MS 830-2003

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MALAYSIAN STANDARD

MS 830:2003

CODE OF PRACTICE FOR THE STORAGE, HANDLING AND TRANSPORTATION OF LIQUEFIED PETROLEUM GASES

(SECOND REVISION)

ICS: 75.200 Descriptors: liquefied petroleum gas, storage, handling, transportation, piping systems, dispensing stations

© Copyright DEPARTMENT OF STANDARDS MALAYSIA

DEVELOPMENT OF MALAYSIAN STANDARDS The Department of Standards Malaysia (DSM) is the national standardisation and accreditation body.

The main function of the Department is to foster and promote standards,


standardisation and accreditation as a means of advancing the national economy, promoting industrial efficiency and development, benefiting the health and safety of the public, protecting the consumers, facilitating domestic and international trade and furthering international cooperation in relation to standards and standardisation.

Malaysian Standards are developed through consensus by committees which comprise of balanced representation of producers, users, consumers and others with relevant interests, as may be appropriate to the subject in hand. These standards where appropriate are adoption of international standards. Approval of a standard as a Malaysian Standard is governed by the Standards of Malaysia Act 1996 (Act 549). Malaysian Standards are reviewed periodically. The use of Malaysian Standards is voluntary except in so far as they are made mandatory by regulatory authorities by means of regulations, local by-laws or any other similar ways.

The Department of Standards appoints SIRIM Berhad as the agent to develop Malaysian Standards. The Department also appoints SIRIM Berhad as the agent for distribution and sale of Malaysian Standards. For further information on Malaysian Standards, please contact:

Department of Standards Malaysia OR Level 1 & 2, Block C4, Parcel C Federal Government Administrative Centre 62502 Putrajaya Malaysia

SIRIM Berhad 1, Persiaran Dato' Menteri P.O. Box 7035, Section 2 40911 Shah Alam Selangor D.E.

Tel: 60 3 88858000 Fax: 60 3 88885060 http://www.dsm.gov.my

Tel: 60 3 5544 6000 Fax: 60 3 5510 8095 http://www.sirim.my

Email: [email protected]

MS 830:2003

CONTENTS


Page Committee representation …………………………………………………………….

v

Foreword ………………………………………………………………………………..

vi

Sections 1

Scope and general ………………………………………………………………………

1

2

Container design and construction………………………………………………………

11

3

Piping, valves and fittings ………………………………………………………………..

17

4

Equipment …………………………………………………………………………………

25

5

Capacity, location and installation of aboveground storage containers up to first-stage regulator…………………………………………………………………

30

Capacity, location and installation of underground/mounded storage containers up to first-stage regulator……………………………………………………

44

7

Transportation of LPG

………………………………………………………………..

52

8

Transfer of liquids ………………………………………………………………………..

56

9

Filling capacities of LPG containers and cylinders

…………………………………

62

10

Cylinder filling ……………………………………………………………………………..

64

11

Storage of cylinders awaiting use or resale ……………………………………………

71

12

Cylinders in use……………………………………………………………………………

75

13

Automotive LPG dispensing station

………………………………………………….

80

14

Electrical and electrostatic hazard precautions ……………………………………….

84

15

Fire protection ……………………………………………………………………………..

90

16

Design and use of mobile gas -fired equipment………………………………………..

96

6

Annexes A

Normative references

………………………………………………………………. 102

B

Properties of LPG

C

Pressure testing of pipework at LPG installations

…………………………………………………………………..

i

…………………………………

105 107

MS 830:2003

CONTENTS (continued)


Page D

Rate of discharge for safety relief valves on containers ………………………………

108

E

Rate of discharge for safety relief valves for LPG Vaporis ers (other than atmospheric)……………………………………………………

110

F

Deflection walls ……………………………………………………………………………

111

G

Emergency procedure guide (for vehicles carrying dangerous goods)……………..

112

H

Emergency procedure guide (Liquefied petroleum gas (LPG))………………………

115

J

Method of calculating maximum permitted liquid volume which can be placed in a container at any liquid temperature ……………………….

118

K

Procedures for visual inspection and requalification of cylinders…………………….

123

L

Fire safety signs …………………………………………………………………………..

132

M

Protective bollard poles…………………………………………………………………..

134

N

Refuelling procedures at automotive LPG dispensing stations

…………………..

136

P

LPG emergency procedures

………………………………………………………….

137

Q

How to control LPG leaks and fires

………………………………………………..

138

1

Design pressures ……………………………………………………………………….

11

2

Safety distances for direct -fired vaporisers ……………………………………………

28

3

Relief valve start-to -discharge setting for regulator……………………………………

29

4

Minimum separation between an LPG container and a storage of a gas other than LPG ………………………………………………….

31

5

Distance to any opening enclose underground drain …………………………………

40

6

Inspection of aboveground containers ………………………………………………….

42

7

Maximum permitted filling ration for LPG containers and cylinders

……………..

63

8

Maximum permitted liquid volume for containers up to 8 kl water capacity ………………………………………………………………………..

63

Location of storage outside of building ………………………………………………….

73

Tables

9

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MS 830:2003



Page 10

Cylinder location and safety distances ………………………………………………….

75

11

Safety distance…………………………………………………………………………….

78

12

Electrical equipment classified areas……………………………………………………

87

13

Fire protection ……………………………………………………………………………..

95

B1

Approximate properties of LPG

…………………………………………………….

106

D1

Rate of discharge for discharge for safety relief valves on containers ………………

109

J1

Liquid volume correction factors …………………………………………………………

119

J2

Maximum filling percentage for aboveground containers (up to 5 kl water capacity) ……………………………………………………………….

120

Maximum filling percentage for aboveground containers (over 5 kl water capacity) ………………………………………………………………..

121

Maximum filling percentage for underground/mounded containers (all capaci ties)………………………………………………………………..

122

LPG cylinder damage limits

129

J3

J4

K1

………………………………………………………….

Figures 1

Location of aboveground containers in refineries and bulk plants……………………

37

2

Location of aboveground containers for bulk storage at consumers’ premises …………………………………………………………………….

38

Location of aboveground containers in automotive LPG dispensing stations …………………………………………………………………………

39

Location of underground/mounded containers for bulk storage at consumers” premises ………………………………………………………..

47

Location of underground/mounded containers for automotive LPG dispensing stations ………………………………………………..

48

Location of underground/mounded containers in refineries and bulk plants…………………………………………………………………

49

7

Safety distances for cylinder filling and cylinder storage……………………………..

66

8

Check for gas leakage in cylinder……………………………………………………….

67

3

4

5

6

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MS 830:2003



Page 9

Illustration showing two manifolded groups of cylinders ……………………………..

76

10

Extent of classified area ………………………………………………………………….

89

F1

Location of deflection walls ………………………………………………………………

111

K1

Suggested method of measuring isolated pitting………………………………………

127

K2

Suggested method of measuring general corrosion ………………………………….

128

K3

Visual inspection report form…………………………………………………………….

131

M1

Protective bollard poles for dispenser …………………………………………………..

135

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MS 830:2003

Committee representation


The Petroleum and Gas Industry Standards Committee (ISC H) under whose authority this Malaysian Standard was developed, comprises representatives from the following organisations: Association of Consulting Engineers Malaysia Association of Malaysian Oil and Gas Engineering Consultants Department of Occupational Safety and Health Department of Standards Malaysia Energy Commission ExxonMobil Malaysia Sdn Bhd Fire and Rescue Department FMM-Malaysian Industrial Gases Manufacturers Group Malaysian Petroleum Institute Malaysian Plastics Manufacturers Association Ministry of Domestic Trade and Consumer Affairs PETRONAS Public Works Department Road Transport Department Shell Malaysia Trading Sdn Bhd The Institution of Engineers, Malaysia University Teknologi Malaysia Universiti Teknologi Petronas The Technical Committee on Liquefied Petroleum Gas and Related Products which developed this Malaysian Standard consists of representatives from the following organisations: BP Malaysia Department of Occupational Safety and Health Energy Commission Fire and Rescue Department Gas Malaysi a Ministry of Domestic Trade and Consumer Affairs Persatuan Kontraktor Retikulasi Gas Petronas Dagangan Berhad Road Transport Department Shell Malaysia Trading Sdn Bhd SIRIM Berhad (Secretariat) Universiti Teknologi Malaysia

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MS 830:2003

FOREWORD


This Malaysian Standard was developed by the Technical Committee on Liquefied Petroleum Gases and Related Products under the authority of the Petroleum and Gas Industry Standards Committee. This Malaysian Standard is the second revision of MS 830:1994, Code of practice for the storage, handling and transportation of liquefied petroleum gases. Major modifications in this revision are as follows: a)

the definition of “Regulator” has been added as Clause 1.4.49;

b)

the definition of “Qualification of personnel” has been added as Clause 1.5;

c)

the phrase “or other codes approved by the relevant authority” has been added to Clause 2.2.1, 2.3.1 and 2.8.1;

d)

Clause 3.2.4 and 3.2.6 have been amended to exclude “wrought iron, black or galvanised steel or brass”;

e)

referenced ASTM B42, ASTM B88 and ASTM B380 have been replaced with BS EN 1057 wherever relevant;

f)

Clause 3.2.7 has been amended to exclude “Approved asbestos compound gaskets”;

g)

the height of the deflection wall has been revised to “not lower than 2 m” in Clause 5.2.6.2 a);

h) new requirement for materials for steel support has been added as in Clause 5.2.7; i)

new requirement for ASME storage containers has been added as on Clause 5.2.7.3;

j)

the sign “No handphone” has been added to Clause 5.7.1 d), 7.5.1 c), 10.7.1 d), 11.5.2 d), 13.6.1 d) and L1;

k)

“Dangerous marking as approved by the relevant authorities” has been added to Clause 7.5.1.1 and 7.5.1.2;

l)

the extent of classified area for storage containers other than cylinders in Zone 2 has been changed to “Beyond 1.5 m but within 4.5 m in all direction from the container connections or shell.” in Table 12;

m)

the phrase of “at least one 40 BC fire extinguisher shall be provided” has been replaced by “one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam shall be provided" in 15.3.2;

n)

the phrase of “at least one chemical fire extinguisher of 20 B minimum rating” has been replaced by “with two fire extinguishers of minimum 144 BC or of minimum 9 l of water/foam” in 15.3.4;

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MS 830:2003

o)

the phrase of “at least one dry chemical fire extinguisher of 40 B minimum rating shall be provided” has been replaced by “two fire extinguishers of 144 BC minimum rating or of minimum 9 l of water/foam shall be provided” in 15.4.1; and

m)

Annex C has been revised.

This revised Malaysian Standard cancels and replaces MS 830:1994. Compliance with a Malaysian Standard does not of itself confer immunity from legal obligations.

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MS 830:2003

CODE OF PRACTICE FOR THE STORAGE, HANDLING AND TRANSPORTATION OF LIQUEFIED PETROLEUM GASES (LPG) (SECOND REVISION)


SECTION 1: SCOPE AND GENERAL 1.1

Scope

This Malaysian standard specifies requirements for the location, design, construction, commissioning and operation of installations for the storage and handling of LPG. 1.1.1

This standard shall not apply to the following:

a)

Refrigerated storage of LPG or refrigeration systems.

b)

Plant or equipment in which LPG is processed or produced, or vessels which form an integral part of that processing equipment (but does include post manufacturing storage).

c)

Industrial gas-consuming equipment (see MS 930).

d)

Installation of consumer piping or appliances (see MS 930).

e)

Marine and pipeline terminals, natural gas processing plants or petrochemical plants (excluding refineries).

1.1.2 LPG stored or used in systems within the scope of this standard shall not contain of transportation ammonia. When such a possibility exists (such as may result from the dual use or storage equipment) the LPG shall be tested in accordance with B2.1 . 1.2 Normative references (see Annex A). 1.3

General properties of LPG

1.3.1 LPG, as defined in this standard (see 1.5.33), are gases at normal room temperature and atmospheric pressure. They liquefy under moderate pressure, readily vaporising upon release of this pressure. It is this property which permits transporting and storing them in concentrated liquid form, while normally using them in vapour form. The potential fire hazard of LPG vapour is comparable to that of natural or manufactured gas, except that LPG vapours are heavier than air. The ranges of flammability are considerably narrower and lower than those of natural or manufactured gas. For example, the lower flammable limits of the more commonly used LPG are: Propane, 2.15 % and butane, 1.55 %. These figures represent volumetric percentages of gas in gas -air mixture.

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MS 830:2003


1.3.2 The boiling point of pure normal butane is -0.56 ?C, of pure propane -42.2 ?C . Both products are liquids at atmospheric pressure at temperatures lower than their boiling points. Vaporisation is rapid at temperatures above the boiling point, thus liquid propane normally does not present a flammable liquid hazard, for additional information of these and other properties of the principle LPG, see Annex B. 1.4

LPG odorisation

1.4.1

LPG to be odorised

LPG shall be odorised by the addition of a warning agent of such character that it is detectable by a distinct odour, down to a concentration in air of not over one -fifth of the lower limit of flammability (see note) (see 1.2.1 and Annex B for flammable limits of the LPG). NOTE. It is recognised that no odorant will be completely effective as a warning agent in every circumstance. It is recommended that odorants be qualified to comply with 1.3.1 by test or experience. Experience has shown that ethyl mercaptan in the ratio of 1.2 kg per 100 kl of liquid LPG has been recognised as an effective odorant.

1.4.2

Omission of odorisation

a)

When specially permitted by the relevant authority, odorisation may be omitted if harmful in the use or further processing of the LPG, or if odorisation will serve no useful purpose as a warning agent in such further use or processing. When so permitted, a large notice shall be prominently displayed on the container indicating that unodorised LP G is being stored or carried;

b)

Unodorised LPG installations shall be equipped with an emergency shutdown system which will automatically stop the flow of gas if a gas detector senses the presence of a concentration of gas in air of more than 25 % of the lower explosive limit (LEL). Where more than one gas is stored the detector shall be set for that gas with the lowest LEL;

c) Gas detectors shall be installed: i) around the installation; ii) at the loading point if direct fill is not being used; and iii) at the point of usage of the unodorised gas. d) Gas detectors shall: i) shut off the flow of gas as in b); and ii) initiate an audible alarm of at least 105 decibels, and a visible alarm. 1.5

Definitions

For the purposes of this standard, the following shall apply: 1.5.1

A boveground storage container

A storage container, no part of which is below ground level, and which is not covered by earth, sand or other similar material.

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MS 830:2003


1.5.2

Approved

Acceptable to the authority having jurisdiction. In determining the acceptability of installations or procedures, equipment or materials, the authority having jurisdiction may base acceptance on compliance with appropriate standards. In the absence of such standard, said authority may require evidence of proper installation, procedure or use. The authority having jurisdiction may also refer to the listings or labelling practices of nationally recognised testing laboratories, inspection, agencies, or other organisations concerned with product evaluations which are in a position to determine compliance with appropriate standards for the current production of listed items and the satisfactory performance of such equipment or materials in actual usage. 1.5.3

Authority

The organisation, office or individual responsible for 'approving' equipment, an installation, or a procedure. 1.5.4

Authorised person

A person specifically appointed by a LPG marketer to perform the duties of that position. 1.5.5

Automotive LPG dispensing station

A facility open to the public which consists of LPG storage containers, piping and pertinent equipment, including pumps and dispensing devices, and any buildings, and in which LPG is stored and dispensed into permanently mounted fuel containers of vehicles. 1.5.6

Basement

Any storey or storeys of a building which is or are at a level lower than the ground storey. In the context in which the term is used in this standard, where more than 50 % of the perimeter walls are open and of which one shall be the longest side, it shall not be classified as being a basement. 1.5.7

Boundary (or site boundary or property boundary)

The boundary of the whole of the site under the same occupancy as that on which the installation is included. 1.5.8

Bulk plant

See 1.5.17. 1.5.9

Cargo tank

A container permanently mounted on a tank vehicle chassis for the purpose of carrying liquids. 1.5.10

Charging

See 1.5.19.

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MS 830:2003

1.5.11

Container


A pressure vessel for containing LPG, and covering both vessels for bulk storage and transport and smaller vessels such as portable containers for the transporting or storing of the LPG. See also static storage container, portable container, portable storage container, cylinder, cargo tank and skid tank. 1.5.12

Container appurtenances

Items connected to container openings needed to make a container a gas-tight entity. These include, but are not limited to safety relief valves, excess flow valves, non-return valves, shutoff valves, internal valves, liquid level gauges and pressure gauges. 1.5.13

Container assembly

An assembly consisting essentially of the container and fittings for all container openings, These include safety relief valves, excess flow valves, shut off valves, liquid level gauges and protective housings. 1.5.14

Cylinder

A portable container not exceeding 0.5 kl water capacity and used for the storage and transfer of LPG. 1.5.15

Direct gas-fired container heater

A gas -fired device which applies hot gas from the heater combustion chamber directly to a portion of a container surface in contact with LPG liquid. 1.5.16

Dispenser (or dispensing device )

A device normally used to transfer and measure LPG for engine fuel into a fuel container, serving the same purpose for an automotive LPG dispensing station as that served by a gasoline dispenser in a gasoline service station. 1.5.17

Distributing plant

A facility, the primary purpose of which is the distribution of gas and which receives LPG in tanker lots, distributing this gas to the end user by portable container (package) delivery, by road or rail tanker, or through gas piping. Such plants have bulk storage (8 kl-water capacity or more) and usually have container filling and tanker loading facilities on the premises. So called 'bulk plants' are considered as being in this category. Normally no persons other than the plant management or plant employees have access to these facilities. 1.5.18

Excess-flow valve (or excess-flow check valve)

A valve designed to close when the liquid or vapour passing through it exceeds a prescribed flow rate as determined by pressure drop. 1.5.19

Fill, filling

Transferring liquid LPG into a container.

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MS 830:2003

1.5.20

Filling by mass

Filling a container by weighing the LPG in the container. No temperatures determination or correction is required as a unit of mass is a constant quantity regardless of temperature.


1.5.21

Filling by volume

Filling a container by determination of the volume of LPG in the container. Unless a container is filled by a fixed maximum liquid level gauge, correction of the volume for liquid temperature is necessary. 1.5.22

Filling ratio

The ratio between the greatest quantity of LPG permitted in a container and the quantity of water at 150 °C, which would completely fill the container. The filling ratio may be either: a)

mass filling ratio. The LPG water mass ratio; it varies with the LPG composition but not its temperature; or

b)

volumetric filling ratio. The LPG/water volume ratio; it varies with both LPG composition and temperature.

1.5.23

Fixed liquid level gauge

A type of liquid level gauge using a relatively small positive shut off valve and designed to indicate when the liquid level in a container being filled reaches the point at which this gauge or its connecting tube communicates with the interior of the container. 1.5.24

Fixed maximum liquid levee gauge

A fixed liquid level gauge which indicates the liquid level at which the container is filled to its maximum permitted filling ratio. 1.5.25

Flammable and combustible liquids

Liquids as defined in MS 761. 1.5.26

Flexible connector

A short (not exceeding 1 m overall length) component of a piping system fabricated of flexible material (such as hose) and equipped with suitable connections on both ends. LPG resistant rubber and fabric (or metal), or combination of them, or ale metal may be used. Flexible connectors are used where there is the need for, or the possibility of, greater relative movement between the points connected than is acceptable for rigid pipe. 1.5.27

Float gauge

A gauge constructed with a float inside the container resting on the liquid surface which transmits its position through suitable leverage to a pointer and dial outside the container indicating the liquid level. Normally the motion is transmitted magnetically through a nonmagnetic plate so that no LPG is released to the atmospher e. Also called magnetic gauge.

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MS 830:2003

1.5.28

Gas -free

A container or area is considered to be ‘gas free' when the concentration of flammable and/or toxic gases in it is within safe prescribed limits for persons to enter.


1.5.29

Ground storey (or ground floor)

The lowest storey of a building to which there is an entrance from the outside or above the level of the ground at the front of the building. 1.5.30

Ignition source

See 1.5.54. 1.5.31

Industrial plant

An industrial facility, which utilises LPG incident to plant operations, with bulk storages of LPG and which receives LPG in tanker lots. Normally LPG is used through piping systems in the plant, but may also be used to fill small containers, such as for engine fuel on industrial (i.e. forklift) trucks. Only plant employees have access to these filling facilities. 1.5.32

Internal valve

A primary shut off valve for containers which has adequate means of actuation and which is constructed in such a manner that its seat is inside the container and that damage to parts exterior to the container or mating flange will not prevent effective seating of the valve. 1.5.33

Liquefied petroleum gas (LPG)

Any fluid having a vapour pressure not exceeding that allowed for commercial propane composed predominantly of the following hydrocarbons, either by themselves or as mixture: propane, propylene, butane (normal butane or iso-butane) and butylenes (including isomers). 1.5.34

Load, loading

See 1.5.19. 1.5.35

LPG marketer

A company which receives LPG in bulk for distribution to the general public or to agents, who in turn sell the LPG to the general public. 1.5.36

LPG system

An assembly consisting of one or more containers with a means for conveying LPG from the container(s) to dispensing or consuming devices (either continuously or intermittently) and which incorporates components intended to achieve control of quantity, flow, pressure, or state (either liquid or vapour). 1.5.37

Magnetic gauge

See 1.5.27.

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MS 830:2003

1.5.38

Mounded storage container

A storage con tainer, above or partly in the ground, completely covered on all sides by backfilling materials to prescribed requirements.


1.5.39

Non-return valve (or check valve )

A valve which permits flow in one direction only. 1.5.40

Permanent Installation

See 1.5.57. 1.5.41

Piping, piping systems

Pipe, tubing, hose and flexible rubber or metallic hose connectors made up with valves and fittings into, complete systems for conveying LPG in either the liquid or vapour state at various pressure from one point to another. 1.5.42

Portable container

A container designed to be readily moved, as distinguished from containers designed for stationary installations. Portable containers designed for transportation filled to their maximum filling ratio include ‘cylinders', 'cargo tanks' and 'skid tanks', all three of which are separately defined. Such containers have all container appurtenances protected in such a manner that they can be safely transported in the filled or partly filled condition. Containers designed to be readily moved from one usage location to another, but substantially empty of product are 'portable storage container' and are separately defined. 1.5.43

Portable storage container

A container similar to, but distinct from those designed and constructed for stationary installation, designed so that it can be readily moved over the highways, substantially empty of liquid, from one usage location to another. Such containers either have legs or other supports attached, or are mounted on running gear (such as trailer or semi-trailer chassis) with suitable supports, which may be of the fold -down type, permitting them to be placed or parked in a stable position on a reasonably firm and level surface. For large volume, limited duration product usage (such as at construction sites and normally for 12 months or less) portable storage containers function in permanently installed stationary containers. 1.5.44

Quick-closing internal valve

An internal valve designed to be closed both automatically by the operation of one or more sensing devices (which may be fusible links) and manually from a remote position, by the release of the means of holding the valve open. 1.5.45

Quick connectors

Devices used for quick connection of the Acme thread or levercam types. This does not include devices used for cylinder-filling connections.

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MS 830:2003

1.5.46

Rail tanker

A unit consisting of a railway vehicle with a container permanently attached to it, or forming an integral part of the vehicle.


1.5.47 Regulator A device which automatically regulates the outlet pressure of gas passing through it to a predetermined limit. 1.5.48

Road tanker

A road tank vehicle designed for the transportation of LPG, the container being either chassis mounted or of semi-trailer construction. 1.5.49

Rotary ga uge

A variable liquid level gauge consisting of a small positive shut-off valve located at the outer end of a tube, the bent inner end of which communicates with the container interior. The tube is installed in a fitting designed so that the tube can be rotated with a pointer on the outside to indicate the relative position of the bent inlet end. The length of the tube and the configuration to which it is bent is suitable for the range of liquid levels to be gauged. By a suitable outside scale, the level ni the container at which the inner end begins to receive liquid can be determined by the pointer position on the scale at which a liquid-vapour mixture is observed to be discharged from the valve. 1.5.50

Safety relief valve

An automatic pressure-relieving device actuated by the pressure upstream of the valve and characterised by full opening pop action. 1.5.51

Shut off valve

A manually operated stop valve. 1.5.52

Skid tank

A container of more than 0.5 kl water capacity used to transport LPG handled as a ‘package’, that is, filled to its maximum permitted filling ratio. Such containers are mounted on skids or runners and have all container appurtenances protected in such a manner that they can be safely handled as a ‘package’. Such containers might be used on an exchange fill basis, or might be left on-site for refilling from tankers. 1.5.53

Slip tube gauge

A variable liquid level gauge in which a relatively small positive shut off valve is located at the outside end of a straight tube, normally installed vertically and communicates with the container interior. The installation fitting for the tube is designed so that the tube can be slipped in and out of the container and the liquid level at the inner end determined by observing when the shut off valve vents a liquid vapour mixture.

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MS 830:2003


1.5.54

Sources of ignition

Devices or equipment which, because of their modes of use or operation, are capable of providing sufficient thermal energy to ignite flammable LPG vapour-air mixture when introduced into such a mixture or when such a mixture comes into contact with them, and which will permit propagation of flame away from them. They include but are not limited to naked flames, exposed incandescent material, electrical welding arcs and electrical or mechani cal equipment not approved for use in hazardous locations. NOTE. In the context in which the term is used in this standard. A motor vehicle will not be treated as being an ignition source.

1.5.55

Special protection

A means of limiting the temperature of a LPG container for purpose of minimising the possibility of failure of the container as the result of fire exposure. When required in this standard, special protection consists of any of the following: applied insulating coatings, mounding, burial, water spray fixed systems or fixed systems or fixed monitor nozzles, meeting the criteria specified in this standard, or by any means approved for this purpose. 1.5.56

Static storage container

A container intended to remain permanently in place once installe d. 1.5.57

Stationary installation

An installation of LPG containers, piping and equipment for use indefinitely at a particular location; an installation not normally expected to change in status, condition or place. Also called permanent installation. 1.5.58

Underground storage container

A storage container, no part of which, except for the fittings attached to the container, is above ground level, and the excavation for which is back filled, after installation of the container, with back filling materials to prescribed requirements. 1.5.59

Vaporiser

A device for converting liquid LPG to vapour. 1.5.60

Vaporiser, atmospheric

A vaporiser in which heat from the surrounding air of the ground is transferred through the surface of the container. 1.5.61

Vaporiser, direct -fired

A vaporiser in which heat furnished by a flame is directly applied to some form of heat exchange surface in contact with the liquid LPG to be vaporised.

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MS 830:2003

1.5.62

Vaporiser, indirect -fired


A vaporiser in which heat furnished by steam, hot water or other heating medium is applied to a vaporising chamber or to tubing pipe, coils or other heat exchange surface containing the liquid LPG to be vaporised; the heating of the medium used being at a point remote from the vaporiser. Als o called vaporiser, indirect. 1.5.63

Variable liquid level gauge

A device to indicate the liquid level in a container throughout a range of levels. See float, rotary and slip tube gauge. 1.5.64

Volumetric filling

See 1.5.21. 1.5.65

Water capacity

The amount of water, in either kilograms or litres at 15 ?C required to fill a container full of water. 1.5.66

Zone 0

An area in which any flammable atmosphere is continuously present for long periods, in concentrations within the lower and upper limits of flammability. 1.5.67

Zone 1

An area in which a dangerous atmosphere is likely to occur in normal operating conditions. 1.5.68

Zone 2

An area in which a dangerous atmosphere can occur only in abnormal conditions and not in normal operation. 1.6

Qualification of personnel

Persons whose primary duties fall within the scope of this standard shall be trained and qualified according to the requirements of the authority having jurisdiction.

