehiclemounted mobile or motor fuel tanks at a filling station or fleet service center, a____ should be considered to reduce filling time and minimize operator waiting that could contribute to lack of attention during the filling operation. If the power supply at the site will only support low-voltage, singlephase electric motors, the pump size and volume must be matched to the ____. If site requirements or jurisdictional authority approval mandates the use of a buried or mounded underground supply tank, the pump selection should be made after consulting the ____ . In terms of propane pump ratings, ____ is the difference between the pressure at the outlet side of the pump and the pressure at the inlet side of the pump.
2.
3.
4.
5.
6.
Three factors must be known to verify that the explosion-proof motor is appropriate for the dispenser installation and pump: a. b. c.
56
A. B. C. D. E.
pump manufacturer or distributor limitations of the power supply minimum higher volume pump to make turns or bends
F. G. H. I. J.
over filling small cylinders maximum differential pressure strainer screen size specifications manufacturer instructions
7.
For LP-gas installations, a _____ differential of 125 psig is allowed by Underwriters Laboratories, Inc. listing and NFPA 58. If a pump is equipped with an internal bypass (sometimes called a pump relief valve), it must set according to ____, typically at least 1025 psig higher than the external bypass valve setting. Flexible connectors of the proper length must be selected, and should be installed so that they are as close as practical to a straight line; they should never be used in place of pipe fittings ____. The pump should be protected by the installation of an inline strainer upstream of the pump inlet; pump manufacturer IOM instructions give ____ for protecting the pump from debris that could damage internal components.
8.
9.
10.
57
5.1.4
Performance Criteria Self-Check: Applying Propane Pump Operating Characteristics & Selecting the Dispenser Pump
Directions: I can identify: 1.
A primary safety consideration in selecting the pump for a dispenser that will be used mainly to fill small cylinders. A consideration in the selection of a pump for a dispenser primarily used to fill one or more relatively large motor fuel tanks at a service station or fleet service center. The probable determining factor in pump selection at a dispenser installation site where only a low-volume pump in combination with relatively low horsepower pump motor can be used. Who should be consulted before selecting and installing the pump and tank for a buried or mounded underground tank-supplied dispenser. The meaning of differential pressure. Three factors that must be known to select the explosion-proof motor for a specific pump installation. The maximum differential pressure setting allowed by NFPA 58 and UL listing for propane pump bypass valves. When a propane pump is equipped with an internal bypass, how the proper setting of the pumps internal bypass is determined. Two installation practices that should be followed when installing a flexible connector to protect a pump from stress created by piping connected to the pump.
2.
3.
4.
5. 6.
7.
8.
9.
10. Where to find the screen size requirement for an inline strainer for a specific pump installation.
58
5.1.5
Identifying Dispenser Emergency Shutdown Systems and Fire Extinguisher Requirements
Table of Contents
Identifying Dispenser Emergency Shutdown Systems and Fire Extinguisher Requirements .......................................................................................................... 61
Applying NFPA 58 Code Requirements To Selecting Dispenser Emergency Shutdown System Components................................................................................................ 61 Applying NFPA 58 Code Requirements for Fire Extinguishers Used at Propane Dispensers ................................................................................... 63
59

1. Identifying Dispenser Emergency Shutdown Systems and Fire Extinguisher Requirements
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning identifying dispenser shutdown systems and fire extinguisher requirements and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to identifying dispenser shutdown systems and fire extinguisher requirements. (Skills Assessment)
Read Performance Objective 1: Identifying Dispenser Shutdown Systems and Fire Extinguisher Requirements
60
5.1.5
Specific measures are required by the LP-Gas Code for the prevention of dispenser gas leaks or fires and for use in the event of an emergency. In this module you will learn to: (1) (2) Apply NFPA 58 code requirements for selecting dispenser emergency shutdown system components Apply NFPA 58 code requirements for fire extinguishers used at propane dispensers Applying NFPA 58 code requirements to selecting dispenser emergency shutdown system components.
(1)
NFPA 58
2008
Pump requirements 6.17.2.3 (D) A pump operating control or disconnect switch shall be located near the pump. Remote control points shall be provided for other plant operations such as container filling, loading or unloading of cargo tank vehicles and railroad tank cars, or operation of the engine fuel dispenser. Vehicle fuel dispenser and dispensing station requirements 6.24.3.9 An identified and accessible remote emergency shutoff device for either the internal valve or the emergency shutoff valve required by 6.24.3.8(1) or (2) shall be installed not less than 3 ft (1 m) or more than 100 ft (30 m) from the liquid transfer point. 6.24.3.10 Emergency shutoff valves and internal valves that are fitted for remote closure as required in this section shall be tested annually for proper operation. 6.25.4.4 Emergency controls shall be conspicuously marked, and the controls shall be located so as to be readily accessible in emergencies.
61
Figure 1. Remote Emergency Shutdown Switch
In the discussion of internal liquid withdrawal valves in module 5.1.2, the use of cable or pneumatic actuators in an emergency shutdown system was noted. Although such emergency shutdown systems for dispenser supply tank valves is not required by code, many marketers and installers do make use of emergency valve closing options in their dispenser installations. (Figure 2.)
Figure 2. Motor Fuel Dispenser with Electrical Pump and Pneumatic Internal Valve Shutdown (A remote emergency shutoff device is required not less than 3 feet or more than 100 feet from the transfer point.)
62
(2)
Applying NFPA 58 code requirements for fire extinguishers used at propane dispensers.
NFPA 58
2008
6.24.4.2 Each industrial plant, bulk plant, and distributing point shall be provided with at least one approved portable fire extinguisher having a minimum capacity of 18 lb (pounds) of dry chemical with a B:C rating. Where fire extinguishers have more than one letter classification, they can be considered to satisfy the requirements of each letter class. 6.25.4.3* LP-Gas fires shall not be extinguished until the source of the burning gas has been shut off.
63
REVIEW:

Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. A. B. C. D. E. fire sprinkler control switch or circuit breaker hydrant B:C or A:B:C rating control or disconnect switch
1.
To comply with NFPA 58, a pump operating _____ shall be located near the [dispenser] pump. An identified (markings visible at the point of liquid transfer) and accessible ____ shall be installed at a location not less than 20 feet or more than 100 feet from the dispensing device(s) to shut off the power in the event of a fire, accident, or other emergency. A fire extinguisher at a propane dispenser requires an 18-pound dry chemical extinguisher with a ____.
2.
3.
64
5.1.5
Performance Criteria Self-Check: Identifying Dispenser Emergency Shutdown Systems and Fire Extinguisher Requirements
Directions:
I can identify: 1. 2. The NFPA 58 requirements for propane pump operating switches. The NFPA 58 requirements for a designated switch or circuit breaker to shut off the power in the event of a fire, accident, or other emergency at a propane motor fuel dispenser. The type of fire extinguisher required at dispenser installations.
3.
65
66
5.1.6
Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, and Adapters
Table of Contents
Table of Contents..................................................................................................... 67 Learning Activities.................................................................................................... 68 Selecting Filling Adapters Based on the Dispenser Application............................... 69 Applying NFPA 58 Code Requirements To Selecting Dispenser Transfer Hose(s) and Hose Protection Devices ....................................................... 71 Review ..................................................................................................................... 75 Performance Criteria Self-Check ............................................................................. 77
67

1.Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, and Adapters
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning selecting dispenser transfer hose(s), hose end valves, hose safety devices, and adapters and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to selecting dispenser transfer hose(s), hose end valves, hose safety devices, and adapters. (Skills Assessment)
Read Performance Objective 1: Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, and Adapters
68
5.1.6
Selection of proper dispenser transfer hoses, end valves and adapters relies on a thorough understanding of the functional requirements for the propane dispenser; that is, an analysis of the types of containers serviced by its operation. In this module you will learn to: (1) (2) (1) Select filling adapters based on the dispenser application (types of containers serviced) and hose-end valves to meet NFPA 58 code requirements Apply NFPA 58 code requirements for selecting dispenser transfer hose(s) Selecting filling adapters based on the dispenser application (types of containers serviced) and hose-end valves to meet NFPA 58 code requirements.
NFPA 58
2008
6.24.3.13 A listed quick-acting shutoff valve shall be installed at the discharge end of the transfer hose.
For every dispenser transfer hose application, a quick-acting hose-end valve is a code requirement. Before selection of transfer equipment for a dispenser installation can be completed, the Propane Dispenser Installation Plan worksheet (Module 5.1.1) should be reviewed. The types of propane containers that will be serviced will dictate the number and kinds of transfer hoses, hose-end valves, and adapters needed. Cylinder filling dispenser transfer hose, end-valve and filling adapter selection should not only consider the cylinder valve connection, but the safety aspects of the operation as well. In the discussion of dispenser pump selection, it was pointed out that a primary consideration is providing a system that minimizes the hazard of overfilling small containers. For that purpose a pump with a lower volume capacity is recommended. The same principle applies to the hose diameter and hose-end valve and adapters. For a dispenser that is dedicated and limited to filling small cylinders, smaller is better when specifying pump capacity, transfer hose diameter, and hose-end valves. For cylinder filling, -inch O.D. LP-gas hose with a quick-acting hose-end valve (Figure 1) and the appropriate adapter is typically used. (Figures 2-4) Any piping or pipe fitting used to attach the adapter to the hose-end valve must be schedule 80 steel pipe, heavy wall brass pipe or steel fitting that meets NFPA 58 requirements.
69
Figure 2. POL Filling Adapter
Figure 1. Quick-Acting Hose End Valve (Cylinder Filling)
Figure 3. Motor Fuel Cylinder Disconnect Coupling Filing Adapter
Figure 4. Type-1 and OPD Filling Adapter Additional adapters can be added to the POL filling adapter (Figure 2) to service cylinders equipped with Hansen quickdisconnect vapor valves (Figure 5) or liquid withdrawal valves (Figure 6).
Figure 5. Female POL to Hansen Quick Disconnect Valve Filling Adapter
Figure 6. Female POL to Liquid Withdrawal Valve Filling Adapter
Larger motor fuel cylinder and ASME tank filling dispensers call for larger capacity pumps and transfer equipment. For filling cylinders and ASME tanks equipped with 1-inch ACME filler valves, 1-inch LP-gas hose, a quick-acting hose end valve and appropriate filling adapter are needed. The integral hose-end valves and adapters shown in Figures 7 and 8 are minimum loss types. The end-valve shown in Figure 7 also incorporates a removable back-check valve that can be used to stop propane leaking from a container filler valve that will not seal.
70
Figure 7. 1-inch ACME Minimum Loss Hose-End Valve (2)
Figure 8. 1-inch ACME Minimum Loss Hose-End Valve
Applying NFPA 58 code requirements to selecting dispenser transfer hose(s) and hose protection devices.
NFPA 58
2008
Vehicle fuel requirements
dispenser
and
dispensing
station
6.24.3.5 An excess-flow check valve or a differential back pressure valve shall be installed in or on the dispenser at the point at which the dispenser hose is connected to the liquid piping. 6.24.4.2 A listed emergency breakaway device complying with UL 567, Standard Pipe Connectors for Flammable and Combustible Liquids and LP-Gas, and designed to retain liquid on both sides of the breakaway point, or other devices affording equivalent protection approved by the authority having jurisdiction, shall be installed. (Figure 9a & 9b)
71
The breakaway device required by 6.22.4.2 is designed to prevent an uncontrolled release of pressurized propane that would result from a pullaway incident where a dispenser hose is connected to a vehicle-mounted tank, causing the hose to breakaway from the dispenser piping. Figures 9a and 9B show breakaway devices that can be installed in the hose or at the hose connection and/or at the base of a motor fuel dispenser to provide breakaway protection in the event of a pullaway.
Figure 9a. Dispenser Base Piping or Hose Emergency Breakaway
Figure 9b. Dispenser Hose Emergency Breakaway
72
NFPA 58
2008
5.9.6.4 Hose, hose connections, and flexible connectors used for conveying LP-Gas liquid or vapor at pressures in excess of 5 psig, and as provided in Section 6.19 regardless of the pressure, shall comply with 5.9.6.4(A) through 5.9.6.4(D). (A) Hose shall be designed for a working pressure of 350 psig with a safety factor of 5 to 1 and shall be continuously marked with LP-GAS, PROPANE, 350 PSI WORKING PRESSURE, and with the manufacturers name or trademark. (B) Hose assemblies, after the application of couplings, shall have a design capability of not less than 700 psig. (C) If a pressure test is performed, such assemblies shall be pressure tested at 120 percent of the maximum working pressure (350 psig minimum) of the hose. (D) Hose assemblies shall be leak tested at time of installation at not less than the operating pressure of the system in which they are installed. 6.24.4.1 Hoses shall comply with the following: (1) Hose length shall not exceed 18 feet unless approved by the authority having jurisdiction. (2) All hoses shall be listed. (3) When not in use, hoses shall be secured to protect them from damage.
Provision (C) of 5.9.6.4 is generally understood to be included in this section due to U.S. DOT requirements for cargo tank delivery hose assemblies applicable to hose assemblies and end fittings that may be tested by a manufacturer or fabricator. It is not generally understood to apply to bulk plant or dispenser transfer hoses. In contrast, provision (D) is a specific requirement for hoses installed at dispenser installations. NFPA 58 does not specify a method for leak testing dispenser hose assemblies except for explicitly prohibiting the use of a flame to detect a leak in 6.14. In practical terms, installers generally meet the requirement of 5.9.6.4 (D) and 6.14 by pressurizing newly installed dispenser piping and transfer hose(s) with propane, and then checking for leakage at the normal operating pressure produced by the ambient temperature using a combustible gas indicator or suitable leak detector solution.
73
NFPA 58 7.2.4 Hose Inspection

2008 7.2.4.1 Hose assemblies shall be observed for leakage or for damage that could impair their integrity before each use. 7.2.4.2 These hose assemblies shall be inspected at least annually. 7.2.4.3 Inspection of pressurized hose assemblies shall include the following: (1) Damage to outer cover that exposes reinforcement (2) Kinked or flattened hose (3) Soft spots or bulges in hose (4) Couplings that have slipped on the hose, are damaged, have missing parts, or have loose bolts (5) Leakage other than permeability leakage 7.2.4.4 Hose assemblies shall be replaced, repaired, or continued in service based on the results of this inspection. 7.2.4.5 Leaking or damaged hose shall be immediately repaired or removed from service. 6.9.6.2 Flexible metallic connectors shall not exceed 60 in. (1.52 m) in overall length when used with liquid or vapor piping on stationary containers of 2000 gal (7.6 m3) water capacity or less. 6.13 Hydrostatic Relief Valve Installation. A hydrostatic relief valve or a device providing pressure-relieving protection shall be installed in each section of piping and hose in which liquid LP-Gas can be isolated between shutoff valves so as to relieve the pressure that could develop from the trapped liquid to a safe atmosphere or product-retaining section.
NFPA 58
2008
Figure 10. Hydrostatic Relief Valve with Weather Cap Protecting Pipe and Connected Hose
74
REVIEW:
Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided, or complete the statement by filling in the lines provided. E. F. G. H. 350 psig hydrostatic relief valve quick-acting the operating pressure of the system in which they are installed
A. B. C. D.
excess-flow check valve 120 times normal operating pressure at time of installation retain liquid on both sides of the breakaway point 1.
For every dispenser transfer hose application, a _____ hose-end valve is a code requirement. A(n) ____ or a differential back pressure valve shall be installed in or on the dispenser at the point at which the dispenser hose is connected to the liquid piping. A listed emergency breakaway device designed to ____, or other devices affording equivalent protection approved by the authority having jurisdiction, shall be installed on vehicle motor fuel dispensers. Propane dispenser hose shall be listed for LP-gas and designed for a working pressure of ____ with a safety factor of 5 to 1.
2.
3.
4.
5.
NFPA 58 required markings for LP-gas hose includes: a. b. c. d.
6.
a b
NFPA 58 requires that hose assemblies shall be leak tested ____

a
at not less than ____ .

