2020 Guide To Good Industry Practices Bulk LPG Installations

Guide to Good Industry Practices
Bulk LPG Installations

WLPGA Good Industry Practice Guide for Bulk LPG Installations
Contents
Acknowledgements 4
1.0 Background 5
2.0 Good Practice Guidelines for Bulk LPG Installations 6
3.0 Tank Location and Layout 7

3.1 General
3.2 Separation Distances
3.3 Fire Walls
3.4 Site Security
3.5 Protection Against Damage from Vehicles
4.0 Tank Design 17

4.1 General
4.2 Design code
4.3 Design Conditions
4.4 Corrosion Protection
4.5 Tank Supports
4.6 Tank Markings and Labelling
4.7 Mounded and Underground Tanks
4.8 Skid Mounted and Mobile tanks
5.0 Tank Fittings 24

5.1 General
5.2 Pressure Relief Valves
5.3 Drain Connections
5.4 Contents Gauge
5.5 Service Valves
5.6 Filling Connections
5.7 Pressure Gauges
5.8 Temperature Gauges
5.9 Hydrostatic Relief Valves
5.10 Emergency Shutdown Valves
5.11 Lightning Protection
Guide to Good Industry Practices – Bulk LPG Installations Page 1

6.0 Pumps, Compressors, Vapourisers and Dispensers 32
6.1 General
6.2 Pumps
6.3 Compressors
6.4 Vapourisers
6.5 Dispensers
7.0 Pipework and Regulators 37

7.1 Pipework
7.2 Pressure Regulators
7.3 Identification and Markings
8.0 Electrostatic and Electrical Precautions 44

8.1 Electrostatic Precautions
8.2 Electrical Equipment Installations
8.3 Hazardous Areas
9.0 Fire Precautions 48

9.1 General
9.2 Fire Protection
9.3 Other Facilities Where Fire Protection is Needed
9.4 Portable Firefighting Equipment
10.0 Tank Commissioning and Decommissioning 54

10.1 General
10.2 Commissioning
10.3 Decommissioning
11.0 Transfer Operations 56

11.1 General
11.2 Road Tanker Loading/Unloading
11.3 Rail Tanker Loading/Unloading
11.4 Completion of Transfer
11.5 Ship Loading/Unloading
11.6 Draining
12.0 Training 63
12. 1 General
12.2 Training Program
12.3 Change Control
12.4 Training Record
12.5 Fire Instruction and Training
13.0 Written Operating and Emergency Procedures 65
13.1 General
13.2 Customer Sites
14.0 Maintenance and Examination 67

14.1 General
14.2 Maintenance Scheme
14.3 Frequency of Periodic Examination
14.4 Periodic Examination of Tanks and Pipework
14.5 Periodic Examination of Other Equipment
14.6 Routine Examination
14.7 Records
Appendix 1: Written Scheme of Examination 73
Appendix 2: Definitions 74
References 75
Disclaimer 76

WLPGA Good Industry Practice Guide for Bulk LPG Installations
Acknowledgements
David Tyler and Vic Mariñas reviewed and updated this Guide in 2020 with support from WLPGA
members. The WLPGA would like to thank the following members of the steering committee who
reviewed the final draft and made valuable comments:
Steve Reynolds Elgas

Greg Kerr GMK Consulting
Suyash Gupta Indian Autogas Coalition
Can Toydemir Ipragaz
Christian Fredberg Kosan Crisplant a/s
Richard Hakeem Liquid Gas UK
Makoto Arahata LPG Centre
Arnaud Lobry Makeen Energy
Bruce Swiecicki NPGA
Blaise Edja Oryx Energies
Tucker Perkins PERC
Cinch Munson PERC
Mercedita G. Pastrana Philippines LPGIA
Abdelkader Benbekhaled Salamgaz
Rob Crewe SHV Energy
Nicolas Rouer Siraga
Stanislas Thibault Total
Maurício Jarovsky Ultragaz

1.0 Background
The WLPGA is committed to providing independent advice to LPG stakeholders to ensure safety in the operation of
LPG equipment.
The two WLPGA Guidelines - Good Business Practices and Good Safety Practices - have been used extensively during
the last fifteen years all over the world to provide guidance across all areas of the LPG industry.
These two Guidelines have been designed to provide general advice to all stakeholders on best practices throughout
the supply and distribution chain.
Following the success of these Guidelines it was decided to develop and publish more detailed advice in certain areas
of the supply and distribution chain that are considered more critical and where more prescriptive advice would be
helpful.
This Guide, reviewed and updated in 2020, deals with the subject of Bulk LPG Installations, which addresses the
engineering, operation and safety requirements for terminals and depots, cylinder filling plants, customer
installations and Autogas refuelling sites.
This document is a Guide and not a Standard. This guide does not supersede any code, standard or regulation that
has been adopted by any country or local jurisdiction. However, the information in this Guide may be useful to
individual countries or companies where such codes, standards or regulations do not already exist. In those cases,
consideration may be given to making some of this advice mandatory.

2.0 Good Practice Guidelines for Bulk LPG Installations
An example of a Bulk LPG facility
LPG is commonly stored in pressure vessels in various facilities i.e. terminals and depots, cylinder filling
plants, Autogas refuelling stations and customer sites. The LPG storage capacities of these facilities can
range from 100,000 metric tonne (MT) for big import terminals to as small as 0.5MT (500kg) for a domestic
installation. Whatever the size of an LPG installation, any safety incident - whether due to equipment
failures or external threats - has the potential to cause injury and/or property damage. Not only to people
working within these facilities but also the population in the surrounding communities.
It is therefore important to all stakeholders in the industry to manage and reduce the risks associated with
operating an LPG facility to As Low As Reasonably Practicable (ALARP). This can be achieved with suitable
design and engineering standards, reliable equipment, safe operations, and comprehensive and rigorous
maintenance programmes combined with effective staff training programmes.
This Guide aims to provide information on good safety practices relevant to LPG bulk installations which
are adopted from widely recognise industry codes of practice and standards, as well as best practices from
key reputable LPG companies. Information in this Guide should always be used in conjunction with local
standards and regulations. If the requirements of the local standards or regulations are less than the Guide,
the latter should be adopted to ensure a higher level of safety for the LPG facility.
The recommendations in this Guide applies to pressurised LPG facilities covering terminals and depots,
cylinder filling plants, Autogas refuelling sites and industrial, commercial, agricultural and domestic
installations, both permanently installed and refilled onsite.
This Guide does not cover refrigerated terminals, caverns, salt domes and mobile cylinder installations.

3.0 Tank Location and Layout
The location and layout of an LPG bulk installation should take into consideration the size of the storage
tanks and nature of operations that will be occur onsite. Siting the tanks properly with respect to nearby
structures, prevailing wind - coupled with good design - will significantly reduce risks and limit the impact
of incidents associated with LPG i.e. gas clouds or jet flames. The worst-case scenario of an LPG tank BLEVE
(Boiling Liquid Expanding Vapour Explosion) is not considered here as experience has shown this risk to be
minimal. This section provides recommendations on the location of LPG tanks and separation distances to
other structures and boundaries.
3.1 General
3.1.1 Location
 All aboveground LPG bulk tanks should be located in the open with adequate ventilation and
be easily accessible for operation, maintenance and any firefighting activities. LPG tanks should
be sited according to the required separation distances (see 3.2)
 The ground underneath, or adjacent to, connections into LPG tanks or LPG ancillary equipment
should be concreted or compacted and free from depressions, pits, culverts or drains. If all
connections are congregated at one end of the tank, it may only be necessary to compact or
concrete under the connections. See 3.1.8
 LPG vapour is heavier than air so care should be taken to avoid siting tanks in locations where
the surrounding ground slopes towards vulnerable features e.g. other tanks, buildings, houses,
drains etc., especially where there is an ignition risk, even though these may be outside normal
separation distances
 Locate mounded or underground tanks in a way that maximises the ventilation around the
pressure relief valves and manhole, according to the separation distances required in local
legislation, or 3.2, whichever is the greater.
 No part of the LPG tank should be located underneath a structure of the premises, or any
extensions from it, e.g. roof eaves, car ports etc. nor beneath overhanging tree branches,
unless the installation is made in accordance with local codes and standards
 LPG bulk tanks should not be installed on roofs of buildings due to the inherent hazards/risks
associated with leakage, fire and access for emergency response and services. If this cannot be
avoided, the local enforcing authorities should be consulted
 The location of the bulk tanks should be accessible to vehicle delivery. It should allow filling
hoses to be routed without having to pass through buildings or over walls or fences or similar
features that may cause abrasion or other damage to the hoses
 The location should provide a clear line of sight between the receiving tank and delivery vehicle
for the person in control of the product transfer operation, particularly if only a single person
is involved in the transfer operation
 If the frequency of delivery to a customer’s premises is high, e.g. an Autogas refuelling site or
customer installation, consideration should be given to increasing the storage capacity,
increasing the separation distances and/or providing additional fire protection
3.1.2 Screening
If trees or shrubs are planted to screen LPG tanks, they should not obstruct ventilation, i.e. locate
them only on one side of the tanks. Take care to plan too for:
 The size of the trees/shrubs when fully grown
 The capacity of tree roots to interfere with underground pipes, foundations or concrete
footings
 The chance of tree branches breaking off in high winds and falling onto the tank or
associated pipes and fittings
 Access needs for maintenance purposes
 The risk of having an unnecessary fuel source in the vicinity in the event of a fire (see
3.1.3)
3.1.3 Flammable Materials
Long grass, weeds, deciduous trees or shrubs and trees plus any combustible material should be
removed from within 3 metres of any 2,500 litres water capacity or smaller LPG tank and within 6
metres of larger tanks. Never use sodium chlorate or other chemicals (which present a fire risk) to
clear weeds near LPG tanks.
3.1.4 Horizontal Direction
 Where possible, arrange horizontal LPG tanks so that they are in parallel and do not point
towards other tanks containing dangerous substances, nearby occupied buildings or important
equipment.
 Tanks should not be installed one on top of another. This mitigates the risk of gas being
released and ignited from one tank causing fire impingement on the other
3.1.5 Multiple Tanks
 Not more than nine installed LPG tanks should be in a single group. Any tank in one group
should be separated from the nearest tank in another group by at least 7.6 metres, unless a
fire wall is built between the two groups
 If more than one row of tanks is installed, the adjacent ends of the tanks in each row should be
separated by at least 3 metres
 Within a group of tanks, the distance between adjacent tanks should be (D1 + D2)/4 where D
is the diameter of the tanks, with a minimum separation distance of 1 metre
3.1.6 Overhead Electric Cables
LPG tanks, vapourisers, pumps and gas/air mixing plants etc. should not be located directly beneath
electrical power cables. In particular, LPG tanks should be sited:

 At least 1.5 m away from a line drawn vertically down from a cable carrying less than 1 kV
 At least 7.5 m away if the cable is carrying 1 kV or more
 Or a competent engineer, usually from the local electricity supplier, makes a judgement on
a specific installation on its own merits
3.1.7 Bunded Enclosures
LPG tanks should not be sited inside the bunded enclosure of tanks holding:
 Any flammable liquid
 Heated liquids such as heavy fuel oil or bitumen
 Liquid oxygen or cryogenic substances
 Any other hazardous substances
3.1.8 Spillage Planning
LPG spillage containment (e.g. evaporation areas) should be installed for:
 Propane tanks of 56,250 litres water capacity or greater, with connections below the liquid
level, unless they are plugged or blanked off
 Butane tanks of 11,250 litres water capacity or greater, with connections below the liquid
level, unless they are plugged or blanked off
Spillage containment areas should be safely sited away from boundaries, occupied buildings and
ignition sources. The ground below the tank and its connections should slope and be compacted
or concreted to avoid pools of liquid building up. It should allow escaping LPG to be directed to a
safe evaporation area which should never be closer to LPG tanks than 3 metres. Low walls
(usually 500 mm or less) can also act as an effective channel.
3.1.9 Siting Near Cylinders
In general, LPG cylinders should not be stored close to bulk tanks to avoid any unnecessary
restrictions to access. However, if it is necessary for overriding security reasons, or a reserve bulk
supply for short-term use, then these conditions can be considered:
 Less than 50 kg may be stored adjacent to the tank
 If storing cylinders with horizontally venting pressure relief valves (PRV’Ss) with a total
quantity in excess of 50 kg – separate by 7.5 metres from tanks of over 5,000 litres water
capacity or 3 metres from tanks below this size.
 If storing vertically venting cylinders (e.g. for forklift trucks) – separate by at least 1metre
from the tank and do not exceed 300kg of storage close to the tank.

For siting of cylinder stacks inside depots and filling plants, see 3.2.5.
3.1.10 Natural Phenomenon
Local rules should be applied to safeguard against natural phenomena, including:
 Lightning – Protection is not usually needed in temperate countries, but may be required
in tropical countries or those with a high frequency of lightning strikes
 Earthquakes – Supports and foundations should meet local design requirements. In areas
located in earthquake zones, seismic valves may be installed to shut off gas flow during an
earthquake
 Flooding – Try to avoid siting tanks where there is a known flood risk. Liquid LPG has a
density around half that of water so prevent flotation by securely anchoring tanks.
Underground tanks should be securely anchored where there is a high-water table
 Hurricanes or Cyclones – Where prevalent, consideration should be given to the effect of

high wind loading
3.2 Separation Distances
 Separation distances are designed to protect the LPG installation from the immediate radiation
effects of fires involving other facilities as well as to minimise the risk of escaping LPG from being
ignited before it has dispersed or diluted
 Most countries should have local regulations on separation distances for LPG tanks and these
should be fully complied with. If local regulations do not exist, companies should comply with
separation distances by referring to Tables 1 to 5 in this section
 Separation distances for above ground, mounded or underground tanks are measured from the
nearest surface.
 All separation distances in this section are based on tank installations that are fully compliant
with requirements in other sections of this guide with the minimum of joints and flanges in
pipework and a rigorous asset integrity management regime applied
3.2.1 Separation Distances between Tanks, Important Buildings and Other Properties
Separation distances of LPG tanks to important buildings, boundaries, fixed sources of ignition and
other tanks are indicated in Table 1 below. This is based on Table 6.4.1.1 in NFPA 58 Liquefied
Petroleum Gas Code 2020 edition.

Table 1 - Separation Distances Between Tanks, Important Buildings and Other Properties
Notes to Table 1
1. Separation distances in Table 1 for tanks with 1,900 to 7,600 litres water capacity can be reduced to 3m for a single
tank of 4,500 litres or less water capacity where such tank is at least 7.6m away from another LPG tank.
2. Separation distances in Table 1 between tanks and buildings used exclusively for filling of LPG cylinders should refer
to 3.2.6. If the quantity of LPG cylinders filled is less than 300 kg. i.e. for forklift cylinder supply, the minimum
distance will not apply.
3. Separation distances in Table 1 may be reduced by half by the provision of a fire wall designed and constructed in
accordance to section 3.3. Alternatively, separation distances may be reduced by provision of a greater fire
protection than that set out Table 1. However, specialist advice should be sought from the enforcing and/or fire
authorities in this case.
4. If the aggregate capacity of a multi-tank installation comprising of tanks with less than 500 litres capacity is 1,900
litres or more, the aggregate capacity should be used instead of capacity per tank provided that the installation is
separated from any other installation by at least 7.6 metres. The minimum distances between tanks will not apply in
such installations.
3.2.2 Flammable Liquids
Tanks containing a flammable liquid with a flashpoint of 65oC or less should be sited not less than
the separation distances given in Table 2.
LPG Tank
Liquid Oxygen Capacity Separation Distance
Water Capacity Nominal Capacity (litres) (metres)
(litres) (MT)
Up to 265,000 Up to 60 Up to 566,000 6.0
Up to 4,500 Up to 2 7.5
More than 566,000
From 4,500 to 265,000 2 to 120 15.0
Above 265,000 Above 120 All capacities Perform full Risk Assessment
Table 2 - Separation Distances - Flammable Liquids and LPG Tanks

3.2.3 Liquid Oxygen/Other Flammable Substances
LPG and liquid oxygen tanks should be sited according to the separation distances in Table 3.
Separate LPG tanks from other tanks holding toxic or dangerous liquids stored under pressure by
at least 15 metres.
LPG Tank
Liquid Oxygen Capacity Separation Distance
Water Capacity Nominal Capacity (litres) (metres)
(litres) (MT)
Up to 265,000 Up to 60 Up to 566,000 6.0
Up to 4,500 Up to 2 7.5
More than 566,000
From 4,500 to 265,000 2 to 120 15.0
Above 265,000 Above 120 All capacities Perform full Risk Assessment
Table 3 - Separation Distances - Liquid Oxygen and LPG Tanks
3.2.4 Separation Distances from Cylinder Filling Plant
LPG tanks should be sited such that the distance between any part of the cylinder filling building
and the storage tank meets the minimum distances in Table 4. Furthermore, cylinder filling
buildings should be located at least 15 metres away from boundaries and other buildings.
Tank Capacity Minimum Distance

(litres) (metres)
Up to 135,000 10
>135,000 15
Table 4 - Separation Distances – Cylinder Filling Plant to LPG tanks
3.2.5 Separation Distance from Cylinder Stacks
 LPG cylinders in the cylinder filling plants (both filled and empty) should be stored at least 15
metres away from LPG tanks. The quantity for each cylinder stack should be limited to 5 MT
and the next stack should be at least 7.6 metres away
 LPG cylinders in automotive retail sites should be stored at least 7.6 metres away from the
LPG storage tanks
3.2.6 Separation Distances in Automotive Retail Sites
Where there are no local regulations LPG tanks should be sited with respect to other
facilities/equipment in an Automotive retail station in accordance with Table 5. If local
regulations exist and require larger distances, they should be used instead.

Minimum distance
Automotive Retail Site Feature
(metres)
LPG dispenser 3
Liquid fuel dispenser 3
Motor vehicle LPG filling connection 3
Buried tank (Flammable liquid) manway 3

fill connection and vents
Above ground storage tank/bund 6
(Flammable liquid) flash point <65oC
Parked motor vehicles 1.5
LPG cylinder storage area 8
Site boundary, buildings, fixed sources of Refer to Table 1

ignition
Table 5 - Separation Distances for LPG tanks in Automotive retail sites
3.2.7 Other Requirements in Automotive Retail Sites
 No separation distance is required between LPG dispensers and flame-proof liquid automotive
fuel dispensers. LPG dispensers can therefore be installed on the same island as flame-proof
liquid automotive fuel dispensers
 LPG dispensers and vehicle LPG filling connections should be at least 4.5metres away from site
boundaries, buildings, and fixed sources of ignition
 LPG dispensers should be located away from any flammable liquid tanks by at least 3 metres if
underground, and 6 metres if above ground
 Any spillage from the flammable liquids tank, i.e. during filling, should be directed away from
the LPG tank and/or prevented from remaining under or near the LPG tank. Pool fires from
flammable liquid spillages should not result in flame impingement on LPG facilities
3.3 Fire Walls

3.3.1 Purpose
Fire walls shield the public and vulnerable equipment from thermal radiation caused by fire, and they ensure
an adequate vapour dispersion distance to boundaries, buildings and sources of ignition in the event of an
LPG leak occurring. They also enable the use of shorter separation distances.
3.3.2 Siting
Fire walls should not be used on more than two sides of a facility, or where the ventilation would be impaired,
and normally they should only be used on one side of a tank or tank grouping. In exceptional circumstances

fire walls may be used along one long side and two short sides of a tank installation if a risk assessment shows
that measures have been taken to bring the risk to As Low As Reasonably Practicable (ALARP). Also:
 They should be sited no closer than 1.5 metres from the nearest point of the tank
 Separation distances may be reduced to the distance around the ends of the fire wall to a public
place as defined in Table 1
 A fire wall for a tank up to 2,500 litres water capacity may form part of a building
3.3.3 Construction
Fire walls should be solid, without any openings, and made of brick, concrete or other suitable non
– combustible material (see Figures 1 & 2). They should also be:
 Capable of resisting fire for 60 minutes
 Totally within the boundary of the LPG storage area
 (For tanks up to 2,500 litres water capacity), as high as the top of the tank or highest piece
of high pressure or liquid pipework or fitting connected directly to the tank, and may form
part of a building or site boundary
 (For tanks over 2,500 litres water capacity), at least 2 metres high, or as high as the top of
the tank, or highest piece of high pressure or liquid pipework or fitting connected directly
to the tank, whichever is the greater
Figure 1 - Fire wall for tanks 2,500 litres or less