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MS 830:2003

SECTION 2: CONTAINER DESIGN AND CONSTRUCTION


2.1

Application

This section includes design, fabrication and marking requirements for containers, and features normally associated with container fabrication, such as container openings, appurtenances required for these openings to make the containers gas-tight entities and physical damage protecting devices. 2.2

Design code

2.2.1 Containers up to 0.5 kl water capacity shall be designed, fabricated and tested in accordance with MS 641 or MS 642 or other codes approved by the relevant authority. Such containers are commonly called LPG cylinders. 2.2.2 Containers exceeding 0.5 kl water capacity shall be designed, fabricated and tested in accordance with the ASME Code, BS PD 5500, AS 1210 or other codes approved by the relevant authority. 2.3

Design pressure

2.3.1 For aboveground containers up to 0.5 kl water capacity the design pressure shall be in accordance with MS 641 or MS 642 or other codes approved by the relevant authority. 2.3.2 For aboveground containers exceeding 0.5 kl water capacity the minimum design pressure shall be in accordance with Table 1. Table 1. Design pressures For gases with vapour pressure in kPa (gauge) at 37.8 ?C not to exceed

Minimum design pressure kPa (gauge)

550

690

690

860

860

1 080

1 030

1 290

1 200

1 510

1 480

1 750

2.3.3 For underground and mounded containers the minimum design pressure shall be 1 750 kPa (gauge) (see note). NOTE. Because of low soil temperature usually encountered and the insulating effect of the earth the average vapour pressure of products stored in underground containers will be materially lower than when stored aboveground. This reduction is the actual operating pressure. Therefore, it provides a substantial corrosion allowance for these containers when installed underground.

2.4

Marking of containers

2.4.1 Each container shall be conspicuously and permanently marked with the following information: a)

manufacturer's name or trade-mark, serial number and year of manufacture; 11


MS 830:2003

b)

pressure vessel code to which it is made;

c)

the water capacity in litres (l) or kilolitres (kl);

d)

class of vessel (e.g. Class 1);

e)

design pressure in kilopascals (kPa);

f)

date of initial hydrostatic test;

g)

date of hydrostatic retest;

h)

the maximum safe working pressure in kilopascal (kPa);

i)

the tare mass in kilograms (kg) of container (for containers to be filled by mass); and

k)

official stamp of the inspecting authority.

2.4.2 The appropriate class label in accordance with MS 1513: Part 5: Sub-part 2 or the other relevant authority having juris diction shall also be marked on aboveground containers or displayed on a notice in the vicinity of underground/mounded containers. 2.5

Container openings

2.5.1 Containers shall be equipped with openings suitable for the service for which the container is to be used. Such openings may be either in the container proper or in the manhole cover or part in one and part in the other. 2.5.2 Containers of more than 110 l water capacity, designed to be filled volumetrically shall be equipped for filling into either the vapour space or liquid phase with a vapour return line. This requirement shall apply to installations at consumers’ premises and other locations except refineries and bulk plants. 2.5.3 Containers with water capacity of 8 kl or less shall not have more than two plugged openings. 2.5.4 Connections for safety relief valves shall be located and installed in such a way as to have direct communication with the vapour space, whether the container is in storage or in use. If located in a well inside the container with piping to the vapour space, the design of the well and piping shall permit sufficient safety relief valve discharge capacity. If located in a protecting enclosure, the enclosure shall be designed to protect against corrosion and allow inspection. 2.5.5 Containers to be filled on a volumetric basis shall be fabricated so that they can be equipped with a fixed liquid level gauge(s) capable of indicating the maximum permitted filling level(s) computed in accordance with the procedures in Annex J. 2.6

Protection for container openings

2.6.1

Opening requiring protection

An opening through a container shell to either liquid or vapour space shall be provided with protective valves in accordance with 2.6.2 except the following openings: 12


MS 830:2003

a)

An opening to which safety relief valves are fitted.

b)

An opening not greater than 1.4 mm diameter or one provided with an internal flow-limiting orifice of 1.4 mm diameter, as for a pressure gauge or liquid level gauge.

c)

A plugged or blanked opening.

d)

A filling connection mounted directly on a container of not more than 8 kl capacity, provided that the opening is fitted with either an approved combination non-return valve and excess-flow valve, or one double non-return valve, or two single non-return val ves.

e)

An opening for which all the following conditions apply:

2.6.2

i)

the total capacity of the system does not exceed 8 kl;

ii)

the discharge from a withdrawal connection is controlled by a manually operated shut off valve which is attached directly into the withdrawal connection, or is an integral part of a substantial fitting attached to the withdrawal connection, or is attached directly into a substantial fitting attached to the withdrawal connection;

iii)

the shut off valve is equipped with an attached handwheel or the equivalent;

iv)

the controlling orifice between the vapour space in the container and the outlet of the shut off valve does not exceed 8 mm diameter; and

v)

a regulator is attached to the outlet of the shut-off valve, either directly or by means of a flexible annealed copper tube provided that the regulator is not more than 0.5 m from the container and is supported and protected on or at the container.

Types of protection

The arrangement of protective valves required by 2. 6.1 shall be one of the following: a)

An internal excess-flow valve plus an external manual shut -off valve.

b)

An internal excess-flow valve with a quick-closing internal valve (see note).

NOTE. A quick-closing internal valve used together with an excess-flow valve gives more positive protection in a container than is afforded by an excess-flow valve alone. Where a quick-closing internal valve is fitted in a container opening and an internal excess-flow valve is not provided, or the quick-closing internal valve does not operate as an excess-flow valve, an external excess-flow valve having a rated capacity not greater than 1.5 times the design flow shall be fitted in a steel mounting that is sandwiched between the flange of the quick-closing internal valve and the mating pipe or valve flange .

c)

An internal excess-flow valve plus a quick-closing internal valve (see note).

NOTE. For installation in an opening designed for inward flow only, a non-return valve is preferred to an excess-flow valve since it gives more positive protection

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MS 830:2003

d)

An internal non-return valve plus an external manual shut-off valve (see note).


NOTE. Where an external non -return valve is installed as per f), it shall be fitted in a steel mounting that is sandwiched between the flange of the quick closing internal valve and the matting pipe or valve flange.

e)

An approved combination non-return valve and excess flow valve, or one double non-return valve or two single non -return valves provided that this option may be employed only for a filling connection which is mounted directly on an aboveground tank that does not exceed 8 kl capacity.

f)

An external non -return valve plus a quiet closing internal valve.

g)

An external emergency shut off valve directly attached to the vessel or the vessel outlet nozzle, plus a manual shut off valve, provided that this option may be used only where: i)

the LPG installation, or the LPG portion of a composite installation, is continuously manned by persons able to operate the shut off valves during that period when the tank is in service, i.e. when the valves are open;

ii)

the tank is not smaller than 200 m capacity; and

iii)

the size of the attached pipe is not less than 100 mm.

3

The above protective valves shall comply with the requirem ents of 3.3. 2.7

Container appurtenances

2.7.1

Safety relief valves

Containers shall be equipped with one or more safety relief valves connected directly to the vapour space. 2.7.2

Liquid level gauging devices

Liquid level gauging devices shall be provided on all containers filled by volume. Fixed level gauges or variable gauges of the slip tube, rotary tube or float types (or combination of such gauges) may be used to comply with this requirement. 2.7.3

Pressure gauges

Pressure gauges shall be attached directly to the vapour space for containers exceeding 2 kl water capacity. 2.7.4

Drains in containers

2.7.4.1 A container of above 0.5 kl water capacity shall be provided with a drain connection to permit drainage to atmosphere. Each drain connection shall be provided with a shut off valve. This shut off valve shall be provided with a length of piping terminating with a second shut off valve. The drain valve adjacent to the container connection shall be of a quick shut off type and the second valve shall be of a throttling type. The length of the piping between the two valves shall be such that the risk of simultaneous obstruction of both valves, e.g. by the freezing of any accumulated water, is minimised.

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MS 830:2003


A sufficient length of piping shall be provided downstream of the second valve to ensure that the discharge will not take place beneath the container. The second valve and the piping shall be adequately supported and secured to prevent mechanical damage or breakage by jet forces. Both valves on the drain system shall have a means of actuation which cannot be readily removed or moved from the closed position except by intentional operation. No drain or blow off line shall discharge into or be in the proximity of any public drainage system or any other drainage system where this would be liable to create a hazard. 2.7.4.2 The additional pipework and second valve required downstream of the drain valve by 2.7.4.1 may be fitted at the time of drainage provided that the fixed drain valve is protected by an emergency valve, e.g. an excess-flow valve fitted upstream. 2.7.4.3 The outlet of the drain valve system shall be blank-flanged, plugged or otherwise secured against tampering when not in use. 2.7.4.4 Pipework between the drain system valves and between any valve and a blankflanged or plug, etc. shall be protected by hydrostatic safety relief valves (3.3.7). 2.7.5

Temperature gauge

Where a temperature gauge is fitted, the sensing device shall be installed in a pocket that is located in the lower section of the container and is permanently attached to the container to prevent accidental removal of the pocket when removing the gauge. 2.7.6

Filling connection

2.7.6.1

Container mounted filling connection

A filling connection mounted directly on a container shall be provided with an external excessflow valve and an internal non -return valve. 2.7.6.2

Remote filling connection

A filling connection which is remote from the container shall comply with the following requirements: a)

An internal non -return valve or an internal excess-flow valve shall be provided at the container.

b)

An external excess-flow valve and a manual shut off valve shall be provided at the outer end of the rigid portion of the extension piping.

c)

Any vapour return line incorporated in the system shall be provided with an excess-flow valve and a manual shut off valve close to the filling connection.

d)

A remote filling connection shall be anchored and designed so that the protective valves and piping to the container remain intact should the tanker be moved without disconnecting. Shear fittings and concrete anchorages or bulkheads may be used.

2.7.6.3 During the filling operation, a pressure increase may occur and consideration should be given to either fitting internal spray pipes or the use of vapour balancing lines for pressure equalisation between the delivery tanker and the storage container. 15

MS 830:2003

2.8

Protection against physical damage to portable container appurtenances


2.8.1 Portable containers of 0.5 kl, water capacity or less shall incorporate protection against physical damage to container appurtenances and immediate connections to these while in transit, storage and while being moved into position for use. The protection features required shall be in accordance with MS 641 or MS 642 or other codes approved by the relevant authority. 2.8.2 Portable containers of more than 0.5 kl water capacity, including skid tanks or for use as cargo tanks, shall incorporate protection against physical damage to container appurtenances by recessing, protective housing, or by location on the vehicle. Such protection shall comply with the provisions under which the containers are fabricated and shall be designed to withstand static loadings in any direction equal to twice the mass of the containe r and attachments when filled with LPG, using a safety factor of not less than 4, based on the ultimate strength of the material to be used.

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MS 830:2003

SECTION 3: PIPING, VALVES AND FITTINGS


3.1

Application

This section includes basic design requirements and material specifications for pipe, tubing, pipe and tubing fittings, valves (including hydrostatic relief valves), hose, hose connections and flexible connectors used to connect container appurtenances with the balance of the LPG system. 3.2

Piping

3.2.1

Design

All pipework shall be designed to allow for expansion and contraction of the pipework and container and also to ensure that such pipework does not cause stress to the container, container fittings or pipework. 3.2.2

Welding and brazing

Welding and brazing shall comply with the requirements of the inspecting authority. 3.2.3

Flexible piping

Provision shall be made, in design or by provision of flexible piping, to compensate for stresses and vibration in the piping system. Flexible connectors, if used, shall comply with the relevant requirements of 3.2.9. Flexible piping shall be as short as possible and in any case shall not exceed 1 m in length. 3.2.4

Pipe

Pipe shall be steel, copper, or polyethylene and shall comply respectively with the following or other equivalent specifications approved by the authority: a)

Steel pipe: ASTM A106.

b)

Copper pipe: BS EN 1057.

c)

Polyethylene pipe: ASTM D2513 or ISO 4437. Polyethylene pipes made to other standards shall include the ISO method of determination of long -term hydrostatic strength at 20 °C derived from 80 °C testing.

3.2.5

Tubing

Tubing shall be steel, copper, or polyethylene and shall comply respectively with the following or other approved equivalent specifications: a)

Steel tubing: ASTM A539.

b)

Copper tubing: BS EN 1057.

c)

Polyethylene tubing: ASTM D2513.

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MS 830:2003

3.2.6

Pipe and tubing fittings


Fittings shall be steel, copper or polyethylene and shall comply with 3.2.6.1, 3.2.6.2 and 3.2.6.3. Cast iron pipe fittings (elbows, tees, crosses, couplings, unions, flanges or plugs) shall not be used. 3.2.6.1

Pipe joints in steel or copper pipe may be screwed, welded or brazed.

a)

Fittings used at pressures higher than container pressure, such as on the discharge of liquid transfer pumps, shall be suitable for a working pressure of at least 2 410 kPa (gauge).

b)

Except as provided in 3.2.6.1 a), fittings used with liquid LPG, or with vapour LPG at operating pressure over 860 kPa (gauge) shall be suitable for a working pressure of 1 750 kPa (gauge).

c)

Fittings for use with vapour LPG at pressure not exceeding 860 kPa (gauge) shall be suitable for a working pressure of 860 kPa (gauge).

d)

Brazing filler material shall have a melting point exceeding 538 °C.

3.2.6.2 Tubing joints in steel or copper tubing shall be made with approved gas tubing fittings and may be flared or brazed. a)

Fittings used at pressures higher than container pressure, such as on the discharge of liquid transfer pumps, shall be suitable for a working pressure of at least 2 410 kPa (gauge).

b)

Except as provided in 3.2.6.2 a), fittings used with liquid LPG, or with vapour LPG at operating pressure over 860 kPa (gauge), shall be suitable for a working pressure of 1 750 kPa (gauge).

c)

Fittings for use with vapour LPG at pressure not exceeding 860 kPa (gauge) shall be suitable for a working pressure of 860 kPa (gauge).

d)

Brazing filler material shall have a melting point exceeding 538 °C.

3.2.6.3 Joints in polyethylene pipe and tubing shall be made by heat fusion in accordance with the manufacturers' instructions. Polyethylene fittings shall conform to ASTM D2683 or ASTM D3261. For the purpose of this standard, methods of heat fusion shall mean butt fusion, socket or electrofusion and methods other than these shall first be approved by the authority having jurisdiction. 3.2.7

Gaskets

Gaskets shall be resistant to the action of LPG under the service conditions to which they are subjected. Gaskets shall be made of metal having a melting point higher than 816 °C, or shall be confined within an assembly having a melting point higher than 816 °C. Aluminium 'O' rings and spiral wound metal gaskets are also acceptable. Where a flange is opened, the gasket shall be replaced.

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MS 830:2003

3.2.8

Jointing compound

Jointing compounds shall be resistant to the action of LPG under the service conditions to which they are subjected.


3.2.9 3.2.9.1

Hoses, hose connections, quick connectors and flexible connectors Materials

Hoses, hose connections and flexible connectors shall be fabricated of materials resistant to the action of LPG both as liquid and vapour. If wire braid is used for reinforcement it shall be of corrosion resistant material such as stainless steel. Where a hose is provided with an inbuilt earthing wire , this shall be of stainless steel. 3.2.9.2

Hoses and quick connectors shall be approved by the relevant authority

3.2.9.3

Design and working pressures

Hoses, hose connections and flexible connectors used for conveying LPG in liquid or vapour phase at pressures in excess of 35 kPa (gauge) shall comply with: a)

Hoses shall be designed for a minimum bursting pressure of 8 750 kPa (gauge) and shall be permanently and clearly marked 'LPG' not greater than 3 m intervals.

b)

Hoses assemblies, after the appli cation of connections, shall be capable of withstanding, without leakage, a test pressure of 2 410 kPa (gauge) for 10 min when tested hydrostatically.

3.2.9.4

Hose couplings

Any hose that requires to be connected and disconnected frequentl y during normal operation, shall be provided with either a threaded Acme-form coupling or a POL coupling. Any other hose connection shall be permanent threaded or flanged connections. The following sizes of Acme thread are recommended: a)

For liquid: 3¼ in or 1¾ in; and

b)

For vapour: 2¼ in or 1¾ in.

3.2 9.5

Electrical continuity

The electrical resistance measured overall on each length of hose complete with end connections shall not exceed 0.75 ohm/m. 3.2.9.6

Inspection and testing

After being brought into use, hoses shall be periodically inspected and tested as follows: a)

visually inspected at intervals not exceeding one month for damage over the whole length in use;

b)

hydrostatically tested at intervals not exceeding one year at a pressure of 2 410 kPa (gauge) for 10 min, including the connections; and 19

MS 830:2003

c)

tested for electrical continuity, the frequency of tests depending on the extent of use to which the hoses are put. A record of these tests shall be kept.

Hoses which fail inspecti on or testing under a), b) and c) shall be discarded.


3.2.10

Piping within buildings

LPG vapour at pressures exceeding 140 kPa (gauge) or LPG liquid shall not be piped into any building except that approval may be given by the authority having jurisdicti on for the following situations. a)

Buildings used exclusively to house equipment for vaporisation pressure reduction, gas mixing, gas manufacturing or distribution.

b)

Buildings or separate areas of buildings used exclusively to house internal combustion e ngines.

c)

Buildings or separate areas of buildings used exclusively for industrial purposes.

d)

Buildings or separate areas of buildings used exclusively for research and experimental laboratories.

e)

Buildings, structures, or equipment under construction or repair.

NOTE. Separate areas in b), c) and d), means fire-isolated areas unless otherwise approved by the relevant authority.

3.2.11

Testing of piping installations

The testing of LPG piping installations shall be carried out by the installer in accordance with the relevant procedures detailed in Annex C. The installer shall certify in writing that the complete installation so tested is proved free of leaks, before the installation is put into service. 3.3

Valves

3.3.1

Materials

Pressure containing metal parts of valves (except appliance valves), including excess-flow valves, non return valves, safety relief valves, and manual shut off valve used in piping systems, shall be of steel, ductile (nodular) iron, malleable iron or brass. Steel shall meet the requirements of ASTM A182. Ductile iron shall meet the requirements of ASTM A395 or equivalent. Malleable iron shall meet the requirement of ASTM A47 or equivalent. All materials used, including valve seat discs, packing, seals and diaphragms shall be resistant to the action of LPG under service conditions. Any valve external to the container shall be of ‘fire-safe’ type, i. e. one which incorporates secondary provisions to prevent leakage if the primary seat or seal has been damaged by heat.

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MS 830:2003

3.3.2

Design

3.3.2.1

All valves shall be suitable for the appropriate working pressure, as follows:

a)

valves used at pressures higher than container pressure, such as on the discharge of liquid transfer pumps, shall be suitable for working pressure of at least 2 410 kPa (gauge);

b)

except as provided in 3.3.2.1. a), valves to be used with liquid LPG, or with vapour LPG a pressure in excess of 860 kPa (gauge), but not to exceed 1 750 kPa (gauge), shall be suitable for working pressure of at least 1 750 kPa (gauge); and

c)

valves (except appliance valves) to be used with vapour LPG at pressures not to exceed 860 kPa (gauge) shall be suitable for a working pressure of at least 860 kPa (gauge).

3.3.2.2

Valve indicators or marking

A valve shall be provided with the following indicators or marking: a)

A means for indicating clearly the open and closed position shall be provided. Where a lever valve is fitted with a fixed handle, the valve shall be opened when the handle is in the direction of the pipe. Where a valve handle is removable, a separate metal plate shall be provided and this plate shall be clearly and indelibly marked to indicate the open and closed positions of the valve.

b)

Any valve other than for a safety relief valve, pressure gauge or fixed liquid level gauge shall be marked to indicate whether it connects to liquid or vapour space.

3.3.2.3

Direction of flow

A manual-isolating valve that is subjected to container pressure shall be installed so that the valve gland is not subjected to direct container pressure when the valve is shut. NOTE. Compliance with this requirement necessitates the mounting of valves in certain locations such as a container inlet isolating valve contrary to any direction-of-flow marking on the valve.

3.3.3

Excess-flow valves

An excess-flow valve shall comply with the following requirements: a)

The flow rate for closure of an excess flow valve should be below that likely to result from complete fracture of the line it is protecting but should, to prevent premature closing, be substantially above the normal service flow rate expected.

NOTE. If because of system complexity, a single excess-flow valve at the container is unable to protect against a downstream pipe failure, one or more additional valves may be installed downstream, but is not usual to install such protection beyond the first pump, compressor or regulator after the container outlet.

b)

An excess-flow valve shall incorporate a bypass that has an opening not greater than 1 mm in diameter to allow equalisation of pressure, except where an excessflow valve is integral with an internal quick-closing valve and a manual means for equalisation of pressure is incorporated. An excess-flow valve shall be marked with the manufacturer's identity, model identi fication and the closing flow rate. 21

MS 830:2003


Where two or more containers are grouped with common liquid and vapour connections, the common liquid and vapour lines shall be fitted with excess-flow valves, unless the common line has a cross-sectional area equal to, or in excess of, the combined areas of the individual container lines, in which case the excess-flow valve in the container shall suffice. Installation of excess-flow valves in liquid and vapour lines shall be made in such a manner that any undue strain beyond the excess-flow valve will not cause breakage between the container and such valve. 3.3.4

Quick-closing internal valve

A quick closing internal valve shall incorporate at least one provision for thermal closure by actuation of the heat-sensing device and at least one provision for manual closure from a safe remote position. Such valves shall be kept closed when the line they serve is not in actual use. 3.3.5

Safely relief valves on containers.

3.3.5.1

General requirements

Every safety relief valve shall be in direct communication with the vapour space of the container at all times, except as provided in 3.3.5.6. 3.3.5.2

Design

Safety relief valves should preferably be of the spring-loaded type. Gravity loaded relief valves shall not be used. If pilot operated relief valves are used, the design of the valves should be such that the main valves will operate and protect the container in the event of any failure of the pilot system. Safety relief valves shall be so designed and constructed that the breakage of any part will not obstruct the free discharge of vapour under pressure, that they cannot be overloaded inadvertently, and that the possibility of tampering with their pressure setting will be minimised. Where the pressure setting or adjustment is external, the safety relief valve shall be provided with approved means of sealing the adjustment. 3.3.5.3

Set pressure

A safety relief valve shall be so set that it will start to discharge at a pressure not exceeding 10 % above the set pressure marked on the safety relief valve. Any additional safety relief valve fitted may be set to start-to-discharge at a pressure not exceeding 105 % of the design pressure provided that the aggregate valve capacity shall be sufficient to allow the discharge of the maximum quantity without a rise in pressure to more than 110 % of the design pressure. 3.3.5.4

Rate of discharge

The rate of discharge of safety relief valve for aboveground containers shall be in accordance with Annex D except that for refineries the rate of discharge for safety relief valves shall comply with API 520 and the testing of safety relief valves shall be in accordance with API RP 521. For underground/mounded containers other than those located in refineries the rate of discharge of safety relief valves shall be not less than 30 % of the prescribed value in Annex D.

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MS 830:2003

3.3.5.5

Testing

Safety relief valves shall be tested in accordance with the requirements of the relevant authority. Safety relief valves shall be retested at periods not exceeding five years.


3.3.5.6

Valve between safety relief valve and container

Preferably each container should have more than one safety relief valve. To permit removal for testing and maintenance, shut off valves may be installed between each safety relief valve and the container, provided that shut off valves so used are normally fully open and are fitted with a mechanical device linking all such valves on one container in such a manner that any one shut off valve can be closed only when all other valves are fully open. The capacity and number of safety relief valves so used on each container shall provide full relief capacity when any one is inoperative. Alternatively, a proprietary multi-valve arrangement may be used. When a container has only one safety relief valve, a manual shut off valve shall not be installed. 3.3.5.7

Marking

Each container safety relief valve shall be plainly and permanently marked with the following information: a)

manufacturer's name or trade-mark;

b)

catalogue number;

c)

pressure at which the valve is set to discharge (set pressure), in kilopascals; and

d)

actual rate of discharge of the valve in cubic metres per minute of air at 16 °C and 101.5 kPa (absolute).

The date of the last test shall be marked on a tag attached to the valve. 3.3.6

Safely relief valve discharge lines

3.3.6.1

General

All safety relief valve discharge outlets shall be so located as to provide protection against physical damage, and discharge pipes shall be fitted with loose rain caps. Return bends and restrictive pipe fittings shall not be used. The discharge from the safety relief valve shall be vented away from the container upward and unobstructed to open air (except for light rain cap), in such a manner as will prevent impingement of escaping gas upon the container or other equipment. The vent pipe shall be not less than the nominal size of the safety relief valve discharge outlet. Suitable provision shall be made either by a weephole deflector or a drain so that any liquid or condens ate that may accumulate inside the safety relief valve or its discharge pipe will not render the valve inoperative. If a drainpipe is used, means shall be provided to protect the container, adjacent containers, piping or equipment against impingement of flame resulting from ignition of LPG escaping from the drain. 23

MS 830:2003

Any cover that is provided for the protection of the safely relief valve of a portable skid tank shall be designed to allow free discharge of gas from the valve so that a flame will burn clear of the tank and valve in the event of ignition. The cover shall be designed to prevent retention of moisture.


3.3.6.2

Common discharge header

If desired, discharge lines from two or more safety relief valves on the same or on different units may be run to a common discharge header, provided that the flow capacity of the header is greater than the total flow capacity of the individual discharge lines and that the setting of all safety relief valves is nominally the same. 3.3.7

Hydrostatic safety relief valves on liquid lines

A safety relief valve shall be installed between each pair of shut off valves on LPG liquid piping, so as to relieve hydrostatic pressure to atmosphere and shall be so placed that, in the event of its operation, escaping LPG cannot impinge on containers, fittings or other equipment, nor on the ground. The minimum setting of safety relief valve installed in piping shall be not less than 140 % or more than 200 % of the container safety relief valve setting. For fittings rated at 850 kPa (gauge) to 1 000 kPa (gauge), the setting of such safety relief valve shall be not greater than 1 750 kPa (gauge) and for fittings rated at 1 750 kPa (gauge) to 2 100 kPa (gauge), not greater than 3 100 kPa (gauge). The discharge from such safety relief valve shall not terminate in any building. A safety relief valve should not be installed in the pump discharge piping if the same protection can be provided by installing the safety relief valve in the suction piping.