b
75
A. B. C. D.
excess-flow check valve 120 times normal operating pressure at time of installation retain liquid on both sides of the breakaway point
E. F. G. H.
350 psig hydrostatic relief valve quick-acting the operating pressure of the system in which they are installed
7.
Two NFPA 58 requirements for the protection of dispenser hoses are: a. b.
8.
NFPA 58 requires a ____ or other device providing pressure-relieving protection shall be installed in each section of piping and hose in which liquid LP-Gas can be isolated between shutoff valves.
76
5.1.6
Performance Criteria Self-Check: Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, and Adapters
Directions:
I can identify: 1. 2. The type of hose-end valve required for any dispenser hose. The type of valve that must be installed in or on the dispenser at the point at which the dispenser hose is connected to the liquid piping. The device and its minimum protective characteristics that must be installed in or on dispensers where a dispenser hose is subject to a uncontrolled release of gas due to a pull-away. The design working pressure and safety factor required by NFPA 58 for hose used with propane dispensers. Information that must marked on propane dispenser hoses. When and at what pressure dispenser hoses must be tested for leakage. How dispenser hoses must be treated when not in use, and the maximum length given for dispenser hoses in NFPA 58. A device used to provide pressure-relieving protection for each section of piping and hose in which liquid LP-Gas can be isolated between shutoff valves as required by NFPA 58.
3.
4.
5. 6. 7.
8.
77
78
5.1.7
Identifying Auxiliary Equipment Used With Propane Dispensers
Table of Contents
Table of Contents..................................................................................................... 79 Learning Activities.................................................................................................... 80 Identifying Auxiliary Equipment Used with Propane Dispensers.............................. 81 Selecting Dispenser Support and Mounting Components........................................ 81 Selecting Scales for Cylinder Filling Dispenser Applications ................................... 84 Selecting Liquid Meters for Motor Fuel Dispensing.................................................. 87 Identifying Dispenser Vehicle (Traffic) Protection Requirements..............................88 Review ..................................................................................................................... 89 Performance Criteria Self-Check ............................................................................. 90
79

1. Identifying Auxiliary Equipment Used with Propane Dispensers
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning identifying auxiliary equipment used with propane dispensers and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to identifying auxiliary equipment used with propane dispensers. (Skills Assessment)
Read Performance Objective 1: Identifying Auxiliary Equipment Used with Propane Dispensers
80
5.1.7
Identifying Auxiliary Equipment Used with Propane Dispensers
Dispensers used to service portable cylinders may require suitable scales for filling by weight. Motor fuel dispensers serving consumers vehicle-mounted ASME tanks may need liquid meters with temperature correction features. In this module you will learn to: (1) (2) (3) (4) (1) Select dispenser support and mounting components Select scales for cylinder filling dispenser applications Select liquid meters for motor fuel dispensing Identify dispenser vehicle (traffic) protection requirements Selecting dispenser support and mounting components. Horizontal tank dispensers may use any of the following support systems: 1. Manufactured steel supports welded to the tank by an approved ASME code shop (Figure 1) 2. Manufacturer-designed field assembled support system (Figure 2) 3. Manufactured steel skid system 4. Installer-fabricated and assembled support system that does not involve welding on the ASME tank
Figure 1. Manufacturer Supported (ASME Code Shop) Horizontal Dispenser With Pump & Meter Cabinet
81
Figure 2. Manufacturer Designed, Field Assembled Support
Each of the illustrated support systems must be installed as prescribed in the manufacturer installation instructions. Any horizontal dispenser must be installed on a proper foundation, usually a reinforced concrete pad.
Vertical tank dispensers, because of the wind loading design requirements of NFPA 58 or seismic design requirements that may apply, must utilize tank manufacturer support systems and strictly adhere to their installation instructions.
82
Figure 4. Vertical Dispensers With Pump & Meter Cabinet
Figure 5. Vertical Dispenser Installation
After a vertical tank dispenser is installed, application of a specified fire retardant coating to support structures may be required. If so, the tank manufacturer should be contacted for retardant specifications and installation instructions.
83
(2)
Selecting scales for cylinder filling dispenser applications. Portable cylinders serviced by a dispenser installation may be filled by weight or volume. When filled by weight, scales selected for dispensers installed at locations other than a bulk plant should be simple to use by dispenser operators who are given modest but adequate training. Single-beam style scales are most frequently selected for their simplicity and durability. Typical dispenser scales have 1,000 pound ratings; minimum counter poise weights up to 200 pounds should be provided that will allow the scales to properly weigh cylinders weighing up to 190 pounds when filled with propane.
Figure 6. Scale & Transfer Hose Protection
Platform balance beam scales in manual and automatic cylinder filling operations are used to determine when the proper filling weight for DOT cylinders is reached, and when to stop the flow of liquid propane into the cylinder. In most states and jurisdictions, they must bear certification decals from weights and measures officials, and be periodically inspected and calibrated for accuracy.
84
Platform scales consist of: A floating platform to hold the cylinder An arrangement of levers An indexed balance beam A beam weight (poise) Counter weights (counterpoise) to balance the beam, and to set the beam to weight objects heavier than the index calibration of the balance beam alone A balance beam pivot point (fulcrum)
Figure 7. Single Beam and Double Beam Scales Single beam scales are used to determine the proper filling weight for the cylinder by adding the cylinder tare weight, the maximum permitted propane weight, and the weight of the dispensing hose, hose end valve, and adapters. The total of the three weights must be set on the single beam using the beam weight, and additional counter weights as may be required. Double beam scales incorporate two balance beams into one assembly. Instead of a single scale reading equal to the cylinder tare weight, and the weight of the propane and dispensing hose, this type of scale separates the two readings for more accurate reading and convenience. One scale is set for the cylinder tare weight, while the second scale is set for propane weight and dispenser hose weight. After the cylinder is filled, the second scale can be reset for only the propane fill weight so that the net weight and proper filling weight can be checked.
85
Platform scales require periodic maintenance and daily checks for accuracy. They must be level and protected from weather, especially accumulation of water, snow or ice. Each day before cylinder filling operations are started, the scale(s) should be checked for proper registration at zero (no weight on the platform) and with a known weight. When a weight discrepancy is discovered during filling, the scale itself may be contributing to the difficulty. The following areas should be checked: An accumulation of leaves, snow, ice and other debris can frequently cause the platform to bind and produce an inaccurate scale reading. Check and clean these recessed areas frequently. The platform is removable on some scales by prying off the retaining clips. Occasionally, the edges can be bent outward during inspection so that when the platform is replaced, these pried-out edges scrape against the side of the pit. If necessary, straighten bent edges. Clean and periodically lubricate loops, pivots and bearings. Do not use oil on scale parts unless instructed to do so by the scale manufacturer. All scales should be checked periodically using standard dead weights that approximately total the combined tare weight of the various cylinders filled and their propane contents.
86
(3)
Selecting liquid meters for motor fuel dispensing. Where qualified persons operate dispensers to fill vehicle-mounted ASME mobile or motor fuel tanks for the public, the liquid meter must meet state weights and measures standards. Typically, weights and measures agencies minimum liquid meter requirements specify that the meter must be: 1. Designed so that the meter must be re-set to a zero reading prior to the start of each fuel sale; 2. Designed to assure that liquid, and not vapor, is measured; and 3. Periodically calibrated and certified as accurate by a representative of the weights and measures agency, and usually required to be marked with a dated official calibration seal or decal. Note: In some jurisdictions, the meter must be outfitted with a temperature compensator to assure the accuracy of the metered delivery at different temperatures adjusted to a standard temperature volume.
Figure 8. Liquid Meter With Delivery Re-Set Register
Figure 9. Weights & Measures Meter Certification Decal
Private fleet dispensers not used for sales of propane to the public are typically exempted from weights and measures regulations. Their use of liquid meters is limited to generation of fleet operating information and cost allocation. Their meters, if used, are not generally equipped to meet requirement 3 listed above.
87
Service station (self-service refueling) dispensers offer a number of additional features and are presented in more detail in Module 5.1.8 of this training program. (4) Identifying dispenser vehicle (traffic) protection requirements. NFPA 58, 2008 edition, in 6.6.1.2 states that, LP-gas containers or systems of which they are a part shall be protected from damage from vehicles. The type of vehicular traffic protection provided for a particular dispenser installation will depend on a number of factors: 1. Specific protection measures set out by state or local authorities having jurisdiction 2. Site features including approaches that can be used by vehicles 3. The type and location of propane tank(s) (aboveground, buried or mounded underground) and other dispenser components 4. Applicable company-specific standard operating procedures Where protection is needed, it is generally provided by the use of one or more of the following: Concrete-filled steel crash posts set in concrete footings Industrial (chain link wire mesh) fencing Substantial guard rail and post barricades Reinforced concrete barricades
Figure 10. Vehicle Damage Protection Provided By Combination of Crash Posts & Industrial Fencing
88
REVIEW:
Identifying Auxiliary Equipment Used with Propane Dispensers

Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. Otherwise, complete the statement by writing on the lines provided. E. tank manufacturer F. 200 pounds G. temperature compensator
A. B. C. D.
single-beam style scales 100 pounds double-beam style scales welding on the ASME tank 1.
Installer-fabricated and assembled support system must not involve _____, unless the installer has an ASME tank code certification. If a vertical tank dispenser is installation requires the application of a fire retardant coating to support structures, the ____ should be contacted for retardant specifications and installation instructions. ____are most frequently selected for use in non-bulk plant dispenser installations due to their simplicity and durability. Typical dispenser scales have 1,000 pound ratings; minimum counter poise weights up to ____ should be provided that will allow the scales to properly weigh portable cylinders during and after filling. One of the typical requirements of weights and measures authorities for propane liquid meters used in the sale of propane sold by volume is that the meter be equipped with a ____.
2.
3.
4.
5.
6.
The type of vehicular traffic protection provided for a particular dispenser installation will depend on a number of factors: a. b. c. d.
89
5.1.7
Performance Criteria Self-Check: Identifying Auxiliary Equipment Used with Propane Dispensers
Directions:
I can identify: 1. A prohibited action that applies to installer-fabricated and assembled dispenser support system. Who should be consulted for retardant specification and installation instructions if a fire retardant system is required for a vertical tank dispenser installation. The most frequently used type of scales for cylinder servicing dispenser installations not part of a bulk plant. The minimum rating for scales typically used a non-bulk plant dispenser, and the minimum counter poise weights needed for typical cylinder filling operations. Typical liquid meter requirements of weights and measures agencies for propane liquid meters used in sales of propane. Factors that must be considered when determining the type of vehicular traffic protection needed for a specific dispenser installation.
2.
3.
4.
5.
6.
90
5.1.8
Identifying Metering Systems & Maintenance Procedures For Service Station Dispensers
Table of Contents
Table of Contents..................................................................................................... 91 Learning Activities.................................................................................................... 92 Identifying Metering Systems & Maintenance Procedures for Service Station Dispensers...................................................................................... 93 Identifying Components of Motor Fuel Dispensers .................................................. 93 Selecting Components of Motor Fuel Dispensers According to Their Applications.. 95 Installing Motor Fuel Dispensers.............................................................................. 98 Identifying the Types and Operating Characteristics of Liquid Meters ..................... 99 Identifying Components of Metering Systems........................................................ 100 Identifying Normal Liquid Meter Operating Conditions........................................... 106 Recognizing and Reacting to Abnormal Liquid Meter Operating Conditions.......... 107 Applying Troubleshooting Guides To the Maintenance of Liquid Meters ............... 111 Review ................................................................................................................... 119 Performance Criteria Self-Check ........................................................................... 122
91