(Source: UK LPGA COP 1)

Figure 2 - Tank compound with fire wall and security fence
(Source: UK LPGA COP 1)
3.4 Site Security

3.4.1 General
All tanks, fittings and equipment should be protected from accidental damage or vandalism. The
level of security required will depend on how accessible the tank site is to the public.
3.4.2 Sites with Restricted Public Access
These sites may not need individual fences for tanks, pumps and vaporisers if the tanks are smaller
than 9,000 litres water capacity and valves and fittings are inaccessible, e.g. use open mesh wire
fencing between the support pillars. A lockable cover may be used if the key is available in an
emergency and the cover is locked at all other times except during tank filling. Examples of sites
with restricted public access include domestic installations, industrial installations with perimeter
fences and having continuous surveillance, etc.
3.4.3 Sites with Unrestricted Access to Public
Sites such as Autogas (LPG for transport) refuelling stations, open plan industrial sites, housing
estates, etc. where the public has uncontrolled access, should be secured by a security fence based
on the following guidelines:
 Up to 2,500 litre water capacity LPG storage tanks – the fence should be at least 1.5 metres
from the tank
 Above 2,500 litre water capacity LPG storage tanks – the fence should be at least 3 metres
from the tank

 Arrangements should also prevent the build-up of combustible materials and uncontrolled
siting of ignition sources within the separation area (e.g. weeds, rubbish etc)
3.4.4 Security Fence Construction
 The design of security fences should not

significantly impair ventilation across the site.
Wooden designs should be avoided as they
burn easily and obstruct ventilation
 The security fence should be at least 1.8

metres high and made of strong industrial
grade wire mesh e.g. 12-gauge chain link, or
12-gauge 52mm x 55mm mesh welded
panels, fixed to concrete or steel pillars
Above ground tank inside secure compound
 There should be at least two means of exit at
opposite sides of the security fence to minimise the distance personnel have to travel to escape
in case of an incident. Gates or access should open outwards and be easily and immediately
opened from inside. They should not be self- locking and should provide an unobstructed
means of escape
3.5 Protection Against Damage from Vehicles

3.5.1 Location
Do not site tanks, pipes and associated equipment in areas used by vehicles; if this cannot be
avoided, install strong bollards or crash barriers appropriate to the size and weight of vehicles likely
to use the roads in the area. Never rely simply on the security fence or the use of warning signage
or road marking.
3.5.2 Vehicle Parking Area
Designating a parking area for vehicles away from the LPG tanks can reduce the risk of vehicular
damage. Classify the parking areas according to the type of vehicle being parked i.e.
 Vehicles controlled by the site operator should be parked no closer than 3 metres,
providing that ventilation around the tank is not obstructed
 Vehicles not controlled by the site operator (e.g. driven by the public), should not be
parked any closer than 3 metres or the separation distances in Table 1, whichever is the
greater

4.0 Tank Design
4.1 General
LPG is a hazardous product which needs to be contained inside pressure vessels and any uncontrolled
discharge prevented. Tank failures due to poor construction can result in serious consequences. For this
reason, pressurised tanks should be designed and manufactured to a recognised code or standard to ensure
their safety.
At customer sites, where the majority of the pressurised tanks are installed, tanks that are supplied and
owned by customers should be verified by the LPG supplying company that the specifications comply with
the required standards or codes and that they are fit for service before filling.
4.2 Design Code
LPG tanks should be designed, manufactured, inspected and tested in accordance with a recognised design
code e.g. ASME VIII, etc. Where local regulations require the use of national standards or alternative codes
it is important to confirm that they at least equal the requirements of ASME VIII or the equivalent.
The design of any tank should be based on the application of a single standard only. The application of
mixed standards to the design of a tank should be avoided.
4.3 Design Conditions

4.3.1 Maximum Pressure
 Tanks should be designed to safely contain the vapour pressure of the product at the assessed
temperature for the location and conditions where the tank will be installed, and dependent
on the reflectivity of the tank
 Where tanks will be used for butane, propane, and mixtures of the two, at different times, the
standards shown for propane should be followed EXCEPT for minimum safe operating
pressure, which should follow the butane recommendation
 In determining the maximum design safe operating pressure, the assessed temperature will
either be established by national and/or local regulations, by the design code for the location,
or Table 6 can be used for guidance for tanks which are painted white
4.3.2 Vacuum Conditions
If the product to be contained in the tank is butane, and where the atmospheric temperature at its
intended site could fall below zero degrees (freezing), then the tank should be capable of
withstanding negative pressure. Alternatively, the installation can incorporate positive means for
preventing unacceptable vacuum conditions to occur in the tank i.e. the use of a propane vapour
pressurisation system or a hot vapour return system.

Table 6 - Developed Pressure
Location Tank Water Capacity Assessed Temperature Developed Pressure

(litres) o
C Bar gauge
Butane Propane
< 7,000 6.5 16

Temperate Climate 35
>7,000 5.5 15
<7,000 7.2 18
Tropical Climate 40
>7,000 6.2 17
<7,000 7.9 20
Desert Climate 45
>7,000 6.9 19
Note: In practice, many tanks are manufactured to standard design pressures.
4.3.3 Construction
 Pressurised LPG tanks are either spherical or cylindrical in shape. Larger capacities tend to be
spherical which requires less space but a more complex construction process
 Cylindrical LPG tanks have either semi-ellipsoidal or hemispherical ends depending on the
requirement. The majority of cylindrical LPG tanks are designed for horizontal installations but
vertical tanks are also used, primarily if space is a premium
 LPG tanks should be of welded steel construction. The steel used should have suitable
properties, particularly regarding impact resistance and for operation over a range of
temperatures between minus 20oC and 50oC
 Tanks with capacities up to 2,500 litres should have a hinged, lockable hood to protect fittings
and prevent unauthorised tampering
 Above ground tanks should be painted a light colour, preferably white, to increase reflection and
minimise the temperature rise of the contents from solar heat gain
4.3.4 Maximum Filling Capacity
LPG vessels, including tanks and cylinders, are commonly filled to around 80% of their water
capacity to allow for the high liquid expansion rate of LPG with increased temperature.
 The maximum quantity of LPG which may be filled into any tank should be such that the tank
will not exceed 97% liquid full due to expansion of its contents at the assessed temperature
(ref 4.3.1). This is to prevent uncontrolled discharge of LPG through the pressure relief valve
 The maximum filling capacity by volume is calculated as follows:

Vf = 0.97 x V x gi/gL
Where: Vf = maximum safe fill volume, litres
V = water capacity of storage tank, litres
gi = density of LPG at assessed temperature (ref 4.3.1), kg/litre
gL = density of LPG at lowest possible fill temperature, kg/litre

 To avoid overfilling of LPG tanks, a common practice is to terminate filling once the liquid
level reaches 80-85% of tank capacity, as indicated by level gauges.
4.4 Corrosion Protection
The tank and tank supports should be adequately protected against corrosion preferably by zinc metal
spraying and painting. This should be done after suitable preparation such as grit blasting or chemical
treatment. Any form of corrosion protection should allow for tank expansion/contraction occurring
with changes in temperature and internal vapour pressure. Attention should be given to the protection
of the internal faces of flanges and flange studs/bolts against corrosion.
4.5 Tank supports
 Design for tank supports should comply with the relevant tank construction code of practice. In
particular the tank supports should:
o Allow the tank to move within the range of temperature change

o Permit the drainage of any water
o Located (for horizontal tanks) to give minimum deflections and movements to the tank
shell
o Be reinforced with extra supports where appropriate
 Supports may not be necessary for underground tanks, but they may be required where it is
necessary to anchor the tank because of potential flotation, especially in areas prone to flooding
 Tanks should be installed on structural steel, concrete or brick supports, with solid foundations.
Supports should be fire resistant to a standard of at least 2 hours (except 460mm high or smaller
feet, tank saddles or skirts for vertical tanks.
 The supports should be strong enough to support the tank when full of water. Vertical tanks should
have an open support structure that encourages effective airflow and provides explosion relief.
Where cylindrical supporting skirts are used, pipes from the tank within the skirt should have
welded or welded flanged joints
4.6 Tank Markings and Labelling

4.6.1 Purpose
 Tank markings help highlight the hazards associated with the product contained inside the tank
and prevent confusion at any time during normal operations or an emergency, which may
either precipitate or aggravate an incident
 The markings and labels should be visible, legible, and indelible. If tags or plates are used, they
should be securely fixed to the parts to which they relate. Paper labeling should never be used.
4.6.2 Specific Information
The following design, manufacturing and operational information should be plated on the tank:
 Design code
 Maximum operating pressure