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MS 830:2003

SECTION 4: EQUIPMENT 4.1

Application


This section includes fabrication and performance requirements for the pressure containing metal parts of LPG equipment such as pumps, compressors, vaporisers, strainers and regulators. The requirements for vaporisers do not apply to engine fuel vaporisers. All LPG equipment used in the system shall be suitable for the appropriate working pressure. 4.2

Pumps and compressors

Pumps and compressors shall comply with the requirements in 8.7. 4.3

Vaporisers

4.3.1

Indirect-fired vaporisers

4.3.1.1


An indirect-fired vaporiser shall comply with the following requirements. a)

The vaporiser shall be designed and constructed in accordance with ASME Code, BS PD 5500, AS 1210 or other codes approved by the relevant authority.

b)

The vaporiser may be connected to the liquid section or both the liquid and gas sections of the storage container provided however that there shall be in each connection to the storage container a manually operated valve which shall be capable of completely shutting off all gas or liquid flow from the container to the vaporiser.

c)

The vaporiser shall be provided with suitable automatic means to prevent liquid passing through the vaporiser to the LPG vapour discharge piping.

d)

The vaporiser shall not be equipped with fusible plugs.

e)

The vaporiser shall have at or near the vapour outlet, a safety relief valves providing an effective rate of discharge in accordance with Annex E, and complying with 3.3.6.

f)

The heating medium pipes into and leaving the vaporiser shall be provided with suitable means for preventing the flow of LPG into the heating systems in the event of pipe rupture in the vaporiser.

g)

Gas -fired heating systems associated with indirect-fired vaporisers shall be equipped with automatic safety devices to shut off the flow of gas to main burners if the pilot flame should fail. When flow through the pilot exceeds 2 MJ/h, the pilot shall also be equipped with an automatic safety device to shut off the flow of gas to th e pilot, should the pilot flame be extinguished.

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MS 830:2003

4.3.1.2

Marking


An indirect fired vaporiser shall be marked with the following information and any other requirements stipulated by the relevant authority: a)

a reference to the standard to which the vaporiser is constructed;

b)

design pressure, in kilopascals (kPa);

c)

design temperature, in degree Celsius (?C);

d)

total surface area inside the vaporiser, in square metres, as detailed in E1.1 a) of Annex E; and

e)

manufacturer's name or identification mark.

4.3.1.3

Installation

An indirect fired vaporiser shall be installed in accordance with the following requirement. a)

The vaporiser shall not be installed in a building except where the building is used exclusively for LPG equipment other than for filling purposes. Such buildings shall be of non-combustible construction and well ventilated near the floor and roof.

b)

The horizontal distance from any vaporiser to an opening into an enclosed or underground drain shall be not less than 3 m.

c)

Vaporisers shall be equipped with means of draining off any heavy products which may collect in the liquid section of the system. If draining off is to be carried out near to sources of ignition (e.g. flames of other vaporisers) provision shall be made to lead the discharge by pipe or hose to a safe location.

d)

Heating or cooling coils shall not be installed inside a storage container.

e)

Indirect vaporisers shall be installed at a minimum distance of 1.6 m from the nearest storage container.

f)

The de vice that supplies the necessary heat to the transfer medium, if it is a source of ignition shall be so located that: i)

the vapour path from the container shell to the device is not less than 10 m; and

ii)

the vapour path from container valves, and filling and discharge connections to the crevice is not less than 10 m.

If the heating device is in the same building as the vaporiser, such device shall be separated from all compartments or rooms containing LPG vaporisers pumps and central gas mixing devices by a wall, without openings therein, constructed from reinforced concrete at least 150 mm thick or of brick at least 225 mm thick.

26


MS 830:2003

4.3.2

Atmospheric vaporisers

a)

The vaporiser shall be above ground in the open and installed at a minimum safety distance of 1.5 m from the nearest container.

b)

A vaporiser of less than one litre capacity heated by the ground or surrounding air, need not be equipped with a safety relief valve, provided that safety tests certified by the relevant authority demonstrate that the assembly is safe without safety relief valves.

c)

The vaporiser shall be so located and protected as to prevent tampering and physical damage.

4.3.3

Direct fired vaporisers

4.3.3.1


A direct-fired vaporiser shall compl y with the requirements of 4.3.1.1 a), b), c) and d), and in addition the following requirements shall be met: a)

The vaporiser shall have at or near the vapour outlet, a safety relief valve providing an effective rate of discharge in accordance with Annex E. The safety valve shall be so located as not to be subjected to temperatures in excess of 60 ?C. The discharge from the safety valve shall comply with 3.3.6.

b)

The vaporiser shall be provided with means for manually turning off the gas supply to the main burner and pilot.

c)

The vaporiser shall be equipped with automatic safety device to shut off the flow of gas to main burners if the pilot flame should fail. When flow through the pilot exceeds 2 MJ/h, the pilot shall also be equipped with an automatic safety device to shut off the flow of gas to the pilot, should the pilot flame be extinguished.

d)

No direct-fired vaporiser shall be connected to a container that has a storage capacity less than ten times the hourly capacity of the vaporiser.

e)

The vaporiser shall be equipped with a device which will automatically extinguish the main burner in the event of failure of liquid supply to the vaporiser.

4.3.3.2

Marking

A direct fired vaporiser shall be marked with the following information and any other requirements stipulated by the relevant authority: a)

a reference to the standard to which the vaporiser is constructed;

b)

design pressure, in kilopascals (kPa);

c)

design temperature, in degree Celsius (°C);

d)

manufacturer's name or identification mark;

e)

rated input to the burner; 27


MS 830:2003

f)

the surface area of the heat exchanger, in square metres, as detailed in E1.1 a) of Annex E;

g)

the outside surface area of the vaporiser, in square metres, as detailed in E1.1 a) of Annex E; and

h)

the maximum vaporising capacity, in litres per hour.

4.3.3.3

Installation

A direct fired vaporiser shall be installed in accordance with the requirements of 4.3.1.3 a), b) and c), and in addition the following requirements shall be met. a)

Pressure regulating and pressure reducing equipment not an integral part of the vaporiser if located within 3 m of a direct -fired vaporiser shall be separated from the open name by a non-combustible vapour-tight partition or partitions.

b)

The vaporiser shall not take the product pressure above the design pressure of the vaporiser equipment or above the design pressure of the container.

c)

The vaporiser, irrespective of its capacity, shall be so located that:

d)

i)

the vapour path from the container shell to the vaporiser is not less than 10 m; and

ii)

the vapour path from container valves, and filling and discharge connections to the vaporiser is not less than 10 m.

The vaporiser shall be installed at the minimum safety distances from buildings, property boundaries, streets and roads in accordance with Table 2. Table 2. Safety distances for direct-fired vaporisers Capacity of vaporiser (l/h) Up to 70 Over 70 to 500 Over 500

4.3.4

Minimum safety distance (m) 3 8 15

Direct gas-fired container heaters

Gas-fired heaters w hich directly heat the storage container shall not be used. 4.3.5

Electrically heated vaporisers

Electrically heated vaporisers, if of flameproof construction shall be considered indirect-fired vaporisers. If not of flameproof construction they shall be considered as direct-fired vaporisers. 4.4

Strainers

4.4.1 Strainers shall be designed to minimise the possibility of particulate materials clogging damaging pumps, compressors, meters or regulators. The strainer element lines and shall be accessible for cleaning. 28

MS 830:2003

4.5

Regulators


4.5.1 Regulators used to control distribution or utilisation pressure shall be as close as possible to the container or vaporiser outlets as it is practicable. First-stage regulating equipment shall be outside of buildings except when used with a) containers of less than 0.5 kl water capacity for the purpose of being filled in buildings or structures complying with 10.2, and b) liquid piping systems covered in 3.2.10. 4.5.2 Regulators shall be securely attached to container valves, containers, supporting standards or building walls. a)

First-stage regulators shall be either directly connected to the container shutoff valve or outlet of vaporiser where used, unless attached thereto with flexibility provided in the connecting piping or the interconnecting piping of manifolded containers or vaporisers; and

b)

All regulators for outdoor installations, except regulators used for portable industrial application, shall be designed, installed, or protected so that their operation will not be affected by the elements (rain, mud or debris). This protection may be integral with the regulator.

4.5.3 For regulating equipment installed outside of buildings, the discharge from a pressure relief valve device shall be located not less than 1 m horizontally away from any building opening below the level of such discharge, and not beneath any building unless this space is well ventilated to the outside and is not enclosed for more than 50 % of its perimeter. 4.5.4 For industrial buildings where two-stage regulation is used, the second -stage regulator may be located inside a building. On regulators installed inside buildings, the discharge from the pressure relief device and from above the regulator and relief device diaphragms shall be vented to the outside air with the discharge outlet located not less than 1 m horizontally away from any building opening below the level of such discharge. This provision does not apply to appliance regulators otherwise protected or to regulators used in connection with 4.5.1a). 4.5.5 Final stage regulators (excluding appliance regulators) shall be equipped with one or both of the following: a)

A pressure relief valve on the low pressure side having a start -to-discharge setting within the limits specified in Table 3 below.

b)

A shut off device that shuts the gas off at the regulator inlet when the downstream pressure reaches the overpressure limits specified in the table below. Such a device shall not open to permit flow of gas until it has been manually res et. Table 3. Relief valve start-to-discharge setting for regulator Regulator delivery pressure kPa (gauge)

Relief valve start-to-discharge setting, % of regulator delivery pressure Minimum Maximum

7 or less

170

300

Above 7, not over 21

140

250

Above 21

125

250

29

MS 830:2003

SECTION 5: CAPACITY, LOCATION AND INSTALLATION OF ABOVEGROUND STORAGE CONTAINERS UP TO FIRST-STAGE REGULATOR


5.1

Application

This section specifies requirements on the capacity, location and installation of above ground storage containers up to first-stage regulator. This section does not apply to LPG cylinders. 5.2

Container location and safety distances

5.2.1


5.2.1.1 buildings.

Above ground storage containers shall be located in the open air outside

5.2.1.2 Storage containers within a group shall be located so that their longitudinal axes are parallel to each other and preferably are directed away from any nearby storages of hazardous gases or flammable or combustible liquids. Subjected to the approval of the relevant authority, cylindrical storage containers may be placed end to end, provided that the distance between the ends is not less than 3 m or twice the diameter of the larger container, whichever is the greater. 5.2.1.3 Storage containers shall not be installed one above the other. An aboveground container shall not be directly above any underground container. 5.2.1.4 To avoid accumulation of liquid or vapour beneath or in the immediate vicinity of a container, the container shall not be situated in or vertically above a depression on the site, nor should the area under or around the container be filled with aggregate with a high percentage of voids. No bunding around LPG containers is required but a diversion wall may be provided to control a spill. 5.2.2

Overhead transmission lines

The placing of storage containers within 1.5 m measured horizontally from the vertical plane of overhead transmission lines shall be avoided, unless a suitable overhead earthing screen is provided extending 1.5 m beyond the container plan area. 5.2.3

Gas storage other than LPG

The minimum separation between a LPG container and storage of a gas other than LPG shall be as shown in Table 4. 5.2.4

Flammable and combustible liquids storages

LPG containers shall not be located within the bunded areas of flammable and combustible liquids storages. Diversion kerbs, grading, compounds or the equivalent shall be provided to prevent the accumulation of flammable and combustible liquids under a LPG container. Above ground storage containers shall be at least 2 m from the fill point of an underground container containing flammable or combustible liquid.

30

MS 830:2003

Table 4. Minimum separation between an LPG container and a storage of gas other than LPG Gas storage


a)

Minimum separation dista nce (m)

Liquid oxygen in containers or cylinders i)

up to 5 kl of LPG capacity

10

ii)

over 5 kl up to 20 kl of LPG capacity

15

iii)

over 20 kl of LPG capacity

refer to relevant authority

b)

Compressed oxygen in cylinders

c)

Combustible gases other than LPG

d)

Other compresse d gases in cylinders

e)

Gases other than LPG or oxygen, in containers

5.2.5

6 treat as being LPG 6 specific approval for each install

Ignition source

A storage container shall be located so that: a)

a fixed ignition source does not fall within a Zone 0, 1 or: 2 area; and

b)

the horizontal distance from container valves, and filling and discharge connections to fixed ignition source is not less than 4.5 m.

5.2.6

Safety distances

5.2.6.1

General

Safety distances are intended to protect the LPG facilities from the radiation effects of fires involving other facilities as well as to minimise the risk of escaping LPG being ignited before being dispersed or diluted. Safety distances shall be measured horizontally and radially from the container shells to the specified feature (e.g. an adjacent storage container, building, and property boundary) except that where deflection or radiation walls are used, the distance shall be measured in a horizontal line around such walls. 5.2.6.2

Use of deflection walls

Deflection walls (see note) used to achieve safety distances shall comply with the following requirements: a)

a deflection wall shall not be lower than 2 m high and shall have a 4 h fire resistance rating (see note);

b)

the deflection wall shall be located in accordance with the requirements of Annex F;

c)

not more than two separate deflection walls located on opposite sides of the LPG container shall be built. A continuous wall or two separate walls containing an acute angle shall not be built around an LPG container; and 31

MS 830:2003

d)

the deflection wall shall not be located on the property boundary, if the neighbouring or adjacent property may be built upon.

NOTES:


1. Deflection walls can pose a serious hindrance in fighti ng a fire if poorly positioned. 2. A wall constructed from brickwork, masonry or concrete, 200 mm thick or reinforced concrete 150 mm thick, is deemed to have a 4 h fire resistance rating.

5.2.6.3

Changed site conditions

Where alterations on the installation site result in a breach of the requirements for safety distances, the containers affected shall be moved so as to restore compliance or the container(s) shall be taken out of service. 5.2.6.4

Refineries and bulk plants

Location of aboveground storage containers in refineries and bulk plants shall comply with the minimum safety distances given in Figure 1. 5.2.6.5

Bulk storage at consumers' premises

This applies to commercial and industrial consumers' premises such as industrial plants and hotels where there is bulk storage of LPG. Location of aboveground storage containers in these premises shall comply with the minimum safety distances given in Figure 2. The following requirements shall also apply: a)

The number of storage containers in any one group shall not exceed six. Any container in one group shall be at least 7.5 m from the nearest storage container in another group unless a deflection wall is erected between the groups. When deflection walls are used to separate groups of containers, the direct distance from each container in one group to the nearest container in another group shall be at least 4 m. This requirement does not apply to installations of cylinder systems.

b)

Containers up to 0.5 kl water capacity may be permitted with zero distance to buildings, property boundaries, etc. provided the space in the opposite direction is clear for a minimum distance of 3 m. Not more than two such containers shall be permitted to be installed in a group with zero distances. Such groups of two containers shall be separated from other containers by a minimum distance of 8 m.

c)

Vaporisers, other than direct-fired type, shall be installed at a minimum distance of 1.5 m from the nearest storage container. Direct-fired vaporisers shall be installed at the minimum safety distances given in Figure 2. Further requirements for vaporisers are given in 4.3.

5.2.6.6

Automotive LPG dispensing stations

This applies to location of aboveground storage containers in sites where LPG is dispensed into permanently mounted fuel containers of vehicles.

32

MS 830:2003


Location of aboveground storage containers in these premises shall comply with the minimum safety distances given in Figure 3. For reasons of space and cost economy a so-called 'compact unit' (a unit where the storage container, compressor, pump and dispenser column are mounted on a steel frame) is permitted provided that the storage container does not exceed 8 kl water capacity. Such compact units do not have to meet the minimum safety distance between storage container and dispenser but have to comply with the other safety distances. The compact unit can be prefabricated and transported complete to the site. Further requirements for automotive LPG dispensing stations are given in Section 13. The maximum num ber of storage containers in any one group and the safety distance between groups of containers shall comply with 5.2.6.5 a). 5.2.7

Vertical LPG storage containers in industrial consumers' premises

5.2.7.1 Vertical LPG storage containers are allowed to be installed in industrial consumers' premises only. The capacity of each container shall not exceed 20 kl and must be so located to comply with the minimum safety distances given in Figure 2. The vertical LPG storage containers must be designed in accordan ce with the applicable provisions for horizontal ASME storage containers and shall be fabricated with lifting lugs or some other suitable means to facilitate erection in the field. Vertical containers designed for permanent installations in stationary service aboveground shall be installed on reinforced concrete or steel structural supports on reinforced concrete foundations which are designed to meet the following loading provisions: a)

Containers shall be designed to be self-supporting without the use of guy wires and shall satisfy proper design criteria taking into account wind, seismic (earthquake) forces, and hydrostatic test loads.

b)

Design pressure (see Table 1) shall be interpreted as 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 aboveground in accordance with MS 1553. Wind speeds shall be based on a Mean Occurrence Interval of 50 years.

d)

Seismic loading on containers shall be based on a seismic analysis of the proposed installation which meets the approval of the authority having jurisdiction.

5.2.7.2

Steel supports shall be protected against fire exposure with a material that has a fire resistance rating of at least 2 h.

5.2.7.3

Vertical ASME containers used in liquid service shall not be manifolded to horizontal ASME containers. Vertical ASME containers of different dimensions shall not be manifolded together.

33


MS 830:2003

5.3

Installation (excluding compact units)

5.3.1

Foundations and supports

All stationary containers shall be installed on substantial masonry or concrete foundations. Horizontal storage containers shall preferably have two supports. Where necessary, containers shall be securely anchored or weighted to prevent floating. All foundations and fastenings shall be designed to provide complete safety under all anticipated loading, including wind and vibration. The minimum design load shall be the mass of the container and its attachments together with the mass of the water required to completely fill the container. Where more than one container is installed and the containers have common vapour or liquid connections or both, then the containers shall be supported so that their maximum liquid levels are in the same horizontal plane. However, where approved suitable valving or piping is installed to prevent uncontrolled liquid levelling, then such requirement need not apply. 5.3.2

Support for cylindrical containers

5.3.2.1

Concrete or masonry supports, pads or footings with steel cradle

Cylindrical storage cylinders may be mounted on non-fireproof steel cradles which are constructed on concrete or masonry supports, pads or footings, provided that the distance from the lower surface of the tank to the top of the concrete or masonry supports, pads or footings does not exceed 250 mm. The container shall also be so mounted that the outside bottom of the container is not more than 1.5 m ab ove the surface of the ground. Suitable means of preventing corrosion; by the attachment of a fully seal-welded doubling plate with round corners shall be provided on that portion of the storage container in contact with the foundations or saddles. 5.3.2.2

Fire -proofed steel supports

Where the distance between the lower surface of the container and the top of the concrete or masonry foundation exceeds 250 mm, steel cradle supports shall be encased in brick or concrete, or in other material having a fire -resistance rating of at least 2 h. Where fire-proofed steel supports are used, positive means shall be employed to prevent the ingress of moisture between the fire -proofing and the steel support. 5.3.3

Supports for spherical containers

Steel leg supports shall be encased in a fireproof material to a height of not less than the horizontal level of the lower edge of the equator plate, but in no case shall the support be unprotected for a distance greater than 300 mm below the lowest point of attachment of the leg to the sphere. The fireproof material shall be concrete or other material having a fireresistance rating of at least 2 h. Where fire-proofed steel supports are used, positive means shall be employed to prevent the ingress of moisture between the fire -proofing and the steel support.

34

MS 830:2003

5.3.4

Expansion and contraction of containers


All aboveground storage containers shall be installed in such a manner as will allow for expansion and contraction of the container. All fixed piping connections shall be located between the fixed end pedestal and the fixed end of the container, or suitable expansion arrangements shall be provided in the piping. 5.3.5

Interconnected containers

Where two or more LPG containers are interconnected either to the vapour or liquid space, the following requirements shall apply: a)

The start-to-discharge pressure of all safety relief valves shall be the same.

b)

The maximum liquid level of all containers shall be on the same horizontal plane, except that a number of containers with differing levels may be filled off a common filling pipe provided that the arrangement of valves together with the associated operating procedures will ensure that uncontrolled levelling cannot cause over-filling of any one container.

c)

Where liquid return is provided for multiple containers having a common withdrawal pipe, the system shall be capable of returning liquid to the container or containers from which liquid is being drawn.

d)

Where containers are connected by a common liquid line, a vapou r balancing line interconnecting the vapour space of all containers shall be provided.

e)

Where two or more containers are direct filled, the arrangement of pipework and auxiliary equipment shall be such that quick access and egress is not hindered.

5.3.6

Interconnected withdrawal pipe

Where two or more containers are interconnected by a common liquid withdrawal pipe but have independent filling connections mounted directly on each container. a)

A vapour balancing pipe of adequate size to ensure rapid levelling shall interconnect the vapour spaces of all containers.

b)

The aggregate container capacity shall not exceed 16 kl unless it is specifically approved.

5.3.7

Security and damage protection

5.3.7.1

Container security

A container which is readily accessible to the public shall be provided with a means to prevent tampering with any container fitting which could lead to an escape of gas. The provision shall be capable of being locked and may be one of the following: a)

a fully surrounding fence complying with 5.3.7.2 or an equivalent security fence surrounding the whole of the property;

b)

a fence surrounding only those components requiring protection; or 35


MS 830:2003

c)

a lockable dome or cage complying with 5.3.7.3, provided that the container capacity does not exceed 8 kl and the container is not in a school, playground or park.

5.3.7.2

Security fence

A security fence shall be at least a chain wire fence of a strong construction and shall not be less than 2 m high. In addition: a)

A fully surrounding fen ce shall be at least 1.5 m from the nearest point of the container and provided with a lockable outward -opening gate at opposite ends of the enclosure (see note).

NOTE. The gates shall be kept locked when unattended and both gates shall be unlocked throughout operations inside the enclosure.

b)

A partial fence surrounding valves or pumps only shall be installed so that access through the fence is not possible; not less than one lockable gate, 1 m wide, that allows easy access to the equipment shall be provided.

5.3.7.3

Lockable dome or cage

The lockable dome or cage shall be so designed that: a)

the possibility of tampering with the protected fittings is prevented;

b)

if gas discharging from a safety relief valve is ignited, the resulting flame will burn clear of the container; and

c)

moisture is not retained.

The dome or cage shall be kept locked at all times except when adjustment to or maintenance of container fittings by an authorised person is required. 5.3.7.4

Damage protection

Any container or other part of an installation which is not fenced and which because of its location is susceptible to damage from manoeuvring vehicle shall be protected against impact by such vehicles by one of the following arrangements: a)

75 mm water pipe filled with concrete or cement spaced at a maximum of 1.2 m apart, at least 1.5 m from the container and at least 1.2 m high except that if 4 m or more distant from container they may be 0.5 m high; and

b)

crash guards at least 700 mm high and 1.5m from the container.

36


MS 830:2003

Water capacity of individual container (kl) < 135

Minimum safety distance (m) A

B

C

D

E

F

D1 ? D 2

30

3

6

5

10

R

S

T

4

135 to 265

D1 ? D 2

45

3

6

5

10

> 265

4 D1 ? D 2

60

3

6

5

10

see Figure 7

4

NOTE. The location of the deflection wall shall comply with the requirements shown in Annex F.

Figure 1. Location of aboveground containers in refineries and bulk plants

37

U


MS 830:2003

Water capacity of individual container (kl)


B

C

D

G

Up to 0.5

none

None*

3

6

10

Over 0.5 to 2.5

1

4.5

3

6

10

Over 2.5 to 10

1

7.5

3

6

10

Over 10 to 135

D1 ? D 2

H

see 4.3.3.3 (d) 15

3

6

10

4

NOTES: 1. The location of the deflection wall shall comply with the requirements shown in Annex F. 2. For location of indirect-fired vaporiser, see 5.2.6.5 c) and 4.3.1.3 e), f). *Subject to the requirements in 5.2.6.5 (b)

Figure 2. Location of aboveground containers for bulk storage at consumers’ premises

38


MS 830:2003



B

C

D

J

K

L

M

Up to 0.5

1

1

3

6

1

3

5

6

Over 0.5 to 2.5

1

3

3

6

3

3

5

6

Over 2.5 to 10

1

7.5

3

6

7.5

3

5

6

Over 10 to 70

1.5

15

3

6

15

3

5

6

NOTE. The location of the deflection wall shall comply with the requirements shown in Annex F.

Figure 3. Location of aboveground containers in automotive LPG dispensing stations

39

MS 830:2003

5.3.8

Location of filling connection


5.3.8.1 Filling connections should be as close to the container as is practicable but not directly underneath. Offset/remote fill points should be used whenever vehicle access would otherwise be difficult. 5.3.8.2 Filling connections should be located within the storage fenced area when practicable if outside, then the terminal fitting shall be adequately protected against vehicle damage and tampering by unauthorised persons. 5.3.8.3

Filling connections shall be easily accessible.

5.3.8.4 Filling connections shall be located so that the safe positioning of the tank vehicle and its quick removal in an emergency is facilitated. 5.3.8.5 Offset/remote filling connections including vapour returns shall be clearly labelled 'liquid' or 'vapour' as appropriate and shall terminate aboveground level and shall allow a horizontal connection to be made with delivery hose(s). 5.3.8.6 Filling connections shall be located so that separation distances from buildings, property boundaries, etc. are not less than the safety distance given in Figures 1, 2 or 3 as appropriate, up to a maximum of 15 m and provided that the filling connection is not less than 1 m horizontally from any opening into a building that is at a lower level than filling connection. The vapour path distance from filling connection to a fixed ignition source shall be as required in 5.2.5 b). The horizontal distance from a container filling connection to the commencement of the enclosed portion of any underground drain shall not be less than the distance specified in Table 5 unless the drain entrance incorporated a gas flow barrier. The filling connection shall be so located that it permits compliance with 8.4.1. Open drains which have a depth of more than 0.6 m and a width which is less than the depth shall be considered as an enclosed drain by reason of the possibility of entrapment of LPG vapour by open drains of such configuration. NOTE. The gas flow barrier shall not exceed a height of 0.6 m.

Table 5. Distance to any opening enclosed underground drain Water capacity of container (kl)

Distance to opening into enclosed under-ground drain (m)

Up to 0.5

1.5

1

2

2

4

5

5

8

6

10

7

15

8

20

9

50

10

100

11

200

12

Over 500

15

40

MS 830:2003


5.3.8.7 An effective earthing connection shall be provided at the filling point of container greater than 2.5 kl water capacity for container electrically bonded to the LPG supply vehicle. 5.3.9

Piping

5.3.9.1

Support of piping

All exposed above ground piping shall be adequately supported. The distance between supports for copper pipe shall not exceed 0.5 m. 5.3.9.2

Underground pipes

Underground piping that is subject to container pressure shall be provided with a protective coating at least equal to that for underground containers (see 6.2.4.2, 6.2.4.3 and 6.2.4.4). Other underground piping shall have corrosion protection appropriate to the conditions. 5.3.9.3

Aboveground pipes

For containers up to 8 kl water capacity fitted with a lockable dome or cage and not fenced off, exposed service piping shall be of steel or encased in steel. 5.3.9.4

Insulated joints

Where underground piping that is attached to a cathodically protected container or piping system emerges aboveground, an insulated joint shall be fitted adjacent to the point of emergence and any piping and fittings on the aboveground side of it shall be earthed. An insulated joint shall have an electrical resistance exceeding 1 MO. Single-insulated joints may be used provided that effective testing in situ is possible, otherwise double -insulated joints shall be used, such joints being pre-fabricated and tested before being welded into position. 5.3.10

Painting of containers

All aboveground storage containers shall be painted and such paint shall be effectively maintained to prevent corrosion. It is recommended that the storage containers be painted white. 5.3.11

Cleanliness around containers

The area surrounding an aboveground storage container shall be kept free from combustible material for at least the following distances: i)

containers up to 8 kl water capacity: 3 m; and

ii)

containers greater than 8 kl water capacity: 6 m.

5.3.12

Inspection

Aboveground containers shall be inspected by the owners in accordance with the requirements in Table 6 and records of such inspection are to be made available for examination by the relevant authority.

