1. Installing DOT/ICC Exchange or Stationary Cylinders
4.2.7
Proper cylinder installations must meet code requirements and safe working practices for service employees.
In this module you will learn to identify:
Factors related to the installation of DOT cylinders
Procedures for installing DOT cylinders
Student Book  © 2004 Propane Education & Research Council
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2. Factors Related to the Installation of Cylinders
Safety Precautions The following safety precautions are based on NFPA 58 and OSHA safety standards.
Wear vinyl safety gloves and safety shoes during the loading, delivery, and installation of cylinders.
Because of the size and weight of DOT cylinders that contain propane, proper equipment should be used for lifting or moving the cylinders. Stationary cylinders filled on site should be handled with little or no liquid propane in them.
Figure 1.
Student Book  © 2004 Propane Education & Research Council
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3. Factors Related to the Installation of Cylinders
Safety Precautions
Electrical tools that are used for installation must be three-wire (grounded) or double-insulated as prescribed by NIOSH, ANSI and OSHA standards.
When using electrical hand tools, always use three-wire electrical extension cords with proper ground lugs and a grounded power supply.
When working with electrical tools, do not place any tools or extension cords in water puddles or damp grass.
When transporting cylinders to a customer site, always use proper equipment (i.e. tie-down straps, chains, etc.) to minimize cylinder movement on the truck while in transit.
Student Book  © 2004 Propane Education & Research Council
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4. Factors Related to the Installation of Cylinders
Safety Precautions
Only authorized employees of the company should assist during installation. AVOID ASKING FOR OR ACCEPTING ASSISTANCE FROM A CUSTOMER WHEN CYLINDERS ARE BEING INSTALLED.
Do not allow the customer or any children to be in the immediate work area during installation. Politely explain the possibility of injury and ask them to leave.
Do not leave equipment unattended until all tools and equipment have been returned to the service truck and locked up.
Student Book  © 2004 Propane Education & Research Council
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5. Factors Related to the Installation of Cylinders
Customer Relations The installation requires personnel to talk with the customer, verifying their preferences and communicating safety information and product warnings.
Installation Planning and Documentation Because code and specific installation site requirements must be met, it is a good practice to use a worksheet during planning and installation.
Some states require a similar worksheet to be filed with the local authority having jurisdiction or a state regulatory agency in order to obtain a permit to install cylinders. Review company procedures to determine when and how a cylinder installation worksheet should be used.
Student Book  © 2004 Propane Education & Research Council
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6. Factors Related to the Installation of Cylinders
Figure 2. Sample Planning & Installation Worksheet for a DOT Cylinder Installation
Student Book  © 2004 Propane Education & Research Council
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7. Procedures for Installing DOT Cylinders
Step1:
Prepare the cylinder(s), tools, and equipment required for the installation.
Be sure to check the manufacturer test date and/or requalification dates on the cylinder. Do not transport or install any cylinder that is in need of being requalified.
Select the proper equipment for transporting and handling the cylinders.
Select appropriate cylinder foundation materials.
Figure 3.
Solid
Masonry
Block
Foundations
Two 100-Pound Exchange Cylinders or
a Single 200-Pound Stationary Cylinder
Single 420-Pound Stationary Cylinder
Student Book  © 2004 Propane Education & Research Council
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8. Procedures for Installing DOT Cylinders
Multiple Cylinder Installations When more than two cylinders are installed, it is a recommended practice to install at least two cylinders on each masonry foundation.
Concrete Foundations Check company procedures and state and local codes for requirements on concrete foundations
Figure 4. Placing Vehicle Chock Blocks
Student Book  © 2004 Propane Education & Research Council
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9. Procedures for Installing DOT Cylinders
Step 2:
Verify the proper location for the cylinder(s) on the customer site.
Figure 5. Distance Requirements for DOT Cylinders
Student Book  © 2004 Propane Education & Research Council
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10. Procedures for Installing DOT Cylinders
Do not sacrifice or ignore any safety requirements for a location preferred by the customer! If another location cannot be found that meets all distance requirements, politely explain to the customer the reasons for the location.
Figure 6.
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11. Procedures for Installing DOT Cylinders
Figure 7.
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12. Procedures for Installing DOT Cylinders
Figure 7.
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13. Procedures for Installing DOT Cylinders
Step 3:
Prepare the foundation for the cylinders.
Step 4:
Properly unload and install the cylinder(s) on the foundation and prepare the cylinder(s) for service.
Figure 8. Masonry Block Foundation
Student Book  © 2004 Propane Education & Research Council
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14. Procedures for Installing DOT Cylinders
Figure 9. Unloading and Installing Exchange Cylinders
Student Book  © 2004 Propane Education & Research Council
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15. Procedures for Installing DOT Cylinders
Step 5:
Explain any maintenance or safety precautions to the customer.
The area 10 feet in any direction from the cylinders must be kept clear of loose or stored combustible materials.
Sources of ignition must be kept at least 10 feet from the cylinders.
Any valve or cylinder leaks must immediately be reported to the company.
Explain the operation and function of the shutoff valve. Instruct the customer to close the shutoff valve in the event of any unusual odors or emergency conditions. Vent a small quantity of propane from the maximum fixed liquid level gauge. Ask the customer to “sniff” the vapor after the gauge is closed to determine if the customer can smell propane odorant.
Explain the function of the relief valve.
Provide the customer with copies of all applicable company safety information and product warning notices.
Student Book  © 2004 Propane Education & Research Council
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16. Procedures for Installing DOT Cylinders
IMPORTANT: If the cylinders installation includes installation of new vapor distribution lines, the new or modified lines must be pressure tested as required by NFPA 58 and 54. Prior to placing the distribution system into service, a leak check should be completed and documented as well.
Follow your company’s procedures for completing & documenting all tasks you perform related to cylinder installation.
Student Book  © 2004 Propane Education & Research Council
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17. Time to See If You Got the Key Points of This Module…
Complete the Review on page 13.
See if you are ready for the Certification Exam by checking off the performance criteria on page 14.
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