 Minimum operating pressure
 Maximum design temperature
 Minimum design temperature
 Date of manufacture
 Manufacturer’s identity
 Serial Number
 Water capacity
 Date of test
 Test pressure
 Inspection authority’s identification
4.6.3 Labels
 ‘Liquefied Petroleum Gas’ should be clearly painted on the tank or, if there is any risk of
confusion, a more detailed description of tank contents; the words ‘Highly Flammable’ or a
suitable visual symbol should also be added
 Emergency contact telephone numbers should be displayed or readily available particularly at

customer sites
4.6.4 Warning Notices
 Prohibition of smoking or naked flames, and ‘NO Unauthorised Entry’ signs (if applicable)
should be indicated by warning notices complying with local regulations.
 Warning signs should be durable, clearly visible and legible from the applicable separation
distance (Table 1) and should be firmly fixed to the fence/wall or the tank itself
4.6.5 De-stenched/Odourless LPG
Special precautions are required when LPG is supplied or used after de-stenching or with a low
odour e.g. for use in aerosols as a propellant. This includes the following:
 Clearly mark tanks to indicate contents are de-stenched or odourless
 Fit pressure gauges to all tanks
 Identify pipework as carrying odourless products
 Where practicable pipework should be welded and flanged
 Provide sampling points, drain connections and means of isolating plant sections where
quality is a consideration
 Filling connections on the tank installation and delivery vehicle hose end should have left-
hand screw threads, or alternative distinctly different connections to those used for

stenched product, to prevent the delivery of odourless product into stenched storage or
vice versa
 A competent person familiar with the product should carry out regular visual inspections
for leaks
 Install gas detection systems
4.7 Mounded and Underground Tanks

4.7.1 Location
Mounded and underground tanks should be

located outside of buildings and in ground
which is well drained and less prone to
flooding. Buildings or any structures should
not be constructed over any underground or
mounded tanks.
4.7.2 Superimposed Load
Consideration should be given to the additional

stress caused by the pressure of the back fill or
covering and any other superimposed load such as
differential settlement, flotation restraint, frost,
snow or drought protection. Typical Mounded LPG Tank Installation
4.7.3 Excavation
Excavation should be large enough to allow for easy installation and a gap of at least 1 metre between the
tank and the walls before backfilling.
4.7.4 Foundation
 A solid foundation for the tank is required, protected from scouring and erosion by storm waters and
flooding. Underground tanks may be placed in excavated ground without additional added foundations
where ground conditions are appropriate
 Measures to avoid flotation or movement should be provided in the event of flooding
4.7.5 Covering
 Mounded tanks should be covered and underground tanks backfilled with a material that is:
 Inert and non-corrosive
 Non-abrasive and free of particles which are likely to damage the tank coating
 Resistant to thermal radiation
 A consistent minimum of 300 mm in depth (when compacted) for tanks up to 13,000 litres water
capacity. For larger tanks this should be increased to 500 mm
 Robust enough to resist jet flame impingement

 In the case of underground tanks, protected by an impact resistant coating to a relevant standard,
some of the earth removed to install the tank may be used to back-fill the installation. The use of
dry washed sand is preferred for back filling.
 The area above the tank may be covered with concrete slabs or covered in shingle. If turf is used
consideration should be given to the need for ongoing maintenance (e.g. keeping grass short and
preventing weeds).
4.7.6 Manhole
A manhole of minimum 600mm nominal diameter should be fitted to mounded and underground tanks to
provide access for inspection. If this is not done, it may be necessary to excavate the tank when inspection is
due (when tank fittings are attached directly to the tank and not via a manhole).
4.7.7 Corrosion Protection
 A suitable system of cathodic protection (typically sacrificial anode for small installations and impressed
current for large installations) should be provided. Appropriate current and voltage readings should be
taken periodically, recorded and analysed to ensure that the condition of the tank is effectively
monitored
 Tanks provided with cathodic protection should be electrically isolated from metallic piping to ensure
the life of the anodes will not be shortened unnecessarily.
 External surfaces of the tank should be suitably prepared and treated with a coating manufactured and
applied in accordance with a recognised standard, to both protect against chemical and mechanical
damage and minimise cathodic protection current drain
 Avoid damage to the tank coating during installation. Fault detection equipment should be used to
check that the coating is intact. Rectification of any damage should be completed before back-filling the
tank
4.7.8 Small Mounded/Underground Tanks
Special requirements for tanks below 5,000 litres water capacity are as follows:
 A manhole to facilitate internal periodic inspection is not needed, provided a cathodic protection system
is fitted and the effectiveness of the protection is monitored and recorded at intervals not exceeding a
year. If the effectiveness of the cathodic protection is proved to continue to be satisfactory, the
maintenance interval may be extended. Under these conditions the tank may remain in service
underground for up to 20 years
 Locate the underground tank such that vehicular traffic does not pass over it, unless a load bearing
structure has been constructed to prevent any load being transferred to the tank
 Small underground tanks may be installed in open ground without supports on a bed of sand or other
suitable material if account is taken of the need to avoid uneven stressing of the tank shell, flotation and
movement
 A means of removing liquid product should be located in the top section of the tank, with an internal
pipe to the bottom of the tank
 A protective valve cover need not have a hole for relief valve discharge

4.8 Skid Mounted and Mobile Tanks
4.8.1 Skid Mounted Tanks
LPG tanks which are fabricated with permanently mounted skids or runners that are not designed
to transport LPG.
4.8.2 Mobile Tanks
LPG tanks which are mounted on their own wheels, or a trailer, should be designed and operated
in accordance with road transport specifications. Under no circumstances should a mobile tank
incorporating a tank designed for static use be used for delivery operations.
4.8.3 Separation Distances
All skid mounted and mobile tanks should comply with the fixed tank separation distances in Table
1. Preference should be given to fixed tank installations, as skid mounted and mobile tanks are not
as safe, being temporary and uncontrolled in nature.

5.0 Tank Fittings
5.1 General
5.1.1. Suitability
Tank fittings used should be made of materials compatible with LPG and designed to suit the range
of pressures and temperatures that will occur in service.
5.1.2 Minimum Fittings
Every tank should have at least one each of the following:
 A pressure relief valve directly connected to the vapour space
 A maximum liquid level indicator, or maximum level fill stop valve, and a contents gauge.
Where both devices are installed, they should be independent of each other to provide a
separate means to monitor contents and prevent overfilling
 A filling connection
 A service outlet connection(s) for vapour and/or liquid duty if required
 A drain connection, or some other way of draining liquid product, and possible contaminants,
from the tank.
 A pressure gauge for tanks over 5,000 litres water capacity
 A temperature gauge may be required if stock reconciliation needs to be carried out
 A vacuum prevention measure where excessive vacuum may occur i.e. storage of butane in
low temperatures
5.1.3 Location of Fittings
Minimise the number of direct connections below the liquid level to lower the risk of leakage of
liquid LPG. Wherever possible, only one connection, excluding the drain line, should be provided
and all the rest should terminate at the vapour space.
5.2 Pressure Relief Valves

5.2.1 General
All above ground tanks should be fitted with one or more pressure relief valves (PRV), in compliance
with a recognised code of practice, which will protect the tank in the event of a fire. The setting
and sizing of the pressure relief valve(s) should protect the tank from overpressure of more than
120% of the design pressure, which could be generated under fire exposure conditions.

5.2.2 Mounded and Underground Tanks
For mounded or underground tanks, the full flow capacity of pressure relief valves may be reduced
to a value that can be shown to adequately protect the tank. Calculation of this value should also
consider whether the relief valves are required to prevent overpressure of the tank by overfilling
and may therefore require a capacity to relieve liquid LPG at the maximum filling rate. This should
not be lower than 30% of the required flow capacity for an equivalent above ground tank.
5.2.3 Isolation Valves
Care should be taken to ensure that the design and certified discharge capacity of pressure relief
valves are not restricted by the introduction of check valves etc. which may be used to facilitate
exchange whilst the tank remains in service, i.e. the relief valve(s) may have to have more capacity
than that calculated without the check valve in order to deliver the correct amount of LPG when a
check-valve is used (seek manufacturer’s data for flow reduction).
 Manual isolation valves should not be fitted between the tank vapour space and a single
pressure relief valve. They may inadvertently be left closed and block the PRV
 With single pressure relief valves – an automatic shut-off valve should be installed to allow for
the removal of the relief valve for servicing/testing to take place; this should be fully ‘open’
when the relief valve is in place and ‘closed’ before the relief valve is removed. The tank should
never be left unprotected and a replacement relief valve should be fitted immediately
 Where multiple pressure relief valves are fitted with provision to allow for the removal and
servicing of individual pressure relief valves, the remaining pressure relief valves should have
adequate capacity to provide full protection for the tank
5.2.4 Vent Pipes
Vent pipes are fitted on pressure relief valves to prevent ignited LPG flames from impinging on the
tank, pipework, equipment or nearby tanks. They should be used on tanks over 1,500 mm internal
diameter and greater than 5,000 litres water capacity. In fitting vent pipes, the following should be
considered
 Vent pipes should be adequately supported, with outlets at least 1.8 metres above the tank
for above ground and mounded tanks, and at least 2.1 metres above ground level for
underground tanks to which they are fitted
 Vent pipes should be carefully designed to avoid the risk of mechanical damage to the relief
valve(s)
 Vent pipes should be protected against corrosion and be fitted with loose-fit rain caps, with
provision for water drainage
 Vent pipes may need protection in high wind areas

5.3 Drain Connections
LPG tanks require a specific valve and piping arrangement to ensure draining can be done safely and the
freeze up of drain valves is to be avoided.
5.3.1 Specifications
 Drain connections should be provided with two shut off valves in series which are of the quick
acting type that can be used during draining operations. The nominal bore diameter of each
valve should not be greater than 50 mm
 Both valves on the drain system should have a means of actuation which cannot readily be
removed, or moved from the closed position, except by intentional operation
 The two valves should be separated by at least 500 mm to avoid freezing water, which may be
present in the LPG, obstructing both valves at the same time, but close enough to allow
operation of both valves by a single person
 The second valve, and piping, should be adequately fixed in place to prevent breakage by
vibration and jet forces or mechanical damage and should not discharge under the tank
 At customer premises, the drainpipe and second valve should be removed, and the primary
valve plugged or flanged off. When draining is performed by trained personnel, they should
bring with them the required drainpipe and second valve. At depots, the entire drainage
assembly may remain in place. Small tanks may alternatively be fitted with a check valve and
internal dip tube
 Keeping the second valve to not greater than 25 mm nominal bore diameter and using spring-
loaded dead man operation type can enhance the safety of the installation.
5.3.2 Safety Distance
Drain lines should discharge more than 6 metres away from any system of surface water drainage.
5.4 Contents Gauges