41

MS 830:2003

5.4

Containers for temporary storages

5.4.1

General


Containers intended for use at a location for temporary storage for a period not exceeding 6 months may be exempted only from the requirements of 5.3.2. 5.4.2

Metal supports

A container intended for use at a given general location for a period not exceeding 6 months, need not have fire-resisting foundations or saddles, provided that: a)

the container shall have adequate ferrous metal supports; and

b)

the outside bottom surface of the container shall be not more than 600 mm above ground level. Table 6. Inspection of aboveground containers Frequency of test

Containers with manholes

Containers without manholes

Every 5 Years

Full external examination. Ultrasonic test may be used to supplement the external examination if necessary

As for container with manholes

Every 10 Years

Full internal visual examination in addition to the 5 yearly external examination

Ultrasonic or hydrostatic test

Where the clearance between the outside bottom surface of the container and the ground is greater than 600 mm, supports shall have a fire resistance rating of at least 2 h. The top of the supports shall be in contact with the skid members of the containers. Where containers are not located on a hard surface, adequate provision shall be made to prevent the possibility of settlement of movement. 5.4.3

Piping connections

Where a container is not permanently located on fireproof foundations, piping connections shall be sufficiently flexible to minimise the possibility of breakage or leakage through connections if the container settles or moves. 5.5

Discharge from safety relief valves

5.5.1 The discharge from a safety valve shall not be less than 1.5 m measured horizontally from any opening in a building which is situated below such discharge. The discharge shall be directed away from the building and shall not be located in enclosed areas, such as lightwells. 5.5.2 The discharge lines from safety relief valves fitted to all containers shall be directed vertically upwards and away from the container and for containers exceeding 8 kl water capacity, shall terminate at a point at least 2 m above the container.

42

MS 830:2003

5.5.3 Where the safety relief valve of containers of 8 kl water capacity or less is under a lockable dome or cage, adequate provision shall be made for the dispersal of gas from such safety relief valve, without deflection or impingement on to such container or adjacent container or containers, equipment, or any combustible substance.


5.6

Accessibility to fittings

5.6.1 Elevated valves and fittings normally used in the filling and emptying of aboveground storage containers shall be accessible from properly installed ladders and platforms. 5.7

Signs and notices

5.7.1 The following messages in the form of signs (notices may be included if so wished) shall be clearly displayed at a container or storage area: a)

No smoking;

b)

No naked lights;

c)

Nearby material is a fire risk; and

d)

No handphone.

Signs shall be in accordance with Annex L and of suitable size. Warning notices shall be in letters at least 50 mm high. 5.8

Illumination

5.8.1 Installations for which LPG transfer will occur at night on a scheduled basis shall be provided with fixed lighting, able to provide illumination at a level not less than 50 lux at all valves, couplings, and gauges that may be involved in the transfer operation. 5.9

Conveyance

5.9.1

Containers not exceeding 8 kl water capacity

Storage containers not exceeding 8 kl water capacity may be conveyed, if approved on a road vehicle, or on a trailer, provided that the LPG content does not exceed 5 % of the nominal capacity of the container. 5.9.2

Containers exceeding 8 kl water capacity

Storage containers exceeding 8 kl water capacity shall be conveyed only in a completely purged and gas free condition. All storage containers being conveyed under this requirement shall be securely attached to the road vehicle or trailer, to prevent movement in any direction.

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SECTION 6: CAPACITY, LOCATION AND INSTALLATION OF UNDERGROUND/MOUNDED STORAGE CONTAINERS UP TO FIRST STAGE REGULATOR


6.1

Application

6.1.1 This section specifies requirements on the capacity, location and installation of underground/mounded storage containers up to first-stage regulator. This section does not apply to LPG cylinders. 6.1.2 Underground containers shall be completely buried under the ground. Mounded containers are containers which are partly or wholly above the general ground level but are entirely covered with earth or sand to prescribed requirements given in 6.4.1 and 6.4.2. Mounded containers shall be treated as underground containers. 6.1.3 Where applicable, underground/mounded container installation shall comply with the appropriate requirements of Section 5. 6.2

Special requirements for underground/ mounded containers

6.2.1 Approved storage containers shall not be buried underground/mounded unless written permission has first been granted by the relevant authority. 6.2.2

Container design pressure

The minimum design pressure of underground/mounded storage containers shall be 1 750 kPa (gauge). 6.2.3

Lifting lugs

All underground storage containers shall be provided with lifting lugs or other approved means for lowering the container into position without damage to the container or to the corrosion resistant coating provided in accordance with 6.2.4. Any damage shall be repaired in accordance with 6.2.4. NOTE. Underground containers should have a liquid education pipe running down into a shallow well (e.g. a short piece of 75 mm diameter pipe, blanked off) in the base of the container for cleaning out purposes.

6.2.4

Corrosion control

6.2.4.1

General

Each underground/mounded container shall be provided with a corrosion resistant coating and with cathodic protection. 6.2.4.2

Surface preparation

Before application of coating material, the external surfaces of the container shall be suitably prepared by grit blasting or chemical treatment.

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MS 830:2003


6.2.4.3

Coating material

The external surfaces of the container shall be covered with a corrosion -resistant coating which will provide an electrical insulator between the containers and earth. The coating material shall be strongly bonded to all external surfaces of the containers and shall be inert, non -absorbent to moisture, of high dielectric strength and of adequate mechanical strength to resist damage during handling of the container or from its burial in soil. The preparation of the surface and the handling and application of the material shall be in accordance with the codes approved by the relevant authority (see Annex A). 6.2.4.4

Testing of coating

After coating of the container is completed, the electrical resistance of the coating and its continuity shall be spark tested over the whole surface using a potential suitable for the characteristics of the particular coating, in accordance with the codes approved by the relevant authority (see Annex A). Any flaws detected in this test shall be repaired and retested. Any damage to the coating sustained during handling or installation of the container shall also be repaired and the repair spark tested as above, before burying the container. 6.2.4.5

Cathodic protection

Every underground/mounded container and associated underground/mounded pipework shall have an adequately designed cathodic protection system. This system may be of the sacrificial anode or impressed current type but in either case shall be provided with a point at which a test can be made to determine the efficacy of the system. Tests shall be made every 6 months and records of such tests shall be kept and be available to the relevant authority. Where there is cathodic protection common to the container and an underground/mounded pipeline as in 6.4.6.1, the insulated joint may be bonded across or omitted. 6.3

Container location and safety distances

6.3.1


6.3.1.1 Underground/mounded storage containers shall not be placed inside building or in open pits. 6.3.1.2 Storage containers shall not be located beneath the bunded area of flammable or combustible liquid storages. 6.3.1.3 Storage containers shall not be installed one above the other. An underground container shall not be directly below any aboveground container. 6.3.1.4 An underground/mounded LPG container shall not be less than 3 m from an underground container containing flammable and combustible liquids.

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MS 830:2003


6.3.1.5 Underground containers shall be protected from aboveground loading due to vehicular traffic or other cause, either by fencing off the area under which the containers are buried, or by reinforced concrete slab or other adequate cover to prevent the weight imposing concentrated direct loads on the container shell. If the container area is not fenced off, the container manhole cover and the container fittings shall be protected against damage and tampering. The perimeter of the area under which containers are buried shall be permanently marked. 6.3.2

Safety distances

6.3.2.1 The safety distances refer to the horizontal distance in plan between the nearest point on the storage container and a specified feature (e.g. an adjacent storage container building, property boundary). 6.3.2.2 The number of underground/ mounded storage containers in any one group shall not exceed six. Any container in one group shall be at least 7.5 m from the nearest storage container in another group. 6.3.2.3 Safety distances for underground/ mounded storage containers in various locations shall comply with the requirements in 6.3.2.4 and 6.3.2.5. 6.3.2.4

Bulk storage at consumers' premises

This applies to commercial and industrial consumers' premises such as industrial plants and hotels where there is bulk storage of LPG. Location of underground/mounded storage containers in these premises shall comply with the minimum safety distances given in Figure 4. Location of vaporisers shall comply with 5.2.6.5 c). Further requirements for vaporisers are given in 4.3. 6.3.2.5


Location of underground/mounded storage containers in automotive LPG dispensing stations shall comply with the minimum safety distances given in Figure 5. Further requirements for automotive LPG dispensing stations are given in Section 13. 6.3.2.6

Refineries and bulk plants

Location of underground/mounded storage containers in refineries and bulk plants shall comply with the minimum safety distance shown in Figure 6. 6.4

Installation

6.4.1

Foundations

All underground/mounded containers shall be installed on a consolidated bed of noncorrosive inert material such as sand at least 150 mm thick evenly along its length. If necessary, containers shall be securely anchored to prevent floating.

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MS 830:2003


6.4.2

Backfilling

Backfilling material immediately adjacent to the container shall consist of at least 150 mm of non -corrosive inert material such as water-washed sand free from soil, rocks, gravel or ashes and other deleterious matter. Backfilling sand shall have a minimum resistivity of 100 ? when tested after th orough moistening with distilled water. The sand shall be well tamped into place during the backfilling operation. Mounded containers shall have the upper surface covered with earth to a depth of at least 600 mm.

Water capacity of individual container (kl) Up to 135

Minimum safety distance (m) A 1.5

B 3

C 3

D 6

G 10

H See 4.3.3.3(d)

NOTE. For location of indirect-fired vaporisers, see 5.2.6.5 c) and 4.3.1.3 e), f).

Figure 4. Location of underground/mounded containers for bulk storage at consumers’ premises 47


MS 830:2003


A

B

C

D

J

K

L

M

Up to 70

1.5

3

3

6

3

3

5

6

Minimum safety distance (m)

Figure 5. Location of underground/mounded containers for automotive LPG dispensing stations

48


A

B

C

D

F

< 135

2.5

15

3

6

7.5

135 to 265

2.5

20

3

6

7.5

> 265

2.5

30

3

6

7.5

Minimum safety distance (m) S See Figure 7

R See Figure 7


MS 830:2003

T

U

15

10

15

10

15

10

Figure 6. Location of underground/mounded containers in refineries and bulk plants

If vehicles can pass above the underground containers, it shall be covered by at least 300 mm of sand superimposed with reinforced concrete not less than 150 mm thick, but also adequate to support any likely superimposed loading, and extending at least 300 mm in all directions beyond the outline of the container. If traffic access is prevented a covering of at least 600 mm of sand or earth is acceptable.

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MS 830:2003

Care shall be taken, throughout the life of the container, to avoid introducing ashes or other corrosive material above or in close proximity to it. 6.4.3

Access pit


Where valves and fittings of the container are located in an access pit, adequate provision shall be made for the proper drainage and ventilation of the pit. The access pit shall not be larger than necessary for the operation and maintenance of the valves and fittings located therein and shall be not more than 1 m deep. It shall be adequately protected by means of a locked cover. 6.4.4

Location of filling connection

The requirements in 5.3.8 shall apply. 6.4.5

Discharge from safety relief valve

6.4.5.1

Point of discharge

For all underground/mounded containers, the discharge from the safety relief valve shall terminate vertically and directly upward at a point at least 3 m above ground level. 6.4.5.2

Discharge rate for underground/ mounded container before filling

If no LPG is put into a container until after it is placed underground or mounded, the rate of discharge of the safety valve shall not be less than 30 % of the capacity in accordance with Annex D. 6.4.5.3

Gas in container during installation

If LPG is present in the container during its installation, the rate of discharge shall be in accordance with the requirements for aboveground containers as given in Annex D. 6.4.6.

Piping

6.4.6.1

Underground pipes

All underground/mounded piping connected to the container shall be provided with a protective coating of a quality at least equal to that of the container itself and tested in the same manner as the container. Where the container is connected to an underground pipeline, other than the pipework associated with the installation itself and in the immediate vicinity of it, an insulated joint shall be installed in the pipeline adjacent to the container. Where soil conditions are unstable and settling of piping or foundation walls or heavy vehicular traffic may occur, adequate measures shall be provided to prevent excessive stressing of the piping. Piping shall be buried in a sufficient depth or covered in a manner so as to protect the piping from physical damage. Consideration should be given to protect the piping from physical damage when it passes through flowerbeds, shrub beds and other such cultivated areas.

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6.4.6.2

Aboveground pipes


Where underground piping that is attached to a cathodically protected container or piping system emerges aboveground, an insulated joint shall be fitted adjacent to the point of emergence and any piping and fittings on the aboveground side of it shall be effectively earthed. Where pipework terminates in an access pit, the insulated joint shall be fitted immediately above the bottom of the pit and the pipework above the bottom of the pit and the pipework above the insulated joint shall be effectively earthed. 6.4.6.3

Insulated Joints

Insulated joints shall comply with the requirements of 5.3.9.4. 6.4.7

Inspection

The following conditions shall apply in respect of inspection of underground/mounded storage containers: a)

Before any underground/mounded container is uncovered for inspection and opening or for any other purpose, it shall be fully purged; provided however that where external inspection only is intended and the container is not to be opened, the pressure shall be re duced to 35 kPa (gauge).

b)

When any fault is found in the protective coating, it shall be stripped off completely in the immediate vicinity of the fault and the underlying metal surface examined. Such defective coating shall be repaired and tested to the satisfaction of the relevant authority before recovering the container.

c)

The relevant authority may extend intervals between periodic inspections where tests positively prove the effectiveness of the coating; provided however that all underground/mound ed containers without manholes shall be uncovered for inspection at least once every 10 years. Underground/mounded containers with manholes shall be given a full internal visual examination and ultrasonic or hydrostatic test at least once every 10 years.

d)

The use of test plates buried separately from the container shall not be taken as evidence to justify extension of inspection periods.

e)

The safety relief valve and pressure gauge shall be removed for testing at intervals not exceeding 5 years.

6.4.8

Odorising

All LPG stored in underground/mounded containers shall be odorised in accordance with 1.4.

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MS 830:2003

SECTION 7: TRANSPORTATION OF LPG


7.1

Application

This section covers the design and construction of containers used in the transportation of LPG in bulk by road and rail, the design of vehicles and ancillary equipment and operating practice. The requirements of this section apply equally to road and rail vehicles except where specific exclusions are made. 7.2

Container design and construction

7.2.1 Portable containers used in the transportation of LPG in bulk by road and rail shall comply with the appropriate requirements of Section 2 and in addition shall meet the requirements of 7.2.1.1 and 7.2.1.2. 7.2.1.1 The design stress shall include an allowance to enable the container to withstand shocks normally encountered by movements on road or rail. When the container is selfsupporting the container design shall provide for carrying the additional stresses normally carried by the chassis frame. Provisions shall be made for distributing the localised stresses arising from attachments to the container. 7.2.1.2 All attachments to the container shall be protected against accidental damage which may result from collision, overturning, or other operational cause. 7.2.2 Where a portable container may be placed on a vehicle and used for delivering LPG without dismounting it, then the container vehicle combination shall comply with 7.3.1 and 7.3.2. 7.3

Vehicle design

7.3.1

Road tankers

Road tankers intended for the transport of LPG shall comply with the requirements of the relevant authorities. 7.3.2

Rail tankers

Rail tankers intended for the transport of LPG shall comply with the requirements of the relevant authorities. 7.4

Use of trailers

7.4.1 Where a portable container containing LPG is conveyed on a road vehicle or trailer, the trailer shall not be towed by a road tanker carrying LPG in bulk. 7.4.2 Where a portable container not greater than 2.5 kl water capacity is conveyed on a trailer towed by a truck, the truck shall not carry more than 250 kg LPG in cylinders.

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MS 830:2003

7.5

Accessories

7.5.1

Warning signs, lights


7.5.1.1 Every tanker shall be provided with the following warning equipment and danger marking as approved by the relevant authorities: a)

portable reflectors complying with MS 1409;

b)

a reflective sign or a portable flashing light, where the vehicle is not fitted with a flashing light; and

c)

two sets of ‘No smoking’, ‘No naked lights’ and ‘No handphone’ signs (see Annex L) for placement, one at each end of the vehicle.

7.5.1.2 Every commercial vehicle used for conveyance of LPG in cylinders shall be marked and firmly fixed in the vehicle with the following warning equipment and danger marking as approved by the relevant authorities: a)

portable reflectors complying with MS 1409;

b)

a reflective sign or a portable flashing light, where the vehicle is not fitted with a flashing light; and

c)

two sets of ‘No smoking’, ‘No naked lights’ and ‘No handphone’ signs (see Anne x L) for placement, one at each end of the vehicle.

7.5.2

Protective gloves

Protective, impermeable, thermal insulating gloves shall be provided for persons engaged during transfer operation involving a bulk conveyance container. 7.5.3

Instructions and procedures

Every tanker shall be provided with the following instructions: a)

container filling and emptying procedures (8.5); and

b)

emergency procedure guides in accordance with Annexes G and H.

7.5.4

Wheel checks

A tanker which is of a type permitt ed to operate without spring brakes shall be provided with at least two checks not less than 150 mm high. 7.5.5

Portable light

A portable lead-light suitable for Zone 1 hazardous area application shall be provided, connections being made by means of suitable socket fitted in a convenient position in the cabin of the vehicle, or alternatively an approved torch shall be carried. A separate flameproof lamp, together with a flameproof switch for its operation may be mounted near the valve controls on the container.

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MS 830:2003

7.5.6

Flexible hoses


Flexible hoses used for loading or unloading tank vehicles shall comply with the requirements of 3.2.9. 7.6

Tanker operations

7.6.1

Training

The person for the time being in charge of the operation of the tanker shall be trained in the handling of the product. 7.6.2

Duties of person in charge of vehicle

The person in charge of the tanker shall ensure that before moving the vehicle on any delivery run the accessories specified in 7.5 are being carried. 7.6.3

Fire extinguishers

All portable fire extinguishers shall be inspected, recharged and pressure tested in accordance with the requirements of the relevant authority. 7.6.4

Refuelling

When LPG is being transferred from the cargo tank into the engine fuel tank, the tanker shall be stopped and the precautions set out in Section 8 shall be observed. 7.6.5

Tanker inside buildings

An LPG tanker shall not be stored, parked or garaged in a structure which has less than three sides open, or is otherwise so enclosed as to prevent the complete dispersion of any LPG which might escape. The requirements shall not apply to a prime mover fuel tank which contains LPG. 7.6.6

Stationary road tank vehicles

7.6.6.1

Location

A road tank vehicle containing LPG shall not be allowed to remain stationary in a public place (including a street or road) within a town or city or to remain stationary within 15 m of a building except for such time and for such purpose as are reasonably necessary in connection with the delivery of LPG or for brief rest steps or for an essential repair or tyre change. 7.6.6.2

Lighting

A road tank vehicle shall not be parked or left unattended in a street or road at night unless the vehicle is well lighted and conspicuous, either by its own lighting or the street lighting, and a reflective sign or flashing light is displayed at or near the rear of the vehicle.

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MS 830:2003

7.6.6.3

Battery isolation switch

The battery isolation switch shall be opened when the vehicle is not under the direct control of a responsible person, except for short term parking at night, or when the vehicle lights are required under 7.6.6.2.


7.6.7 7.6.7.1

Servicing and repairing of road tank vehicles Vehicle chassis and engine

The following precautions shall be taken when it is necessary to carry out service or repair work on the chassis or engine of a LPG road tank vehicle: a)

The vehicle shall not be parked near a source of heat, open flames or similar source of ignition.

b)

The driver shall instruct the responsible persons in the workshop the nature of the container contents and instruct them not to temper with the container valves and fittings.

c)

All primary shut off valves shall be closed and liquid or vapour in the hose piping vented to a safe location prior to moving the vehicle into the building. All hose connections shall be capped.

d)

The system shall be checked for leaks and any found shall be repaired before the vehicle is moved inside the building.

e)

The container shall be gauged to determine that it is not filled beyond the maximum filling capacity in accordance with 9.2. If over-filled, it shall be corrected before the vehicle is moved inside the building.

7.6.7.2

LPG container

Repair work shall not be carried out on the container or primary shut off valves while the vehicle is in the workshop and the container contains LPG. No hot or major work shall be commenced on a LPG container or its appurtenances until the container has been purged and an authorised person has issued a ‘Gas -free certificate’. NOTE: Care shall be taken to ensure that an LPG container is gas free before any work is carried out on it, particularly since vapours are likely to be released from any deposit, sedimentation, or gas pocketing in the container and pipework after initial opening and testing. This hazard is accentuated where hot work is being carried out.

7.6.8

Smoking, naked lights and explosive articles

Smoking, naked lights and articles capable of causing fire or explosion shall not be permitted on or near a road tank vehicle carrying bulk LPG.

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MS 830:2003

SECTION 8: TRANSFER OF LIQUIDS 8.1

Application


This section covers transfers of liquid LPG from one container to another whenever this transfer involves connections and disconnections in the transfer system, or the venting of LPG to the atmosphere. 8.1.2 8.2 8.2.1

The requirements of this section do not apply to decanting (10.5). General requirements Transfer

No storage container, road or rail tanker or cylinder shall be filled with LPG unless it is in good condition and comply with the design. Fabrication, inspection, marking and other appropriate provisions of this standard. Where transfer of LPG is affected on a consumers’ premises, the consumer shall be notified that delivery is to be made. No delivery of LPG shall be made at night unless appropriate light for the location is provided. For transfer operations, transfer hose shall not be run through any building or cross any road or highway. The protective gloves required by 7.5.2 shall be worn during transfer operations. 8.2.2

Transfer personnel

8.2.2.1 Personnel responsible for the operation of equipment and the handling of LPG shall understand the physical characteristics of the product, be adequately instructed in the correct operation of the equipment and be familiarised with the relevant sections of this standard appertaining to their spheres of responsibility. 8.2.2.2 All persons concerned with the storage and handling of LPG shall be trained in the fundamentals if fire-fighting and fire control with particular reference to fires involving LPG. They shall also be trained in the correct handling of any fire fighting and fire-control equipment provided and shall be exercised in this respect at frequent intervals. The location of all gas and liquid piping and valves, main electrical isolati ng switches and hydrants shall be known and their use understood. 8.2.2.3 Emergency procedures in accordance with 13.7.4 shall be clearly displayed. All personnel concerned shall be familiar with them and trained to handle emergency situations. 8.3

Super vision of transfer

8.3.1 Transfer operations shall be conducted by competent personnel meeting the provisions of 8.1.2. At least one person trained in the transfer operation shall remain in attendance from the time connections are made until the transfer is completed, shut-off valves are closed and lines are disconnected. 8.3.2 In the case of road rail tanker, unless the tank vehicle and the storage container or cylinder are readily visible and accessible one from the other, then two competent persons shall be in attendance throughout transfer operations, one at the vehicle and one at the storage container or cylinder. The person in attendance shall be capable of driving the vehicle in an emergency. 8.3.3 A person shall be in attendance at the road vehicle whilst it is positioned on the public road or street during discharge. 56

MS 830:2003


8.4

Location of tank vehicle

8.4.1 When any road tank vehicle is used to transfer LPG into storage containers exceeding 8 kl water capacity at one location, the vehicle shall be located off the public street and as far as practicable from open doorways and shall not obstruct entrances to buildings or fire escapes. In no case shall a road tank vehicle be located closer than 3 m to a storage container, and not less than 2.5 m separa tion shall be maintained between the vehicle and the filling connection to the storage container. The trained person shall ensure that the road tank vehicle be so positioned for quick egress without recourse to backing in the event of an emergency. 8.5 Container filling and emptying procedures 8.5.1

Precautions to be observed

Filling procedures and precautions shall be observed in the order stated in 8.5.2 to 8.5.4. Where any valve is open to transfer liquid, the operating handle or wheel shall remain in position on the valve. 8.5.2

Before transfer of liquid

The following procedures and precautions shall be checked before transfer of LPG: a)

The receiving container shall be checked to ensure that it is in safe working condition and that the grade of LPG to be transferred is compatible with its content and design working conditions.

b)

The receiving container shall be checked to ensure that it has sufficient ullage to receive the quantity being transferred to it.

c)

The interconnecting system, i. e. pipew ork, fittings, valves, hoses, etc. shall be checked to ensure that it is in safe working condition and that only valves, etc. required for the transfer operation, or any other operation proceeding simultaneously, are open.

d)

The interconnecting systems shall be checked to ensure that product cannot be charged into lines, equipment, or containers not designed to handle it and that unacceptable product contamination will not occur.

e)

If the pump is driven by the tanker’s main driving engine or an auxiliar y engine, so that the engine must remain running during delivery, the isolating switch for the alternator or generator field coil shall be closed. Otherwise any engine not required for pumping shall be stopped and shall remain stopped until the tanker is ready to be driven away.

f)

The area shall be checked to ensure that ignition sources, smoking, or naked flame does not exist within 10 m of the connections at either end of the transfer hose.

g)

Wheel chocks shall be placed in position unless the tanker incorporates spring brakes.

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MS 830:2003

h)

‘No smoking’, ‘No naked lights’ and ‘No handphone’ sign shall be placed at either end of the tanker unless the tanker is so marked front and back.

i)

Before the transfer hose is connected the anti -static (bonding) lead shall be connected when the container being filled is 2.5 kl or larger.

j)

Where fittings are provided with bleed valves to relieve any build-up of pressure, such valves shall first be operated and then the terminal caps of pipework and hoses shall be removed.

k)

All connections for transmission of the product shall be made vapour tight.

8.5.3

During transfer of liquid

The following procedures and precautions shall be followed during transfer of LPG: a)

All necessary valves shall be opened and the pump started.

b)

Filling shall be stopped if any ignition source becomes active within the area specified in 8.5.2 (f) or if any fault or malfunction causes gas to escape.

c)

The operator or person-i n-charge shall remain in the immediate vicinity of the transfer operation during transfer and shall ensure that the receiving container is not overfilled.

d)

The filling ratio for the container shall not be exceeded.

e)

Where filling without vapour return or transferring with vapour compression is being undertaken care shall be taken to ensure that the safety relief valve does not blow off.

8.5.4

After transfer of liquid

The following procedures and precautions shall be followed after transfer of LPG: a)

The pump or compressor shall be stopped.

b)

All necessary valves shall be closed.

c)

If dry hoses are used, pump and engines shall be stopped prior to venting the hose, and venting shall be completed prior to uncoupling the hose;

NOTE. Where a compressor is available, the liquid in the liquid line should preferably be blown into the receiving container before venting takes place.

d)

Hose couplings shall be disconnected and the terminal caps of pipework and hose shall be replaced immediately.

e)

Hoses shall be stowed away. Long hoses which are to be wounded up under power shall first be cleared of all obstructions which could impede the hose movement or cause damage.

f)

Electrical connections and anti -static leads shall be disconnected and stowed away. 58


MS 830:2003

g)

The isolation switch in the field circuit of the generator or alternator shall be closed.

h)

Wheel checks and warning notices shall then be removed and stowed away.

i)

The operator shall inspect the area by walking around the vehicle to ensure that all of the above precautions have been complied with.

8.5.5

Emergency stoppage of operations

The person incharge of operations shall ensure that transfer operations are stopped and all valves closed in the event of the following occurrences; a)

uncontrolled leakage;

b)

a fire in the vicinity; and

c)

a severe electrical storm in the vicinity in the case of an operation which involves venting of LPG.

8.5.6

Purging and filling containers and systems.