1. Identifying Metering Systems and Maintenance Procedures for Service Station Dispensers
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning identifying metering and dispensing equipment used with service station motor fuel dispensers and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to identifying metering and dispensing equipment used with service station motor fuel dispensers. (Skills Assessment)
Read Performance Objective 1: Identifying Metering Systems and Maintenance Procedures for Service Station Dispensers
92
5.1.8
Identifying Metering Systems & Maintenance Procedures for Service Station Dispensers
Service station dispensers used to fill vehicle-mounted ASME tanks are usually single-purpose pieces of equipment in contrast to dispensers that service cylinders and ASME tanks. Even so, they represent a wide variety of designs and have differing operating characteristics depending on the needs of the customers they serve. In this module you will learn to: (1) (2) (3) (4) (5) (6) (7) (8) (1) Identify components of motor fuel dispensers Select components of motor fuel dispensers according to their applications Install motor fuel dispensers Identify the types and operating characteristics of liquid meters Identify components of metering systems Identify normal liquid meter operating conditions Recognize and react to abnormal liquid meter operating conditions Apply troubleshooting guides to the maintenance of liquid meters Identifying components of motor fuel dispensers. Motor fuel dispensers are available in a variety of designs to meet different functions ranging from fully mechanical units for single fleet users, to multiple credit card or cash transaction electronic equipment servicing the refueling needs of the motoring public. (Figures 1 and 2)
Figure 1. Dispenser Pump & Mechanical Meter Cabinet
Figure 2. Self-Service Electronic Meter Cabinet
93
The dispenser cabinet shown in Figure 1 is usually located at the propane supply tank and includes the transfer pump, mechanical registering liquid meter, transfer hose, hose-end valve and adapter and the mounting hardware for each system component. The equipment is simple and designed for use by trained personnel in a commercial business. By contrast, the self-service dispenser cabinet pictured in Figure 2 is typically located away from the supply tank and pump. It houses an electronic liquid meter and its electronic display panel capable of communicating with the customer, credit card companies and the service station cashier. This dispenser provides transfer hose connections and a hose-end valve storage slot that also serves as a pump interlock switch. Styled for consumer use, it has the convenience features familiar to motorists who have experience using gasoline or other motor fuels. Each dispenser is fully functional for a particular type of customer and installation. Selection of the appropriate equipment and dispenser type for these distinctly different customer applications will determine if the installation is a good investment or a losing business venture Vehicle refueling dispensers with electronic point-of-purchase features do not have to be remotely located away from the propane supply tank and pump, and many sites with existing gasoline and/or diesel dispensers can be effectively served by steel skid-mounted dispensers and supply tank units. (Figure 3)
94
Figure 3. Vertical and Horizontal Motor Fuel Dispensers With Pump & Meter Cabinet
(2)
Selecting components of motor fuel dispensers according to their applications. The dispensing cabinet pictured in Figure 1 is equipped with a propane liquid meter and a mechanical transaction register head. A variety of mechanical registers can be used with the base meter unit (Figure 4) offering a wide range of features including single delivery gallon and tenths of gallon registration and reset a gallons totalizer that provides an on-going accounting in full gallons for all deliveries pumped while the register is in service and properly operating mechanical delivery ticket stamping for each delivery
95
Figure 4. Rotary Piston Measuring Chamber Liquid Meter Configured for Register Head Operation The same liquid meter can be equipped for electronic data generation for use with electronic ticket printing, self-service dispenser display panel operations, or remote electronic accounting systems by adding a rotation pulse generator linked to appropriate electronic receiving and capture hardware and software. (Figure 5)
Figure 5. Rotary Piston Measuring Chamber Liquid Meter Equipped with a Pulse Generator for Electronic Data Systems
96
Another meter style available uses a series of blocking and displacement rotors in its measuring chamber. (Figure 6) It can be configured for single or multiple delivery operation to serve a single customer or two customers from the same dispenser cabinet. (Figure 7)
Figure 6. Single Customer Configuration
Figure 7. Two Customer Dispensing Configuration
Self-service dispensers typically locate the meter and its piping and electrical and/or electronic connections in the lower section of the cabinet. (Figure 9)
Figure 8. Meter Installed in Self-Service Dispenser
97
Other dispenser options that must be selected based on application include the overall type and style of the dispenser, the customer interface display and panel design, and the transaction remote electronic registration and controls used (cashier pump controls, resets, and transaction charges management equipment). Figures 9 and 10)
Figure 9. Self-Service Hose-End Valve and Pump Interlock Switch
Figure 10. Customer Credit Card Interface and Display Panel
The dispenser design selected is very important for some motor fuel dispenser installations where the installation offers other fuels, and the operator has brand identification or franchise dealer site styling standards that must be met. (3) Installing motor fuel dispensers.
NFPA 58 specifically requires that dispensers must be installed according to their manufacturers installation instructions. Where the dispenser is installed at a multiple fuel re-fueling station, the provisions of NFPA 30A apply as well. Figure 11 illustrates minimum separation distances that apply to motor fuel dispensers at multiple fuel re-fueling stations.
98
Figure 11. Propane Dispenser at Multi-Fuel Vehicle Refueling Installations While the dispenser supply tank(s) minimum buildings and other properties must comply with distance requirements for the dispenser must consult local jurisdictional requirements before dispenser. (4) separation distance to important NFPA 58, the minimum separation comply with NFPA 30A. Always installing any propane motor fuel
Identifying the types and operating characteristics of liquid meters. Pump systems often have a liquid meter in the discharge piping, especially when they are installed on propane cargo vehicles or at motor fuel dispensing stations, where the propane marketer must know how many gallons of propane have been pumped into a receiving container in order to bill the customer accurately. The meter itself is usually part of the metering system consisting of the meter, a vapor eliminator with an integral strainer, and a differential valve at the meter port outlet. (Figure 12.) Most meters will also be equipped with a temperature compensator to adjust the meter reading automatically for changes in volume caused by increases or decreases in the temperature of the propane.
99
Figure 12. Propane Liquid Meter (5) Identifying components of metering systems. The meter is composed of a vapor eliminator, measuring chamber, temperature compensator, differential valve, and a register. The Measuring Chamber. Liquid meters are positive displacement devices. They are operated by trapping fixed amounts of propane in fluid tight compartments formed by moving parts inside the measuring chamber. The propane moves the internal parts of the meter much as a crowd of people moves the turnstiles on their way to the stadium. Inside a rotating piston meter is a hollow, cylindrical "piston" that lies on the bottom of the measuring chamber in a highly polished cylinder ring, as illustrated in Figure 13a. As propane enters the meter through the measuring chamber inlet, it fills the inside of the rotary piston and forces the piston around and to the left along the inside of the cylinder ring, as illustrated in Figure 13b. As the piston moves, it carries the liquid on the inside of the piston, but it also forces the liquid ahead of it toward the chamber outlet.
100
a.
b.
c.
d.
Figure 13. Measuring Chamber
When the piston reaches the bottom of its stroke, as illustrated in Figure 13c, liquid from the measuring chamber inlet continues to push the piston around the inside of the cylinder ring, but the liquid now fills the spaces behind, not inside of the piston. As the piston nears the top of its stroke, as illustrated in Figure 13d, the piston finishes forcing the liquid ahead of it out through the measuring chamber outlet, and the liquid inside the piston begins to leave the chamber as well. At top dead center, the area outside the piston is once again filled with liquid and the cycle begins again. The piston spindle is in constant contact with the control roller in the center of the cylinder ring and makes one revolution around the roller for every complete revolution of the piston. Since a fixed amount of liquid passes through the measuring chamber with each revolution, the meter can keep track of how much liquid has been delivered by "counting" the revolutions of the spindle. It does this by means of a series of interlocking gears that are driven by the spindle and convert the revolutions of the spindle into a volumetric reading on the meter register above the meter. Not all meters have the same kind of measuring chambers, just as some pumps use gears or rotors instead of sliding vanes to trap the liquid and move it through the transfer system. For example, the measuring system illustrated
101
in Figure 14 depends on a set of synchronized levers encased in a cylindrical chamber and connected to each other by gears in the back of the measuring chamber. As liquid enters the measuring chamber, it is controlled by two "displacement" rotors and a "blocking" rotor which form a series of liquid tight compartments at different points around the inside of the chamber. This causes a fixed amount of propane to be allowed to pass through the meter with each revolution of the displacement rotors and can be translated into gallons by means of a transmission connected to the back of the rotors.
Figure 14. Measuring Chamber, Transmission and Seal Gear Train. The gear train is usually located directly above or behind the measuring chamber and consists of a series of gears and shafts that convert the movement of the components inside of the measuring chamber into a force large enough to operate the register on top of the meter. The gear train is a reduction set. This means that it reduces the speed of the input shaft by a fixed amount in exchange for a greater force at the output shaft. The actual reduction ratio is determined by the size of the various gears in the gear train
102
and depends on the units that will be shown on the meter register. All meters have some type of provision for changing the ratio between the final output of the gear train and the gears in the register by small amounts. Such devices are often referred to as "gear shifters" or "adjusters" and are used to compensate for errors in meter readings of less than .30% caused by wear to internal parts or slight differences in the method of delivery. For errors larger than 0.30%, the meter reading is corrected by replacing a pair of "change gears" at the gear train output. See Figure 15 for a change gear arrangement.
Figure 15. Change Gear Arrangement There is usually a seal either on the input or the output shaft of the gear train to prevent the propane from leaking out of the meter body and entering the register. The seal is usually a U-shaped packing or O-ring that fits around the drive shaft and is designed to be replaceable in case it begins to leak.
103
Temperature Compensators. Since propane liquid changes volume significantly even with relatively small changes in temperature, most propane meters are equipped with devices that sense the temperature of the product and automatically correct the volume measured by the meter to the equivalent volume at 60 F. Such devices, known as temperature compensators, are usually installed between the gear train and the register and consist of a special liquid filled thermostat and a variable ratio drive unit. As the liquid in the thermostat expands and contracts, it operates an external lever that alters the final drive ratio of the gear train and changes the rate at which volume readings accumulate on the meter register.
Figure 16. Temperature Compensator (Cover Cutaway)
To aid in calibrating the meter, the temperature compensator usually has some provision for altering the amount of change it produces with a given change in the temperature of the product. It also has some means of locking out the compensation gears so that errors in the meter and errors in the compensator can be isolated from each other during testing. The Register. The type of register a meter has depends primarily on its application. For example, small meters at cylinder filling docks or campground dispensing stations may be equipped with a register like the one illustrated in Figure 17. The two hands indicate the total amount of propane that has been delivered, and can be reset to zero with the handle at the side of the register. The numbers in the small window at the center of the face plate are used to keep track of the total amount of propane delivered. The day, week, or month totals can be taken from this totalizer.
104
Figure 17. Meter Registers Not all registers are so simple. Some, such as the computer meter illustrated in Figure 18, are far more complex and automatically print the total volume of propane delivered, the price per unit volume, the sales tax, date and time of delivery, customer name, address, account number, and the total price for the delivery. Ease of operation is foremost and basic with the electronic register illustrated below. Information can be up-loaded or down-loaded from the office computer for automatic posting of accounts and data information. A 4line display in the delivery truck cab or service station office computer directs the operator to the next move or procedure in case the operator forgets the procedure or is unfamiliar with it. Electronic registers are typically used on propane cargo vehicles where the driver must leave a printed record of the delivery and a bill for the customer. Other similar registers print only the start and finish readings on the meter or the total volume delivered.
Figure 18. Electronic Register
105
(6)
Identifying normal liquid meter operating conditions. Because even the smallest deviations from the correct tolerances inside the measuring chamber are enough to affect a meter's accuracy, most states require propane marketers to have their meters recalibrated or "proven" on a regular basis. This is generally done with a volumetric prover (tank of certified capacity), which is filled through the meter being tested with the temperature compensator locked out. The reading on the meter is then compared to the quantity of the propane shown on the provers liquid scale. If they do not agree, the meter is adjusted accordingly. Since certain types of wear may not be apparent at normal flow rates, a second reading is usually taken at a slower rate and compared again to the volume in the prover. Finally one or more prover runs are made with the temperature compensator engaged to obtain a final accuracy check after all required adjustments are made. Meters with temperature compensators are usually tested three or more times. They are tested twice with the compensator disconnected and then a third time with it engaged. After the third test, the volume of propane in the prover is corrected to 60 F by consulting a temperature/volume table and compared to the reading on the meter register. The temperature compensator is then adjusted accordingly. Typically, the responsible agency usually places a seal on the meter when it has been proved and found accurate. If the seal is broken for any reason, consult your company policy. The same regulations that require meters to be proved on a regular basis also cover other parts of metering systems, including installation of devices to keep vapor from entering the meter, the design of the register head, and other factors that may affect the accuracy of the meter's reading. Weights and measures regulations vary from one locality to another. Check your company's policies and state and local codes to ensure which regulations and procedures must be followed. When liquid meters are operating normally: 1. Bulk plant month-to-month inventory records will not indicate shortages or significant overages when gallons sold are compared to gallons received at the plant. 2. Except for regular, soft clicking of the meter gear train, meter operation is not noisy. 3. Register and totalizer operation will be smooth and regular without skips.
106
4. The register will fully indicate a zero reading in all decimal places when the meter is reset. 5. Registration will immediately begin when piping and hose end valves are open and the pump is operating. 6. Metering will be maintained at the same general rate when all piping and hose end valves are fully open with the pump operating. (A gradual slowing of metering rate under these conditions may indicate a tear or hole in the meters differential valve diaphragm that will eventually cause the meter to stop the flow of liquid). (7) Recognizing conditions. and reacting to abnormal liquid meter operating
Although state and local regulations governing meters are designed to protect the customer against being billed for more propane than is received, the marketer often loses when a meter is poorly calibrated. As meter parts wear, the tolerances inside the measuring chamber increase so that the meter actually "gives more" than is shown on the register. This is especially true at slow flow rates. It is always to the company's advantage to be sure that meters are checked on a regular basis and recalibrated as necessary. Propane cargo vehicle drivers and other personnel should be alert at all times for signs of developing meter trouble. These include erratic meter operation, obvious over or under registration, increasingly noisy operation, and excessively slow delivery rates. All of these symptoms should be reported and corrected as quickly as possible. When internal parts become so worn that the meter can no longer be brought into calibration, it is often possible to restore the meter to good condition by replacing worn parts or the entire measuring chamber. For example, in a rotary piston meter the diaphragm and control rotor usually wear first and are easily replaced. Damage to the piston or cylinder, which usually is the result of foreign particles in the propane supply or dry running, requires replacement of the entire measuring chamber. Except for the replacement of the shaft seal and gaskets to stop leakage of propane, repairs to the gear train and/or register are too complicated for the average dealership and are usually left to specialized, factory authorized, repair stations. The damaged register or gear train is usually exchanged for one that has been completely rebuilt.
107
Maintenance of Meter Components Strainers. Meters are highly sensitive to dirt and debris which can scratch the lining of the measuring chamber and, in extreme cases, jam the meter. All metering systems should include a strainer to trap and filter foreign matter in the propane line and prevent damage to the meter. On small meters, the strainer may be installed in the inlet piping separate from the meter, as illustrated in Figure 19. The strainer is usually an integral part of the vapor eliminator and is located so that propane entering the eliminator must pass through the chamber before it reaches the meter's measuring chamber.
Figure 19. Strainer Meter strainers can seriously restrict the flow of liquid through the delivery system, if they become clogged or excessively dirty. They should be cleaned and checked on a regular basis for this reason. Special procedures are required to bleed off the pressure inside the meter and must be carried out before beginning any maintenance or repair operation. Never attempt to bleed down a meter solely by opening the hose end valve on the delivery hose; doing so reduces the pressure only in the hose, not in the meter. Internal meter pressure reduction requires closing all valves that communicate with the tank, and venting pressurized gas from the balance line connecting the vapor eliminator and differential valve.
TA
! ING RN WA OT N E DO AT ER OP
GO
UT
108
Never open any strainer until it has been fully isolated from the rest of the system, and the pressure inside the strainer has been reduced to 0 psig. Meter strainers are especially dangerous, since they contain amounts of propane liquid large enough to cause serious injury to the hands and face even after the meter has been disconnected from the system. Always consult manufacturers instructions prior to servicing the meter, strainer and differential valve. Preventing Vapor from Entering the System. Propane meters must be kept liquid full for several reasons. They depend on propane liquid for lubrication of all close fitting parts inside the measuring chamber. If the measuring chamber fills with vapor or propane boils off into vapor as it passes through the meter, it can lead to significant damage to the chamber and rapid wear to the moving parts inside. Because all propane meters are positive displacement devices, they will measure vapor as well as liquid. Since propane vapor occupies a far greater volume than the equivalent amount of liquid, the meter will over register any time there is vapor in a measuring chamber. Most state and local codes require meters to be equipped with some type of a device to prevent vapor from entering the meter before or during delivery. A vapor eliminator and differential valve perform this function. Vapor eliminators, as illustrated in Figure 20, usually consist of a float chamber, a float, and a release valve that opens into a line leading back to the vapor space of the supply tank. As long as the float chamber is full of liquid, the float stays high in the chamber and holds the vapor release valve closed. As vapor begins to enter the float chamber, it slowly displaces the liquid, and the float sinks lower. When the float has dropped low enough, the valve at the top of the chamber opens and accumulated vapor flows out and through the return line, back to the storage tank. The float chamber then begins to fill with liquid again, and the float rises, re-closing the release valve.
109
Figure 20. Vapor Eliminator Keeping the Meter Closed. The vapor eliminator is installed together with a differential valve in most metering systems to keep the system full of liquid, when the system has been shut down between deliveries. The inlet to the vapor eliminator is equipped with a back check valve to prevent liquid from escaping into the inlet piping. At the other side of the meter is a differential valve, which stays closed whenever outlet pressure from the meter is equal or less than 8 psi above the vapor pressure of the propane liquid in the system. This ensures that the meter will open only when the pump is running and has raised pressure in the meter high enough to prevent vapor from forming in the meter. Since the back check valve in the eliminator makes it possible for the float chamber to be closed off when it is liquid full, the eliminator is equipped with a hydrostatic relief valve to allow expanding propane liquid to escape before it can damage the float chamber or the meter itself. Differential Valves. Some differential valves are attached directly or built into the meter, as illustrated in Figure 21a. Others are installed separately in the outlet piping directly downstream, as illustrated in Figure 21b. In either case, the differential valve works in essentially the same way. As Figure 12 (page 8) illustrates, a short section of tubing connects the differential valve and vapor eliminator. Normal tank pressure is then directed onto the top of a
110
rubber diaphragm or behind a piston inside the valve body. Together with the force of an adjustable spring, the vapor pressure serves to keep the valve closed when the pump is not running and prevents liquid from moving through the meter in either direction.
a.
b.
Figure 21. Differential Valves When the pump is turned on, the meter quickly fills with liquid raising the internal pressure and collapsing or releasing through the vapor eliminator any vapor that may have formed in the meter. When the internal pressure exceeds the combined pressures of the supply tank vapor pressure and the spring in the differential valve, the valve will reopen. Neither vapor eliminators nor differential valves require significant maintenance under normal conditions. If either should fail, it is usually the result of a collapsed float (or a pin hole in the float allowing it to fill with liquid) or worn release valve, or, in the case of the differential valve, a torn diaphragm or damaged valve seat. Damage to any of these parts will cause the meter to behave erratically or stop the flow of liquid altogether. If repair parts are needed, they are readily available from the manufacturer and are easily installed. (8) Applying troubleshooting guides to the maintenance of liquid meters. When abnormal operating conditions are encountered in metered liquid transfer systems it is important to remember that the problem may exist in any part of the system, and that the system includes not only the liquid meter, but the piping, valves, pump and the pump protective devices as well. If the pump is not installed according to manufacturer instructions it is possible that the rate of liquid transfer and the operation of the liquid meter will slow according to the length of time the pump is operated. Assuming that the
111
problem is isolated to the liquid meter may be the wrong conclusion and lead to costly and frustrating waste of time and effort. In this section troubleshooting liquid meters is presented as a systematic approach that includes consideration of the entire pump/transfer system.
TA
O&M Procedures Manual
! IN G RN T WA NO E DO AT ER OP
GO
UT
General Safety Precautions for Troubleshooting Propane Transfer Equipment Remove all sources of ignition from the transfer area while the system is in operation. Keep a recently inspected fire extinguisher having a minimum capacity of 18 lb. dry chemical with a B:C or A:B:C rating within reach at all times. Always wear vinyl safety gloves and protective glasses when inspecting liquid transfer lines and equipment. Never look directly into or place any part of the body over the outlet of a hydrostatic relief valve. Do not open any liquid line or attempt to inspect any internal part of pumps or meters without first isolating the equipment from the rest of the system, reducing the internal pressure to 0 psig, and allowing any residual propane liquid to boil off. Liquid may remain in some parts of the system at atmospheric pressure after blowing down the system. To avoid costly mistakes and the frustration they produce, the troubleshooting charts included in this section, or ones like them that are prepared by the manufacturers of the equipment, should be utilized. Although the format of such charts may vary, they always involve the same basic steps as follows: 1. Definition of the problem. 2. One or more inspections/tests to isolate the cause of the problem. 3. Appropriate corrective action. For example, notice that Column 1 in TABLE A and TABLE B, on the pages 115-118, PROBLEM lists the various kinds of problems that may be encountered with pumps or meters. The next two columns, POSSIBLE CAUSES and LOCATING THE PROBLEM, list the possible causes of each
112
problem and give a detailed procedure to help determine which of the causes is actually responsible. The last column, CORRECTING THE PROBLEM, describes the action that should be taken. NOTE: The corrective actions in the last column are based on manufacturer's guidelines and common industry practices. Check company policies an the manufacturer's literature for the equipment if in doubt about the correct action to take.
CAUTION
Do not open any liquid line or attempt to inspect the internal parts of pumps or meters without first being familiarized with the procedures concerning the isolation of components from the rest of the transfer system. Failure to follow those procedures may result in serious personal injury, fire hazard, and potential loss of life and property. Although the source of some types of problems can be identified by visual inspections, anything more than the most simple type of difficulty requires the knowledge of the internal behavior of the equipment. More specifically, it is necessary to know the following information: Pressure at the pump inlet, Pressure at the pump discharge, Pressure at the supply tank, and Pressure at the differential valve sensing line, and Pressure of the tank being filled. The pressure readings at various points in the system, as illustrated in Figure 11 serve to indicate the source of the problem. With the system at rest, the readings on all four of the gauges should be the same, since the pressure shown will simply be the vapor pressure of the propane in the system. When the appropriate valves have been opened and the pump started, the tank pressure, the pump inlet pressure, and the meter pressure should remain approximately the same, but the pump discharge pressure should rise substantially (showing a good differential pressure across the pump). When there is a problem in the system, the pressure gauges will behave much differently.
113
Figure 22. Pump System Schematic Although many types of meter problems affect the transfer capabilities of the system and may be diagnosed with the help of pressure gauges as described above, other problems do not and must be dealt with in other ways. Usually such problems involve erratic under-registration or over-registration, excessive meter noise, or failure to meter the propane that passes through the system. These problems and the steps that they require for correction are listed in TABLE B, on page 26. Using the troubleshooting charts to locate and correct pump or meter problems Always begin finding the entry in the extreme left-hand column that best describes the problem. Next, review the possible causes of the problem listed in the second column. If the particular cause stated is not responsible for the problem being experienced, eliminate it from the list. Otherwise, begin with the first possible cause and carry out the tests described in the third column to determine what is responsible for the problem. Most times the causes that are easiest to test for are listed first. It is wise to proceed in order through the list of causes. When the cause of the problem has been located, carry out the appropriate corrective action from the last column on the right. Always remember that the key to successful troubleshooting is patience. If the process is carried out hurriedly, chances are good that the cause of the problem will not be found, or the wrong component will be repaired/replaced. Be patient and use troubleshooting charts properly and costly mistakes and wasted effort are more likely to be avoided.
114
TABLE A. TROUBLESHOOTING PUMPS AND METERED DELIVERY SYSTEMS