5.4.1 Purpose
Content gauges are used for indicating accurately when a tank is full at its maximum normal
capacity. Gauges that operate by releasing LPG into the atmosphere should have a maximum
opening diameter of 1.5 mm for its bleeder
Contents gauges should indicate clearly whether they read in % of water capacity, % of fractional
LPG capacity, or actual contents in gallons, litres, tonnes, etc.
5.4.2 Fixed Liquid Level Devices
These indicate when the maximum liquid level is reached during filling by allowing vapour or liquid
to discharge to atmosphere from a valve attached to a dip tube, the design length of which is
determined by the maximum permissible fill for the grade of LPG stored. Where possible, bleed

jets from fixed liquid level gauges should be fitted so that the discharge jet is vertical. This enables
the most rapid dilution of the vapour cloud and the least possible size of flammable cloud.
5.4.3 Tanks Below 5,000 Litres
Tanks below 5,000 litres will normally be fitted with a simple magnetic float gauge in addition to
the mandatory fixed liquid level device.
5.4.4 Tanks 5,000 Litres and Above
These tanks should normally be equipped with a contents gauge which may be a simple magnetic
float gauge, capacitance gauge or rotary gauge etc., in addition to a fixed liquid level gauge. Larger
storage tanks in terminals and depots requiring more accurate content gauges for stock accounting
purposes are typically equipped with radar type level gauges.
5.4.5 Maximum Level Fill Stop Valve
An alternative to a fixed liquid level gauge described in 5.4.2 is a purpose designed automatic shut-
off valve which is activated by a float or other means so that it shuts positively during filling when
the maximum level is reached. Fill stop valves and actuation mechanisms should be of adequate
proven reliability for a life expectancy not less than the storage tank inspection or maintenance
interval.
5.4.6 Slip Tubes and Sight Glasses
These devices are not recommended for use as level indicators on LPG tanks for safety reasons.
They should be replaced with more suitable devices when the tank is next gas freed.
5.4.7 High - and Low - Level Alarms
These may be fitted to monitor abnormally high and low liquid levels. High level alarms if fitted
should be designed to interlock with emergency shut down valves (ESD) to shut off the flow of LPG
into the storage tank when the highest set point has been reached. Low level alarms are fitted as
protection for pumps against cavitation or ‘dry running’.
5.5 Service Valves

5.5.1 Requirements
All tank vapour and liquid service outlet connections should have a service/isolation valve, except
where pressure relief valves are fitted, or where tank connections are less than 1.5 mm in diameter.
They should be suitable for LPG and be fitted directly to the tank or immediately after the first
flange.

5.5.2 Protection
Vapour connections greater than 8 mm diameter and liquid connections

(including drains) greater than 3 mm diameter should be protected with
an excess flow valve (installed upstream), non-return valve or a remotely
operated emergency shutdown valve.
5.5.3 Multi-Valves
Vapour service valves on small tanks (typically up to and including 9,000 Emergency shut down valve
litres water capacity) may be incorporated in either individual or
combination brass multi-valves. This eliminates the need to have too many openings on a small
tank.
5.5.4 Liquid Service Valves
These should be fire safe, quick acting ball valves. For tanks up to and including 9,000 litres water
capacity a specifically designed LPG liquid offtake valve incorporating an excess flow valve may be
used.
5.6 Filling Connection

5.6.1 Direct Connection
LPG tanks should be equipped with a liquid fill connection, which connects directly to the vapour
space of the tank. The filling connection should be positioned for easy access to connect the filling
gun. For larger tanks, this can be achieved by extending the fill connection at the top of the tank to
a convenient point at ground level to avoid having to drag the filling hose up access steps.
Alternatively, the liquid fill connection can be designed to enter the tank via a welded boss and
internal pipe to the vapour space. If access steps are fitted, they should be designed to enable safe
access by the operator.
5.6.2 Spray Filling
The internal discharge from fill connections should be designed to form a liquid spray in the vapour
space of the tank to facilitate rapid transfer. Care should be taken to avoid liquid spray entering
the vapour service connections.
5.6.3 Manual Shut-Off
The filling connection should be equipped with a manual shut- off valve and automatic back check
valve. On tanks below 5,000 litres capacity where a manual shut-off valve is not fitted, the delivery
tanker should use a filling gun adaptor with an additional back check valve. If the automatic filler
valve on the tank fails to close, the adaptor on the end of the filling gun can be left in place and
capped to seal off the leakage until the valve on the tank can be replaced. The road tanker should
therefore carry a spare adaptor if it is to continue making deliveries to similarly equipped tanks.
5.6.4 Vapour Balance
During the filling operation, the pressure inside the tank may increase and vapour balancing lines
will help equalise the pressure between the delivery vehicle and receiving tank to expedite filling.

This is commonly used for internal depot transfers but not recommended for metred customer
deliveries because the vapour returns are not accounted for in the metred quantity delivered.
5.6.5 Couplings and Adapters
 Filling systems should be designed and installed to avoid the use of adapters during normal
operations. A common system used in the industry is the ACME type quick connect coupling.
Right Hand Acme threaded couplings are normally used for tanks storing commercial grades of
odourised LPG. Left Hand Acme threaded couplings are used for tanks storing unodourised
product for distinction (see 4.6.5). ACME couplings come in different thread sizes and the
correct one should be selected for compatibility
 Self-sealing couplings provide added safety but are not compatible with ACME couplings. They
are designed to emit minimal LPG and seal automatically once disconnected from the fill point
even when disconnection occurs accidentally
 Where there is an opportunity to standardise to one type of fill coupling, the use of self-sealing
couplings is recommended
5.7 Pressure Gauges
Pressure gauges, when fitted, should be installed directly into the vapour space of the tank and easily
readable from ground level. Pressure gauge connections should be protected either by a tapping
reduced internally to a bleed hole not larger than 1.5 mm diameter or by a suitable excess flow valve
and shut-off valve.
5.8 Temperature Gauges
Temperature gauges, when fitted (normally for stock accounting purposes), should be installed in blind
pockets. These should be in the form of blind tubes of suitable length and strength, oil filled,
permanently welded to the tank and constructed in accordance with the tank design Code.
5.9 Hydrostatic Valves

5.9.1 Requirement
Wherever liquid LPG may be trapped along the pipework (for example between shut-off valves or
blank flanges), protection against excessive pressure caused by thermal expansion of the contents
should be provided. This is normally achieved using hydrostatic relief valves.
5.9.2 Discharge Setting
Hydrostatic relief valves should be set to discharge above the maximum working pressure in the
line but not greater than the design pressure of the pipework and components in the section to be
protected. For hydrostatic relief valves which discharge to the open air, the set pressure should not
be less than the following:
Propane: Not less than 24 bar gauge (Not less than 18 bar gauge where ANSI150
or equivalent flanges are used);

Butane: Not less than 10 bar gauge.
5.9.3 Installation
Hydrostatic relief valves which discharge to the open should be located and orientated so as not
to endanger personnel, tanks or equipment, and should be fitted with rain caps where their
location dictates.
5.10 Emergency Shutdown Valves

5.10.1 Type
Emergency shutdown (ESD) valves are remotely operated, positive, fail closed, shut-off valves, used
to isolate tanks and sections of piping/equipment in emergency situations.
5.10.2 Automatic Operation
ESD valves should preferably be actuated automatically, e.g. by a fusible link in the energy supply
to the actuator, by the plant alarm system and/or gas detection system, or by manual control. They
should preferably be pneumatically actuated and designed to operate in a controlled manner (not
snap action) to avoid pressure surges which could lift hydrostatic relief valves, or on opening cause
inadvertent operation of excess flow valves etc.
5.10.3 Installation
ESD valves should be installed for tanks of 5,000 litres and greater capacity with liquid service
connections having a nominal internal diameter 25 mm or greater and where:
 There are routine LPG depot operations such as cylinder filling, tanker transfer activities,
or
 The public has unrestricted access to the activity e.g. hospitals or schools, or
 Where there are people who may be present, and who are not familiar with the emergency
procedures and where prompt evacuation would be difficult e.g. Autogas refuelling sites
and forklift truck facilities
Consideration should be given to installing ESD valves in smaller sized liquid services or even vapour
services at strategic points in critical locations such as Autogas refuelling sites and cylinder filling
plants to ensure overall emergency control.
5.10.4 Locations
Careful attention should be given to the location of the remote controls for ESD valves, and to the
number of ESD valves included in a single shut-down system. For example, in a small depot or
customer installation it may be considered safer to include all ESD valves in a single system, such
that all ESD valves in the system are closed simultaneously, whereas in other plants it may be
necessary to use several ESD systems.

The shutdown controls should be located at various positions over the site and should be clearly
indicated with an appropriate notice.
 For LPG depots and filling plants, the location of the controls for ESD valves will depend
on the manner in which the plant is supervised and operated, but the number of positions
from which the ESD valves can be activated should be limited to the minimum required for
safe operation
 For Autogas sites, the controls should be located at the control point in the sales kiosk, LPG
tank compound adjacent to each exit, and incorporated at the site main exterior
emergency switch
 industrial and commercial installations, the controls should be located not less than 7.5 m
and not more than 30.0 m from the tank or liquid transfer point and should be along the
path of egress from the point of transfer
5.11 Lightning Protection
Lightning protection is often not required on LPG tanks, but local requirements should be checked and
applied, particularly in respect of vertical tanks.