8.5.6.1 When new containers and systems are to be taken into commission or containers and system which have been g as-freed are to be filled they shall first be cleared of air. 8.5.6.2 Air shall be replaced by an inert gas, water, or LPG depending on circumstances. If water is used to replace the air, provision shall be made for its complete removal. If LPG vapour is used to replace the air, then the container and system will for a period of time contain a flammable mixture and the flammable mixture will be vented from the container and system: adequate precautions of preventing its ignition are essential. 8.5.6.3 In the case of air removal by means of an inert gas or LPG vapour, sampling and testing of the container contents and the mixture discharged from the vent or vents shall be carried out to determine the completeness of the air removal and the flammability of the issuing gas. 8.5.6.4 On filling the container and system care shall be taken to prevent excessive chilling by the too rapid evaporation of the LPG pumped into it. 8.6

Venting of gas or liquid

8.6.1 Gas or liquid shall not be vented to the atmosphere to assist in transferring contents of one LPG container to another container. However venting under the following conditions is allowed: a)

Venting for the operation of fixed liquid level, rotary or slip tube gauges, provided the maximum flow does not exc eed that from a 1.4 mm opening.

b)

Venting the LPG between shut-off valves before disconnecting the liquid loading line from the container. Where necessary, suitable bleeder valves shall be used.

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MS 830:2003

c)

Venting vapour from approved pumps utilising LPG in the vapour phase as a source of energy, provided the rate of discharge does not exceed that from an opening of 3 mm diameter and such venting and liquid transfer shall be located not less than 7.5 m from buildings, property boundaries, roads, streets and sources of ignition.

8.7

Pumps and compressors

8.7.1

Suitability

A pump or compressor intended for handling LPG shall be suitable for use with LPG. A pump drive which is located within the hazardous zone surrounding the pump shall be suitable for us e within that zone. 8.7.2

Pressure limitation

In addition to the specific requirements of 8.7.3 and 8.7.4 a pump or compressor installation shall incorporate an automatic means to prevent the design pressure of any container, pipe or component from being exceeded. If this means consists of a primary recirculation system which has a manual shut off valve in the line, or a quick-closing internal valve of a type which does not automatically open under pump pressure, a secondary safety recirculation system shall be provided which shall have no means of rendering it inoperative. This secondary system may have a pressure setting greater than that of the primary system. 8.7.3

Pumps

A pump installation shall incorporate the following: a)

A pressure gauge provid ed with a flow restriction in accordance with 2.6.1 b), located on the discharge side of the pump before any external pressure relief or shut-off valve. The gauge should be liquid-damped.

b)

A constant differential by pass valve installed in the pump discharge of any positive pump and delivering to the supply tank of the pump or to the suction side of the pump through a line of sufficient size to carry the full capacity to the pump.

8.7.4

Compressors

A compressor installation shall comply with the following requirements: a)

a compressor shall draw from a vapour space and may discharge to either the liquid or the vapour space.

b)

means shall be provided to prevent liquid from entering the compressor suction. If such means is not integral with the compres sor, a liquid trap shall be installed as close as possible to the compressor in the suction line.

c)

pressure gauges provided with a flow restriction in accordance with 2.6.1 b) shall be installed on the suction side and on the discharge side of a compressor. The gauges should be liquid damped.

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8.7.5

Pump location

A pump shall be so located that the surrounding hazardous zone does not overlap a boundary or impinge on a building (other than buildings used specifically for storage and handling of LPG) or ignition source.


8.8

Flexible hose

8.8.1 Flexible hose used for conveying LPG in liquid or vapour phase at pressure exceeding of 35 kPa (gauge) shall be designed, fabricated and tested in accordance with the requirements of 3.2.9. 8.9

Precautions as to type of gas

8.9.1 The LPG marketer, the person in charge of transfer operations, and the consumer shall take all precautions to ensure that only those gases, for which the system is designed and approved, are employed in its operation, particularly with regard to pressure and materials of construction.

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SECTION 9: CYLINDERS 9.1

FILLING

CAPACITIES

OF

LPG

CONTAINERS

AND

Application


This section includes requirements covering the maximum permissible LPG content of containers and the methods of verifying this quantity. 9.2

LPG capacity of containers

9.2.1 The maximum LPG content of any container shall be that quantity which equals to the maximum permitted filling ratio given in Table 7. The filling ratio depends o n the size of the container, whether installed aboveground or underground and the density of the liquid LPG at 15 °C placed in the container. 9.2.2 Determination of the LPG content of a container complies with Table 6 may be either by mass or by volume 9.3.1, 9.3.2 and 9.3.3. 9.3

Compliance with maximum permitted filling ratio requirements

9.3.1

Filling by mass

The maximum mass, M (in kilograms), of liquid that may be introduced into a container may be calculated from the formula: M=CxD where, M is the maximum permitted mass which can be placed in a container, in kilograms; C is the water capacity of the container, in kilograms; and D is the maximum permitted filling ratio from Table 7, in percentage. 9.3.2

Filling by volume

Because the contents of a static storage container cannot normally be controlled by mass, some means is required for calculating the maximum volume of liquid that may be placed in a container at any liquid temperature. The maximum permitted liquid volume, as a percentage of the total container capacity, may be determined for LPG at any liquid temperature by the method in Annex J. 9.3.3 Alternative maximum permitted liquid volume for containers up to 8 kl water capacity The maximum liquid volume, as a percentage of the total container capacity, given in Table 8 may be used in view of the maximum permitted filling ratio given in Table 7 for containers up to 8 kl total water capacity as a means of determining the maximum quantity that may be placed in the container (see note to Table 8).

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Table 7. Maximum permitted filing ratio for LPG containers and cylinders


Density at 15 ?C (kg/l)

Maximum filing ratio (per cent) Aboveground up to 5 kl total water capacity

Aboveground over 5 kl total water capacity

Undergro und/mounded All capacities

0.473 to 0.480 0.481 to 0.488 0.489 to 0.495

38 39 40

41 42 43

42 43 44

0.496 to 0.503 0.504 to 0.510 0.511 to 0.519

41 42 43

44 45 46

45 46 47

0.520 to 0.527 0.528 to 0.536 0.537 to 0.544

44 45 46

47 48 49

48 49 50

0.545 to 0.552 0.553 to 0.560 0.561 to 0.568

47 48 49

50 51 52

51 52 53

0.569 to 0.576 0.577 to 0.584 0.585 to 0.592

50 51 52

53 54 55

54 55 56

0.593 to 0.600 0.601 to 0.608 0.609 to 0.617

53 54 55

56 57 58

57 58 59

0.618 to 0.626 0.627 to 0.634

56 57

59 60

60 61

NOTE. This table applies to uninsulated containers and cylinders. For insulated road and rail tankers reference should be made to the relevant authority for approval to use filling ratios set out into U.S. Department of Transport Regulations No. 73.314 f) - i).

Table 8. Maximum permitted liquid volume for containers up to 8 kl water capacity

LPG

Maximum permitted liquid volume (Percentage of total water capacity of container) Aboveground container Underground and mounded container (Liquid temperature (Liquid temperature assumed is 5 ?C) assumed is 10 ?C)

Propane (approx. density 0.51 kg/l)

80

89

Mixtures (approx. density 0.55 kg/l)

83

91

Butane (approx. density 0.58 kg/l)

86

93

NOTE. This table is intended as a quick reference method for small deliveries of LPG only, in places where there may not be a temperature measuring device or the necessary conversion tables to make a calculation as in Annex J. The method is safe as far as any danger of overfilling is concerned but it shall not be used for containers greater than 8 kl water capacity.

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SECTION 10: CYLINDER FILLING 10.1

Application


This section covers plants for the filling of cylinders of LPG and the handling and storage of cylinders at such plants. This may include the refilling of cylinders at consumers’ premises for their consumption. 10.2

Cylinder filling locations and platforms

10.2.1


10.2.1.1 Cylinder shall be filled with LPG only in buildings designed for that purpose or in the open air. The filling of cylinders shall not be done in basements or upper storeys of a building. 10.2.1.2 Floors may be near ground level or raised to vehicle platform height. If floor is raised, the space underneath should preferably be filled in or, if it is left open, it shall be unobstructed and without depressions to ensure ventilation. The open space beneath the floor shall not be used for any storage purpose and shall be kept clean and free from any combustible material. 10.2.1.3 As far as possible, the floor of the building or area should be without channels, or other depressions which could accumulate gas. Where channels or pits in buildings are necessary for conveyors or other equipment they shall be adequately ventilated by ducts to the ou tside of the building. 10.2.1.4 A covered cylinder filling platform may be used, provided that at least two sides of the platform are not enclosed or alternatively, means of ventilation shall be provided for the approval of the relevant authority. 10.2.1 .5 If the filling is not carried out within a fenced area, a fence of at least 2 m high shall be provided to enclose the filling and storage areas. A building or fenced area shall have at least two means of exit located as far apart as practicable. Doors or gates shall be opened outwards, shall not be self locking, and shall be capable of being opened readily from the inside. 10.2.1.6 No duct, drain, or blow -off line shall be directed into or discharged near sewer systems or drains used for other purposes. 10.2.1.7 Water drains from the filling building or area, where they pass to an outside drainage system, shall be provided with effective seals. 10.2.1.8 Piping, where it passes through a concrete or brick wall, shall be protected by a casing within which it is free to move. 10.2.1.9

Adequate lighting shall be provided to illuminate the working and storage areas.

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10.2.2

Safety distances


The cylinder filling building or filling area in the open shall be located in relation to buildings (other than buildings used specifically for storage and handling of LPG), property boundaries, cylinder storage area, LPG tankers discharge/filling locations, flammable and combustible liquids storages and bulk LPG storage containers in accordance with the minimum safety distances in Figure 7. 10.3

Cylinder filling

10.3.1

Inspection of cylinder prior to filling

10.3.1.1 Prior to filling cylinder shall be visually inspected for mechanical damage and for damage by denting or corrosion and any unsafe cylinder rejected. Visual inspection shall include an examination of the cylinder valve and a check on whether the cylinder is due for periodic test. Cylinders must be retested or requalified in accordance with Annex K. 10.3.2

Filling system

10.3.2.1 Cylinder shall b e filled accurately and checks made to ensure that overfilling does not take place. Filling may be by mass or volume. Filling of cylinders by volume may be carried out when the cylinder is fitted with a fixed liquid level gauge. Without prejudice to the safety requirements, all cylinders shall not be under filled to less than labelled weight. 10.3.2.2 The system shall be designed in such a way that there is minimum leakage when the connection to the cylinder valve is released. 10.3.2.3 Conveniently acc essible stop valves shall be fitted to the end of each branch filling line from the header immediately before the filling unit. An approved emergency shutdown device shall be fitted to the liquid supply line to the filling platform. 10.3.2.4 Hydrostatic relief valves shall be fitted in pipeline where liquid may be trapped between closed valves. 10.3.3

Filling limits

The maximum quantity of LPG filled into a cylinder shall be in accordance with the requirements of Section 9. 10.3.4

Venting of overfilled and leaking containers

When the contents of an overfilled cylinder are adjusted by venting, a suitable vent shall be used to carry the vented gas from the filling building for dispersal in a safe place. Alternatively, venting may be done in a safe place i n the open air. 10.3.5

Inspection after filling

Each cylinder valve and cylinder after filling shall be inspected to ensure that it is free from leaks and satisfactory for service.

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Aggregate capacity of storage


Water capacity of storage (kl)

Nominal mass of LPG storage (tonne)

Up to 13.5

B

R

S

Up to 6

5

1.5

Over 13.5 to 27.0

Over 6 to 12

6

2

Over 27.0 to 45.0

Over 12 to 20

7

2.5

Over 45.0 to 67.5

Over 20 to 30

8

3

9

3.5

See Figure 1

Over 67.5 to 112.5

Over 30 to 50

Over 112.5 to 135.0

Over 50 to 60

10

4

Over 135 to 225.0

Over 60 to 100

11

4.5

Over 225.0 to 337.5

Over 100 to 150

12

5

Over 337.5 to 562.5

Over 150 to 250

15

6

Over 562.5

Over 250

20

7

Figure 7. Safety distances for cylinder filling and cylinder storage

66

T

U

25

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MS 830:2003

10.3.6

Acceptable limit of leakage


A cylinder with a leakage of not more than 1.5 g/h is acceptable for use (see note). Cylinders of suspected leakage of more than 1.5 g/h shall be tested as shown in Figure 8 to determine the actual amount of leakage. A cylinder with a leakage of more than 1.6 g/h shall not be used. NOTE. For cylinder there may occur insignificant leakages that are impracticable to detect under normal production conditions even if the operator makes great efforts with suitable equipment. For this reason a leakage of not more than 1.5 g of escaped gas per hour is considered acceptable. A leakage of 1.5 g/h clearly manifests itself and can be check-mea sured by immersing a cylinder in water and using a special graduated glass as shown in Figure 8.

10.4

Handling and storage of cylinders

10.4.1

Handling of cylinders

10.4.1.1 Unless otherwise specifically required, filled cylinders shall be handled in the vertical position. Cylinders shall be placed so that the safety relief valve is always in direct communication with the vapour space. 10.4.1.2 Cylinders shall be handled with care, at all times avoiding damage to the cylinder and to the valve. Conversion scale: cm 3/min 7.0

G LP Gas/h 1.022

7.5

1.095

8.0

1.168

8.5

1.241

9.0

1.314

9.5

1.387

10.0

1.460

10.5

1.533

11.0

1.606

Figure 8. Check for gas leakage in cylinder

10.4.1.3 Valve outlet plugs or caps shall not be removed without making sure that the cylinder valve is closed. 10.4.1.4 Valves on empty cylinders shall be closed and where a valve protecting cover is supplied it shall be in place. 10.4.1.5

No attempt shall be made to heat a cylinder.

10.4.1.6 Tests for suspected leaks shall be made using a gas detector or soapy water BUT NEVER WITH A NAKED FLAME. 67

MS 830:2003

10.4.2

Storage of cylinder


10.4.2.1 The layout of the cylinder store shall be such as to facilitate quick removal of cylinders in case of emergency and the safety distances in Figure 7 shall be observed. 10.4.2.2

Cylinders shall not be in proximity to corrosive or highly flammable substances.

10.4.2.3

When cylinders are stored outside, precautions shall be taken to:

a)

provide them with clean dry standing;

b)

prevent access by unauthorised persons; and

c)

prevent accidental damage by vehicles etc.

10.4.2.4

Cylinders shall be stored only in a place with adequate floor level ventilation.

10.4.2.5 Cylinders shall always be stored at or above ground level and away from basements, drains, hollows, etc. where vapour might collect. 10.4.2.6

Cylinders shall not be exposed to excessive heat.

10.4.2.7 Fire appliances shall always be available and shall be kept convenient to and outside the store. 10.4.2.8

Cylinders in store shall have valves closed even though they may be empty.

10.4.2.9 Cylinders shall be stacked in storage in such a manner that all cylinders are at all times accessible for inspection and that any cylinder may be readily removed. Cylinders shall be placed so that the safety relief valve is always in direct communication with the vapour space. 10.4.2.10 Valve caps and/or plugs, where provided, shall be in position on filled cylinders when in storage or during transport. 10.5

Decanting

10.5.1

Restriction

This requirement relates to decanting by which transfer of product from cylinder to cylinder is carried out, without the use of a pump, using onl y the product differential pressure. Decanting shall be permitted only for the following situations: a)

for legitimate sampling purposes;

b)

for evacuation of product during emergencies; and

c)

for leaking or overfilled cylinders.

Decanting for the purpose of resale or distribution is prohibited.

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MS 830:2003

10.5.2


10.5.2.1

Decanting shall be only from cylinder into cylinder.

10.5.2.2

The cylinder to be filled shall be in good condition.

10.5.2.3 Pipework, hoses and fittings used for decanting purposes shall be of highpressure quality (3.2.9). The hose shall not be more than 10 mm nominal bore and not more than 3 m long. 10.5.2.4 There shall be prominently displayed at the decanting point with adequate instructions for the decanting procedure which shall include a warning to stop filling as soon as the fixed liquid level gauge indicates that the maximum permitted liquid level has been reached. 10.5.2.5 The cylinder being decanted shall be upright and the cylinder being filled shall be arranged for filling so that the fixed liquid level gauge and the safety relief valve are exposed to the vapour space. 10.5.2.6 Persons experienced in the decanting operation shall be in attendance throughout such operation. 10.5.3

Security

When decanting equipment in an area accessible to the public ceases to be under general supervision, as when closing for the night, the dispensing point shall be protected from tampering by one of the following: a)

the whole of the decanting equipment including the cylinder shall be stored in a locked ventilated enclosure outside any building; or

b)

decanting apparatus shall be removed for secure indoor storage and the operating valve shall be rendered inaccessible to the public.

10.5.4

Location and safety distances

The decanting point shall be located outdoors and the following safety distances from the decanting point shall be maintained: a)

to an opening into a building: 2 m;

b)

to an ignition source: 10 m;

c)

to buildings or to any flammable materials stored above ground on neighbouring property: 5 m;

d)

to streets and roads: 3 m; and

e)

dispensers for any type of fuel: 3 m.

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MS 830:2003

10.6

Cleanliness

10.6.1 Readily ignitable material such as weeds, long grass, or any combustible material shall not be allowed to remain within 6 m of the cylinder filling or decanting or cylinder storage areas.


10.7

Signs and notices

10.7.1 The following messages in the form of signs (notices maybe included if so wished) shall be clearly displayed at the filling area or decanting point or storage area. a)

No smoking;

b)

No naked lights;

c)


d)

No handphone.

Signs shall be in accordance with Annex L and of suitable size. Warning notices shall be in letters of at least 50 mm high.

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SECTION 11: STORAGE OF CYLINDERS AWAITING USE OR RESALE 11.1

Application


This section applies to the storage of cylinders not exceeding 125 l water capacity (55 kg LPG nominal mass) per cylinder filled, partially filled or emptied at: a)

dealers or retailers’ premises;

b)

commercial and industrial users' location; and

c)

dispensing station.

11.1.2

The requirements of this section do not apply to:

a)

cylinders connected for use at commercial and industrial users' location (see Section 12); and

b)

cylinders stored in LPG charging plants (see Section 10).

11.2


11.2.1 Cylinders in storage shall be located so as to minimise exposure to excessive temperature rise, physical damages or tampering by unauthorised persons. Cylinders shall be stored above normal flood levels. 11.2.2 Cylinders when stored inside buildings shall not be located near exits, stairways or in areas normally used or intended for the safe exit of people. 11.2.3 11.2.4

Cylinder valves shall be protected in accordance with 2.8.1. The outlet valves of cylinders in storage shall be closed by suitable caps.

11.2.5 Empty cylinders which have been in LPG service may be stored in the open. When stored in a compartment or store they shall be considered as full cylinders for the purpose of determining the maximum quantity of LPG permitted. 11.2.6 The walls, floors and ceilings of cylinder storage compartment shall be constructed from materials having at least a 2 h fire resistance rating (see note). Ventilation opening shall be in accordance to 12.2.2.7 d). NOTE. A wall constructed from brickwork, masonry or concrete, 100 mm thick, or reinforced concrete 75 mm thick is deemed to have a 2 h fire resistance rating.

11.3

Storage within buildings

11.3.1 Cylinders shall not be stored in a building or part thereof or structures attached thereto when the building is used as a shopping complex, departmental store, theatre, cinema, educational institution, hotel, night-club, supermarket, clinic, club or place of worship except for storage allowed in 11.3.2.

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MS 830:2003

11.3.2 Cylinders having a maximum individual water capacity of 1.2 l, (0.5 kg LPG nominal mass) are permitted to be stored or displayed in a building used as a shopping complex, departmental store or hotel lobby. The display of such cylinders shall be limited to a total of 24 units of each brand and size. The total quantity on display shall not exceed 90 kg of LPG.


11.3.3

Storage in commercial premises

Cylinders shall only be stored in commercial premises meeting the requirements of 11.3.4 and 11.3.5. The storage shall be on ground level directly accessible to the outside. 11.3.4 Commercial premises for the storage of cylinders shall be of the detached, semidetached or terrace type of construction and shall not be more than 5 storeys and with no basement and shall not house any of the types of occupancy specified in 11.3.1 on any floor or part thereof. Such premises shall be separated from neighbouring premises by a solid wall of total thickness of not less than 200 mm. The quantity of LPG stored in such commercial premises shall not exceed 135 kg unless storage is within special compartments or rooms as provided in 11.3.5. 11.3.5

Storage within special compartments or rooms

Special compartments or rooms in commercial premises as specified in 11.3.4 for the storage of cylinders shall be constructed in accordance with the requirements of 11.3.5.1 to 11.3.5.7. The quantity of LPG stored in any one special compartment or room shall not exceed 4 500 kg. 11.3.5.1 The walls, floors and ceilings of a cylinder storage compartment that are within or adjacent to other parts of the building shall be constructed from materials having at least a 2 h fire resistance rating (see note). NOTE. A wall constructed from brickwork, masonry or concrete, 100 mm thick, or reinforced concrete 75 mm thick is deemed to have a 2 h fire resistance rating.

11.3.5.2 A portion of the exterior wall or roof having an area of not less than 10 % of that of the combined area of the enclosing walls and roof shall be of single strength glass or other similar explosion relieving construction. 11.3.5.3 At least one wall of the compartment or room shall be an exterior wall. There shall be at least one door opening directly to the outside or in to a safe area of no fire risk opening directly to the outside. 11.3.5.4 Where openings from such storage rooms to other parts of the building are necessary and permitted, such openings shall be protected by a 1½ h non-combustible door and no domestic habitation, sleeping accommodation or cooking activity shall be permitted on the same floor. 11.3.5.5 Such storage rooms shall be provided with adequate defused illumination from lighting points on the outside of the room or building. 11.3.5.6 Such storage rooms shall be ventilated both top and bottom to the exterior wall only. The openings from such vents shall be at least 1.5 m away from any other openings into any building. Top and bottom vent openings shall each have a total area of not less than 3 % of the floor area.

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MS 830:2003

11.3.5.7 The floors of such storage rooms shall not be below ground level. Any space below the floor shall be of solid fill or properly ventilated to the open air. 11.3.5.8 Buildings or parts of buildings used for LPG cylinder storage shall be used for no other purposes and be inaccessible to unauthorised persons.


11.3.5.9

LPG cylinders shall be kept in a vertical position with the valves uppermost.

11.3.5.10 LPG cylinders for domestic use shall not be stacked with more than 3 cylinders high. Commercial LPG cylinders shall not be stacked. 11.4

Storage outside of buildings

11.4.1

Location of storage outside of buildings

Storage outside of buildings for cylinders awaiting use or resale shall be located in accordance with the minimum safety distance in Table 9 with respect to: a)

the nearest permanent building or group of buildings;

b)

the boundary of adjoining property which may be built upon;

c)

public roads;

d)

the boundary of adjoining property occupied by schools, places of worship, hospitals, playgrounds or other places of public gatherings; and

e)

automotive service station fuel dispenser. Table 9. Location of storage outside of building Quantity of LPG stored *(kg)


Up to 220

0

221 to 2 500

3

2 501 to 4 500

6

Over 4 500

7.5

* Each lot of cylinders stored in the open separated by a solid wall of 100 mm thickness and 3 m high can be considered separately for the purpose of safety distance clearance.

11.4.2 Cylinders shall be stored within a suitable enclosure or otherwise protected against tampering. 11.4.3 Cylinders stored outdoors shall be free from vegetation such as grass, weeds, etc. within 3 m. 11.4.4 Cylinders shall be stored at least 6.1 m away from any automotive service fuel dispenser and at least 2 m from the filling point or vent point of an underground container containing flammable or combustible liquids.

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11.5

Signs and notices


11.5.1 All storage areas shall clearly display a warning notice with the words 'LPG STORE' printed in red letters on a white background. The letters of the wording shall be at least 75 mm high and 12 mm thick. 11.5.2 The following messages in the form of signs (notices may be included if so wished) shall be clearly displayed at all storage areas: a)

No smoking;

b)

No naked lights;

c)


d)

No handphone.

Signs shall be in accordance with Annex L and of suitable size. Warning notices shall be in letters of at least 50 mm high.

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MS 830:2003

SECTION 12: CYLINDERS IN USE 12.1

Application


This section applies to the location and installation of cylinders not exceeding 125 l individual water capacity connected for use in commercial, industrial, educational and institutional premises but excludes cylinders connected for use in domestic dwellings. 12.2

Cylinders in use, outdoor installations

12.2.1

Location of cylinders

A cylinder installation outside a building shall comply with the following requirements: a)

The water capacity of individual cylinder in a manifolded group of cylinders shall not exceed 125 l. If more than one manifolded group of cylinders are installed at a consumer site each manifolded group shall be separated from the border by at least 7.5 m. A deflection wall of 2 h fire resistance rating and a minimum height of 2 m may be used to reduce this distance to 3 m provided the vapour path shall not be less than 7.5 m. (See also Figure 9)

b)

The installations shall be fenced and locked to prevent unauthorised access and tampering.

c)

Any opening in to the building which is below the level of the relief valve shall be at least 1 m horizontally from the nearest cylinder. Table 10. Cylinder location and safety distances (see also Figure 9) Aggregate water capacity of cylinders in a manifolded group of cylinders (kl)

Minimum safety distance (m) From building A

From property boundary B

From a fixed ignition source

Up to 2.5

None

None

Over 2.5 to 10

7.5

7.5

Fixed ignition source shall not fall within Zone 0, 1 or 2 area

d)

One or more cylinders may be installed below a window, provided that there is a minimum distance of 150 mm between the top of any cylinder valve and the bottom of the window opening.

e)

A cylinder shall be located at a distance of at least 5 m from flammable or combustible liquid storage and other forms of combustible materials. This distance may be reduced to 3 m by using a deflection wall of 2 h fire resistance rating.

f)

Any exterior source of ignition, openings into direct-vent (sealed combustion system) a ppliances or mechanical ventilation air intakes shall be at least 1.5 m in any direction away from the nearest cylinder or opening to the compartment whichever is nearer.

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MS 830:2003

12.2.2

Installation


12.2.2.1 Cylinders shall be installed on firm level and no n-combustible base and protected from direct contact with the soil. The area surrounding the cylinders shall be kept clear of combustible materials such as weeds, dry grass, paper, etc. 12.2.2.2 Cylinders shall be installed upright with the valves uppermost and properly secured to prevent the cylinders from failing over. In flood prone areas, deliberate measures shall be taken to prevent cylinders from falling over or being carried away.

Figure 9. Illustration showing two manifolded groups of cylinders

12.2.2.3

Cylinders shall not be installed below ground level.

12.2.2.4 Where the discharge of the safety relief valve is horizontal, then the cylinders shall be arranged such that the discharge from the safety relief valve will not impinge on a cylinder of flexible connection. 12.2.2.5 Only authorised persons shall make, repair, alter or open connections in any LPG cylinder installation, except for the actual connection or disconnection of cylinders. 12.2.2.6

The position of the cylinders in a manifold installation shall facilitate:

a)

changing and quick removal of any cylinder in case of necessity;

b)

access to connections and regulating devices; and

c)

operation of cylinder valves.

NOTE. A manifolded group of cylinders is a collection of cylinders connected to a central piping that is connected to a regulator. It is noted that Figure 9 illustrates only a possible configuration for the manifolded groups of cylinders and does not limit other design possibilities.