PROBLEM Pump turns, but no flow; low pump capacity; pump won't build pressure POSSIBLE CAUSE Supply tank empty or near empty LOCATING THE PROBLEM Check liquid level gauge CORRECTING THE PROBLEM No corrective action possible. Remember that a reduction in pumping rate always accompanies low tank level. This is due to vaporization, loss of heat pressure, and vortex effect, all of which are worse in cold weather. Repair damage according to manufacturer's instructions.
Low pump speed
Bobtails/Transports: Check engine speed control and drive system. Inspect for damaged or broken universal joints, drive shafts, and drive shaft keys. Stationary Installations: Check for damage to the motor coupling or slippage in the sheaves and V-belts.
Valves(s) incorrectly closed/open
Check internal valve to be sure the operating lever is in the full open position. Make sure all valves in the system are in the position required for normal operation. Check each valve in sequence, starting from the supply tank and working toward the receiver tank. Install pressure gauges at points shown in Figure 11. Open/close all valves as required for normal pumping operations and start pump. Match readings on gauges with one of the conditions described below.
Tighten or replace V-belts as necessary. (Always replace V-belts as a set.) Check condition of fusible link(s) and return spring(s) if so equipped. Repair as needed. Re-adjust valve actuating linkage to proper open and close position. Open/close the valve.
All other causes
NOTE: If malfunction is accompanied by abnormal pump noise, operate pump only long enough to read gauges. Operating pump for longer amounts of time may intensify the problem and/or damage the pump.
GAUGE READINGS Pump inlet pressure drops more than 2-3 psig; outlet pressure and supply tank pressure remain unchanged.
Check for (1) Clogged inlet strainer, (2) Closed excess flow valve, or
(3) Ice in the supply tank or inlet piping.
(1) Clean strainer. (2) Close manual shutoff valves down stream vale side of excess flow and wait for valve to reopen. Then slowly reopen the shutoff valves. (3) Thaw carefully. Inject methanol into supply tank to disperse water.
115
TABLE A. TROUBLESHOOTING PUMPS AND METERED DELIVERY SYSTEMS (Continued)

GAUGE READINGS Supply tank and pump inlet pressures remain the same; pump outlet pressure rises to normal level or above; meter pressure substantially above supply tank pressure Internal damage to liquid withdrawal valve. (1) Manual or automatic bypass valve open. Check to be sure manual bypass valve is closed; then slowly close manual shutoff valve in return line to supply tank. If outlet pressure increases, bypass valve is stuck open or set to open at too low a pressure. (2) Automatic bypass valve stuck shut; internal safety relief valve returning pump discharge to inlet side of pump. (Usually accompanied by abnormal pump noise as a result of cavitation.) Open manual bypass valve and listen for reduction in pump noise. If noise drops significantly, slowly close valve and watch pressure gauge at pump outlet. If pressure increases slowly and then drops suddenly, automatic bypass valve is stuck shut or set too high. (3) Wear or damage to internal parts of pump. (3) Disassemble pump and check for worn side plates, vanes, or liner; check internal safety relief valve for proper operation. If side plates are worn, check drive assembly for proper alignment. Disassemble meter and repair or replace faulty parts. On differential valve, check for ruptured diaphragm or seals. On vapor eliminator, check for damaged or fouled valve seat, collapsed or leaking float, and jammed or binding linkage. Repair according to manufacturer's instructions. (1) Repair or adjust bypass valve.
(2) Repair or adjust bypass. Determine cause of high differential pressure and correct as necessary.
Supply tank and pump inlet pressures remain the same; pump outlet pressure rises to normal level or above; meter pressure substantially above supply tank pressure.
(1) Damaged vapor eliminator, or (2) damaged differential valve. Isolate meter from supply tank. Carefully disconnect the vapor sensing line and allow meter to bleed down to atmospheric pressure. If vapor continues to escape from the differential valve, the valve is damaged. If vapor continues to escape from the vapor eliminator, the eliminator is not functioning properly.
116
TABLE A. TROUBLESHOOTING PUMPS AND METERED DELIVERY SYSTEMS (Continued)

PROBLEM GAUGE READINGS All pressure readings normal but no flow from system and/or no movement on meter register. POSSIBLE CAUSE LOCATING THE PROBLEM METERED SYSTEMS ONLY (1) Clogged meter strainer. (1) Check and clean meter strainer. (2) Disassemble meter. (2) Damaged meter parts (rotors, gears, inlet back check valve, etc.). (3) Malfunction of differential valve (stuck or frozen shut). Leaking diaphragm. (4) Clogged vent line. ALL SYSTEMS All pressure readings normal but pump outlet pressure is 75 psi higher than supply tank pressure. Closed valve or other restriction in discharge piping. Very high differential pressure. Check to be sure all valves are fully open. Check pressure gauge on receiver tank, if so equipped. Install vapor equalization line if permitted by company policy and state and local regulations. Otherwise, reduce pump speed. NOTE: Without vapor equalization, a pump can remove only about 3% of supply tank capacity per minute without severe cavitation. Check pumping system by attempting to fill another container. (1) Close manual by-pass valve. (2) Adjust or repair/replace automatic by-pass valve. (3) Repair/replace internal valve assembly as needed. (4) Repair pump as necessary. (3) Check for damaged parts. Repair or replace as necessary. CORRECTING THE PROBLEM
(4) Clear line.
Problem with filler valve in receiver tank. Inlet pressure remains unchanged; outlet pressure rises slightly; there is slow or no flow through the meter. (1) Open manual by-pass valve. (2) Malfunction of external automatic by-pass valve. (3) Pump internal by-pass valve is malfunctioning in open position. (4) Excessive pump wear.
117
TABLE B. TROUBLESHOOTING LIQUID METERS

PROBLEM Slow meter POSSIBLE CAUSE Pumping system malfunction Abnormally high differential pressure Clogged meter strainer Internal damage to meter or meter accessories Restriction in discharged piping downstream from meter Consistent overor underregistration Erratic operation/ over-registration Meter out of calibration Leak in differential valve diaphragm or seals Blockage in return line from vapor eliminator to supply tank Close hose end valve on delivery hose and run pump at normal speed. If meter "creeps" forward, diaphragm or seal is leaking. With pump off, close manual shutoff valve in vapor return line. Carefully disconnect the vent line from vapor eliminator; then slowly reopen the shutoff valve and listen for escaping LP-gas vapor. If no vapor escapes, the line is blocked. Read "General Causes of Poor Pump Performance" in this instruction sheet and check system for design flaws that may increase cavitation beyond acceptable limits or contribute to vapor formation in the system. Purge and disassemble meter. Inspect vapor eliminator for proper operation. Check and recalibrate the meter as required by state and local regulations. Disassemble and repair meter. LOCATING THE PROBLEM CORRECTING THE PROBLEM
See "Low pump capacity" in TABLE A, page 115
Clean out line.
Vapor entrained in liquid due to poor pump system design
Rebuild system as necessary.
Erratic operation/ underregistration
Vapor release valve stuck shut, allowing vapor to enter the meter Wear on moving parts in measuring chamber or drive train Damage to meter register Damaged register
Repair as necessary.
Purge and disassemble meter. Inspect moving parts for excessive wear or damage according to the manufacturer's instructions.
Repair or replace parts as necessary.
No register reading when liquid is flowing
Remove register and check final stage of drive train for movement when system is in operation. If movement is present, register is damaged. Purge and disassemble meter. Inspect moving parts in measuring chamber, transmission, and drive train for damage.
Replace register.
Damaged drive train, rotors, transmission, etc.
Repair or replace parts as necessary.
118
REVIEW:
Identifying Metering Systems & Maintenance Procedures for Service Station Dispensers
Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. E. F. G. H. 10 feet NFPA 30A NFPA 54 20 feet
A. B. C. D.
manufacturer installation instructions pulse generator documented sniff tests appropriate equipment and dispenser type
1.
Selection of the _____ for the specific customer application is important because the selection may determine if the installation is a good investment or a losing business venture. Standard mechanical propane liquid meters can be equipped for electronic data generation for use with electronic ticket printing, selfservice dispenser display panel operations, or remote electronic accounting systems by adding a rotation ____. NFPA 58 specifically requires that dispensers must be installed according to ____. Where a propane motor fuel dispenser is installed at a multiple fuel refueling station, the provisions of ____ apply. According to NFPA 58 propane dispensers must be separated from other fuel dispensers by at least ____.
2.
3.
4.
5.
119
Directions:
Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. A response may be used more than one time. F. G. H. I. J. rotor vapor eliminator recalibrated or proven measuring chamber final stage of the gear train
A. B. C. D. E.
register differential valve documented sniff tests equivalent volume at 60 F solely by opening the hose end valve on the delivery hose
6.
a b
A propane liquid meter may be composed of a ____measuring chamber,

a
temperature compensator, and a _____.

