1. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 1 3.3.3 Operating a Dispenser to Fill DOT Cylinders Operating a dispenser to fill DOT cylinders with propane requires the operator to know the regulations that apply and the characteristics of manual or automatic filling equipment. In this training module you will learn to identify: (1)DOT regulations and code requirements that apply to cylinder filling (2)Operating characteristics of platform scales (3)Operating characteristics of propane dispensers (4)Pre-filling requirements for DOT/ICC cylinders (5)Steps for filling the cylinder (6)Overfill prevention devices for DOT cylinders (7)Precautions to use when filling a cylinder

2. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 1 DOT Regulations that Apply to Cylinder Filling Federal regulatory requirements for cylinder filling and requalification include but are not limited to: 49 CFR § 173.301—Before each filling of a cylinder, the person filling the cylinder must visually inspect the outside of the cylinder. A cylinder that: 1.has a crack or leak 2.is bulged 3.has a defective valve 4.a leaking or defective pressure relief device 5.bears evidence of physical abuse, fire or heat damage 6.detrimental rusting or corrosion may not be filled and offered for transportation. A cylinder overdue for periodic requalification with a hazardous material will not be filled.

3. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 1 & 2 DOT Regulations that Apply to Cylinder Filling Federal regulatory requirements for cylinder filling and requalification include but are not limited to: Pressure relief devices must be tested for leaks before the charged [filled] cylinder is shipped from the cylinder filling plant. Required cylinder markings on a cylinder must be legible. The weight of liquefied gas [propane] filled into the cylinder must be checked, after disconnecting the cylinder from the filling line, by the use of an accurate scale. No cylinder may be filled and offered for transportation in commerce unless that cylinder has been requalified and marked in accordance with [DOT regulations]. A cylinder passing requalification by the external visual inspection must be marked in accordance with § 180.213

4. 3.3.3 Student Book © 2004 Propane Education & Research Council DOT Regulations that Apply to Cylinder Filling Requalification Markings V10001 0604 E V10001 V10001 0604 E Valid for 5 years from the date Valid for 5, 7 or 12 years from the date, depending on the meaning of “ x ” Valid for 5 years from the date

5. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 2 NFPA Code Requirements for Cylinder Filling NFPA 58 2001 NFPA 58 2004 NFPA 58, LP-Gas Code, requires that cylinders must be filled, continued in service, and transported in compliance with DOT regulations. Further, any cylinder that is due for requalification must not be refilled until it is requalified using requalification methods prescribed by DOT. 5.2.3 Cylinders Filled on Site gives inspection and rejection criteria for stationary cylinders.

6. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 3 Operating Characteristics of Platform Scales Figure 2a. Diagram of a Single Beam Scale In most states and jurisdictions scales must bear certification decals from weights and measures officials, and be periodically inspected and calibrated for accuracy.

7. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 4 Operating Characteristics of Platform Scales Single Beam Scales Figure 2b. Single Beam Scale are used to determine the proper filling weight for the cylinder by adding the cylinder tare weight; the maximum permitted propane weight; the weight of the dispensing hose, hose end valve, and adapters. The total of the three weights must be set, using the beam weight and additional counter weights as may be required.

8. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 4 Operating Characteristics of Platform Scales Double Beam Scales Figure 3. Double Beam Scale incorporate two balance beams into one assembly. Instead of a single scale reading, this 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. 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.

9. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 5 Operating Characteristics of Propane Dispensers Propane dispensers are comprised of the following: 1.An ASME tank 2.Tank valves and propane liquid distribution piping 3.Propane pump with by-pass circuit 4.A platform scales 5.Dispenser hose, quick-closing hose end valve, and cylinder filling adapters 6.Optional liquid meter

10. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 5 Operating Characteristics of Propane Dispensers Cylinder dispensing equipment can be classified as Manual shutdown Automatic shutdown Figure 4. Dispenser Operator Inspecting a DOT Cylinder

11. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 5 & 6 Operating Characteristics of Propane Dispensers Manual shutdown dispensers rely on the operator to determine when the maximum permitted filling limit for a cylinder is reached, and to stop the flow of liquid into the cylinder by manually closing one or more valves. Regardless of whether the dispensing equipment is manually operated or if it uses automatic shutdown systems, the operator must set the platform scale for the proper filling weight: Marked Cylinder Tare Weight + Marked Cylinder Water Capacity x 0.42 + Weight of dispenser hose, end valve, & adapters Total = Scale Filling Weight Setting

12. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 6 Operating Characteristics of Propane Dispensers Automatic shutdown systems are classified according to the actuation method and include: Hydraulic Electric Pneumatic Figure 5. Multiple-Station Automatic Shutoff System

13. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 6 & 7 Operating Characteristics of Propane Dispensers Figure 6. Hydraulic Shutdown System These systems normally consist of a sensor or trip lever mounted on the balance beam of the scale, and a master control valve that controls the flow of liquid propane to the dispensing hose. Hydraulic Shutdown

14. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 7 Operating Characteristics of Propane Dispensers Figure 7. Electric Shutdown System Electric Shutdown

15. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 8 Operating Characteristics of Propane Dispensers Figure 8. Pneumatic Shutdown System Pneumatic Shutdown

16. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 9 Pre-Filling Requirements Verify Proper Design Information & Markings Figure 9. Identification Markings Required on DOT/ICC Propane Storage Exchange Cylinders

17. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 10 Pre-Filling Requirements Figure 10. Typical DOT and ICC Cylinder Codes

18. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 10 Pre-Filling Requirements Requalification Requirements Cylinders must carry a current requalification date. V10001 0604 E V10001 V10001 0604 E Valid for 5 years from the date Valid for 5, 7 or 12 years from the date, depending on the meaning of “ x ” Valid for 5 years from the date

19. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 10 Pre-Filling Requirements Cylinder Capacity Specific Gravity at 60° F (15.6° C) 0 to 1,200 U.S. gal. (1,000 Imp. gal., 4.5m3) Total Water Capacity.504 -.51042% Cylinders may be filled to a point that assures they will not become liquid full when the liquid is at the highest anticipated temperature.

20. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 11 Pre-Filling Requirements Cylinder Labeling Requirements A consumer information/warning label must be applied to all portable refillable LP-gas cylinders of 100 lb. LP-gas capacity or less not filled on-site. The label shall include information on the potential hazards of LP-gas. Sample Consumer Warning Label

21. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 11 & 12 Pre-Filling Requirements Purging Air From Propane Storage Cylinders An effective method of purging air from cylinders is by using propane vapor to force the air out of the cylinder. Figure 11. Cylinder Purging Manifold

22. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 13 Pre-Filling Requirements Purging Air From Propane Storage Cylinders Step 1: Prepare the cylinder for purging. Install the necessary fittings to connect the vapor hose to the cylinder service valve. The fittings used vary according to the type of valves in the cylinder. Figure 12b. Female POL X CGA 555 Adaptor Figure 12a. Female POL X 3/8" Female Pipe Thread Adaptor

23. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 14 Pre-Filling Requirements Purging Air From Propane Storage Cylinders Figure 15. Standard CGA 510 (POL) Connection

24. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 15 Pre-Filling Requirements Purging Air From Propane Storage Cylinders Step 2: Connect the vapor line to the cylinder. If a service valve that does not have a female POL opening is installed in the cylinder, attach any required cylinder service valve adapter to the POL adapter that is permanently installed in the vapor line hose end valve. Step 3: Pressurize the cylinder with propane vapor to 15 psig. Step 4: Bleed off the pressure in the cylinder. All flame or spark producing devices should be turned off or removed to a distance of 25' from the cylinder.

25. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 16 Pre-Filling Requirements Purging Air From Propane Storage Cylinders Step 5: Repeat the purging process. To ensure that approximately 97% of the air has been purged from the cylinder, repeat Steps 3 and 4 at least four more times. Leave the vapor return hose connected. After the final purging is vented, close Valve 1 and re-pressurize the cylinder. Close all valves including the cylinder service valve after the cylinder is pressurized and check the cylinder for leakage.

26. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 16 Prepare the Cylinder for Filling Before filling any cylinder ensure there are no sources of ignition within 25 feet of the point of transfer. To ensure the cylinder is properly filled, the scales must be "zeroed" periodically. Referring to the design information on the cylinder set the scales for the tare weight of the cylinder, the propane capacity of the cylinder and the weight allowances for the hose, hose- end valve, and adapter.

27. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 17 Prepare the Cylinder for Filling When filling portable propane storage cylinders by volume, open and close the bleeder valve on the fixed liquid level gauge to be sure vapor vents from the bleeder orifice. If a white mist of propane liquid vents from the bleeder orifice of the fixed liquid level gauge, the cylinder may be full or overfilled. Do not proceed with the filling operation until you have weighed the cylinder to be sure that it needs filling. If the cylinder is overfilled reduce the liquid level in a safe area according to company procedures.

28. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 17 Prepare the Cylinder for Filling Connect the Filler Hose to the Cylinder Figure 18. ACME Hose End Valve Connector Figure 19. POL Hose End Valve Connector

29. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 18 Prepare the Cylinder for Filling Connect the Filler Hose to the Cylinder Figure 20. Adapter for Liquid Service Valves

30. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 18 Prepare the Cylinder for Filling Connect the Filler Hose to the Cylinder Figure 21. ACME Quick-Closing Connectors

31. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 19 Procedures for Cylinder Filling Filling Portable Cylinders by Weight—Manual Dispensers NOTE: Operator must be in attendance during the entire filling procedure. Step 1: Open the liquid outlet valve on the storage/supply tank and any valves in the by-pass return line. Step 2: Connect the dispensing hose to the cylinder fill valve. Step 3: Open the service valve on the cylinder as applicable. Step 4: Start the pump. Step 5: Open the hose end valve. Step 6: Close the hose end valve as soon as scale beam or indicator tips.

32. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 19 Procedures for Cylinder Filling Filling Portable Cylinders by Weight—Manual Dispensers Step 7: Close the cylinder valve. Step 8: Shut off the pump. Step 9: Disconnect the dispensing hose. Step 10: Check the weight of filled cylinder after filling connector has been disconnected. Step 11: Check the cylinder valves, especially the relief valve for leaks.

33. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 19 Procedures for Cylinder Filling Filling Portable Cylinders by Weight—Manual Dispensers Step 12: Valve outlets on cylinders of 45 lbs. propane capacity or less must be either plugged or equipped with a quick closing or quick connect coupling. Step 13: If required, apply DOT shipping label or cylinder warning label.

34. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 20 Identifying Overfill Prevention Devices An OPD is a special cylinder service valve that is equipped with a device which stops the flow of gas liquid into the cylinder when the cylinder is about 80% filled. OPD cylinder valves are distinctively marked and are equipped with a unique handwheel, a modified triangle, to make identification easier. OPDs have distinctive three cornered, hand wheels. “OPD” is stamped on the upper portion of the valve body and on the handwheel. Figure 21. Determining If a Cylinder Has an OPD

35. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 21 Precautions for Cylinder Filling Preventing and Handling Emergencies Know the location and how to operate emergency shutdown and pump controls. Know the location and condition of the fire extinguisher(s). Use fire extinguishers to create an escape route, and not to fight a propane fire. Remember that a propane fire can only be safely extinguished by stopping the flow of propane. Read and follow plant fire prevention and emergency evacuation plans. Before operating a dispenser, be sure that ignition sources and combustible materials are not within 25 feet of the point(s) of transfer.

36. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPage 21 Precautions for Cylinder Filling Preventing and Handling Emergencies Except for the time that exchange cylinders are on the scales and being filled be sure that valves are properly protected with a valve cap. Do not allow unauthorized persons to enter or remain in the transfer area. Always use proper cylinder handling techniques.

37. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 21 & 22 Post-Filling Procedures Step 1: Shut off the pump Step 2: Close valves at the storage tank. Step 3: Disconnect and store the hose(s) on a rack inside a fence- protected area, inside the dispenser cabinet, or secured to a supporting structure inside the filling room. At locations that are not weather protected, install a dust cap or plug in hose filling adapter. Step 4: Secure the installation against tampering.

38. 3.3.3 Student Book © 2004 Propane Education & Research CouncilPages 23 - 27 Time to See If You Got the Key Points of This Module… Complete the Review on pages 23 -25. See if you are ready for the Certification Exam by checking off the performance criteria on pages 26 & 27.