6.0 Pumps, Compressors, Vapourisers and Dispensers
6.1 General
 The design of pumps, compressors, vapourisers, etc. and the materials used in their construction
should be suitable for the safe handling of LPG over the range of pressures and temperatures that
the product will reach in service
 Castings that contain pressure should be of suitable carbon steel that have adequate ductility and
resistance to brittle fracture
 The electric motor used should be suitable for operating in a potentially flammable atmosphere
according to the zone if located within a hazardous area Zone 1 or 2
6.2 Pumps
6.2.1 Design
Pumps used at LPG installations should comply with the following:
 Designed with internal bypass to minimise heating of recirculated products which could
lead to cavitation. Positive displacement pumps should have a bypass or other suitable
protection against excessive pressures
 The available pressure head at the pump inlet at maximum off-take rate under the most
onerous specified operating conditions should be adequate to ensure proper operation
and avoid cavitation
 Equipped with mechanical seals rather than packed glands
 Protected by guard such that no part of the transmission is left exposed, to avoid personnel
coming into contact with moving parts
 Protected against dry running where pump is installed on Autogas fuelling sites
6.2.2 Installation
Pump installations should meet the following requirements:
 Pumps should not be located under tanks
 Flange connections should be arranged such that a gasket failure would not result in direct
flame impingement on LPG tanks
 Correct alignment of drive unit and pump should be ensured if they are not integral units
 Pump sets should be installed rigidly on suitable foundations
 Suction piping should be as short and direct as possible

 Positive displacement pumps, and ideally centrifugal pumps, should be fitted with a bypass
back to the LPG storage tank to prevent excessive pressure developing
 A suitable strainer/filter should be fitted on the pump inlet
 A flameproof isolation lockout should be fitted adjacent to the pump set, to prevent
remote starter operation during maintenance shutdown
6.3 Compressors
6.3.1 Design
Compressors used at LPG installations should comply with the following:
 Oil free compressors should be specified to ensure acceptable product quality
 A liquid trap should be fitted in the suction piping to prevent liquid entering the
compressor
 A pressure-relieving device should be fitted on the delivery side of the compressor
 A high-pressure shut-off switch (or similar) should be fitted on the discharge side
 A flame proof means of isolation with lockout should be fitted into the compressor motor
supply to protect personnel and equipment against inadvertent operation
6.3.2 Installation
Compressor installations should comply with the following:
 Located in the open air, with good ventilation, at least 1.5 metres from buildings,
boundaries and any LPG tanks
 Located in buildings only if they are purpose-built (and used) and made of non-combustible
materials, with good (especially low level) natural ventilation and a lightweight roof
6.4 Vapourisers
6.4.1 Types
There are five basic types of vapouriser, all of which should be capable of vapourising LPG at the
maximum offtake rate needed from the installation:
 Low pressure steam-heated
 Hot water heated
 Electrically heated

 Direct gas fired (This type of vapouriser should not be used and should be replaced at the
earliest opportunity)
 Atmospheric
6.4.2 Design
Vapourisers used at LPG installations should comply with the following requirements:
 Heat exchangers should be designed and constructed in accordance with an approved

pressure vessel code
 The design pressure should be not less than 17 bars or the set pressure of the relief valve
whichever is the greater. In all cases the design pressure should be at least that of the LPG
liquid installation
 Shell and tubes in contact with LPG should be constructed of steel
 The design of hot water and steam units should ensure that there is no risk of water (or
steam condensate) freezing during periods of high offtake or low ambient temperature
conditions.
 The vapouriser capacity should be not less than that required for the conversion of liquid
to vapour at a temperature above dew point at the maximum first stage regulator inlet
pressure and maximum offtake rate
 Vapourisers should be provided with automatic means to prevent the passage of liquid LPG
through the vaporiser to the vapor discharge piping
 Water bath type vapourisers should be provided with devices to limit the temperature of
the water bath and prevent the pressure from exceeding the design pressure
 The vapouriser and all piping components, and relief valves up to and including the
discharge valve, should be designed for the same conditions as the inlet pipework
6.4.3 Location
Vapourisers should be sited such that the minimum distance from the nearest important building
or line of property is as follows:
 3 metres for up to 36 kg/hr. capacity
 7.5 metres for 37 to 227 kg/hr. capacity
 15 metres for over 227 kg/hr. capacity
Vapourisers may be mounted on the wall of a building, if the wall can be considered to be a fire
wall, with a defined fire resistance, and have no openings.

6.4.4 Precautions
Precautions should be taken to:
 Prevent the accumulation of condensate in all pipelines carrying LPG vapour. This may take the
form of insulation or heat tracing. Drain pots should be provided and all horizontal pipe runs
should be inclined slightly rising away from the vapouriser so that any condensate runs back to
a drain pot
 Avoid freezing of the steam condensate or water associated with steam or hot water
vapourisers
6.5 Dispensers
6.5.1 Design
LPG dispensers used at Autogas refuelling sites should comply with the following:
 Equipped with a suitable flexible hose and filling control nozzle; liquid flow should only be
possible when the nozzle is connected to the vehicle’s fill connection. The design of the
nozzle should both minimise the release of LPG at disconnection and provide means for
safely venting away any liquid that may be trapped in the nozzle
 Dispensing is controlled by a ‘dead man’s handle’ where release of the control handle or
button will stop the flow of LPG through the dispenser
 Dispenser hoses are provided with a

breakaway/pull-away coupling correctly designed
and installed to minimise damage and loss of
product due to a vehicle driving off whilst still
connected to the dispenser
 Excess flow valves, or emergency shutdown valves

(ESD), are provided to prevent uncontrolled Breakaway coupling
release of LPG in the event of hose failure or
vehicular impact on the dispenser. The excess flow valve or ESD should be positioned in
such a way that it remains intact and functioning even after the dispenser has been
damaged
 A provision for a shear valve or dry break valve in the dispenser base to shut off in case of
high impact
6.5.2 Installation
 LPG dispensers should be installed in accordance with Table 5 and at least 3.0m from the fuel
dispensers for Class I and II liquids. This distance can be reduced to 2.0m with low emission
transfer systems

 LPG dispensers and filling hoses anchoring points at Autogas refuelling sites should be
positioned so that:
o Vehicles can be refueled easily in a convenient position
o Vehicles being refueled do not restrict the movement of others
o Hoses should not be twisted or extended unduly
o Hoses should not be damaged by contact with vehicles, stanchions’ or other

obstructions
 The meters and filling hose attachments to fixed pipework should be located to minimise the
chance of vehicular damage and consideration given to protection by the use of bollards, crash
barriers, curbing, or mounting on a raised plinth
 At attended self-service refuelling stations, meters and filling hoses should be located where
the vehicle being filled can be adequately viewed and supervised from the sales kiosk
 ESD control buttons/switches should be located in the sales kiosk and on the forecourt and be
readily accessible to the cashier/operator to isolate the electrical supply to pumps and
dispensers and to allow remote operation of the ESD valves on LPG storage tanks and, where
fitted in LPG liquid risers to dispensers

7.0 Pipework and Regulators
7.1 Pipework
7.1.1 Design
 Pipework and fittings should comply with the relevant standards and be of a material suitable
for LPG and the extreme service conditions likely to be encountered
 The number of joints in pipework should be minimised. In steel pipework over 50mm nominal
bore it is particularly important to minimise the number of flanges
 Pipework should be welded where possible and flanges should not be orientated in a position
where the failure of a gasket could result in an ignited leakage causing a jet flame to impinge
on an LPG tank or other pressurised equipment
 In addition, it is important to remember that one release, if ignited, may cause a cascade effect
by impinging on another fitting. Eliminate this possibility by good design
7.1.2 Materials
Materials commonly used in LPG pipework are:
 Carbon steel – Seamless pipe to an acceptable thickness or galvanized heavy/medium weight

welded seam pipe
 Copper - Half hard or annealed solid drawn copper. The risks of work hardening should be
considered. Copper pipes or tubes are not suitable for pipework carrying liquid LPG
 Polyethylene (PE) - This type of pipe, if to a suitable standard e.g. ASTM D2513, ISO 4437, etc.
can be used for LPG vapour and LPG/air mixtures, provided it is buried. In general, medium
density PE is suitable for use with LPG vapour at pressures up to 4 bar and a temperature range
of minus 20oC to 40oC
 Corrugated Stainless Steel – Proprietary brands of flexible stainless-steel pipe may be used for
underground liquid LPG service at Autogas forecourts and similar installations
7.1.3 Types of Pipework
LPG pipework can be classified as follows:
 Vapour application below 5 bar - Carbon steel, copper up to 35 mm diameter or PE (for

underground) may be used. Multilayer pipes manufactured to ISO 17484 may be used for
indoor gas piping.
 Vapour application 5 bar and above - Seamless carbon steel to an acceptable thickness or
copper up to 15 mm diameter may be used
 Liquid application - Seamless carbon steel to an acceptable thickness should be used

 Over 50 mm nominal bore - Seamless carbon steel to an acceptable thickness should be used
7.1.4 Type of Fittings
 Screwed joints may be used for pipework with an outside diameter of 50mm or less
 Welded or flanged joints (except when attaching to equipment with screw fittings) should be
used for outside diameters greater than 50 mm and should be of an appropriate class and be
raised face weld neck type. Spiral wound graphite filled metal gaskets (ASME B16.20) are
preferred over asbestos gasket for flanges in pipework carrying liquid LPG. Jointing compounds
for screwed connections, flanged gaskets and any other component parts should be suitable
for use with LPG
 Heat fusion or mechanically jointed fittings may be used for copper, multilayer or polyethylene
pipe. The latter should be designed to resist the pipe from pulling out
7.1.5 Supports and Anchors
 Pipework supports and anchors should be located and designed to ensure that pipework
stresses and deflections due to predictable loads are within acceptable limits. If necessary, this
should include flexibility to accommodate any unavoidable movement e.g. caused by changes
in ambient temperature. The recommended maximum distance between supports for steel
pipe is shown in Table 7 below.
Pipe Size Dia. Span

(mm) (metres)
15 2.0
20 2.5
25 3.0
40 3.5
50 4.0
Table 7 - Distances between Supports for Steel Pipe
 In determining pipe supports and their location, consideration should be given to loads other
than self-weight and other predictable loads, e.g. for small pipework superimposed loads due
to personnel standing on, or pulling on, pipework
 Vibration, surge pressures and valve operating torque should be considered in the design of
pipework and supports incorporating mechanical equipment such as pumps and valves
 When laid in an open trench, pipework should be supported above the bottom. The trench
dimensions and pipe supporting arrangements should be such as to facilitate visual inspection
and maintenance e.g. wire brushing, repainting of the pipe and supports. Trenches should not
enter buildings
 Protection should be provided in the form of load bearing slabs or covers for those sections
over which traffic passes or on which other loads may be superimposed, now or in the future