b
7.
Propane liquid meters may be equipped with temperature compensators that sense the temperature of the product and automatically correct the volume measured by the meter to the ____. Most states weights and measures authorities require liquid meters to be ____ on a periodic basis.
8.
9.
Propane operating personnel should promptly report and/or correct any of these meter abnormal operating conditions: a. b. c. d. 10. Never attempt to bleed down a meter ____; doing so reduces the pressure only in the hose, not in the meter. 11. A liquid meter will over register any time there is vapor in the ____. 12. Most state and local codes require meters to be equipped with a vapor eliminator and a ____ to prevent the meter from over registering.
120
A. B. C. D. E.
register differential valve documented sniff tests equivalent volume at 60 F solely by opening the hose end valve on the delivery hose
F. G. H. I. J.
rotor vapor eliminator recalibrated or proven measuring chamber final stage of the gear train
13.
If the vapor eliminator or differential valve fails, it is usually the result of: a. b. c.
14.
When the transfer pump is operating and all transfer valves are open, if the supply tank and pump inlet pressures remain the same; the pump outlet pressure rises to its normal level or above; and meter pressure is substantially above supply tank pressure, but there is not flow, the condition is probably due to defect in the vapor eliminator or the ____. When there is no change in register reading when liquid propane is flowing the first meter component to check is the ____ for movement.
a
15.
a
If movement is seen, the ____ must be repaired or replaced.

b b
121
5.1.8
Performance Criteria Self-Check: Identifying Metering Systems & Maintenance Procedures for Service Station Dispensers
Directions:
I can identify: 1. The importance of selecting the appropriate dispenser type for a specific motor fuel application. The device that must be added to a propane liquid meter to enable it to communicate with electronic measurement systems. A specific NFPA 58 requirement that applies to the installation of dispenser units. The NFPA code in that applies to installations of motor fuel dispensers at multiple fuel refueling stations. The minimum separation distance required between propane motor fuel dispensers and other fuel dispensers. The major components of a propane liquid meter. The component of a liquid meter that corrects liquid volume at any temperature to the equivalent volume at 60F. The procedure required by state weights and measures authorities to assure the accuracy of propane sold by volume to customers. Liquid meter abnormal operating conditions that should be immediately reported and corrected.
2.
3.
4.
5.
6. 7.
8.
9.
10. Procedures required for controlling the hazard of pressurized propane prior to any meter maintenance or repair operation. 11. A condition that will cause over-registration of a liquid meter.
122
12. The meter components required to prevent vapor from entering the meter before or during liquid transfer. 13. Component failures that will cause erratic meter operation or stop the flow of propane through the meter. 14. Meter components to check if (with the pump running and all transfer valves open) supply tank and pump inlet pressure remain the same; pump outlet pressure rises to normal level or above; meter pressure is substantially higher than supply tank pressure; and there is no flow and/or movement of the meter register. 15. Meter components to check if liquid is flowing but there is no change in register reading.
123
124
5.1.9
Installing Propane Dispensers
Table of Contents
Table of Contents................................................................................................... 125 Learning Activities.................................................................................................. 126 Installing Propane Dispensers ............................................................................... 127 Verifying Compliance with NFPA Code Requirements for Dispenser Installations 127 Locating and Installing Dispenser Foundation and Supporting Structures............. 131 Installing Dispenser Components .......................................................................... 132 Review ................................................................................................................... 134 Performance Criteria Self-Check ........................................................................... 136
125

1. Installing Propane Dispensers
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning installing the propane dispensers and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to installing the propane dispensers. (Skills Assessment)
Read Performance Objective 1: Installing the Propane Dispensers
126
5.1.9
Successful propane dispenser installations are the result of: Thorough analysis of operator needs and the installation site (See Module 5.1.1) Proper component selection Applying a knowledge and understanding of NFPA code requirements Complying with local jurisdictional requirements, including any applicable permit and inspection steps or preparation of a fire safety analysis if needed Coordination with the site owner or manager and any job sub-contractor(s) Good pre-installation job planning and communication with propane company employees involved Application of quality work practices during all phases of the installation In this module you will learn to: (1) (2) (3) (1) Verify compliance with NFPA code requirements for dispenser installations Locate and install dispenser foundation and supporting structures Install dispenser components Verifying compliance with NFPA code requirements for dispenser installations. Section 6.24 of the 2008 edition of NFPA 58 gives specific requirements for dispensers used for motor fuel dispensing. Additional requirements are found in Sections 6.2 and 6.3 of the Code.
NFPA 58
2008
6.24 Vehicle Fuel Dispenser and Dispensing Stations. 6.24.1.1 Section 6.24 includes location, installation, and operation of vehicle fuel dispensers and dispensing stations.
Vehicle fuel dispensers and dispensing stations must be located in accordance with Table 6.5.3 (shown on the next page). Particular attention must be directed to locating vehicle fuel dispensers and dispensing stations away from pits as required by Table 6.5.3, and no drains or blow-offs from the vehicle dispensing unit can be directed toward or within 15 feet of a sewer system opening.
127
From NFPA 58, LP-Gas Code, 2008 edition
During the installation of a motor fuel dispenser, compliance with the following provisions of NFPA 58 should be verified:
128
NFPA 58
2008
6.24.3 General Installation Provisions. 6.24.3.1 Vehicle fuel dispensers and dispensing stations shall be installed in accordance with the manufacturers installation instructions. 6.24.3.2 Vehicle fuel dispensers and dispensing stations shall not be located within a building, except as allowed in Chapter 10. 6.24.3.3 Where a vehicle fuel dispenser is installed under a weather shelter or canopy, the area shall be ventilated and shall not be enclosed for more than 50 percent of its perimeter. 6.24.3.4 Control for the pump used to transfer LP-Gas through the unit into containers shall be provided at the device in order to minimize the possibility of leakage or accidental discharge. 6.24.3.5 An excess-flow check valve or a differential back pressure valve shall be installed in or on the dispenser at the point at which the dispenser hose is connected to the liquid piping. 6.24.3.6 Piping and the dispensing hose shall be provided with hydrostatic relief valves in accordance with Section 6.13. 6.24.3.7 Protection against trespassing and tampering shall be in accordance with 6.18.4. 6.24.3.8 The container liquid withdrawal opening used with vehicle fuel dispensers and dispensing stations shall be equipped with one of the following: (1) An internal valve fitted for remote closure and automatic shutoff using thermal (fire) actuation. (2) A positive shutoff valve that is located as close to the container as practical in combination with an excess-flow valve installed in the container, plus an emergency shutoff valve that is fitted for remote closure and installed downstream in the line as close as practical to the positive shutoff valve. 6.24.3.9 An identified and accessible remote emergency shutoff device for either the internal valve or the emergency shutoff valve required by 6.24.3.8(1) or (2) shall be installed not less than 3 ft (1 m) or more than 100 ft (30 m) from the liquid transfer point. 6.24.3.10 Emergency shutoff valves and internal valves that are fitted for remote closure as required in this section shall be tested annually for proper operation. 6.24.3.11 A manual shutoff valve and an excess-flow check valve shall be located in the liquid line between the pump and dispenser inlet where the dispensing device is installed at a remote location and is not part of a complete storage and dispensing unit mounted on a common base. 6.24.3.12 All dispensers either shall be installed on a concrete foundation or shall be part of a complete storage and dispensing unit mounted on a common base and installed in accordance with
129
6.6.3.1(G) Protection against physical damage shall be provided for dispensers. 6.24.3.13 A listed quick-acting shutoff valve shall be installed at the discharge end of the transfer hose. 6.24.3.14 An identified and accessible switch or circuit breaker shall be installed at a location not less than 20 feet or more than 100 feet from the dispensing device(s) to shut off the power in the event of a fire, accident, or other emergency. 6.24.3.15 The markings for the switches or breakers shall be visible at the point of liquid transfer.
NFPA 58
2008
6.24.4 Installation of Vehicle Fuel Dispensers. 6.24.4.1 Hoses shall comply with the following: (1) Hose length shall not exceed 18 feet unless approved by the authority having jurisdiction. (2) All hoses shall be listed. (3) When not in use, hoses shall be secured to protect them from damage. 6.24.4.2 A listed emergency breakaway device complying with UL 567, Standard Pipe Connectors for Flammable and Combustible Liquids and LP-Gas, and designed to retain liquid on both sides of the breakaway point, or other devices affording equivalent protection approved by the authority having jurisdiction, shall be installed. 6.24.4.3 Dispensing devices for LP-Gas shall be located as follows: (1) Conventional systems shall be at least 10 feet from any dispensing device for Class I liquids. (2) Low-emission transfer systems in accordance with Section 6.24 shall be at least 5 feet from any dispensing device for Class I liquids.
Before the dispenser equipment is installed, two important steps to meet either local jurisdictional authority or NFPA 58 requirements may be needed: 1. Submission of a permit application with a site plan 2. Preparation of a Fire Safety Analysis and an Operation and Maintenance Procedure Manual if aggregate water capacity of propane storage tank(s) is 4,000 gallons or greater
130
(2)
Locating and installing dispenser foundation and supporting structures. After verifying the location of all dispenser components is in compliance with NFPA 58, local codes, and NFPA 30A if applicable, the location for concrete foundation forms, and electrical service trenches should be staked out on the ground. For remote dispenser cabinets, buried piping run trenches should be staked out as well. Foundations, especially those for vertical supply tanks, must strictly conform to manufacturers installation instructions.
Figure 1. Dispenser Foundation & Electrical Service Trench
Motor fuel dispensing units at multi-fuel refueling stations must be installed on raised concrete foundations. Special steel curbing forms for this purpose are available from service station equipment distributors and many fuel dispenser manufacturers. For dispensers located at multiple fuel refueling stations where the propane dispensing cabinet is located at a fueling island, most local jurisdictional authorities require the installation of a breakaway coupling, sometimes called a foot valve. The device is designed to provide a self-closing seal at the breakaway point and stop the flow of fuel between the dispenser cabinet piping and the buried supply piping. It should be installed at the base of the dispenser cabinet as directed by the manufacturer. (Figure 2).
Figure 2. Dispenser Base Piping or Hose Emergency Breakaway
131
NFPA 58
2008
6.16 Corrosion Protection. 6.16.1 All metallic equipment and components that are buried or mounded shall be coated or protected and maintained to minimize corrosion. 6.16.2 Corrosion protection of all other materials shall be in accordance with accepted engineering practice. Buried metallic propane piping shall be coated or protected and maintained to minimize corrosion. Piping should be: placed in the trench; tested for leakage at normal operating pressure; and inspected as required by local code, before the trench is back filled and the foundation is poured.
(3)
Installing dispenser components.
Figure 3. Installing Dispenser Support System Each dispenser installation has its unique set of tasks that must be coordinated and performed to meet differing site and equipment requirements. It is helpful, however, to develop and use an installation checklist to organize the job. A sample checklist is shown on the next page.
132
Dispenser Installation Checklist

Complete Propane Installation Plan (See Module 5.1.1) Select dispenser components and auxiliary equipment Obtain electrical system bid from licensed electrical contractor Complete materials and labor costing and finalize installation agreement Complete Site Plan, Permit Application, & Fire Safety Analysis as needed Layout installation at the site, prepare foundation forms, trenches, and place and pressure test any buried piping and anode for cathodic protection if used (obtain inspections as needed) Place concrete reinforcement steel, hole boxes or PVC chases, and tank securement j-bolts or sleeved bolts, then pour foundations (obtain inspections as needed) Install storage supply tank(s) according to manufacturer instructions Install vehicle protective crash posts, guard rails and/or fencing (2 gates properly located) Install pump (and meter, if applicable) according to manufacturer recommendations All piping is steel schedule 80 of diameter recommended by manufacturer or approved copper tubing for small diameter meter sensing line Pump mounting, external bypass valve, strainer, flexible sections are according to manufacturer recommendations. Pipe union provided for pump service Dispensing cabinet installed according to manufacturer instructions Hose(s) max. 18 feet, hose-end valves, and breakaway coupling installed and protection provided Piping tested for leakage at normal operating pressure (NFPA 58, 2008, 6.14) Class I, Group D, electrical fixtures, conduit and wiring installed (obtain inspection as needed) Wiring proper AWG size to meet pump manufacturer recommendations for motor hp, electrical power supply and length of run Sealing fitting(s) installed; filled with a suitable sealing compound Electrical union located at pump motor connection for motor service Emergency shutdown marked and proper Start up Pump rotation is correct (have electrician switch wire leads if not); drive guard in place If applicable, scales are properly assembled, shipping blocks removed; counter poise weights & holder are proper; scales checked for proper zero and measurement of a known weight Operating personnel are trained and training documented according to company standard operating procedures, NFPA 58, 2008, 4.4, and any state or local regulations
Note that NFPA 58, 2008 edition, in 6.14 does not specify the leakage test method (except to prohibit the use of a flame) or the duration of a gauged pressure test if one is used. Check your local code or company policy to verify if other piping testing requirements apply.
133
REVIEW:

Directions: 1. Complete the following statement by filling in the lines provided. Successful propane dispenser installations are usually the result of: a. b. c. d. e. f. g.
Directions:
Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. E. F. G. H. fire safety analysis propane company personnel minimize corrosion 250 psig
A. B. C. D.
raised concrete foundations normal operating licensed company standard operating procedures
2.
Before dispenser equipment is installed, a _____ and an Operation and Maintenance Procedure Manual must be completed if aggregate water capacity of propane storage tank(s) is 4,000 gallons or greater; or a site plan and permit application must be submitted, if required by state or local jurisdictional authorities. Motor fuel dispensing units at multi-fuel refueling stations must be installed on ____. Buried metallic propane piping should be coated or protected and maintained to ____.
3.
4.
134
Directions:
Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. E. F. G. H. fire safety analysis propane company personnel minimize corrosion 250 psig
A. B. C. D.
raised concrete foundations normal operating licensed company standard operating procedures
5.
A ____ electrical contractor should install the dispenser electrical wiring and other electrical system components.
6.
To meet NFPA 58 requirements, dispenser piping, including hoses, must be tested for leakage at the time of installation at ____ pressure.
135
5.1.9
Performance Criteria Self-Check: Installing Propane Dispensers