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MS 830:2003


12.2.2.7 A specially built compartment within the building boundary but meeting the following requirements shall be considered an outdoor installation and shall be required to meet the safety requirements and distances for outdoor installations. a)

The compartment shall be separa ted from the rest of the building by surrounding walls having 4 h fire resistance rating. The separation shall be absolute in such manner that it will have no openings of access towards the inside of the building proper.

b)

The floor shall be of smooth concrete and at least 100 mm higher than the ground. Rough surface which may cause sparking during cylinder handling shall not be used.

c)

Electrical appliances installed in the compartment shall be at least suitable for Zone 2 application and preferably located above the cylinder.

d)

Ventilation openings of at least 300 cm 2 per 1 m2 of the floor area shall be provided and such opening shall be as closed to the floor as practicable, so as to prevent leaking gas from accumulating inside the compartment.

e)

A door of at least 1.5 m width shall be provided with access orientated towards the outside of the building.

12.2.2.8

Special case

A specially built compartment, meeting the minimum safety distance of Table 11 and the following requirements, is allowed for the installation of cylinder connected for use. a)

The surrounding walls shall be of a material with strength and fire resistance equal to or higher than reinforced concrete of 120 mm thickness or concrete block of 150 mm thickness.

b)

The doorway shall have a fire check door of 1½ h rating.

c)

The roof shall be light material but rigid.

d)

The floor shall be of smooth concrete and at least 100 mm higher than the ground. Rough surface which may cause sparking during cylinder handling shall not be used.

e)

Ventilation opening of at least 300 cm 2 per 1 m2 of floor area shall be provided and such opening shall be as close to the floor as practicable, so as to prevent leaking gas from accumulating inside the compartment.

f)

Electrical appliances installed in the compartment shall be explosion proof and preferably located above the cylinder.

g)

Where two groups of cylinders are on opposite sides of the compartment, then the separation distance shall not be less than 3 m. This distance shall be measured from the surface of the outermost cylinders. This separation distance may be reduced to not less than 1 m by a deflection wall in the middle of the distance separating the two group of cylinders.

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MS 830:2003

h)

The surface of cylinder in the direction of the safety relief valve discharge shall be at least 500 mm from the wall surface.

i)

The walls made of concrete blocks shall be at least 150 mm thick and 1.8 m high and reinforced by reinforcement bars of not less than 9 mm diameter, arranged at intervals of less than 400 mm lengthwise and crosswise, with those reinforcing bar in corners being firmly boarded together. Block opening shall be filled with mortar. Table 11. Safety distance Aggregate water capacity of cylinders In a manifolded group of cylinders (kl)

Minim um safety distance (m) From Class I buildings

From Class II buildings

From a fixed ignition source

Up to 2.5

0

0

Fixed ignition source shall

Over 2.5 to 10

3

0

not fall within Zone 0, 1 or

Over 10 to 135

13.5

10

2 area

NOTES: 1.

Class I buildings are buildings with large congregation such as shopping complexes, departmental stores, theatres, cinemas, educational institutions, hotels, night-clubs, supermarkets, clinics, clubs or place of worships.

2.

Class II buildings are residential dwellings.

12.3

Cylinders in use, indoor installations

12.3.1

Use inside commercial and industrial buildings

Cylinders shall not be installed inside basements (1.4.6). The aggregate water capacity of cylinders in use inside a commercial or industrial building shall not exceed 350 l in any floor 2 2 compartment space of less than 200 m or 500 l in any 200 m of floor compartment space. Exchange cylinders awaiting connection or used cylinders awaiting removal shall be counted in the aggregate water capacity for the purpose of this requirement. 12.3.2

Building construction

Where LPG is to be used in the construction repair or improvement of buildings or structures or their fixtures and portability of equipment is required, cylinders may be used, provided that action is taken to close the valve and disconnect the hose when the LPG is not in use. 12.3.3

Demonstration or display

Cylinders may be located indoors for demonstration or display purposes under the following conditions. a)

Where an authorised person is in constant attendance, the aggregate water capacity shall not exceed 80 l.

b)

Where there is no authorised person in constant attendance, the aggregate water capacity shall not exceed 40 l. 78

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Where the limitations imposed by a) or b) are insufficient, as for an industrial demonstration, an installation of greater water capacity shall not be used without specific approval. 12.3.4

Education


Cylinders used in doors in an educational building shall not exceed an aggregate water capacity of 110 l.

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SECTION 13: AUTOMOTIVE LPG DISPENSING STATION 13.1

Application


This section applies to storage containers, dispensing devices and pertinent equipment at installations where LPG is dispensed into vehicle fuel containers that are permanently mounted in accordance with 2.7 of MS 775 (see note). NOTE. Those fuel containers which are removed from the vehicle for refilling as commonly used in forklift trucks are analogous to changeover cylinders and are refilled at normal cylinder filling installations (Section 10). The filling of such removable containers at automotive LPG dispensing stations is specifically forbidden (13.7.1).

13.2

Storage containers

13.2.1

Design

Storage containers shall be designed and constructed as required by Section 2. 13.2.2

Location and installation

Storage containers shall be located and installed as required by Section 5 or Section 6 as appropriate. 13.2.3

Protection of storage containers

Aboveground containers shall be protected by crash rails or guards to prevent physical damage, unless they are effectively protected by virtue of their location. 13.3

Piping

13.3.1 Piping may be aboveground, underground or both and shall comply with the relevant requirements in Section 3 and 6.4.6. 13.4

Dispensing point

13.4.1

Dispenser

13.4.1.1 The dispenser whose function is to deliver liquid LPG into fuel containers permanently mounted on vehicles shall incorporate the following components. a)

A vapour separator to separate the vapour from the liquid stream prior to metering.

b)

A meter to measure the volume of liquid delivered. No liquid LPG after passing through the meter shall be capable of returning to the storage container.

c)

A differential valve which will prevent the formation of vapour beyond the vapour separator and in the meter.

d)

A flexible dispenser hose with a filing nozzle to deliver LPG to the vehicle fuel container.

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e)

A hose break coupling which will automatically disconnect the flexible dispenser hose from the dispenser in the event of a vehicle driving away while still connected to the flexible dispenser hose.

f)

A device at each end of the hose break coupling to minimise the escape of LPG in the event of the disconnection of the hose break coupling.

g)

Hydrostatic relief valves to prevent overpressure in any part of a system in which liquid LPG may be trapped between closed valves in normal operation.

h)

A pump switch for controlling electrically a remotely mounted pump.

i)

A special handle or switch (dead man's handle) which allows delivery of LPG only when the handle or switch is depressed.

j)

Emergency shut-off valves located at the end of the liquid and vapour return lines beneath the dispenser that will actuate automatically in the case of damage to the dispenser, e.g. by a moving vehicle.

13.4.1.2

The dispenser shall have a feature to prevent unauthorised use or tampering.

13.4.1.3

A twin hose dispenser (duo) may be installed.

13.4.2

Filler nozzle

Filler nozzle shall be compatible with the filler valve specified in MS 775 and shall be equipped with means to: a)

maintain a gas tight seal with the vehicle filler valve without continuous effort on the part of the operator to hold the nozzle;

b)

effect a positive shut off; and

c)

prevent the discharge of LPG except when the nozzle is properly connected to the vehicle filler valve.

13.4.3

Dispenser hose

13.4.3.1 The dispenser hose shall not be longer than 5 m and shall comply with the requirements of 3.2.9. 13.4.3.2 The dispenser hose shall be supported in such a way that direct tension on the dispenser is minimal and means provided to enable the hose to be kept off the ground when not in use. 13.4.4

Location

13.4.4.1 The dispenser shall be installed at minimum safety distances from other facilities in accordance with Figure 3 and Figure 5 as appropriate.

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13.4.4.2 The dispenser shall be mounted on a concrete foundation constructed in the following manner to protect the dispenser from vehicle damage: a)

Each foundation shall be of a height of at least 150 mm and above the surrounding ground.

b)

Each foundation shall extend not less than 300 mm on all sides of the dispenser or in lieu of this, protective bollard poles in accordance with Annex M may be used.

13.4.4.3

No dispenser shall be installed inside any building.

13.5

Transfer of LPG from tanker to storage container

13.5.1 The procedures for the transfer of LPG from tanker to storage container shall comply with the requirements of Section 8. 13.6

Signs and notices

13.6.1 The following messages in the form of signs (notices may be included if so wished) shall be clearly displayed on, or adjacent to and readable from, each dispenser: a)

No smoking;

b)

No naked lights;

c)


d)

No handphone.

Signs shall be in accordance with Annex L and of suitable size. Warning notices shall be in letters of at least 50 mm high. 13.6.2 The following messages in the form of warning notices shall also be clearly displayed: a)

Switch off engine and all electrical equipment;

b)

Apply handbrakes; and

c)

Restart engine only after dispensing hose is disconnected.

13.7

Procedure for dispensing of LPG into fuel containers of vehicles

13.7.1

Restricted dispensing

Containers other than permanently mounted vehicle fuel containers shall not be filled from fuel dispensing units which are used for public dispensing at automotive LPG dispensing stations.

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13.7.2

Attended service

All persons operating the dispenser shall be adequately trained in refuelling procedures outlined in Annex N and shall be instructed in the use of LPG facilities as well as being well versed in the emergency procedures given in Annex P.


13.7.3

Self service stations

13.7.3.1 In all cases, a responsible person in charge must be present in the self service station during operation. 13.7.3.2 Remote control emergency shut off valves(s) must be installed in a system which is (are) operable from the office of the responsible person in charge. 13.7.3.3 Delivery of LPG may only be possible when the responsible person in charge permits the operation of the dispenser. 13.7.3.4 Simple operating instructions for filling must be displayed on or near the dispenser accompanied by explanatory illustrations. 13.7.3.5 It must be possible for the responsible person in charge to be in communication with the customer at the pump. 13.7.4

Emergency procedures

A notice in accordance with Annex P shall be prominently displayed adjacent to each remote shut off point for the liquid outlet valve of the container and readable from that point. The notice shall have a white background; the heading ‘LPG Emergency procedure' shall be in red letters of at least 40 mm high; sub -headings ‘Gas leak' and 'Fire' shall be in red or dark lettering of at least 20 mm high, the text shall be in red or dark lettering of at least 7 mm high. 13.7.5 No vehicle shall be parked within 3 m of any dispenser other than for the purpose of refuelling.

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SECTION 14: PRECAUTIONS


14.1

ELECTRICAL

AND

ELECTROSTATIC

HAZARD

Application

This section covers requirements for the selection, installation and maintenance of electrical equipment for use in areas where LPG is stored or handled and that are therefore potentially hazardous. It does not apply to electrical equipment of LPG systems on vehicles. 14.2

Classification of hazardous areas

14.2.1 In order to determine the type of electrical equipment appropriate to a particular situation, it is necessary to classify the area according to the degree of probability of the presence of a dangerous atmosphere, i.e. an atmosphere containing a significant quantity of flammable gas or vapour in a concentration capable of ignition. 14.2.2

Hazardous areas are classified into the following zones as defined (see note):

Zone 0. An area in which any flammable atmosphere is continuously present, or present for long periods, in concentrations within the lower and upper limits of flammability. Zone 1. An area in which a dangerous atmosphere is likely to occur in normal operating conditions. Zone 2. An area in which a dangerous atmosphere can occur only in abnormal conditions and not in normal operation. NOTE. The definitions for the area classification are based on the general definitions given in BS EN 60079-10 and have interpreted in the light of the particular conditions that apply in the petroleum industry.

14.2.3 By implication an area that is not classified Zone 0, 1 or 2 is deemed to be a nonhazardous or safe area with respect to this standard. In safe areas normal industrial types of electrical apparatus can be installed. 14.3

Extent of classified areas

14.3.1 The extent of classified areas shall be as shown in Table 11. In the application of classified areas, a classified area shall not extend beyond an unpierced wall, roof or other solid vapour tight partition. 14.4

Electrical equipment

14.4.1 The selection, installation and maintenance of electrical equipment (including electrical apparatus, instrumentation and telecommunication equipment) for use in classified areas specified in Table 12 shall comply with the recommendations of the following standards or codes: a)

British Standards Specifications and Codes of Practice relating to equipment for use in hazardous areas (see Annex A); or

b)

any equivalent standards or codes acceptable to the relevant authority.

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14.4.2 Electrical equipment is conveniently divided into various types which can then be related to use in the various zones defined in 14.2.2. The types of electrical equipment which may be used in the various zones are: a)

Zone 0. Only intrinsically safe certified apparatus and circuits.

b)

Zone 1:

c)

i)

intrinsically safe certified apparatus and circuits;

ii)

flame-proof equipment;

iii)

increased safety equipment; and

iv)

pressurised and continuous dilution equipment.

Zone 2: i)

specially selected industrial, non-incendive or restricted breathing equipment; and

ii)

all types of equipment for use in Zone 0 or Zone 1.

Electrical equipment must be tested and certified by the relevant authority as being intrinsically safe flameproof, etc. 14.4.3 Wiring and cables which may be exposed to a flammable atmosphere must be suitably enclosed. Not all conduits systems are suitable, only those using solid-drawn or seamwelded steel conduits screwed into flame-proof fittings as set out in BS 4683: Part 2 or equivalent standard are acceptable. Metal sheathed armoured cable in which a cable or group of cables is enclosed in a lead sheath which is itself protected by a helical wrapping of wire or metal tape can also be used in flammable atmospheres. Mineral insulated metal clad cables can also be used. Suitable sealing glands and compound failed boxes must be used with these forms of wiring; otherwise the terminations are not flameproof. Types of wiring and cables that may be used for installations in hazardous areas shall comply with the appropriate requirements of BS EN 60079-10 and BS EN 60079-14 of equivalent standard. 14.4.4

Earthing and bonding

Earthing and bonding of all electrical equipment shall comply with the requirements of BS EN 60079-10 and BS EN 60079-14. 14.4.5

Electrostatic hazard precautions

14.4.5.1 An effective earthing point and/or bonding connection shall be provided at the storage site for discharging static electricity from bulk tank vehicles, prior to commencing the delivery operation. 14.4.5.2 Storage containers greater than 2.5 kl water capacity shall be electrically earthed as a protection against the accumulation of static electricity and should have electrical continuity with the earth required in 14.4.5.1 or preferably it should be a common earth. The 5 resistance to earth shall not exceed 1 x 10 O. 85

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14.4.5.3 Pipelines and hoses conveying liquid LPG shall have electrical continuity and be effectively connected to earth. Attention is drawn to the need to ea rth the ball and actuating lever of ball valves where non-conducting seals and gland packings are employed. 14.4.6

Main electrical isolator


All electrical equipment shall be linked to main isolators which shall be clearly marked.

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Table 12. Electrical equipment classified areas Location

Extent of classified area

Storage containers other than cylinders

Relief valve discharge

Area Classification

a) Within 1.5 m in all directions from the container connections or shell.

Zone 1

b) Beyond 1.5 m but within 4.5 m in all directions from the container connections or shell.

Zone 2

a) Within direct path of discharge.

Fixed electrical equipment shall not be installed Zone 1

c) Beyond 1.5 m but within 4.5 in all directions from point of discharge.

Zone 2

a) Within 1.5 m in all directions from point of discharge.

Zone 1

b) Beyond 1.5 m but within 4.5 m in all directions from point of discharge.

Zone 2

a) Within 1.5 m in all directions from a point where connections are regularly made or disconnected for product transfer.

Zone 1

b) Beyond 1.5 m but within 4.5 m in all directions from a point where connections are regularly made or disconnected and within the cylindrical volume between the horizontal equator of the sphere and ground (see Figure 10).

Zone 2

a) Within 1.5 m in all directions.

Zone 1

i) Outdoors in open air, at or aboveground level

b) Beyond 1.5 m but within 4.5 m in all directions from the equipment and within the cylindrical volume between the horizontal equator of the sphere and ground (see Figure 10).

Zone 2

ii) Indoors with adequate ventilation (see note 2) iii) Indoors without ventilation

Entire room and any adjacent room not separated by a vapour - tight partition.

Zone 1

a) Entire room and any adjacent room not separated by a vapour-tight partition.

Zone 1

b) Within 4.5 m of the exterior side of any exterior wall or roof that is not vapour tight or within 4.5 m of any exterior opening.

Zone 2

a) Entire space within dispenser enclosure and 450 mm horizontally from enclosur e exterior up to height of 1.5 m above dispenser base. Entire pit or open space beneath dispenser.

Zone 1

b) Up to 450 mm aboveground level within 6 m horizontally from any edge of enclosure. For pits within this area, see the requirements for ‘pits or trenches’ below.

Zone 2

Tank vehicle loading and unloading (see note 1)

Pumps, compressors, gas- air mixers vaporisers (other than direct fired):

and

Automotive LPG dispensing station dispensing units

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b) Within 1.5 m in all directions from point of discharge.

Gauge vent openings

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Location

Extent of classified area

Area classification

Pits or trenches containing or located beneath LPG valves, pumps, compressors, regulators and similar equi pment i) Without mechanical ventilation

ii) With adequate mechanical ventilation

Special compartments or rooms for storage of cylinders Pipelines and connections containing operational bleeds, drips, vent or drain

a) Entire pit or trench.

Zone 1

b) Entire room and any adjacent room not separated by a vapour-tight partition.

Zone 2

c) Within 4.5 m in all directions from pit or trench when located outdoors. a) Entire pit or trench

Zone 2 Zone 2

b) Entire room and any adjacent room not separated by a vapour-tight partition.

Zone 2

c) Within 4.5 m in all directions from pit or trench when located outdoors

Zone 2

Entire room

Zone 2

a) Within 1.5 m in all directions from point of discharge.

Zone 1

b) Beyond 1.5 m from point of discharge: Same as for sites i), ii) and iii) of ‘pumps, compressors, gas - airs mixers and vaporisers’. Container filling i)Indoors with adequate ventilation (see note 2)

ii) Outdoors in open air

a) Within 1.5 m in all directions from a point where connections ar e regularly made or disconnected for product transfer.

Zone 1

b) Beyond 1.5 m and entire room.

Zone 2

a) Within 1.5 m in all directions from a point where connections are regularly made or disconnected for product transfer.

Zone 1

b) Beyond 1.5 m but within 4.5 m in all dir ections from a point where connections are regularly made or disconnected and within the cylindrical volume between the horizontal equator of the sphere and ground (see Figure 10).

Zone 2

NOTES: 1. When classifying extent of hazardous area, consideration shall be given to possible variations in the spotting of tank vehicles at the unloading points and the effect these variations of actual spotting point may have on the point of connection. 2. Where specified for the prevention of fire or explosion during normal operation, ventilation is considered adequate where provided in accordance with the requirements of this standard.

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Table 12. Electrical equipment classified areas (Continued)

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Figure 10. Extent of classified area (see Table 12)

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SECTION 15: FIRE PROTECTION 15.1

Application


This section covers requirements for fire protection of LPG installations. 15.2

General

15.2.1

This section has been written on the basis of the following propositions:

a)

The overall fire protection requirements of an installation should be considered as providing two clear and distinct functions. One is fire fighting i.e. to control and extinguish any fire that may occur. The other is heat protection i.e. to protect containers and ancillaries from being overheated by a fire.

b)

The subject of fire fighting falls into two further sub-divisions. One is the first-aid provision, quickly available to cope with the incidental small fire in the general vicinity of the storage or perhaps a burning gas leak. The other is the larger and more complex class of equipment capable of dealing with a comparatively serious fire.

c)

Heat protection requirements are oriented mainly towards various forms of water cooling which is the most familiar method. However some recognition is given to the less well-known methods i. e. insulating or burying and requirements will be developed as information accumulates.

d)

The scale of the fire-fighting equipment is related to an assessment of a number of factors which might or might not be cumulative. The requirements of this section should therefore be considered as being the basic requirements for average installation conditions. The relevant authority may require a higher level of protection or may permit less protection according to an analysis of a particular sire. Consideration would be based on the following factors amongst others:

15.2.2

i)

hazard conditions within the particular installation;

ii)

the relative density of occupation of the surroundings;

iii)

hazard to or from other pr operties;

iv)

the water supply;

v)

the probable effectiveness of plant fire brigades; and

vi)

the response time and probable effectiveness of the public fire.

Use of existing facilities

Where fire protection facilities would have been required on the site irrespective of the presence of LPG, the facilities needed to cater for the various independent needs may be integrated to avoid duplication, provided that specific approval has been obtained.

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15.2.3

System compatibility

Fire protection equipment such as hoses, connectors, booster connections, foam compound and the like should be compatible with that of the local fire brigade.


15.2.4

Location

Fire protection equipment shall be located so as to be reasonably adjacent to the risk pro tected and accessible in an emergency. 15.2.5

Portable fire extinguishers

Portable fire extinguishers (see notes) shall comply with MS 566 and MS 1179 as appropriate. NOTES: 1. Foam extinguishers are not suitable for LPG fires because these products are gaseous at normal atmospheric temperatures. 2. Heavier types of fire extinguishers that are wheeled for portability are not covered by standards but should comply as far as possible with the appropriate standard from the above list.

15.2.6

Hydrant systems

A hydrant system shall comply with MS 484 and the following requirements. a)

Hydrants shall be located so that each container is within reach under any conditions of fire and wind and the cooling effect is optimised (see note).

NOTE. Best results are achieved by locating two hydrants at diagonally opposite locations relative to the container.

b)

For each hydrant at least one hose and hose fitting, plus one combine jet/spray hose nozzle shall be provided.

c)

Hoses and fire hydrants shall be maintained in accordance with requirements of the relevant authority.

15.2.7

Water supply

The water supply system for fire protection shall comply with the following requirements. a)

Where a garden hose system is specified, it shall consist of at least a 19 mm nominal size hose of non -kink type and the hose length shall not exceed 30 m. The hose system shall be located at a point not more than 18 m from the container. The hose shall be fitted with a 6 mm bore nozzle and permanently connected to a water supply ready for immediate use. The water supply shall be capable of giving a throw of 6 m from the hose nozzle and a discharge rate of 25 l/min.

b)

Water for fire protection shall be provided by town mains wherever practicable.

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c)

Where town mains exist but cannot supply adequate pressure or quantity a booster pump connection shall be provided.

d)

Alternatively, to the above, or where a town mains supply is unavailable static water supply and pump shall be provided on the premises.

e)

A static water supply shall be capable of providing at least 2 h of running time for the entire fire protection system (see notes).

NOTES: 1. Return water channelled back to a reservoir from, a cooling system may be taken into account in the calculation of the durability of a static water supply system. 2. An existing dam, river or lake or the sea, may be taken into consideration as static storage if sufficiently convenient. However, the possible effect of short term or long term of water level variation should be kept in mind.

15.2.8

Supplementary protection equipment

Any supplementary protection equipment required shall consist of either a fixed water spray system or fixed water monitors, able to apply cooling water to the containers at a rate not less than 10 l/min per square metre of total surface area of the container to be cooled. The system shall be adequate to supply the three largest containers of a multiple container installation, unless heat or flame impingement from one container cannot affect the others. In addition the supplementary protection equipment shall comply with the following requirements. a)

The supports of water spray system shall be effectively cooled by themselves being the water carriers, or by being covered by water spray cooling, or they shall be effectively insulated.

b)

A spray system which is automatically operated shall include provision for manual operation and the means of manual operation shall be accessible under all fire conditions.

c)

Automatic systems operated by vapour pressure are not recommended and shall not be installed with multi-container installations which have a common vapour line.

d)

An automatic system shall be designed to fail-safe with the water supply on. Control of water shall be possible from outside any danger area.

e)

A pumping and supplementary fire protection system shall be tested at intervals of not longer than 1 week and a record of tests shall be kept.

f)

The installation shall be such that return water from a cooling system does not endanger foundations by scouring.

15.2.9

Use of insulation

Insulation may be used to provide part of the supplementary heat protection where required for container and the insulating effect may be credited in order to reduce the cooling water required, provided that: a)

the cooling water supplied to the containers is not less than 2 l/min per m of total surface area of the container; 2

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b)

the insulation, if of a type which is susceptible to deterioration by water logging, water erosion, or general weathering, is protected; and

c)

the insulation is of a type specifically designed for the purpose.


NOTES: 1. Some refractory types will fracture if subject to rapid temperature rise, certain other granular insulation materials may be lost if a retaining jacket warps or bursts under the influence of heat. 2. The relevant authority may require regular checks of the container surface to ensure that corrosion has not occurred under the insulation.

15.2.10

Control of LPG leaks and fires

Annex Q illustrates procedures to control LPG leaks and fires. It is not intended to be an exhaustive treatment of the subject and should not be interpreted as precluding other procedures which would enhance safe LPG operations. 15.3

Container storages and installations

15.3.1

Aboveground container

An installation of aboveground uninsulated LPG containers shall be equipped in accordance with Table 13. 15.3.2

Underground mounded containers

An installation of underground containers of 8 k or less total water capacity shall be provided with a garden hose system. Where the storage capacity exceeds 8 kl garden hose system, one fire extinguishers of minimum 144 BC or of minimum 9 l of water/foam shall be provided. 15.3.3

Tanker transfer area

An area in which a tanker may stand while either loa ding or unloading LPG or from a container storage in excess of 125 kl, water capacity shall be provided with a hydrant system, or fixed sprinklers or monitors capable of covering the entire standing area. 15.3.4


Each au tomotive LPG dispensing station shall be provided with two fire extinguishers of minimum 144 BC or of minimum 9 l of water/foam, in addition to the fire protection required for the appropriate storage capacity elsewhere in this section. 15.4

Cylinder storages and installations

15.4.1

Storage capacity above 500 kg

A storage of cylinders which may contain more than 500 kg of LPG shall be provided with not less than one garden system ready for immediate use, where the water supply is adequate. Alternatively, two fire extinguishers of 144 BC minimum rating or of minimum 9 l of water/ foam shall be provided .

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15.4.2

Storage capacity above 5 000 kg

A storage area which may contain more than 5 000 kg shall in addition to the requirements of 15.4.1, be provided with a system of fire hydrants in accordance with 15.2.6.


15.4.3

Installed cylinders

Fire protection shall be provided for installed cylinders and shall comply with either 15.4.1 or 15.4.2 according to capacity. 15.5

Gas leakage and detection

15.5.1 Gas leakage or suspected gas leakage shall be checked by the use of a gas detector, soapy water or by smell BUT NEVER WITH A NAKED FLAME. 15.5.2 Permission to resume work in affected or suspected gas-affected areas shall be subject to satisfactory gas detector readings. 15.5.3 Flammable gas detectors shall be used only by competent personnel, remembering always that LPG vapour is heavier than air. NOTE. The location classes for the purposes of Table 13 mean: Class A: Buildings (other than buildings used specifically for storage and handling of LPG), storage of flammable and combustible liquids (Class I and Class II) public road or railway exist within 20 m of any LPG component. Class B: No buildings (other than buildings used specifically for storage and handling of LPG), storage of flammable and combustible liquids (Class I and Class II), public road or railway within 20 m of any LPG component. Class C: No buildings (other than buildings used specifically for storage and handling of LPG), storage of flammable and combustible liquids (Class I and Class II), public road or railway within 500 m of any LPG component.

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Table 13. Fire Protection


Total capacity of installation (kl)

Type of LPG

Class A location

Class B location

Class C location

Vapour

One 19 mm hose or one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam.

No mandatory requirement.

No mandatory requirement.

Over

Up to

0

8

0

8

Liquid at automotive LPG dispensing stations

If petrol also dispensed, one 19 mm hose or one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam, in addition to the protection already required for petrol dispensing. If LPG only, the hose plus the extinguisher. If more than two containers, a hydrant system.

If petrol also dispensed, one 19 mm hose or one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam, in addition to the protection already required for petrol dispensing. If LPG only, the hose plus the extinguisher. If more than two containers, a hydrant system.