7.1.6 Routing
The routing of piping should be designed to minimise pipe contents and thereby reduce the
potential hazard. The chosen pipe route should:
 Minimise risks of vehicle damage (e.g. avoid site roads or protect with bollards)
 Preferably run above ground and in the open air where practicable
 If buried or underground, pipes should be inherently resistant to corrosion. e.g.

manufactured from polyethylene; if they are manufactured from steel then they should be
adequately protected by cathodic protection, bitumen/tar wraps, impregnated tape etc.
 Avoid or protect from extremes of cold or heat
 Avoid running pipework through buildings if carrying liquid LPG or where the vapour
pressure is likely to be above the national standard low-pressure. Where this is impractical,
the pipe length should be minimised, protected from physical damage and ventilation
around the pipe maximised within the building.
7.1.7 Electrical Continuity
 Pipelines, fittings, and hoses used for liquid phase LPG transfer should have electrical continuity
and be reliably connected to earth. The resistance to earth should not exceed 106 ohms in order
to avoid the buildup of static electricity. Achieving a resistance of no more than 100 ohms
should not be difficult and, unless the pipes suffer significant corrosion, this is unlikely to
degrade over time to levels above 106 ohms
 It is not usually necessary to bridge flanges with bonding straps to achieve an acceptable level
of continuity; however, it may be necessary to bridge certain types of valves and connecting
joints with a bonding strap to obtain continuity
7.1.8 Flexible Hoses
Flexible hoses used in LPG installations and Autogas refuelling sites should comply with the
following:
 Flexible hoses used in LPG service should be designed and manufactured in accordance
with relevant design code. Specifically, rubber hoses should comply with EN 1762,
composite hoses to BS EN 13766 Class A Type 1 and metallic hoses to BS 4089 specifications
or equivalent.
 Hoses for LPG service should be designed for a minimum working pressure rating of not
less than 25 bar and a minimum burst pressure of 100 bar
 Hoses should be electrically continuous. If rubber hoses are steel wire-braided or

reinforced, these should be of stainless steel

 Hoses should be in one continuous manufactured length without intermediate joints or
couplers, except for Autogas dispensing hoses where an intermediate pull-away coupling
is fitted; and there should be no more than two lengths
 Protected by hydrostatic relief valves to the lower of fixed pipe operating pressure, or the
design maximum for the hose, and fitted with emergency isolation devices to prevent risk
of LPG leaking from a failed hose. This may be in the form of excess flow valve, remotely
operated valve or non-return valve
7.1.9 Above Ground Polyethylene (PE) Pipework
Where PE terminals are brought above ground at tanks or premises, the exposed pipework should
be shielded from mechanical or ultra – violet damage by sleeving, and be as short as possible,
normally limited to no more than 2 metres. Alternatively, a suitable fitting may be used below
ground to achieve the transition to metal pipework on either or both terminal transitions.
7.1.10 Underground Pipework
Pipework buried in an open trench, which is backfilled with noncorrosive material, should meet the
following requirements:
 Underground piping should be installed with a minimum depth of cover of 300mm. This
depth should be increased to 460mm if piping is likely to be subject to any super imposed
load that may result in damage. The piping may be encased in a conduit or the trench
provided with well supported load bearing concrete slab covers if the recommended depth
cannot be met
 Backfill should contain no abrasive and potentially damaging particles. For metal pipes anti-
corrosion measures should be used, e.g. cathodic protection, bitumen/tar overwraps,
proprietary wax impregnated tape etc.
 In general, underground liquid or tank pressure pipework should be avoided. Where this is
unavoidable, pipework should be protected from vehicular loading by installing either
loadbearing covers or exclusion fencing. Pipework should be run in shallow brick or
concrete lined trenches covered with open grids where appropriate for safe pedestrian
access
 Design should compensate for any extra constraint or loading due to backfill or
underground siting
 Isolation valves should be fitted at both ends of the underground length of pipe
 Pipes carrying flammable or inert liquids may be laid in the same trench but NOT pipes
carrying toxic or corrosive materials
 Pipework should not be run in the same trench as electric cables unless an outer sleeve or
pipe insulates them
 Electrical cables should be separated at least 300 mm from LPG pipework

 Specialist advice should be obtained where cathodic protection is used on LPG pipework
 A plan should be made to record the pipe layout and, if possible, permanently mark the
route above ground
7.1.11 Pipework Used to Carry Liquid and/or Vapour at Tank Pressure
Pipework carrying liquid LPG and/or vapour at tank pressure should comply with the following:
 Should be well supported and properly installed
 Either loadbearing covers, or exclusion fencing, should be installed. Pipework should be

located in a shallow brick or concrete lined trench covered with open grids where
appropriate for safe pedestrian access
 As an alternative to using brick or concrete lined trenches, liquid-containing pipe may be

run inside an outer ‘sleeve’ pipe, ensuring that this is sealed at both ends (with at least one
end accessible for inspection) and the space between the inner and outer pipe is monitored
for leaks (e.g. by detecting pressure changes)
 Hydrostatic relief valves should be fitted in any pipework in which liquid LPG may be
trapped (e.g. between shut – off valves) to protect against excessive pressure. These valves
should not be fitted beneath tanks. Where valves are fitted under tanks, they should not
allow LPG to escape across the tank surface or nearby access points. Atmospheric
discharges should be to the open air and should not pose any danger to life or equipment.
Where possible hydrostatic relief valves should be orientated to discharge upwards to
maximize dispersion of the LPG vapour
7.2 Pressure Regulators

7.2.1 General
Pressure regulators control wide variations in tank pressure and deliver the required outlet
pressure despite a variable gas flow caused by intermittent use. Installing the incorrect type of
regulators can result in malfunction of the LPG consuming equipment.
7.2.2 Types
There are three basic types of regulators
 First stage (high-pressure) – Designed to reduce vapour supply pressure to the required
intermediate high pressure. Used as a first stage regulator in a two-stage system or where a
high outlet pressure is required
 Second stage (low-pressure) - Designed to reduce intermediate pressure to the required final
operating pressure
 Single-stage - Designed to reduce vapour pressure down to final operating pressure in a single
stage

Although single-stage, low-pressure regulators have been used in some countries with bulk tanks
(and they are usually the norm with simple LPG cylinder usage) they should not be used with bulk
supply systems as they are more susceptible to freezing. Two stage systems give better pressure
control performance and enable the use of small-bore piping.
7.2.3 Design
Regulators should comply with a recognised standard. The design, materials and construction
should be suitable for the full range of operating conditions. Additional safety controls such as
pressure relief valves and high/low pressure cut-offs may be specified depending on the
application.
7.2.4 Selection
Regulators suitable for LPG should be selected by an assessment of the following factors:
 Climatic conditions - should be suitable for the expected ambient temperature range in
country of use, designed to prevent the ingress of rain/snow and insects etc., resistant to
corrosion (especially in marine environments) etc.
 Flow capacity - should be big enough for the highest demand of equipment (but avoid
excessive over capacity to ensure good control performance under low flow conditions and
to minimise cost)
 Inlet pressure - anticipated range
 Delivery pressure - specific or range
 Gas demand - the total gas requirement for all the equipment being supplied including any
potential demand planned
 Regulator setting point and performance curves - to match the requirements of the
installation
 Connections - inlet and outlet thread or flange size and form
 Additional safety controls - such as under/over pressure shut-off, partial pressure relief etc
 Installation conditions, e.g. underground and mounded tanks - perhaps additional

corrosion protection measures may be necessary, or if the location could be flooded then
breather and relief vents should be extended to a point where water ingress can be
prevented etc.
7.2.5 Installation
Ensure that:
 Regulators are adequately supported and correctly orientated in accordance with

manufacturer’s instructions
 First stage regulators are located as close as practicable to the tank/vapouriser connection

 Second stage regulators are located on the exterior wall of the supplied premises. They should
not be installed inside buildings other than in exceptional circumstances, and in such
circumstances the vent and any relief valve etc. should be piped to the outside of the building
 Consideration is given to the security of regulators if unauthorised interference is a possibility
7.3 Identification and Markings

7.3.1 Pipe Colour Code
Use logical markings or colour code to communicate the contents and whether vapour or liquid
phases are present. In many locations the practice is to paint vapour lines yellow and liquid lines
blue for distinction. Other markings may include direction of flow of the LPG in the pipeline.
7.3.2 Valves and Connections
The following should be clearly marked and identified for each valve/ connection:
 How to operate manual isolation valves
 How/where to operate remote isolation valves
 How/where to operate manual fixed water drench systems
 Adjacent connections for propane and butane loading and unloading
 Pressure relief valve set pressure

8.0 Electrostatic and Electrical Precautions
8.1 Electrostatic Precautions
8.1.1 Requirement
Provision should be made to ensure that no electrostatic potential exists between the tanker
delivery connection and the stationary tank fill connection which could generate a spark when the
connection is made or broken. The following should therefore apply:
 All tanks, except those where the capacity does not exceed 2,500 litres water capacity, should
be permanently bonded to an effective grounded earthing point to prevent any build-up of any
static electricity. The earthing point should be situated so that it is readily available for the
delivery tanker to discharge any static electricity by means of its earthing cable before the
delivery hose connection is made
 For tanks up to and including 2,500 litres water capacity, a bonding connection may be
provided on the tank to allow the direct attachment of the tanker earthing/bonding cable
before making the delivery hose connection
 Underground tanks which are not fitted with cathodic protection require an earthing rod
 Underground tanks which are fitted with cathodic protection and do not require an earthing
rod should have a bonding connection on the tank to allow direct connection by the delivery
vehicle earthing lead
8.1.2 Earthing Connections
Earthing connections should comply with the following:
 Electrical continuity between the tank transfer connection(s) and the earthing point or bonding
connection, through the tank should be ensured. Earthing or bonding connections should
always be kept clean, unpainted and free from corrosion to ensure a good electrical connection
 Earthing points should have low electrical resistance to earth and never greater than 1 x 106
ohms to ensure the satisfactory dissipation of static electricity
 For LPG depots, the use of a permissive system linked to tanker bonding, where transfer of LPG
cannot take place until bonding is continuous, is good practice
8.2 Electrical Equipment Installation
 All permanent electrical equipment installed within hazardous areas (see 8.3) should conform to
recognised standards for ignition protected equipment
 Electrical cabling and connections should be made in accordance with the equipment
manufacturer’s instructions and tested in accordance with local regulations