Directions:
I can identify: 1. 2. Actions that usually result in successful propane dispenser installations. Two important steps that may be needed before propane dispenser can be installed. The type of foundations required for motor fuel dispensers at multiple fuel refueling stations. The material that should be used for buried propane piping supplying a dispenser. Who should install electrical wiring for a propane dispenser. The test pressure required by NFPA 58 when testing dispenser piping for leakage. Guidelines for operator training at the time of dispenser start up.
3.
4.
5. 6.
7.
136
Identifying Requirements for Dispensers 5.1.10 With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
Table of Contents
Table of Contents................................................................................................... 137 Learning Activities.................................................................................................. 138 Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons ......................................................................... 139 Identifying Tank Location and Installation Code Requirements ............................. 139 Identifying Tank Valve and Fittings, and Bulkhead and Auxiliary Requirements for a Single Tank Over 4000 Water Gallon Capacity ..................................................... 140 Review ................................................................................................................... 143 Performance Criteria Self-Check ........................................................................... 144
137

1. Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning requirements for dispensers with aggregate storage tank capacity greater than 4000 water gallons and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to requirements for dispensers with aggregate storage tank capacity greater than 4000 water gallons. (Skills Assessment)
Read Performance Objective 1: Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
138
Identifying Requirements for Dispensers 5.1.10 With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
Dispensers for municipal or school bus fleets, air port ground support equipment, and similar applications often require the use of supply containers with aggregate storage tank capacity in excess of 4000 water gallons. Specific LP-Gas Code requirements apply to these larger dispenser installations. In this module you will learn to: (1) (2) Identify tank location and installation code requirements Identify tank valve and fittings, and bulkhead and auxiliary equipment requirements for a single tank over 4000 water gallon capacity Identifying tank location and installation code requirements. Code requirements set out in this module are based on NFPA 58, 2008 edition. Always check with the local authority having jurisdiction for the requirements that apply to any dispenser installation during the design and planning stage of the installation to be sure that all local requirements are met.
(1)
NFPA 58
2008
Three chapters of NFPA 58 contain requirements for dispenser tanks: LP-Gas Equipment and Appliances Installation of LP-Gas Systems LP-Gas Liquid Transfer
When one or more tanks having aggregate (combined total) water capacity in excess of 4000 gallons provide the dispenser propane supply, specific installation requirements must be met, including: 6.25.3 Protection of ASME Containers. 6.25.3.1 Fire protection shall be provided for installations with an aggregate water capacity of more than 4000 gal (15.1 m3) and for ASME containers on roofs. 6.25.3.2 The modes of fire protection shall be specified in a written fire safety analysis for new installations and for existing installations that have an aggregate water capacity of more than 4000 gal (15.1 m3) and for ASME containers on roofs. Existing installation shall comply with this requirement within 2 years of the effective date of this code. 6.25.3.3 The fire safety analysis shall be submitted by the owner, operator, or their designee to the authority having jurisdiction and local emergency responders.
139
6.25.3.4 The fire safety analysis shall be updated when the storage capacity or transfer system is modified. 6.25.3.5 The fire safety analysis shall be an evaluation of the total product control system, such as the emergency shutoff and internal valves equipped for remote closure and automatic shutoff using thermal (fire) actuation, pullaway protection where installed, and the optional requirements of Section 6.26. 6.25.3.6 If in the preparation for the fire safety analysis it is determined that a hazard to adjacent structures exists that exceeds the protection provided by provisions of this code, special protection shall be provided in accordance with 6.25.5. An Operation and Maintenance Procedure Manual must be prepared according to Chapter 14 of NFPA 58 2008. (2) Identifying tank valve and fittings, and bulkhead and auxiliary equipment requirements for a single tank over 4000 water gallon capacity. If a single dispenser supply tank with an water capacity of more than 4000 water gallons is filled using a liquid transfer line that is 1 inch or larger and a pressure equalizing vapor line that is 1 inch or larger, a transfer bulkhead, emergency shutoff valves (ESVs), and one or more remote shutdown stations are required. (NFPA 58, 2008 edition 6.12.1) Figure 1 illustrates the tank valves and fittings, along with transfer bulkhead and remote shutdown station for such a tank installation.
Figure 1. Single Dispenser Supply Tank Greater Than 4000 Water Gallons Capacity Liquid Transfer Hose 1 Inch or Larger This is an example of tank markings. Consult your company policy and local jurisdiction for proper markings.
(Internal valves may be cable or pneumatically actuated, except where pneumatic actuation is the only method approved by the authority having jurisdiction.)
140
Tank valves and fittings as illustrated in Figure 1 include: Relief valves with stacks and weather caps Fixed maximum liquid level gage Pressure gauge Float (liquid level) gauge; (a rotary gauge or slip tube gauge may be used instead) Thermometer Liquid and vapor internal valves (automatic closing in event of fire; pneumatic closing controlled by remote emergency shutdown) Transfer bulkhead with ESVs (automatic closing in event of fire; pneumatic closing controlled by remote emergency shutdown or in the event of a bobtail or transport pullaway) Each of the fittings or auxiliary components listed on the previous page and illustrated in Figure 1 is required for new installations with the following exceptions or alternatives: 1. If the tank is filled through a 1 inch filler valve using a liquid transfer hose smaller than 1 inch, the bulkhead and ESVs at the bulkhead would not be required. 2. The vapor withdrawal opening may be equipped with a positive shutoff valve that is located as close to the container as practical in combination with either a backflow check valve or excess-flow valve installed in the container. 3. If an ASME tank cannot be fitted with an internal valve that provides emergency shutdown protection automatically in the event of fire and remote shutdown capability, an in-line ESV may be used in combination with an excess-flow valve installed in the tank opening and a manual valve installed as close as possible to the excess-flow valve (Figure 2).
141
EXCESS FLOW VALVE 1/4 TURN MANUAL VALVE
VALVE DISC EMERGENCY SHUTDOWN VALVE (ESV)
(plastic tubing pneumatic control line)

Figure 2. Alternative Emergency Shutdown System Using an In-Line ESV
(ESVs may be cable or pneumatically actuated, except where pneumatic actuation is the only method approved by the authority having jurisdiction.)
NOTE
Existing ASME tank installations with water capacity in excess of 4000 gallons installed prior to the effective date of the 2001 edition of NFPA 58, and that were not equipped for automatic shutoff using thermal activation and remote emergency shutdown, must be provided such protection by July 1, 2011. Consult the specific requirements for retrofitting those installations given in NFPA 58. Check your local authority having jurisdiction for any changes to this date.
142
REVIEW:
Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
Directions: Select from the list below the response that most correctly completes each of the following statements. Write the letter of your choice in the space provided. A. B. C. D. 1 inch in-line ESV emergency shutdown the authority having jurisdiction and local emergency responders E. F. G. H. 1 inch 1 inch July 1, 2011 the effective date of adoption of NFPA 58, 2004 edition
When one or more tanks having aggregate (combined total) water capacity in excess of 4000 gallons provide the dispenser propane supply, specific installation requirements must be met, including: 1. Either a Fire Safety Analysis or a written product release prevention and incident preparedness review must be prepared and submitted to _____. The requirements of NFPA 58 regarding ____ requirements for installations over 4000 water gallons aggregate capacity must be met. If a single dispenser supply tank with an water capacity of more than 4000 water gallons is filled using a liquid transfer line that is ____ or larger and a pressure equalizing vapor line that is ____ or larger, a transfer bulkhead, emergency shutoff valves (ESVs), and one or more remote shutdown stations are required. If an ASME tank cannot be fitted with an internal valve that provides emergency shutdown protection automatically in the event of fire and remote shutdown capability, a(n) ____ may be used in combination with an excess-flow valve installed in the tank opening and a manual valve installed as close as possible to the excess-flow valve. Existing ASME tank installations with water capacity in excess of 4000 gallons installed prior to the effective date of the 2001 edition of NFPA 58, and that were not equipped for automatic shutoff using thermal activation and remote emergency shutdown, must be provided such protection by ____.
2.
3.
a
4.
5.
143
5.1.10
Performance Criteria Self-Check:

Identifying Requirements for Dispensers With Aggregate Storage Tank Capacity Greater Than 4000 Water Gallons
Directions:
I can identify: 1. A document that must be prepared and submitted to the authority having jurisdiction and emergency responders covering fire protection and other incident prevention measures for an installation having aggregate propane storage capacity in excess of 4000 water gallons. A fundamental NFPA 58 safety requirement for an installation having aggregate propane storage capacity in excess of 4000 water gallons. The transfer hose sizes that indicate that emergency shutdown valves and a transfer bulkhead are required according to NFPA 58 code requirements. An alternative automatic and remote-controlled emergency shutdown method that may be used for tanks with capacities over 4000 water gallon that cannot be readily fitted with internal valves. The date by which installations over 4000 aggregate water gallon capacity that existed prior to the effective date of NFPA 58, 2001 edition, must be retrofitted to provide the automatic and remote-controlled emergency shutdown requirements of the LP-Gas Code.
2.
3.
4.
5.
144
5.1.11
Identifying Startup Procedures for New and Expanding LP-Gas Storage Facilities
Table of Contents
Table of Contents...........................................................................................145 Learning Activities..........................................................................................146 Training..........................................................................................................147 Tools & Equipment........................................................................................148 Initial Inspection.............................................................................................148 Removal of Nitrogen or Inert Gas..................................................................148 Foreign Material.............................................................................................148 Close Valves..................................................................................................149 Introduce Vapor.............................................................................................149 Seasoning......................................................................................................149 Introduce Liquid.............................................................................................150 Final Inspection: Documentation...................................................................150 Observe Final Transfer..................................................................................150 Review...........................................................................................................152 Performance Criteria Self-Check...................................................................153
145