0

8

Liquid other applications

One 19 mm hose or one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam. If more than two containers a hydrant system.



8

16

Any

One 19 mm hose or one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam. If more than two containers a hydrant system.



16

125

Any

One 19 mm hose plus one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam plus one hydrant system.



125

500

Any

As above, plus a supplementary protection system.

One 19 mm hose and one fire extinguisher of minimum 144 BC or of minimum 9 l of water/foam and one hydrant system.

Any

As above, plus static water supply and a booster pump connection.

Specific approval of the system.

500

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SECTION 16: DESIGN AND USE OF MOBILE GAS -FIRED EQUIPMENT


16.1

General

The design, construction, permitted wheel loadings , equipment and other requirements common to all vehicles should conform to the relevant sections of the current Motor Vehicles Construction and Use (Vehicles carrying Petroleum Products) Regulation and other legislations where applicable. Attention should be paid to adequate braking systems. 16.1.2 This section gives recommendations for the safe use of LPG on mobile equipment such as road planing machines, agricultural flame cultivators and similar applications where fuel is carried on the vehicle. 16.1.3

This section shall not cover:

a)

LPG storage vessels on vehicles where the LPG is providing the motive power for the vehicle.

b)

the units having nominal capacities exceeding 8 kl water capacity.

16.2

Position of LPG vessels on vehicles

16.2.1 For mobile equipment involving the use of open flames the storage vessel should be positioned at the maximum practicable distance from the burner and combustion zone. In no instance should this distance be less than 3 m measured in plan. For open name applications the storage vessel should be protected from direct radiation from the flame or any heated structure either by position or by the provision of a suitable fire-resistant. Heatprotective shield, in order that under all operating conditions the temperature of the contents do not exceed the design reference temperature of the vessel detailed in BS 5355. 16.2.2 Storage vessels should not be positioned inside the vehicle or the driver's cab nor should they be enclosed by any superstructure other than that spe cified in 16.2.1, which should not prevent adequate ventilation. 16.2.3

Vessels up to 130 l water capacity may be installed as following.

a)

External to the vehicle and positioned to avoid radiant heat.

b)

In a compartment used only for storage of the containers and fittings immediately associated with it having adequate ventilation to atmosphere and completely and permanently sealed from the remainder of the vehicle.

c)

The tank may be situated in a compartment isolated from the remainder of the vehicle having adequate ventilation to atmosphere. The safety relief valve with fixed maximum liquid level indicator if this incorporates a gas bleed and the filler connection must be extended by suitable tubing to the outside of the vehicle.

16.2.4 Readily ignitable material should not be placed in compartments used for the storage of the containers and the fittings immediately associated with them. 16.2.5 Vessels should be mounted correctly orientated with respect to their connection and fittings. Where integral mountings are not provided, identification should be given on the vessel showing the correct mounting position. 96

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16.2.6 Where filling connections are inaccessible from ground level safe and adequate access ladders, platforms, grabrails, etc. should afford the driver ease of access to make the connections when carrying the filling hose.


16.2.7 Vessels should not be exposed to radiated heat from the vehicle exhaust system or from any ancillary engine. The use of heat insulation should be considered where necessary. 16.3

Protection

16.3.1 Vessels and their fittings should be protected by position or other means against physical impact. Where this requirement cannot be met by positioning alone substantial collision bars or other suitable protection shoul d be provided. 16.3.2 Vessel fittings should be provided with a positive means of denying access, e.g. a ventilated hinged cover which is capable of being locked in the closed position or a blank flange or plug on the connections. 16.3.3 Vessels should be securely attached to the vehicle preferably by means of integral mounting brackets or by purpose build cradles metal straps or bonds. Mounting structure should be fabricated in steel and designed to permit secure attachment to the vehicle or trailer chassis. 16.3.4 The vehicle should be equipped with at least two 9 kg fire extinguishers of the dry powder type which should be readily accessible from outside the vehicle. Road planers and appliances using liquid LPG offtake should be provided with minimum of two dry powder fire extinguishers of 9 kg capacity each, one mounted on either side of the vehicle and both accessible from outside the vehicle. 16.4

Pipework valves and fittings

16.4.1 Basic design requirements and material specifications for pipe valves and fitting should be carried out in accordance with Section 3. 16.4.2 features:

All liquid and vapour outlets of the vessel shall be equipped with the following

a)

fusible links; and

b)

emergency shuts off valves.

16.4.3 Pipelines should be properly supported and securely attached to the structure of the vehicle and also have adequate flexibility to accommodate vibration or movement within the vehicle chassis. 16.5

Refuelling procedures

16.5.1 The following procedures refer to the transfer of LPG from road tank vehicles to the storage tanks on mobile gas -fired equipment and should be incorporated in the standard instructions issued to the user and the tanker driver. The whole transfer operation shall be the responsibility of an engineer responsible for the project of operation. The engineer responsible or a competent person nominated by him must be present on site to supervise the whole transfer operation. 97

MS 830:2003

NOTE. A competent person is a person who has been formally trained in the properties, handling and safety of LPG meeting the provisions of 8.2.2.


16.5.2

Selection and preparation of transfer site.

The user is responsible for selecting and preparing in advance of delivery, a suitable site for the transfer operation which should, whenever practicable, be a large, well ventilated area having a radius of at least 25 m. Good practice will require consideration of the following factors before making a selection. a)

Access should be denied to the public, where practicable, by coning off a zone within the area and by the erection of clear signs stating 'BAHAYA - GAS SEDANG DIISI - DILARANG MEROKOK' and to incorporate a hazard warning sign for flammable gas as shown in Annex H. This zone must be reasonably level and of such a size as to allow at least 7.5 m between its perimeter and any part of the equipment and road tanker involved in the transfer operation, except as permitted by 16.5.2 k).

b)

The zone must be free of drains, pits, manholes, ventilation openings and open road works and sources of ignition.

c)

Tunnels, tunnel approaches, bridges, cuttings and roundabouts are prohibited areas.

d)

Sections of highways passing through urban areas, or near interchanges should be avoided.

e)

Refuelling within 25 m of premises which are likely to be occupied at all times (such as hospitals, homes for the elderly or handicapped, prison blocks of flats, hotels), is prohibited.

f)

The transfer area should not be in the vicinity of any premises when the area is occupied by significant numbers of persons (such as schools, town centres, shopping centres, office blocks, factories, railway or bus stations). When not occupied however e.g. at night or at weekends, such sites may be considered. It is probable that their use, particularly in urban areas will only be possible by making local arrangements.

g)

The transfer area should not be near other potential hazards, e.g. oil or other flammable substances storage.

h)

The zone should be cleared of all rubbish and any readily ignitable material.

i)

Wherever possible, public roads, except highways, should be avoided and depots, approved parking areas or open spaces should be chosen.

j)

On open highways, i.e. sections of highways other than those referred to in 16.5.2 d) one lane of clear separation should be coned off to separate other vehicles from the mobile gas -fired equipment and road tanker during refuelling.

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k)

Where it is not possible to achieve the full 25 m separation distance during refuelling, but refuelling is not prohibited under 16.5.2 b) to j), the presence of up to a time weighted average of 5 persons other than employees can be accepted within 25 m and outside the barriered 7.5 m zone. This would permit refuelling in sparsely populated areas or on Iightly used roads with occasional passing traffic. The reference to a time weighted average of five persons means that in such circumstance refuelling will not have to be stopped solely, for example, owing to the passage through the area of two cars in quick succession or a bus.

NOTE. Although the user is responsible for selecting the refuelling site, both he and the tanker driver should have the authority to refuse to accept the site selected.

16.5.3

Action to be taken by the user before the transfer operation commences

The following procedures an d precautions together with the provisions of 8.5.2 shall be effected before transfer of LPG. a)

Any substantial accumulation of tar, dirt or flammable waste should be removed from the LPG storage tank mounted on the machine.

b)

Unimpeded access must be provided for all control valves before filling commences.

c)

The main LPG isolating valve and valves on the storage tank of the equipment must be closed and the pilot burners extinguished.

d)

If, on arrival of the LPG tanker, the equipment is operating, then transfer of LPG is not permitted until: i)

the main LPG isolating valve and the valves on the equipment LPG fuel tank have been closed;

ii)

all burners and pilot lights have been extinguished;

iii)

the equipment has been moved at least 25 m from its operating site; and

iv)

a period of 10 min has elapsed after the burners have been extinguished.

e)

Any fires on or in the vicinity of the vehicle or equipment e.g. tar fires around road planers, or vegetation fires around flame cultivators, must be extinguished before the transfer operation commences. To meet this requirement, the burners must be raised or made accessible for inspection.

f)

Before the transfer operation commences, the equipment engines must be switched off and electrical equipment isolated.

g)

The fire extinguisher(s) carried by the mobile gas -fired equipment should be demounted and placed upwind adjacent to the perimeter of the coned area in a readily accessible position.

h)

The equipment operation operator must remain in attendance throughout the entire refuelling operation and must dismount from the vehicle.

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16.5.4

Actions to be taken by the user during transfer operation

The procedures and precautions shall follow the provisions of 8.5.3. 16.5.5

Actions to be taken by the user after transfer of liquid


The procedures and precautions shall follow the provisions of 8.5.4. 16.5.6

Timing of delivery

In the interests of safety the best time to deliver is when the equipment is cool and parked. 16.5.7

Road tanker driver’s responsibilities

The driver must ensure the following: a)

The users’ responsibilities have been implemented.

b)

At least two ‘Safety Warning’ notices have been positioned at strategic points on the perimeter of the transfer zone facing outwards.

c)

One fire extinguisher should be dismounted from the road tanker vehicle and placed on the ground upwind at the perimeter in a readily accessed position.

d)

The surroundings are checked visually before transfer begins to ensure that no unusual or dangerous situations exist e.g. bonfires, stubble burning, etc..

e)

Any accumulated static electricity on a road tanker and the mobile gas-fired equipment should be discharged to earth. The tank on the road tanker should then be electrically bonded to the equipment LPG tank before connecting transfer hose.

f)

He remains in attendance throughout the entire refuelling operation.

g)

When gauges indicate that the receiving tank has almost reached its maximum filled capacity the filling rate shall be reduced.

h)

The fixed level gauge shall be used to determine when the maximum permissible level has been reached and filling must cease at this point.

16.6

Maintenance

16.6.1

When in use daily inspections should be made of all valves rigid and flexible.

16.6.2 Flexible hoses carrying liquid LPG or vapour above 470 kPa should be subjected to annual retest in accordance with 3.2.9.6. 16.6.3 Particular attention should be directed to the general cleanliness of the equipment, any accumulation of flammable waste or other material in the vicinity of the LPG vessel or ancillary equipment should be removed. 16.6.4 The operation of all gas -fired equipment should be checked at frequent intervals and immediate steps taken to rectify any operational faults. 100


MS 830:2003

16.6.5 Thorough regular maintenance should be carried out on the vehicle and ancillary equipment.

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Annex A (normative)


Normative references The following normative references are indispensable for the application of this standard. For dated references, only the editio n cited applies. For undated references, the latest edition of the normative references (including any amendments) apply.

A1.

Malaysian Standard

MS 217, Method for the hydrostatic strength testing of liquefiable and other compressed gas cylinders MS 484, Code of practice for hydrant systems MS 566, Code of practice for fire fighting installations and equipment: Part 3 Portable fire extinguisher MS 641, Specification for LPG cylinders up to 1000 pounds water capacity without electricarc welded longitudinal seam MS 642, Specification for LPG cylinders up to 1000 pounds water capacity with electric -arc welded longitudinal sea MS 775, Specification for LPG fuel systems in internal combustion engines MS 761, Code of practice for the storage and handling of flammable and combustible liquids MS 1179, Specification for portable fire extinguishers MS 1409, Specification for emergency triangular reflector for motor vehicles MS 1513: Part 5 : Sub-Part 2, Packaging – Transport of dangerous goods: Part 5 Consignment procedures: Sub -Part 2: Marking, labelling and placarding MS 1553, Code of practice on wind loading for building structure

A2.

British Standards

BS 4683, Specification for electrical apparatus for explosive atmospheres - The construction and te sting of flameproof enclosures of electrical apparatus BS 5252, Framework for colour co-ordination for building purposes BS 5355, Specification for filling ratios and developed pressures for liquefiable and permanent gases BS EN 50021, Electrical apparatus for potentially explosive atmospheres. Type of protection "n" 102

MS 830:2003

BS EN 60079-10, Electrical apparatus for explosive gas atmosphere classification of hazardous areas BS EN 60079-14, Electrical installations in hazardous areas (other than mines.


BS EN 1057, Copper and copper alloys. Seamless, round copper tubes for air conditioning and refrigeration. Tubes for piping systems BS PD 5500, Specification for unfired fusion welded pressure vessels.

A3.

Australian Standards

AS 1210, Unfired pressure vessels code AS 2832.2, Guide to the cathodic protection of metals. Part 2: Compact buried structures. AS 3894.1, Site testing of protective coatings. Method 1: Non-conductive coatings Continuity testing - High voltage (“brush”) method. National Association of Corrosion Engineers. NACE RP 0188: Discontinuity (holiday) testing of protective coatings. Houston: NACE.

A4.

American society for testing and materials

ASTM A47, Standard specification for ferritic malleable iron castings ASTM A106, Standard specification for seamless carbon steel pipe for high temperature services ASTM A182, Standard specification for forged or rolled alloy -steel pipe flanges, forged fittings, and valves and parts for high-temperature service ASTM A395, Standard specification for ferritic ductile iron pressure-retaining castings for use at elevated temperatures ASTM A539, Standard specification for electric-resistance welded coiled steel tubing for gas and oil pipes ASTM D2513, Standard specification for thermoplastic gas pre ssure pipe, tubing, and fittings ASTM D2683, Standard specification for socket-type polyethylene fittings for outside diameter-controlled polyethylene pipe and tubing ASTM D3261, Standard specification for butt heat fusion polyethylene (PE) plastic fitti ngs for polyethylene (PE) plastic pipe and tubing

103

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A5.

Canadian Standards Association

Z245.20-98, External fusion bond epoxy coating for steel pipe.


Z245.21-98, External polyethylene coating for pipe.

A6.

ISO Standard

ISO 4437, Buried polyethylene (PE) pipes for the supply of gaseous fuels -- Metric series -Specifications

A7.

American Petroleum Society

API RP 521, Guide for pressure-relieving and depressurising systems API RP 520, Sizing, selection and installation of pressure-relieving devices in refineries

104

MS 830:2003

Annex B (normative)


Properties of LPG B1.


B1.1

Source of property values

B1.1.1 The property values for the LPG are based on average industry values and include values for LPG coming from natural gas liquid plants as well as those coming from petroleum refineries. Thus, any particular commercial propane or butane might have properties varying slightly from the values shown. Similarly, any propane-butane mixture might have properties varying from those obtained by computation from these average values (see B1.2 for computation method used) Since these are average values, the interrelationships between them (i.e. kg per litre. specific gravity, etc.) will not cross-check perfectly in all cases. B1.1.2 Such variations are not sufficient to prevent the use of these average values for most engineering and design purposes. They stem from minor variations in composition. The commercial grades are not pure propane or bu tane, or mixtures of the two but may also contain small and varying percentages of ethane. ethylene, propylene, iso-butane or butylene which can cause slight variations in property values. There are limits to the accuracy of even the most advanced testing methods used to determine the percentages of these minor components in any LPG. B1.2


The principal properties of commercial propane and commercial butane are shown in Table 14. Reasonably accurate property values for propane -butane mixtures may be obtained by computation, applying the percentages by mass of each in the mixture to the values for the property it is desired to obtain. Slightly more accurate results for vapour pressure are obtained by using the percentages by volume. Very accurate results can be obtained using data and methods explained in petroleum and chemical engineering data books.

B2.

LPG testing

B2.1

Testing for ammonia contamination

LPG which may be contaminated with anhydrous ammonia is tested as follows. a)

Allow a moderate vapour stream of the product to be tested to escape from the container. A rotary, slip tube or fixed level gauge is a convenient vapour source.

b)

Wet a piece of red litmus paper by pouring distilled water over it while holding it with clean tweezers.

c)

Hold the wetted litmus paper in the vapour stream from the container for 30 s.

d)

The appearance of any blue colour on the litmus paper indicates that ammonia is present in the product (see note). 105

MS 830:2003

NOTE. Since the red litmus paper will turn blue when exposed to any basic (alkaline) solution care in making the test and interpreting the results is required. Tap water, saliva perspiration of hands that have been in contact with water having a pH greater than 7 or with any alkaline solution will give erroneous results.

Table B1. Approximate properties of LPG


Property

Commercial propane

Commercial butane

Vapour pressure in kPa (absolute pressure) at a)

20 ?C

1 000

220

b)

40 ?C

1 570

360

c)

45 ?C

1 760

385

d)

55 ?C

2 170

580

Specific gravity

0.504

0.582

- 42

-9

Initial boiling point at 1.00 atm. pressure, ?C

504

582

Specific heat of liquid, kilijoule per kilogram, 15.56 ?C

1.464

1.276

Cubic meter of vapour per litre of liquids at 15.56 ?C

0.271

0.235

Cubic meter of vapour per kilogram of liquid at 15.56 ?C

0.539

0.410

Specific gravity of vapour (air=1) at 15.56 ?C

1.50

2.01

493 to 549

482 to 538

1 980

2 008

2.15

1.55

9.60

8.60

428

388

216

226

92 430

121 280

49 920

49 140

25 430

28 100

Weight per cubic meter of liquid at 15.56 ?C, kg

Ignition temperature in air, ?C Maximum flame temperature in air, ?C Limits of flammability in air, % of vapour in air-gas mixture a)

lower

b)

upper

Latent heat of vaporisation at boiling point a)

kilojoule per kilogram

b)

kilojoule per litre

Total heating values after vaporisation a)

kilojoule per cubic meter

b)

kilojoule per kilogram

c)

kilojoule per litre

NOTE. Values in this table are values which are generally acceptable in the LPG industry for commercial propane and butane.

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Annex C (normative)


Pressure testing of pipework at LPG installations C1. Connections between container or cylinder and first-stage regulator C1.1 Testing of the connection between storage containers or cylinders and the firststage regulator shall be made at 1 925 kPa (275 psi) (gauge) using soapy water solution to detect leaks at all joints. There shall be no loss in pressure after a period of 1 h.

C2.

All other pipework

C2.1 or C2.3

All other pipework not provided for in C1 shall be tested in accordance with C2.2

C2.2

Low pressure pipework

Pipework operating at pressures not exceeding 3.5 kPa (gauge) shall be tested with air or nitrogen at a pressure of 140 kPa (20 psi) (gauge), using soapy water solution. There shall be no loss in pressure after a period of 30 min. C2.3

High pressure pipework

Pipework operating at pressures exceeding 3.5 kPa (gauge) shall be tested with air or nitrogen at pressure of 350 kPa (50 psi) (gauge), using soapy water solution. There shall be no loss in pressure after a period of 1 h.

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Annex D (normative)


Rate of discharge for safety relief valves on containers D1.

Minimum rate of discharge

D1.1 The minimum required rate of discharge in cubic metres per minute of air at 120 % of the maximum permitted start to discharge pressure for safety relief valves to be used on uninsulated containers may be determined as follows: F = 10.64 A

0.82

where, F

is the required flow capacity of the valve in cubic metres per minute of air at 15 °C and 101.5 kPa (absolute); and

A

is the total outside surface area of container in square metres.

D1.2 When the surface area is not stamped on the nameplate or when the marking is not legible the area can be calculated by using one of the following formulas: a)

cylindrical vessel with hemispherical heads; area = overall length x outside diameter x 3.1416

b)

cylindrical vessel with semi-ellipsoidal heads; and area = (overall length + 0.3 outside diameter) x outside diameter x 3.1416

c)

spherical container. area = (outside diameter)2 x 3.1416

D1.3 Typical rates of discharge for safety relief valves on containers with total outside 2 surface areas up to 1 000 m , are given in Table D1. For intermediate values of surface area the rate of discharge may be interpolated.

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Table D1. Rate of discharge for discharge for safety relief valves on containers Surface area (m2 )

Flow rate (m3 /min)

Surface area (m 2 )

Flow rate (m3 /min)

Surface area (m 2 )

Flow rate (m 3 /min)

5

40

20

124

100

465

6

46

21

129

150

648

7

52

22

134

200

820

8

59

23

139

250

985

9

64

24

144

300

1 143

10

70

25

149

400

1 448

11

76

30

173

500

1 738

12

82

35

196

600

2 018

13

87

40

219

700

2 290

14

93

45

241

800

2 555

15

98

50

263

900

2 815

16

103

60

306

1000

3 069

17

109

70

347

18

114

80

387

19

119

90

426

109

MS 830:2003

Annex E (normative)


Rate of discharge for safety relief valves for LPG vaporisers (other than atmospheric) E1.

Minimum rate of discharge

E1.1 The minimum required rate of discharge for safety relief valves shall be determined as follows. a)

Obtain the total surface area by adding the surface area of vaporiser shelf in square metres directly in contact with LPG and the heat exchange surface area in square metres directly in contact with LPG.

b)

Obtain the minimum required rate of discharge in cubic metres of air per minute, at 15 ?C and 101.5 kPa (absolute) from Annex D for this total surface area.

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MS 830:2003

Annex F (normative)


Deflection walls

A + B = Minimum safety distance X + Y = Minimum safety distance

Figure F1. Location of deflection walls

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MS 830:2003

Annex G (normative)


Emergency procedure guide (for vehicles carrying dangerous goods)

VEHICLES FIRE EMERGENCY PROCEDURES If this happens

Do this Shut off engine and any electrical equipment and leave ‘off’; No smoking or naked lights; Use fire extinguisher, if available; and

Engine Fire

Smother blaze; e.g. use sand or earth or large amounts of water. If unable to control fire, move people from the area: Send messenger to notify fire brigade and police; and Tell them location, material in load and quantity. Shut off engine and any electrical equipment and leave ‘off’; No smoking or naked lights; Throw out burning material; Use fire extinguisher, if available; and

Cabin Fire

Smother blaze. e.g. use sand or earth or large amounts of water. If unable to control fire, move people from the area: Send messenger to notify fire brigade and police; and Tell them location, material in load and quantity.

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If this happens

Do this Shut off engine and any electrical equipment and leave 'off';


No smoking or naked lights; Use fire extinguisher if available, or smother blaze by using sand, earth or large amounts of water, except where cargo requires special procedures; and

Tray Fire

Confine fire. If possible, throw off burning materials or remove other materials from area of fire. If this is not possible, keep goods cool by spraying with water, if available. If unable to control fire, move people from the area: Send messenger to notify, fire brigade and police.; and Tell them location, material in load and quantity. Stop vehicle; Assess fire and its extent in relation to the load and its hazards; Flood tyre with water, if available; After flooding, quickly remove tyre from vehicle if possible;

Tyre Fire

Place tyre 15 m from vehicle; it may later burst into flames; and If fire cannot be put out or tyre removed, start driving again carefully until burning rubber is thrown off. If unable to control fire, move people from the area: Send messenger to notify fire brigade and police; and Tell them location, material in load and quantity. Stop vehicle; Assess fire and its extent in relation to the load and its hazards; Allow brake drum to cool or flood with water if available; and

Brake Drum Overheating

Don't drive vehicle until brake has been dismantled, inspected, and if necessary, repaired. If fire develops and unable to control: Move people fro m the area; Send messenger to notify fire bridge and police; and Tell them location, material in load and quantity.

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EMERGENCY CONTACT

Organisation Location Telephone

114

Ask for

MS 830:2003

Annex H (normative)


Emergency procedure guide

LIQUEFIED PETROLEUM GAS (LPG) Colourless gas with a smell like town gas. Gas is transported under pressure as a liquid in tankers and cylinders. Liquid vaporises rapidly on release and spreads steadily along the ground. Gas is heavier than air and will collect in low-lying areas.

HAZARDS Liquid and gas highly flammable; Gas forms explosive mixture with air;

Fire Exposure

Liquid vaporises rapidly on release and spreads steadily along the ground; Gas causes dizziness and drowsiness; and Vaporising liquid causes frostbite even through normal gloves.

EMERGENCY PROCEDURES If this happens

Do this Shut off engine and any electrical equipment and leave 'off' until vapour hazard is removed;

Spill or leak

If available, use outside 'Emergency Stop' handles; and No smoking or naked lights within 70 m.

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MS 830:2003

If this happens

Do this Move people from the area. Move upwind; Avoid breathing vapour and contact with liquid or gas;


Stop leaks if possible; If possible, separate leaking container and stand so that only gas escapes;

Spill or leak

Spray water to disperse gas cloud but avoid playing water directly on leaking containers as this will increase leakage; Prevent spillage from spreading or entering underground drains by banking with sand or earth; Don't start the vehicle engine or other engines and/or operate electrical equipment in the area; and Inform the fire brigade and police. Shut off engine and any electrical equipment and leave 'off' until vapour hazard is removed; Move people from the area. Move upwind; Send messenger to notify fire brigade and police. Tell them location, material and quantity;

Fire

Attempt to cut off source or gas rather than put out fire; Remove containers from vehicle if not in area of fire, or remove other materials to prevent spread of fire to containers; and If fire gels out of control, evacuate area and warn against entry. Shut off engine and any electrical equipment and leave 'off' until vapour hazard is re moved; Move people from the area. Move upwind; Check for spills or leaks;

Tanker/Vehicle Accident

Send messenger to notify police and fire brigade. Tell them location, material and owner. Indicate condition of vehicle and any damage observed; Don't start the vehicle engine or other engines and/or operate electrical equipment in the area; and If tanker is on fire, evacuate area and warn against entry.

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FIRST AID


Remove patient to fresh air, lay down, and rest;

Gassing

If patient is not breathing, make sure airway is clear and applies artificial respiration. Oxygen may be given, but only under supervision of a trained person; Keep patient warm; and Call doctor at once or transport to doctor or hospital. Hold eyes open and wash continuously with water for at least 15 min; and

Eyes

Transport to doctor or hospital. Immediately wash affected area with plenty of water to prevent frostbite; and

Skin

Transport to doctor or hospital.

EMERGENCY CONTACT Organisation

Location

Telephone

117

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MS 830:2003

Annex J (normative)


Method of calculating maximum permitted liquid volume which can be placed in a container at any liquid temperature J1. Maximum permitted liquid volume of a container at any liquid temperature J1.1 The maximum quantity of LPG which may be placed in a container is dependent upon the temperature of the liquid and the maximum permitted filling ratio. Filling ratio values are given in Table J2. J1.2 The liquid temperature should be obtained by inserting a thermometer in a thermometer-well in the container into which the liquid LPG has been transferred and reading the temperature after the completion of the transfer (see note). If the container is not equipped with a well but is essentially empty of liquid prior to loading, the temperature of the liquid in the container from which liquid is being withdrawn may be used. Otherwise other temperature-sensing device should be installed in the loading line at a point close to the container being loaded and temperatures read off at intervals during transfer and averaging. NOTE. A suitable liquid shall be used in thermometer wells to obtain an efficient heat transfer from the LPG liquid in the container to the thermometer bulb. The liquid used shall be non-corrosive and shall not freeze at h te temperatures to which it will be subjected. Water shall not be used.

J1.3 Knowing the liquid temperature T and the filling ratio R, the maximum permitted volume V T of liquid LPG which may be placed in a container can be determined as follows:

VT ?