1. Startup Procedures
Check-Out
Activities
Your instructor will provide you with a list of incomplete statements concerning installing the propane dispensers and a list of responses. Select the response that most correctly completes each incomplete statement. (Knowledge Assessment) Your instructor or supervisor will require you to complete some operations relating to installing the propane dispensers. (Skills Assessment)
Read Performance Objective 1: Startup Procedures
146
Identifying Startup Procedures for 5.1.11 New and Expanding LP-Gas Storage Facilities
It is important to follow correct procedures when installing a new LP-gas storage facility or adding a transfer system or container to an existing facility. Before on-site work begins, company managers should review these procedures to ensure subsequent safe and proper operation. Your company may also have additional safety and startup requirements or procedures.
In this module you will learn the following procedures: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (1) Training Tools and equipment Initial inspection Removing nitrogen or inert gas Foreign material Closing valves Introducing vapor Seasoning Introducing liquid Final inspection and documentation Observing the transfer Training All personnel involved in the installation must be properly trained and familiar with all applicable safety and startup procedures required by federal, state, or local regulations or company procedures. This training must be documented as noted in NFPA 58, 2008 ed., 4.4.
NFPA 58
2008
4.4 Qualification of Personnel. Persons who transfer liquid LP-Gas, who are employed to transport LP-Gas, or whose primary duties fall within the scope of this code shall be trained in proper handling procedures. Refresher training shall be provided at least every 3 years. The training shall be documented.
147
(2)
Tools and Equipment All necessary tools, equipment and other material, such as proper hose connections and leak-detection devices, must be on site before work begins. Each person must have or be issued the required safety equipment, such as safety glasses and gloves. All personnel must be familiar with and the use of safety equipment as required.
(3)
Initial Inspection Do not assume that the transfer system or tank has been thoroughly inspected, and never take for granted that any valve, plug or other component that was installed in the container before it was shipped is properly installed and gas tight. Before starting work, inspect the transfer system and container thoroughly and completely to determine compliance with NFPA 58 and all applicable state or local regulations and to detect any potential problems, such as a connection that is not completely tightened or a strainer with directional flow that has been installed incorrectly. A thorough initial inspection can prevent unnecessary delays and expense if the transfer system or container works improperly after LPgas is introduced.
(4)
Removal of Nitrogen or Inert Gas Sometimes nitrogen or an inert gas is introduced into the transfer system and container during construction. It is critical that any such gas in the transfer system or container be removed completely prior to conducting the start up. Do not assume that someone has removed the gas. Any such gas that is still present when LP-gas is introduced poses a potential danger. Nitrogen and inert gases have their own vapor pressures, and when LP-gas with its own vapor pressure is combined with the other gas, pressure builds up. This condition could result in a blown pump seal, fracturing of components, or other failure that could cause death, injury or catastrophic damage.
(5)
Foreign Material Never assume that the transfer system or container is free of foreign material such as screws, bolts or rags. These materials could remain undetected in the transfer system and could prevent an emergency shutoff valve or an internal valve from fully closing or cause other problems.
148
(6)
Close Valves Ensure that all applicable valves, such as the transfer hose-end valves, are closed before introducing LP-gas. This action will eliminate dangerous situations like a transfer hose swirling around after the hose is subjected to LP-gas pressure, due to the hose-end valves being left open.
(7)
Introduce Vapor When you are completely satisfied that all of the above procedures have been followed, LP-gas vapor, not liquid, may be slowly introduced into the transfer system and the container. The introduction of LP-gas vapor will test the system and tank for leakage at normal operating pressure as required by NFPA 58 (2008), 6.14. Using a leak detection device, detect and properly correct any leaks.
NFPA 58
2008
6.14 Testing Piping Systems. 6.14.1 After assembly, piping systems (including hose) shall be tested and proven free of leaks at not less than the normal operating pressure. 6.14.2 Piping within the scope of NFPA 54, National Fuel Gas Code, shall be pressure tested in accordance with that code. 6.14.3 Tests shall not be made with a flame.
NOTE: It is better to check for leaks with LP-gas vapor instead of LP-gas liquid, because removing LP-gas vapor from a container to tighten a valve or plug or repair a leak is easier than removing LP-gas liquid. Note also that finding no leakage during cold weather does not necessarily mean there will be no leaks during hot weather when the LP-gas vapor pressure inside the system and vessel increases. (8) Seasoning Once you are satisfied there are no leaks, close all the necessary valves and leave the LP-gas vapor in the system and container for at least 24-hours. This action will season the container (allow ethyl mercaptan to bind with any iron oxide present in the tank or piping) and help prevent any potential odorant fade.
149
(9)
Introduce Liquid When you are satisfied that the system is leak-free and totally operational, LP-gas liquid may be introduced into the LP-gas transfer system and tank. Depending on the amount of liquid introduced and the type of gauging devices installed in the container, it can be determined if the gauging devices are operating properly and accurately.
(10)
Final Inspection: Documentation Once again, inspect the transfer system and container thoroughly to ensure you are fully satisfied with the completed facility. Review NFPA 58 (2008), Chapter 14, to determine if its requirements apply to the facility. If so, ensure that the documents describe all maintenance and transfer processes completely and accurately. If the descriptions of operational and maintenance procedures are incomplete, the necessary revisions must be made and reviewed. Once the documents are in compliance and accepted, an authorized person must ensure that all personnel who operate or maintain the facility are properly trained, that such training is documented, and that authorization for the facility to be fully operational is properly issued.
(11)
Observe Final Transfer Witness the initial LP-gas transfer from the container, being very observant looking for any possible unsafe conditions or transfer problems. Correct any observed or potential problem.
Finally, ensure that all the necessary startup equipment is removed from the site.
150
An Installation Startup Procedure Checklist is located below to help you discharge this critical responsibility.
Installation Startup Checklist Inspect transfer system and container to ascertain compliance with NFPA 58, state or local regulations and company requirements. Inspect transfer system and container to determine any potential problems, such as a connection or valve not completely tightened. Verify transfer system is void of nitrogen or other gases; purge system if needed. All necessary valves are completely closed; especially transfer hose end valves and container valves. Introduce LP-gas vapor slowly into the entire transfer system and container, pressurizing to normal operating pressure as measured in cargo tank supplying vapor. Determine if transfer system and container are gas tight by conducting a leak test and correct any leak found in transfer system or container. Leave LP-gas vapor in transfer system and container for 24 hours to allow iron oxide/mercaptan binding to minimize the possibility of odorant fade. If completely satisfied system is free of leaks or other problems, introduce LP-gas liquid into transfer system. Determine if container and transfer system are gas tight and if tank appurtenances, such as gauging devices, are operational and accurate. Inspect transfer system and container to ascertain that the facility is totally acceptable. If not, take necessary action. If required, review operation and maintenance procedures to ensure acceptability. If unacceptable, revise accordingly. Train affected propane marketer personnel in transfer system and container operation and maintenance. Document operation and maintenance training. Train dispenser operating personnel in all applicable safety and startup procedures, in accordance with company requirements and all federal, state or local regulations. Dispenser operating personnel have all necessary equipment and personal protective equipment (PPE) to perform their job functions. Witness initial transfer operation from container. Correct any problem or potential problem. Document safety and startup training. Ensure all startup equipment and material is fully removed from site.
151
REVIEW:
Identifying Startup Procedures for New and Expanding LP-Gas Storage Facilities
Directions: 1. Complete the following statement by filling in the lines provided. Two reasons to inspect the transfer system and container prior to startup are: a. b.
2.
Why would a transfer hose swirl around when LP-Gas is being introduced into a container?
3.
Following your inspection, the removal of any nitrogen or inert gas, the removal of any foreign materials from the transfer system and container, and that all valves have been closed, LP-gas __________not _________, may be slowly introduced into the transfer system and the container. To allow ethyl mercaptan to bind with any iron oxide present in the tank or piping is referred to as _______________. Answer true or false to the following questions. Nitrogen and LP-Gas have the same vapor pressure. Any nitrogen or inert gasses introduced into the transfer system and container during construction can easily be mixed with LP-Gas.
4.
Directions: 5. 6.
152
5.1.11
Performance Criteria Self-Check: Identifying Startup Procedures for New and Expanding LP-Gas Storage Facilities
Directions:
I can: 1. 2. Verify the transfer system is void of nitrogen or other gases Introduce LP-Gas vapor slowly into the entire transfer system and container, pressurizing to normal operating pressure as measured in cargo tank supplying vapor. Determine if the transfer system and container are gas tight by conducting a leak test. Correct any leak found in the transfer system or container. Introduce LP-Gas liquid into the transfer system.
3.
4. 5.
153
Designing & Installing Dispenser Transfer Systems Performance-Based Skill Assessment Evaluation Packet
Determine Dispenser Application, Operating Requirements & Proper Location Identify Required Dispenser Tank Valves and Fittings Identify Dispenser Electrical System Requirements Apply Propane Pump Operating Characteristics to Select the Dispenser Pump Identify Dispenser Shutdown System & Fire Extinguisher Requirements Select Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, & Adapters Identify Auxiliary Equipment for a Propane Dispenser Select Metering and Dispensing Equipment for a Service Station Motor Fuel Dispenser Install a Propane Dispenser Identify Requirements for a Dispenser Using Supply Tank(s) with Aggregate Water Capacity Greater Than 4000 Gallons Verify the transfer system is void of nitrogen or other inert gases. Introduce LP-Gas vapor slowly into the entire transfer system and container, pressurizing to normal operating pressure as measured in the vapor space of the supply cargo tank. Determine if the transfer system and container are gas tight by conducting a leak test. Correct any leak found in the transfer system or container. Introduce LP-Gas liquid into the transfer system.
5.1
Task 5.1.1a Task 5.1.2a Task 5.1.3a Task 5.1.4a Task 5.1.5a Task 5.1.6a Task 5.1.7a Task 5.1.8a Task 5.1.9a Task 5.1.10a Task 5.1.11a Task 5.1.11b
Task 5.1.11c Task 5.1.11d Task 5.1.11e
Employees Name (Please Print)
Date of Skills Evaluation
Skills Evaluator Name (Please Print)
NOTICE: THE SKILLS EVALUATOR MUST BE THE EMPLOYEES SUPERVISOR OR SOME OTHER QUALIFIED PERSON WHO HAS COMPLETED CETP DESIGNING & INSTALLING DISPENSER TRANSFER SYSTEMS OR IS FAMILIAR WITH THE SUBJECT MATTER. CETP CERTIFICATION REQUIRES THAT THE EMPLOYEE SEEKING CERTIFICATION CANNOT ACT AS HIS/HER OWN EVALUATOR.
Certified Employee Training Program Performance-Based Skill Assessment Evaluation Packet Designing & Installing Dispensers Page 1 3-2008
Table of Contents
General Instructions .................................................................................................... 3 Instructions for Use ............................................................................................. 3 Instructions to the Employee ............................................................................... 3 Instructions to the Skills Evaluator ...................................................................... 4 Task Information .......................................................................................................... 4 Employee Performance Checklist .............................................................................. 5 Employer Record ....................................................................................................... 15
Users of this material should consult the law of their individual jurisdictions for codes, standards and legal requirements applicable to them. This material is not intended to be an exhaustive treatment of the subject, and should not be interpreted as precluding other procedures that would enhance safe LP-gas operations. This training material merely suggests methods the user may find useful in implementing applicable codes, standards, and legal requirements. This publication is not intended nor should it be construed to (1) set forth procedures which are the general custom or practice in the propane industry; (2) to establish the legal standards of care owed by propane distributors to their customers; or (3) to prevent the reader from using different methods to implement applicable codes, standards or legal requirements. This material was designed to be used as a resource only to assist expert and experienced supervisors and managers in training personnel in their organizations and does not replace federal, state, local, or company safety rules. The user of this material is solely responsible for the method of implementation. The Propane Research and Education Council, the National Propane Gas Association, CASTLE Worldwide and Industrial Training Services, Inc. assume no liability for reliance on the contents of this training material. Issuance of this material is not intended to nor should it be construed as an undertaking to perform services on behalf of any party either for their protection or for the protection of third parties.
I. General Instructions
Instructions for Use
This Performance Based Skill Assessment Evaluation Packet is designed to: provide structured on-the-job training for the LP-gas employee under the direction of an experienced and qualified skills evaluator, and standardize conditions under which the employee demonstrates his/her performance of tasks that meet the requirements of the NPGA Certified Employee Training Program.
Each task is divided into one or more operations on which the employees performance is evaluated. Each operation is designated by the following symbol: . Also, under each operation is a performance guide that establishes the standard used by the skills evaluator. When an operation within a task is successfully performed by the employee according to the criteria listed in the performance guide, a check ( ) is placed in the . After completing the checklist for those operations required in the employees job duties, the skills evaluator and employee must sign their respective affidavits. Section IV (page 15 and page 16) is photocopied for the companys personnel training record files. The original of Section IV, pages 15 and 16, must be forwarded to the appropriate
test processing facility to complete certification. On-line Test Candidates: CASTLE Worldwide 900 Perimeter Park Drive, Suite G Morrisville, NC 27560 Paper test Candidates: Industrial Training Services, Inc. 310 C.C. Lowry Drive Murray, KY 42071
Instructions to the Employee

The Performance Based Skill Assessment Evaluation Packet is designed as a training guide to assist you and your evaluator in performing the tasks listed on the front cover. Practice the tasks as many times as needed to become confident and proficient with the documents or equipment. Your skills evaluator will check and observe your performance using the checklist included in each hands-on task assignment. The employee must adhere to all safety precautions. If a safety precaution is violated, then the demonstration shall be stopped and the skills evaluator must instruct the employee on the proper safety procedures that apply before allowing the employee to continue. The packet is designed to establish the basic conditions under which the employee demonstrated his/her level of knowledge and proficiency.
Instructions to the Skills Evaluator

Review Section II, Task Information." Conduct the training as follows: Give a copy of the Performance Based Skill Assessment Evaluation Packet to the employee. Review all of the instructions with the employee and answer any questions or concerns about how it will be used. Demonstrate and/or talk the employee through each of the steps required to do the task. Allow the employee time to ask questions and/or study the steps. Observe the employee performing the required steps; correct him/her as needed. Allow the employee to practice until he/she is confident. Evaluate the employee at his/her request. Complete Section III, Employee Performance Checklist, beginning on page 5. Complete both pages of Section IV, Employer Record, which must be signed and dated by both the Skills Evaluator and employee on page 15. Remove Section IV (pages 15 and 16) from the packet and photocopy. Retain photocopy for your files. For employee certification this form must be received within 12 months of the Certifying Examination date. Mail original to:
On-line Test Candidates: CASTLE Worldwide 900 Perimeter Park Drive, Suite G Morrisville, NC 27560 Paper test Candidates: Industrial Training Services, Inc. 310 C.C. Lowry Drive Murray, KY 42071
This Evaluation Packet and the photocopy of Section IV (pages 15 and 16) should be retained in the Companys employee training files.
II. Task Information

Certification Standard: The employee's certification is based on satisfactory completion of the operations listed under each task in the Performance Based Skill Assessment Evaluation Packet and a Mastery Score on the Certification Area Examination. Prerequisites: References: Evaluation: Successful completion of CETP Certification Area 5.1, Designing and Installing Dispenser Transfer Systems. Applicable LP-Gas Codes and company policies. The skills evaluator must be the employees supervisor or some other qualified person who has completed CETP Designing and Installing Dispenser Transfer Systems or is familiar with the subject matter. CETP certification requires that the employee seeking certification cannot act as his/her own evaluator.
Certified Employee Training Program Performance-Based Skill Assessment Evaluation Packet Designing & Installing Dispensers Page 4
3-2008
III. Employee Performance Checklist

Print or type all entries except signatures and initials. Employee Name Social Security No. Skill Evaluator (Please Print) I, , hereby attest the employee named on (Skill Evaluators Signature) top line of this section has demonstrated the correct performance of the tasks listed below and on following pages. Task 5.1.1a
Determine Disperser Application, Operating Requirements & Proper Location The employee is qualified to perform Task 5.1.1a at the following level:
Date
Satisfactory
Determining Disperser Application, Operating Requirements & Proper Location. 5.1.1a

Performance Guide: At a potential dispenser operator site or at the companys offices, the person being evaluated for certification: 1. Interviewed the potential dispenser operator and obtained all the information required to complete the installation plan, or a company form equivalent to the plan, shown on the next 2 pages; Determined the water capacity supply tank size and type required; Determined the minimum separation distance requirements for the dispenser installation, applying NFPA 58 standards; and Completed a site plan sketch on the installation plan.
2. 3. 4.
3-2008
3-2008
3-2008
Task 5.1.2a
Identify Required Dispenser Tank Valves and Fittings The employee is qualified to perform Task 5.1.2a at the following level:
Satisfactory
Identifying Required Dispenser Tank Valves and Fittings. 5.1.2a

Performance Guide: Using the information obtained for completing the dispenser installation plan, the employee being evaluated for certification correctly: 1. 2. Identified the NFPA 58 supply tank valves requirements for the dispenser installation. Identified the NFPA 58 supply tank fittings requirements for the dispenser installation.
Task 5.1.3a
Identify Dispenser Electrical System Requirements The employee is qualified to perform Task 5.1.3a at the following level:
Satisfactory
Identifying Dispenser Electrical System Requirements. 5.1.3a

Performance Guide: On the installation plan, the employee being evaluated for certification:
1.
2.
Identified the electrical power supply source on the installation plan.

Identified the boundaries of the: Division 1 classified area for electrical components, and Division 2 classified area for electrical components, applying the National Electrical Code (NEC) and NFPA 58 definitions. Contacted a licensed electrician and obtained an installation estimate and bill of materials for the electrical portion of the dispenser installation, including: Heavy-duty conduit and wiring; Class I, Group D fixtures; Electrical seal-offs to meet code requirements; Class I, Group D flexible section(s) and unions; Any other electrical installation requirements, including emergency shutdown stations and markings.
3.
3-2008
Task 5.1.4a
Apply Propane Pump Operating Characteristics to Select the Dispenser Pump The employee is qualified to perform Task 5.1.4a at the following level:
Satisfactory
Applying Propane Pump Operating Characteristics to Select the Dispenser Pump. 5.1.4a
Performance Guide: Consulting a propane equipment supplier or propane pump manufacturer technical services representative, the employee being evaluated for certification correctly: 1. Identified the type of propane pump required for the dispenser installation. 2. Identified the piping requirements for the pump. 3. Identified the valving requirements for the pump and dispenser supply tank.
Task 5.1.5a
Identify Dispenser Shutdown System & Fire Extinguisher Requirements The employee is qualified to perform Task 5.1.5a at the following level:
Satisfactory
Identifying Dispenser Shutdown System & Fire Extinguisher Requirements. 5.1.5a

Performance Guide: Consulting NFPA 58, the employee being evaluated for certification correctly: 1. Identified the emergency shutdown system requirements for the dispenser installation. 2. Entered the location of remote emergency shutdown station(s) and signs on the installation sketch. 3. Identified fire extinguisher requirements for the dispenser installation.
Task 5.1.6a
Select Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, & Adapters The employee is qualified to perform Task 5.1.6a at the following level: Selecting Dispenser Transfer Hose(s), Hose End Valves, Hose Satisfactory Safety Devices, & Adapters. 5.1.5a
Performance Guide: Consulting NFPA 58, the employee being evaluated for certification correctly: 1. Identified NFPA 58 dispenser transfer hose requirements for the dispenser. 2. Selected the proper type, diameter and length of transfer hose(s) required for the dispenser application(s). 3. Selected the proper type of transfer hose-end valves for the dispenser. 4. Selected the proper hose end valve and other adapters required for the dispenser application(s). 5. Identified the hose safety device(s) required for the installation, including proper anchor and attachment means for the hose safety device(s).
3-2008
Task 5.1.7a
Identify Auxiliary Equipment for a Propane Dispenser The employee is qualified to perform Task 5.1.7a at the following level:
Satisfactory
Identifying Auxiliary Equipment for a Propane Dispenser. 5.1.5a

Performance Guide: Consulting NFPA 58, the employee being evaluated for certification correctly: 1. Selected suitable scales for filling DOT cylinders by weight for the dispenser application. 2. Identified any other auxiliary equipment required for the dispenser installation.
Task 5.1.8a
Select Metering and Dispensing Equipment for a Service Station Motor Fuel Dispenser. The employee is qualified to perform Task 5.1.8a at the following level:
Satisfactory Not Applicable*
Selecting Metering and Dispensing Equipment for a Service Station Motor Fuel Dispenser. 5.1.8a
Performance Guide: The employee being evaluated for certification correctly:
*Not applicable means that the company employing the person being evaluated for certification does not install, nor service propane motor fuel service station dispensers.
1. 2. 3.
4.
5.
Selected the appropriate propane meter(s) for the service station installation. Selected the appropriate motor fuel dispenser or dispensing cabinet for the service station installation. Identified the NFPA 58 requirements for minimum separation distance requirements with regard to: Other motor fuel dispensers Other motor fuel storage containers Emergency shutdown controls Located the motor fuel dispenser on the installation plan sketch and marked the separation distances to important structures and features as set out in NFPA 58. Determined protection measures required by NFPA 58 to protect the dispenser from vehicular damage, and properly located them on the installation sketch.
3-2008
Task 5.1.9a
Install a Propane Dispenser The employee is qualified to perform Task 5.1.9a at the following level:
Satisfactory
Installing a Propane Dispenser. 5.1.9a

Performance Guide: Working with the employees supervisor or other qualified employee(s), the employee being evaluated for certification correctly and properly: 1. Verified that all required permits, O&M plans and Fire Protection or Fire Safety Analysis documents for the dispenser installation were obtained from and/or filed with the authority having jurisdiction. 2. Coordinated the installation of dispenser foundations, vehicular protection, and electrical system trenching, obtaining any required inspection approvals at the appropriate stages of installation. 3. Installed the dispenser supply tank(s), pump, meter(s), valves and connecting piping. 4. Completed an installed piping leak test as required by NFPA 58 and the authority having jurisdiction, obtaining any required inspection approvals at the appropriate stages of installation. 5. Installed the auxiliary equipment required for the dispenser installation. 6. After the installation was completed, trained dispenser-operating personnel using appropriate training materials (such as the PERC Dispensing Propane [Safely] program) and demonstrated how to operate the dispenser to fill propane containers. If applicable, delivered and explained the O&M plan to the dispenser operating personnel supervisor.
Task 5.1.10a
Identify Requirements for a Dispenser Using Supply Tank(s) with Aggregate Water Capacity Greater Than 4000 Gallons. The employee is qualified to perform Task 5.1.10a at the following level: Identifying Requirements for a Dispenser Using Supply Tank(s) with Aggregate Water Capacity Greater Than 4000 Gallons. 5.1.10a
Performance Guide: The employee being evaluated for certification correctly and properly: 1. Identified the documents that must be prepared and filed with the authority having jurisdiction for dispenser installations using supply tank(s) with aggregate water capacity greater than 4000 water gallons. 2. Identified any product transfer and emergency shutdown equipment required for the installation. 3. Identified the minimum separation distance requirements set out in NFPA 58 for a dispenser using a single supply tank with water capacity greater than 4000.
Satisfactory
Task 5.1.11a
Verify the Transfer System Is Void of Nitrogen or Other Inert Gases. The employee is qualified to perform Task 5.1.11a at the following level:
Satisfactory
Verifying the Transfer System Is Void of Nitrogen or Other Inert Gases. 5.1.11a
Performance Guide: Wearing any company-prescribed PPE and following company operating procedures, the employee being evaluated for certification: 1. Determined if nitrogen or any other inert gas was present in the dispenser tank or transfer system. 2. If any inert gas was detected, followed company procedures to safely purge any inert gas present.
3-2008
Task 5.1.11b
Introduce LP-Gas Vapor Slowly into the Entire Transfer System and Container, Pressurizing to Normal Operating Pressure as Measured in the Vapor Space of the Supply Cargo Tank. The employee is qualified to perform Task 5.1.11b at the following level: Introduce LP-Gas Vapor Slowly into the Entire Transfer System and Container, Pressurizing to Normal Operating Pressure as Measured in the Vapor Space of the Supply Cargo Tank. 5.1.11b
Performance Guide: Wearing any company-prescribed PPE and following company operating procedures, the employee being evaluated for certification: 1. Performed a preliminary inspection to determine that all dispenser valves and fittings were properly installed, closed and/or tightened as appropriate. 2. Connected the vapor equalizing transfer hose of the cargo tank to the vapor equalizing valve of the dispenser supply tank. 3. SLOWLY opened the vapor equalizing transfer hose-end valve, checked for leakage at the connection, and if no leakage was found, continued to slowly transfer vapor into the dispenser tank. Closed and disconnected the cargo tank transfer hose when the pressure in the dispenser tank equalized to that of the pressure in the cargo tank. 4. Properly stowed the transfer hose.
Satisfactory
Task 5.1.11c
Determine if the transfer system and container are gas tight by conducting a leak test. The employee is qualified to perform Task 5.1.11c at the following level:
Satisfactory
Determining if the transfer system and container are gas tight by conducting a leak test. 5.1.11c
Performance Guide: The employee being evaluated for certification correctly and properly: 1. After verifying that the dispenser tank and all components of the dispenser transfer system were at normal operating pressure, applied a leak detection method to each tank and transfer system component and connection. 2. Observed the detection method applied and determined if any leak was present.
Task 5.1.11d
Correct any leak found in the transfer system or container. The employee is qualified to perform Task 5.1.11d at the following level:
Satisfactory
Correcting any leak found in the transfer system or container. 5.1.11d

Performance Guide: The employee being evaluated for certification correctly and properly: 1. If any leak was found during the leak check, determined if the leak required isolation and/or depressurization of the component. 2. If de-pressurization was required, put on any required PPE, and safely flared or vented the propane vapor until the affected components were de-pressurized to a safe level for making leak repairs. 3. Sealed the leaking surfaces by applying suitable and approved sealing materials (except at metal-to-metal sealing joints such as flare fittings, mating surfaces of ground joint unions, or POL fittings). Properly tightened the sealing components. 4. Re-pressurized the system with propane vapor and verified that the leak was eliminated and the system was gas tight.
3-2008
Task 5.1.11e
Introduce LP-Gas liquid into the transfer system. The employee is qualified to perform Task 5.1.11e at the following level:
Satisfactory
Introducing LP-Gas liquid into the transfer system. 5.1.11e

Performance Guide: Wearing required PPE, and following company procedures, the employee being evaluated for certification correctly and properly: 1. Transferred liquid propane from the cargo tank vehicle into the dispenser supply tank. 2. Stopped the transfer operation when the desired liquid level or maximum permitted liquid level was reached. 3. Disconnected the cargo tank vehicle liquid transfer hose and properly stowed it. 4. Completed the documentation of the propane delivery.
3-2008
[This page intentionally left blank.]
3-2008
IV. CETP Performance Evaluation / Employer Record

THIS PAGE MUST BE RETURNED AS SOON AS POSSIBLE, BUT NO LATER THAN 12 MONTHS AFTER TAKING THE CERTIFICATION TEST, TO THE FOLLOWING ADDRESS:
On-line Test Candidates: CASTLE Worldwide 900 Perimeter Park Drive, Suite G Morrisville, NC 27560 Paper test Candidates: Industrial Training Services, Inc. 310 C.C. Lowry Drive Murray, KY 42071
Employee Information: (print or type) Test Group Number (if known): ________________________ Social Security
Name _________________________ Number _______________________________ Employer _____________________________________________________________ Address ______________________________________________________________ City, State: _________________________ Zip Code _________________________
Affidavit
I affirm that I am the person who has performed those items checked on this checklist. I acknowledge that the performance checklists used are solely for the purpose of skills assessment for the CETP certification requirements, and are not intended to replace or modify company operating or safety procedures, and may not be appropriate for use in all circumstances. I acknowledge that I am responsible for recognizing hazards and abnormal conditions in my workplace and must exercise care and good judgment, always using appropriate equipment, procedures and tools for the tasks I perform. The Propane Education and Research Council, the National Propane Gas Association, CASTLE Worldwide and Industrial Training Services, Inc. assume no liability for my actions, or for my application of the skills assessment performance guides used in this evaluation checklist.
Employees Signature_____________________________ Date__________________
Skills Evaluator Information: (print or type)
Name ________________________________________________________________ Organization/Employer___________________________________________________ Telephone Number______________________________________________________
Affidavit
I affirm that I am the person who has administered this checklist, and that I have conducted this employee skills assessment with integrity. I also affirm that the above named employee is the person whose performance I evaluated, and that the above named person performed the checked tasks at the indicated level without assistance from me or any other person.
Skill Evaluators Signature_______________________________ Date____________

The employee is qualified to perform the listed operations at the following level:
Without Direct Supervision Not Applicable
Determine Disperser Application, Operating Requirements & Proper Location. 5.1.1a Identify Required Dispenser Tank Valves and Fittings. 5.1.2a Identify Dispenser Electrical System Requirements. 5.1.3a Apply Propane Pump Operating Characteristics to Select the Dispenser Pump. 5.1.4a Identify Dispenser Shutdown System & Fire Extinguisher Requirements. 5.1.5a Select Dispenser Transfer Hose(s), Hose End Valves, Hose Safety Devices, & Adapters. 5.1.6a Identify Auxiliary Equipment for a Propane Dispenser. 5.1.7a Select Metering and Dispensing Equipment for a Service Station Motor Fuel Dispenser. 5.1.8a Install a Propane Dispenser. 5.1.9a Identify Requirements for a Dispenser Using Supply Tank(s) with Aggregate Water Capacity Greater Than 4000 Gallons. 5.1.10a Verify the transfer system is void of nitrogen or other inert gases. 5.1.11a Introduce LP-Gas vapor slowly into the entire transfer system and container, pressurizing to normal operating pressure as measured in the vapor space of the supply cargo tank. 5.1.11b Determine if the transfer system and container are gas tight by conducting a leak test. 5.1.11c Correct any leak found in the transfer system or container. 5.1.11d Introduce LP-Gas liquid into the transfer system. 5.1.11e
After completion of Section IV, Employer Record, remove pages 15 and 16 from the packet and photocopy. Retain photocopy for your files. Mail original to: On-line Test Candidates: CASTLE Worldwide 900 Perimeter Park Drive, Suite G Morrisville, NC 27560 Paper test Candidates: Industrial Training Services, Inc. 310 C.C. Lowry Drive Murray, KY 42071
3-2008
PROPANE EDUCATION & RESEARCH COUNCIL

INDUSTRY FEEDBACK FORM
PERC Program Designing & Installing Dispenser Transfer Systems
Item Number If applicable and/or known For Example: PRC 00001 Module Page Lesson Printing date
Action Requested New Text Revised Text Graphic Other
Action and Reason for Proposed Action Include proposed updated text or graphic, and supporting information.
Subject Note: The subject should clearly and accurately express the main idea of your suggestion. For Example: Updated Distance Requirements.
Reference or similar piece Note: Type in details that reference and support your suggestion. For Example: A document or book information (title, pages number, publication date and publisher), a website address, or a federal organization name and regulation number. Method of submitting reference material Fax to (202) 452-9054 Regular Mail to PERC 1140 Connecticut Ave, NW Suite 1075 Washington, DC 20036 E-mail to courtney.gendron@propanecouncil.org Other
Note: If you are unable to type or print your reference details that reference and support your suggestion, please choose a method. You may support your suggestion with additional documents and materials. Propane Education & Research Council encourages you to fax, mail or e-mail additional supporting materials. Contact Information: Name: Company: Address: City, State, Zip: Phone: Email:
You will receive a response, once the Industry Feedback Form is received. If you do not receive a response within an appropriate time, please contact PERC at (202) 452-8975.

Propane

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Propane

Hochgeladen von

Copyright:

Verfügbare Formate

5.

Designing & Installing Dispenser Transfer Systems

NOTICE AND DISCLAIMER CONCERNING LIABILITY

Tools: This task requires special tools or procedures.

PPE: This is a task that requires personal protection equipment.

Technical Tips: This technique may be very useful as you do a task.

Designing & Installing Dispenser Transfer Systems

Determining Dispenser Application, Operating Requirements & Proper Location

Learning Activities Performance Objectives

Check your knowledge by completing the Review.

Determining Dispenser Application, Operating Requirements & Proper Location

Figure 1. Vapor Cylinder & Motor Fuel Cylinders

Figure 2. Sample Dispensing Installation Planning Form (Front)

Provisions for Vertical Tanks.

Figure 5. Probabilistic Seismic Hazard Maps, U.S. Geological Survey http://earthquake.usgs.gov/research/hazmaps/products_data/images/nshm_us02.gif

Determining Dispenser Application, Operating Requirements & Proper Location

Performance Criteria Self-Check: 5.1.1

Determining Dispenser Application, Operating Requirements & Proper Location

Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping

Learning Activities Performance Objectives

Check your knowledge by completing the Review.

Identifying Required Dispenser Tank Valves, Fittings and Dispenser Piping

Appurtenance Vapor shutoff valve I

Pressure relief valve

Fixed maximum liquid level gauge

Overfilling prevention device

R (ASME only) (see 5.7.4.1 (E)) NR

Actuated liquid withdrawal excess flow valve

R ( 125 gal) [see 5.7.4.1(B) through 5.7.4.1 (D)]

Float gauge Double backflow check filler valve

NR R ( 100 Ib filled on site)

R (> 124 gal only) R

Figure 2. Dispensing Station/Vehicle Fuel Dispenser Component Diagram

Figure 3. Internal Type Relief Valve

Internal valves and excess flow requirements.

EXCESS FLOW VALVE 1/4 TURN MANUAL VALVE

Figure 9a. Cable Actuated Liquid Withdrawal Valve

Figure 9b. Pneumatic Actuated Liquid Withdrawal Valve

Figure 10. Multi-valve

Figure 11. Manual Valve with Excess-Flow

13. Float Gauge

Figure 16a. Tank Thermometer Well

Figure 16b. Dial Indicating Thermometer

NFPA 58 Identifying 58 Code Requirements for Dispenser Piping

Identifying Required Dispenser Tank Valves and Fittings

Directions: I can identify: 1.

Identifying Dispenser Electrical System Requirements

Identifying Dispenser Electrical System Requirements............................................ 39

Review ..................................................................................................................... 45 Performance Criteria Self-Check ............................................................................. 46

Learning Activities Performance Objectives

Read Performance Objective 1: Identifying Dispenser Electrical System Requirements

Check your knowledge by completing the Review.

Identifying Dispenser Electrical System Requirements

Vehicle fuel dispenser

Division 1 Division 1 Division 2 Division 1 Division 2

Sphere with a radius of 15 feet--Division 2 Sphere with a radius of 5 feet--Division 1

Horizontal equator of the sphere

Point of connection or source of excessive release of liquid or vapor

Figure 1. Extent of Electrically Classified Area

Motor a nd All Fixtures & Fittings Approved for Cla ss I, Group D

Switch Enclosure 3-Way Junction Enclosure

Electrical Union Heavy-Wall Conduit Sealing Fittings

To Electrical Power Supply