R pF

where, VT

is the maximum permitted liquid volume (in per cent of total container capacity) which shall be placed in a container when the liquid temperature is T;

R

is the filling ratio from Table J2, (%);

p

is the density of LPG at 15 °C placed in container (kg/l); and

F

is the correction factor from Table J1 for correcting liquid volume from 15 ?C to volume at temperature T (see note); which is the temperature of liquid LPG in container (?C).

NOTE. The correction factor is obtained by finding the density at 15°C, p in the column at the top of the table and coming down this column till the actual liquid temperature T is found. The correction factor corresponding to this density and temperature is then read. Interpolation may be used if necessary.

J1.4 After obtaining VT from the above formula the actual maximum litres of LPG which may be placed in a container is obtained by multiplying the water capacity of the container by VT/100.

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MS 830:2003

NOTE. Maximum filling level is for LPG with densities ranging from 0.500 kg/l, to 0.590 kg/l. In relation to liquid temperature and total container volumes are tabulated in Tables J2, J3 and J4. The values in the tables are heavily rounded up so a higher degree of accuracy is gained by calculating. Interpolation for other values of density and temperature may be used if necessary.


Table J1. Liquid volume correction factors Observed temperature

Density at 15 ?C, kg/l 0.050

0.510 Commercialp ropane

0.520

0.580 Commercialb utane

0.590

-40

1.145

1.139

1.133

1.121

-30

1.120

1.116

1.110

1.101

1.111

1.101

1.096

1.091

1.082

-20

1.095

1.091

1.087

1.080

1.080

1.072

1.066

1.063

-10

1.070

1.067

0 5

1.044 1.030

1.042 1.028

1.064

1.058

1.053

1.048

1.045

1.039 1.025

1.035 1.024

1.032 1.022

1.029 1.019

1.027 1.018

10

1.015

1.014

1.013

1.012

1.011

1.010

1.009

15 20

1.000

1.000

1.000

1.000

1.000

1.000

1.000

0.985

0.985

0.986

0.988

0.990

0.990

0.990

25

0.967

0.970

0.972

0.975

0.978

0.980

0.981

30

0.951

0.954

0.957

0.962

0.966

0.970

0.972

35

0.935

0.938

0.942

0.949

0.955

0.960

0.962

40

0.917

0.922

0.927

0.935

0.943

0.949

0.951

45

0.899

0.905

0.910

0.921

0.933

0.938

0.941

50

0.880

0.887

0.894

0.907

0.916

0.937

0.930

55

0.861

0.868

0.876

0.891

0.906

0.916

0.920

60

0.840

0.850

0.860

0.880

0.889

0.904

0.908

(?C)

0.540

0.560

Volume correction factors

EXAMPLE: Assume a container of 10 kl water capacity in which LPG with a density of 0.510 kg/l at 15 ?C is to be placed at a liquid temperature of 23 ?C. Calculate the maximum number of kilolitres of LPG which can be placed in the container. From Table J1. The maximum filling ratio for a container of capacity in excess of 5 kl in which a product having a density of 0.510 kg/l at 15 ?C to be placed is 45 %. Correction factor F, by interpolation from Table J1, for density at 15 ?C of 0.510 kg/l and liquid temperature of 23 ?C is 0.976.

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MS 830:2003

Maximum quantity of LPG that may be placed in the container

VT

x water capacity of container ?


100

?

R

x

water capacity of container

pF

45

10

x

0.150 x 0.976

100

100

? 9.04 kl

Table J2. Maximum filling percentage for aboveground containers (up to 5 kl water capacity) Liquid tempe rature

Density at 15 ?C, kg/ l 0.050

0.510 Commercial propane

0.520

0.540

(?C) -20

74

75

77

78

-10

76

77

79

80

0

78

79

81

5

79

80

10

80

15

82

20 25

0.560

0.580 Commercial butane

0.590

79

82

82

81

83

84

82

83

85

85

82

83

83

86

86

81

83

84

84

87

87

82

84

85

85

87

88

83

84

85

86

86

88

89

84

85

87

87

87

89

89

30

86

86

88

88

88

90

90

35

87

88

89

89

89

91

91

40

89

89

91

91

91

92

92

45

91

91

92

92

92

93

93

50

93

93

93

93

93

94

94

55

95

95

95

95

95

96

96

Maximum filling percentage

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MS 830:2003

Table J3. Maximum filling percentage for aboveground containers (over 5 kl water capacity)


Liquid temperature

Density at 15 ?C, kg/l 0.500


0.520

0.540

0.560


0.590


(?C) -20

80

80

83

84

84

87

87

-10

82

82

84

85

86

88

89

0

84

84

86

87

88

90

90

5

85

85

88

88

89

91

91

10

86

87

89

89

90

92

92

15

88

88

90

90

91

93

93

20

89

89

91

91

91

94

94

25

91

90

92

93

93

95

95

30

92

92

94

94

94

95

95

35

94

94

95

95

95

96

96

40

95

95

97

97

97

98

98

45

97

97

99

98

98

99

99

50

99

99

99

99

99

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Table J4. Maximum filling percentage for underground/mounded containers (all capacities)


Liquid temperature

0.500


(?C)

0.520

Density at 15 ?C, kg/l 0.540 0.560


0.590


-20

82

82

84

85

86

88

89

-10

84

84

86

87

88

90

90

0

86

86

88

89

89

92

92

5

87

87

90

90

90

93

93

10

88

88

91

91

91

93

94

15

90

90

93

92

92

94

94

20

91

91

93

93

93

95

95

25

92

92

94

94

94

96

96

30

94

94

96

96

96

97

97

35

96

96

97

97

97

98

98

40

98

98

99

99

99

99

99

45

99

99

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MS 830:2003

Annex K (normative)


Procedures for visual inspection and requalification of cylinders K1.

Application

K1.1 This annex gives a method of visual inspection and requalification of LPG cylinders designed and constructed in accordance with MS 641 or MS 642.

K2.

Formal periodic requalification of cylinder

K2.1 Cyli nders when used in LPG service must be retested or requalified 12 years after date of manufacture and every 7 years thereafter if the modified hydrostatic retest method is used or every 5 years thereafter if given a complete external visual inspection. The modified hydrostatic retest is done at twice the working pressure. K2.2 Cylinders must not be filled after the retest becomes due until the cylinder has satisfactorily passed a visual requalification and/or a modified hydrostatic retest and been so stamped.

K3.

General

K3.1

Preparation for inspection

K3.1.1 Rust, scale, caked paint, etc. should be removed from that part of the exterior surface where corrosion is evident so that the surface can be adequately observed. K3.1.2 Means shall be provided for inverting the cylinder to facilitate inspection of the bottom. This is important because experience has shown this area to be the most susceptible to corrosion. K3.1.3 Cylinders shall be checked for corrosion, general distortion, leaks, fire damage or any other defects that might indicate a weakness which would render it unfit for service. K3.2

Inspection equipment

K3.2.1 Exterior corrosion, denting, bulging, gouges or digs are normally measured by simple direct measurement with scales or depth gauges. A rigid straight edge of sufficient length may be placed over the defect and a scale used to measure the distance from the bottom of the straight edge to the bottom of the defect. K3.2.2 There are also available commercial depth gauges which are especially suitable for measuring the depth of small cuts or pits. It is important when measuring such defects to use a scale which spans the entire affected area.

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MS 830:2003

K4.

Visual inspection

K4.1

Dents


K4.1.1 Dents in cylinders are deformation caused by the cylinders coming in contact with a blunt object in such a way that the thickness of metal is not materially impaired. K4.1.2 Dents are of concern where the metal deformation is sharp and confined, or where they are near a weld. Where metal deformation is not sharp, dents of larger magnitude can be tolerated. K4.1.3

Rejection rules

a)

Where denting occurs so that any part of the deformation includes a weld, the maximum allowable dent depth shall be 6.5 mm.

b)

When denting occurs so that no part of the de formation includes a weld the cylinder shall be rejected if the depth of the dent is greater than 1/10 of the average diameter of the dent.

K4.2

Cuts, gouges and digs

K4.2.1 Cuts, gouges or digs in cylinders are deformations caused by contact with a sharp object in such a way as to cut into or upset the metal of the cylinder, decreasing the wall thickness at that point. In addition, they raise the stress of the steel. K4.2.2 When measuring cuts gouges or digs, the upset metal should be removed or compens ated for so that only actual depth of metal removed from the cylinder wall is measured. K4.2.3

Rejection rules

a)

When the defect is less than 75 mm in length, reject the cylinder where the defect exceeds that shown in Table K1, Column 1.

b)

When the defect is 75 mm or more in length, reject the cylinder where the defect exceeds that shown in Table K1, Column 2.

K4.3

Bulges

K4.3.1 Cylinders are manufactured with a reasonably symmetrical shape. Cylinders which have definite visual bulges shall be remove d from service. K4.4

Corrosion

K4.4.1 Corrosion or pitting in cylinders involves the loss of wall thickness by corrosive media. There are several kinds of pitting or corrosion to be considered. K4.4.2 Isolated pitting of a small cross-section does not effectively weaken the cylinder wall but may lead to complete penetration and leakage. If the pitting is isolated, the original wall is essentially intact.

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MS 830:2003

K4.4.3

Rejection rules

a)

A cylinder shall be rejected when the isolated pits have penetrated to a depth in excess of that shown in Table K1, Column 3.

b)

Figure K1 gives a suggested method of measuring isolated pitting.

K4.4.4 Line corrosion is when pits are not isolated but are connected or nearly connected to others in a narrow band or line. This condition is more serious than isolated pitting. Line corrosion frequently occurs in the area of intersection of the footing and bottom of a cylinder. This is sometimes referred to as ‘crevice corrosion'. K4.4.5

Rejection rules

a)

For line corrosion 75 mm or longer in length the depth of the deepest pit shall not exceed the limits shown in Table K1, Column 2.

b)

When the cylinder surface has line corrosion less than 75 mm long the maximum measured pit depth shall not exceed the limits shown in Table K1, Column 1.

c)

Depth measurement of line corrosion can be done in accordance with Figure K1.

K4.4.6 General corrosion is that which covers considerable surface area of the cylinder. It reduces the structural strength. It is often difficult to measure or estimate the depth of general corrosion because direct comparison with the original wall cannot always be made. General corrosion is often accompanied by pitting and does not always follow a definite pattern. Where there is appreciable pitting in areas of general corrosion, the pitted depth may usually be considered to be about twice the general corrosion thickness loss. K4.4.7

Rejection rules

a)

A cylinder shall be rejected when the cylinder is generally corroded and the deepest pit measurement exceeds that shown in Table K1, Column 4.

b)

Figure K2 gives a suggested method of measuring general corrosion.

c)

If a cylinder passes a visual inspection and it is subsequently determined that the tare mass is less than 95 % of the original tare mass the cylinder shall be rejected. To determine existing tare mass the cylinder shall be completely emptied and all coatings removed to the bare metal. (A tare mass in excess of 95 % of the original tare mass is no indication that the cylinder is requalifiable, hence the necessity for visual inspection).

K4.5

Leaks

K4.5.1 Leaks may originate from a number of sources, such as defects in a welded or brazed seam, defects at the threaded opening or from sharp dents, digs, gouges or pits. K4.5.2 To check for leaks, th e cylinder must be charged and carefully examined. All seams and pressure openings shall be coated with a soap or other suitable solution to detect for escape of gas.

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MS 830:2003

K4.5.3

Rejection rules


Any leakage, other than leakage at thread connection which can be corrected by tightening is cause for rejection. Where repair is undertaken it shall be resumed to the cylinder manufacturer. K4.6

Fire damage

K4.6.1

Cylinders shall be carefully inspected for evidence of exposure to fire.

K4.6.2

Common evidences of exposure to fire are:

a)

charring or burning of the paint or other protective coat;

b)

burning or discoloration of the metal;

c)

distortion of the cylinder; and

d)

burning or melting of valve.

K4.6.3

Rejection rules

Cylinders which have been subjected to fire must be requalified, reconditioned or repaired by the manufacturer of the cylinder or by the repair facility authorised by the Department of Occupational Safety and Health (DOSH). If the protective coating on the cylinder is only discoloured from smoke or debris and it is found by examination that the coating is intact, the cylinder need not be considered to have been affected by the fire exposure and thus is not subjected to the heat treatment and retest requirements. Valves and safety devices on such cylinders, however, should be examined to determine that they are functioning properly and should be replaced if necessary. K4.7

Neck defects

K4.7.1 Cylinder necks shall be examined for cracks and flaws. Neck cracks are normally detected by testing the neck during charging operations with soapy water solution. K4.7.2 Cylinder neck threads shall be examined whenever the valve is removed from the cylinder. During manufacturing, cylinders have a specified number of full threads of proper form as required by applicable thread standards. J4.7.3

Rejection rules

Cylinders shall be rejected if the required number of threads is materially reduced or if a gas tight seal cannot be obtained by reasonable valving methods. Common thread defects are worn or corroded crests, broken threads, nicked or cut threads.

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MS 830:2003

For isolated pits or line corrosion, measure the corrosion depth of these areas by bridging across, resting the straight edge on uncorroded surface with a pit gauge or other suitable device as shown. A number of points should be measured to determine the deepest penetration.

Any corrosion that cannot be measured with a pit gauge because of its proximity to the footring should be gauged with a scriber. The short right-angle point is ground to a length of 125 mm. The other is ground to a length 25 mm. These points are to be used to approximate depths of pits and corrosion by eye as shown.

Figure K1. Suggested method of measuring isolated pitting

127


MS 830:2003

For general corroded areas measure the corrosion depth as shown in Figure K1. In taking this measurement there will be no original uncorrected surface as a reference. However, past experience has shown that the pitting rate is twice the general corrosion rate, i.e. the maximum depth of penetration based on original surface is 1½ times the deepest pit. Use the actual depth of pit measured, since Column 4 of Table K1 automatically incorporates the extra 50 % general corrosion loss. d is the measured pit depth ½ d is the general corrosion thickness (no longer visible) 1½ d is the total loss of metal thickness Remaining wall thickness is the original wall thickness minus 1½ d

Figure K2. Suggested method of measuring general corrosion

128

MS 830:2003

Table K1. LPG cylinder damage limits


DOT

Water

Inside

Overall

cap

dia.

length

(kg)

(mm)

(mm)

Minimum original thickness

Column 1

Column 2

Column 3

Column 4

Line corrosion cuts, gouges or digs more than 75 mm in length or general corrosion

Line corrosion cuts, gouges or digs more than 75 mm in length

Isolated pits

Pits in general corrosion area

code

Shell

Head

Shell

Head

Shell

Head

Shell

Head

Shell

Head

(mm)

(mm)

21.6

300

370

2.60

2.60

1.30

1.30

0.65

0.65

1.75

1.75

0.87

0.87

21.6

300

370

1.95

1.95

0.97

0.97

0.47

0.47

1.30

1.30

0.65

0.65

65

300

962

2.60

2.60

1.30

1.30

0.65

0.65

1.75

1.75

0.87

0.87

65

300

962

1.95

1.95

0.97

0.97

0.47

0.47

1.30

1.30

0.65

0.65

100

400

875

4.37

7.82

2.17

3.90

1.07

1.95

2.90

5.20

1.45

2.60

123

400

837

3.87

4.67

1.92

2.32

0.95

1.15

2.57

3.12

1.27

1.55

108.6

362

1 118

3.12

3.12

1.57

1.57

0.77

0.77

2.07

2.07

1.05

1.05

108.6

362

1 118

2.17

2.17

1.10

1.10

0.55

0.55

1.45

1.45

0.72

0.72

163

450

1 000

4.00

4.00

2.00

2.00

1.00

1.00

2.67

2.67

1.32

1.32

26- 150 or- 300

900

26- 150

462

1 018

or- 300

139.5

425

1 012

5.00

5.00

2.50

2.50

1.25

1.25

3.32

3.32

1.65

1.65

271

550

1 212

4.77

4.77

2.37

2.37

1.17

1.17

3.17

3.17

1.57

1.57

325

600

1 200

5.20

5.22

2.60

2.60

1.30

1.30

3.47

3.47

1.72

1.72

325

600

1 562

3.55

3.55

1.77

1.77

0.87

0.87

2.35

2.35

1.17

1.17

454.5

725

1 215

6.27

6.75

3.15

3.37

1.57

1.67

4.20

4.50

2.07

2.25

454.5

725

1 387

4.30

4.30

2.15

2.15

1.07

1.07

2.85

2.85

1.42

1.42

NOTES: 1. For any cylinders not listed above select one with the same diameter and DOT Code from this table and use those limits. 2. For these cases where the original thickness is known to exceed the specification minimum the values in Columns 1 through 4 may be increased by an amount equal to the excess thickness.

K4.8

General distortion

K4.8.1 Noticeable distortion may be evaluated by reference to the clauses under denting or bulging. If the valve is noticeably tilted the cylinder shall be rejected. K4.9

Appurtenances

K4.9.1 Footrings and headrings of cylinders should be examined to determine that they are in serviceable condition. Distortion of the footring through service abuse may prevent it from supporting the cylinder properly in an upright and stable position. Likewise distortion of the head ring could prevent it from protecting the cylinder valve. In addition to distortion footrings and headrings shall be examined for looseness and failure of welds. K4.9.2

Appearance may often warrant rejection of cylinder.

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MS 830:2003

K4.9.3 Repairs to footrings and headrings must be made only by a cylinder manufacturer of the same type of cylinder or a cylinder repair facility authorised by DOSH.


K5.

Inspection report form

K5.1 The visual inspection report form (see Figure K3) shall contain the following information: a)

date of inspection (including month and year);

b)

specification number;

c)

cylinder identification:

d)

i)

registered symbol and serial number;

ii)

date of manufacture; and

iii)

ownership symbol (if needed for identification).

type of cylinder coating whether painted, galvanised, etc.: i)

statement as to need of refinishing or recording.

e)

conditions checked (i.e. leakage. corrosion. gouges dents or digs broken or damaged footrings, protective ring or fire damage); and

f)

disposition of cylinder: i)

returned to service;

ii)

scrapped; and

iii)

return cylinder to manufacturer or repair facility for repair.

130

131


MS 830:2003

129

MS 830:2003

Figure K3. Visual inspection report from

MS 830:2003

Annex L (normative)


Fire safety signs L1.

Standard safety signs Sign

Meaning

Smoking is prohibited

Fire, naked light and smoking are prohibited

Nearby material is a fire risk

No handphone

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MS 830:2003

L2.

Standard shapes, sizes and colours

L2.1

The geometric shapes and sizes shall be as shown in the layout below:

L2.2

The following safety colours are to be used for fire safety signs: Colour

BS 5252 reference

Red

0.4E53 •

Yellow

0.8E53 • 10E51 10E55

• Indicates the preferred colour 133

MS 830:2003

Annex M (normative)


Protective bollard poles M1.

Construction of bollard poles

M1.1 The bollard pole shall be constructed from 80 mm diameter mild steel pipe with concrete infill and encased by a 100 mm diameter polyvinyl chloride pipe (other suitable nonsparking material may be used). The space in between the mild steel pipe and polyvinyl chloride pipe shall be filled with lean concrete. M1.2 A 300 mm x 300 mm x 6 mm mild steel plate shall be welded to the end of the bollard pole that is buried in the ground. The other end shall be suitably capped to remove any sharp edges. M1.3 The bollard pole shall be at least 1.35 m long and securely buried vertically to a depth of at least 450 mm and at least 900 mm shall extend above the ground. The bollard pole shall be buried in a concrete footing of at least 450 mm x 450 mm x 600 mm [see Figure M1 a)].

M2.

Arrangement around dispenser

M2.1 At least four bollard poles shall be placed around the dispenser in a square arrangement as shown in Figure M1 b) and the poles shall be spaced at a maximum of 1 m apart.

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MS 830:2003

Figure M1. Protective bollard poles for dispenser

135

MS 830:2003

Annex N (normative)


Refuelling procedures at automotive LPG dispensing stations N1.

The following are instructions for attendants filling vehicle fuel containers with

LPG. N1.1

Do not fill the vehicle unless:

a)

there is no smoking or name within 6 m of the vehicle;

b)

the vehicle ignition is switched off;

c)

there are no obvious leaks or faults in the LPG equipment of the vehicle and the gas dispensing system; and

d)

the vehicle filler valve is in good condition.

N1.2

Do not leave the vehicle unattended during the filling operation.

N1.3

Connect the filler nozzle.

N1.4 Securely replace the protective cap on the vehicle filler valve at the end of the filling operation. N1.5 If a continuous gas escape is apparent when the filler nozzle is disconnected, the non -return valve has malfunctioned, probably because of dirt under the seat. Reconnect the nozzle and operate it briefly to clear the seat. If this proves unsuccessful seal the vehicle filler valve with a metal cap. Advice the driver to have the fault rectified immediately. N1.6 At the end of the day's work, before the site or automotive LPG dispensing stations closed down, check all dispensing equipment to ensure that storage container valves are closed, hoses are properly stowed and electrical equipmen t is switched off. NOTE. Protective gloves are to be available on the site for use during an emergency.

136

MS 830:2003

Annex P (normative)


LPG emergency procedures Gas leak a)

shut emergency stop;

b)

close all valves of containers;

c)

keep bystanders away;

d)

no smoking;

e)

no naked lights;

f)

no engine to be started;

g)

phone fire brigade (insert telephone number of local fire station);

h)

phone (inserts LPG distributor’s name and all-hours number); and

i)

isolate power at main switchboard.

Fire a)

shut emergency stop;

b)

phone fire brigade (insert telephone number of local fire station);

c)

phone (Insert LPG distributor’s name and all-hours number);

d)

close all valves of container;

e)

keep bystanders away;

f)

isolate power at main switchboard; and

g)

follow fire-fighting instructions.

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MS 830:2003

Annex Q (normative)


How to control LPG leaks and fires As in any emergency situation it is of paramount importance to avoid endangering human life in event of fire involving or exposing LPG equipment or serious leakage of LPG without fire. It is very beneficial to invite local fire department personnel to the plant to familiarise them with the plant location means of entrance location of valves and other safety features and to suggest possible ways of handling emergencies. Basic precautions 1.

Approach the fire or gas leak upwind

2. Keep all persons out of vapour cloud area. If necessary to evacuate any area which is in the part of the vapour cloud, do so immediately, eliminating all sources of ignition at the same time.

3. Police the area, keep all persons except those necessary to cope with the condition completely out of the area, but in no case less than the distances shown.

138

MS 830:2003

Leakage without fire


1. If escaping LPG is not burning close any valve available that can stop the flow of gas. Small lines such as copper tubing could be flattened to stop the flow. If a LPG vehicle is involved, consult the driver; or if storage facilities are involved, consult plant personnel regarding possibilities of shutting off leaks.

2. Water spray is effective in dispersing LPG vapour. If available it should be used as soon as possible, directing the spray stream across the normal vapour path and dispersing the vapour into a safe location Those handling the hose should avoid entering the vapour cloud and should keep low behind the spray so that they will be somewhat protected from radiant heat if the vapour should be ignited unexpectedly.

3. In some instances of leakage from a tank without a fire, it may be desirable to move the tank to some remote area such as a blocked -off isolated roadway or open field where it can leak safely away from a source of ignition. However if this is done, the tank should be moved only in an upright position. Never drag the tank in a manner which might damage valves or piping. Any attempt to turn a tank upright for moving it to some remote location should be done carefully to avoid damage to valves and piping and preferably under cover of water spray.

139

MS 830:2003

Leakage with fire


1.

Do not extinguish unless leakage can be stopped, except under certain conditions.

2. If the escaping gas is on fire, apply large quantities of water as quickly as possible to all surfaces exposed to heat. Approach the tank(s) from the sides. Concentrate on piping and metal surfaces of vessels or adjoining vessels equipment or combustible surfaces exposed to flame or intense of the tank(s) shell (see step 7). If a number of tanks are involved use additional streams from the opposite sides for adequate cooling.

3. Consult driver of vehicle or plant-operating personnel (as the case may be) regarding possibilities of shutting off fuel supply. Stopping the flow of gas should be the first consideration after water cooling is established.

4. If the only valve that can be used to stop the flow of fuels is involved in the fire consider the possibility of effecting shut off by protecting firemen with water fog steams protective clothing and gloves while they are closing the valve. Proceed slowly to avoid any flashbacks or trapping firemen in the flames.

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MS 830:2003

5. The controlled burning of escaping LPG (which cannot be shut off by closing a valve) is a commonly accepted fighting practice. Application of sufficient water to keep the shell of the vessel and piping cool will allow the fire to consume the product in the tank without danger of causing failure.

6. Dry chemical portable extinguishers are effective for extinguishing small LPG fires. Extinguishing agent should be directed towards point of vapour discharge. Carbon dioxide may also be used.

7. Failure of LPG tanks usually occurs only when some portion of the metal surface in the vapour space of the vessel becomes over-heated softens and weakens to the point that it will not contain the pressure of the products. In the absence of sufficient water to keep the metal surface cool where it is exposed to direct flames or extreme radiant heat, there is danger of the tank rupturing.

141


MS 830:2003

8. When sufficient water is not available to keep the tank cool, where excessive heat is present, some warning of increased pressure may be noted from the increase in volume of the fire or of noise level. This should be a signal to consider withdrawal of all men to a safe area.

9. Shooting holes in a LPG tank that is involved in fire does not serve any useful purpose and should not be permitted.

10. Where possible, remove container from area before flames of burning building reach the container. It may be advisable to move the container under cover of water spray. It should be moved in only an upright position. Never drag it in a manner that might further damage valves. Any attempt to turn the tank upright to remove it to some remote location to facilitate product withdrawal should be done carefully to avoid damage to valves and piping.

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MS 830:2003

Exposure to fire 1. It is always important to control any exposure to fire. In addition, when LPG storage vessels or equipment are subjected to serious fire exposure such as from a nearby burning building or a fire involving another fuel. It is of prime importance to apply sufficient water to keep the shell of the vessel and piping cool to avoid any unnecessary release of LPG.

2. If the LPG storage vessel becomes heated to the point of causing the relief valve to function, the discharge should be allowed to burn if it becomes ignited. At the same time, continue to apply large volumes of water to the vessel and piping to keep them cool and to allow the relief valve to close after the excess pressure has been relieved.

3. Portable LPG cylinders that are exposed to a fire should be moved, if feasible, to a safe location.

143



Acknowledgements Ir Ahmad Fauzi Hasan (Chairman) Puan Lee Hooi Lan (Secretary) Encik Kamarul Azril Encik Ahmad Fauzi Awang/ Encik Mohd Firdaus Zainal Abidin Encik Azmi Tamat/ Encik Wan Mohamad Zaidi Wa n Isa/ Encik Ahmad Puad Kamaruddin Encik Sree Skandarajah V. Encik Mohd Ismail Md Yunus Encik Hambali Husain Puan Amy Abrizah Abd Aziz Ir Zahamail Omar Cik Teoh Oon Leng Prof Madya Dr Zulkefli Yaacob

Energy Commission SIRIM Berahd BP Malaysia Department of Occupational Safety and Health Fire and Rescue Department

Gas Malaysia Ministry of Domestic Trade and Consumer Affairs Persatuan Kontraktor Retikulasi Gas Petronas Dagangan Berhad Road Transport Department Shell Malaysia Trading Sdn Bhd Universiti Teknologi Malaysia

MS 830-2003

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