 Flame proof glands and connections should be correctly assembled, and all access covers securely
fastened. Ensure any painting has not covered the flameproof gap
8.3 Hazardous Areas
 Hazardous areas are areas in which an explosive gas atmosphere is present, or may be expected to
be present, under ‘normal operations’ in quantities such as to require special precautions.
Practically, for LPG, these are areas where the percentage of LPG in air by volume may be between
its flammability limits of 2% (low) and 10% (high).
 ‘Normal operation’ occurs when the installation is used within its design parameters (as defined
within EC Directive Annex 1, note 2). Failures (such as the breakdown of pump seals, flange gaskets
or spillage caused by accidents) are not normal operations
 Hazardous areas are classified into different zones based on the likelihood of the presence of
combustible gases
8.3.1 Area Classification
 Zone 0
An area in which an explosive atmosphere consisting of a mixture with air of flammable

substances in the form of gas vapour or mist is present continuously or for long periods or
frequently
Note: In the LPG industry there are no Zone 0 areas. Even the inside of an LPG storage tank
does not satisfy the definition of Zone 0 because there is no mixture with air
 Zone 1 Hazardous Area

substances in the form of gas vapour or mist is likely to occur in normal operation occasionally
Note: This would normally be the result of a ‘primary grade of release’. i.e. an area immediately
around a cylinder filling head
 Zone 2 Hazardous Area

substances in the form of gas vapour or mist is not likely to occur in normal operation but, if it
does occur, will persist for a short time. All electrical equipment installed in hazardous areas
should comply with the requirements for that area

8.3.2 Application of Area Classification to LPG Facilities
 The area classification for cylinder filling plants, LPG terminals and depots including in Table 8
is applicable to the following:
o Cylinder filling plants

o LPG terminals and depots including all storage and transfer facilities
o Road tanker loading and unloading facilities
o Ship and barge loading and unloading facilities
o Rail tanker loading and unloading facilities
 At all other sites, including domestic installations, commercial installations - such as

restaurants, hotels, factories and Autogas refuelling locations - local regulations will apply to
the installation of electrical equipment. Where local regulations do not exist, no electrical
equipment should be installed within 2.5 metres of any LPG filling point, connection point, fixed
ullage gauge, pump, compressor, vapouriser or relief valve unless it is rated for application for
the Zone 1
 Appropriate measures should be taken to ensure that equipment that might provide a source
of ignition is not within the hazardous zone during connection and disconnection of LPG
supplies, or maintenance work involving the opening of any part of the LPG system

AREA
LOCATION EXTENT OF CLASSIFIED AREA
CLASSIFICATION
A. LPG Storage tanks Within 4.6 m in all directions from connections, except Zone 2
connections otherwise covered in this table
B. Tank vehicle and tank car loading and Within 1.5 m in all directions from connections Zone 1
unloading regularly made or disconnected for product transfer
Beyond 1.5 m but within 4.6 m in all directions from a Zone 2
point where connections are regularly made or
disconnected and within the cylindrical volume
between the horizontal equator of the sphere and grade
C. LPG Storage tank gauge vent openings Within 1.5 m in all directions from point of discharge Zone 1
Beyond 1.5 m but within 4.6 m in all directions from Zone 2

point of discharge
D. Relief device discharge on storage tanks Within direct path of discharge Fixed electrical
and pipelines equipment not
permitted to be
installed
F. Pumps and vapor compressors
Indoors without ventilation Entire room and any adjacent room not separated by a Zone 1
gastight partition
Within 4.6 m of the exterior side of any exterior wall or Zone 2
roof that is not vaportight or within 4.6 m of any
exterior opening
Indoors with ventilation Entire room and any adjacent room not separated by a Zone 2
gastight partition
Outdoors in open air at or above Within 4.6 m in all directions from this equipment and Zone 2
grade within the cylindrical volume between the horizontal
equator of the sphere and grade
G. Pits or trenches containing or located
beneath LP-Gas valves, pumps, vapor
compressors, regulators, and similar
equipment
Without mechanical ventilation Entire pit or trench Zone 1
Entire room and any adjacent room not separated by a Zone 2
gastight partition
Within 4.6 m in all directions from pit or trench when Zone 2
located outdoors
With mechanical ventilation Entire pit or trench Zone 2
Entire room and any adjacent room not separated by a Zone 2
gastight partition
Within 4.6 m in all directions from pit or trench when Zone 2
located outdoors
H. Special buildings or rooms for storage of Entire room Zone 2
cylinders
I. Pipelines and connections containing Within 1.5 m in all directions from point of discharge Zone 1
operational bleeds, drips, vents, or drains
Beyond 1.5 m from point of discharge, same as part F of

this table
J. Cylinder filling
Indoors with ventilation Within 1.5 m in all directions from a point of transfer Zone 1
Beyond 1.5 m and entire room Zone 2
Outdoors in open air Within 1.5 m in all directions from a point of transfer Zone 1
Beyond 1.5 m but within 4.6 m in all directions from Zone 2
point of transfer and within the cylindrical volume
between the horizontal equator of the sphere and grade
Table 8 - Application of Area Classification to LPG Facilities

9.0 Fire Precautions
9.1 General
9.1.1 Principles
Minimise major fire risks (including escalation) through installation design, layout and resourcing
that both comply with all relevant local legislation and codes of practice, and specifically optimises:
 Best practice in engineering
 The implementation and enforcement of sound operating procedures
 Emergency procedures
 Staff training (both routine and emergency procedures)
 Location of water supplies
 Location and marking of shut-off valves
 Access, protection, and equipment for fire fighters
 Contingency plans and drills for fire incidents
 Arrangements to call fire brigade promptly in the event of a fire
 Prevention or shutdown of any release of LPG is the most effective way of controlling an
incident
9.1.2 Responsibilities
Where the local fire authority is responsible for organising, equipping and maintaining a fire
brigade and managing fire-fighting operations, any fire which may threaten any LPG in storage
should be attended by the fire brigade, who will take control of fire-fighting operations on arrival,
even if they involve site fire teams in their efforts.
9.1.3 Planning
The local fire authority may want to be involved in the planning of any new LPG storage facilities;
if, during planning, further guidance on fire precautions is needed and cannot be found in this
standard, consult the enforcing authority (see definitions in Appendix 2).
9.1.4 Access
All sites should always be accessible without hindrance to fire fighters.

9.2 Fire Protection
9.2.1 General
 The most effective form of fire protection is for there to be no release of LPG or if a release
occurs, to detect it immediately and shut it down. The use of gas and fire detection and
shutdown systems should therefore be strongly considered where a risk assessment indicates
that this approach would bring the risk to ALARP. It should be noted that such systems can be
effective if rigorous testing regimes are in place and their reliability can be demonstrated from
comprehensive records.
 Research regarding fire protection of LPG tanks once a fire is in progress has led to the following
conclusions:
o The only sources of heat that threatens the integrity of an LPG tank are jet flames or
pool fires
o Water sprays are ineffective against a jet flame and only a suitably positioned fire
water monitor will deflect the jet flame from the surface of a tank
o Good design will significantly reduce the probability of a pool fire engulfing a tank, by
directing any LPG spillage away from beneath the tank
o Fires adjacent to an LPG tank which do not engulf the tank in flames are unlikely to
cause failure of the tank. However increased pressure can lead to additional release of
LPG through relief valves
o Underground or mounded tanks are much less at risk from radiant heat and will only
require protection for any exposed parts
o Whilst fixed water sprays have been specified to deliver cooling water to LPG tanks to
protect against radiant heat, reliability has proven problematic. Systems have failed to
deliver water at the full volume, reliably, in a number of emergency cases. Nozzles get
blocked with rust or scale, or pipes on the tanks have failed
o Water monitors positioned to deliver the equivalent volume of water, and set in an
appropriate pattern to cover all parts of the tanks in a dense water spray, are
considered more reliable than spray systems when needed
o Monitors have the additional advantage that should a jet flame impinge on a tank,
water monitors can be redirected and adjusted to a narrower jet, to provide greater
protection against this risk
Given the foregoing this guide recommends the following for large bulk installations:
For existing installations: Fixed water spray systems that perform reliably when required do not
need to be replaced. However, for any major facility refurbishment - or if there are known problems
with existing spray systems - replacement with fixed water monitors delivering the same equivalent
water volumes should be strongly considered.

For new installations: Fixed monitors are strongly recommended to be installed whenever
possible. Some spray systems may still be required dependent on the site layout if, for example
monitors cannot be set to provide the required water coverage to all parts of all tanks (e.g. the tops
of spheres may best be covered using a water deluge system). All local operational staff should be
trained in the use of the fire protection system including the adjustment of the monitors.
9.2.2 Methods of Protecting Tanks from Jet Flames or Pool Fires
 Fire monitors – Sufficient water supply, storage and numbers of monitors should be provided
to enable any area of tank shell to receive a direct jet of water
 Intumescent Coating – Above ground tanks and exposed portions of mounded or buried tanks
may be protected from radiant heat by intumescent coating. This will provide protection for a
time stipulated in the design and application data for the coating
9.2.3 Water Supplies
Where water is the chosen medium for prevention of radiation effects there should be enough
water available for emergency use, specifically:
 Standard fire protection – the water supply should be able to apply enough water for any
tank at a rate of at least 9.8 litres per m2 per minute over the entire tank surface for no less
than an hour
 Sites with no reserve water supplies nearby – plan for standard fire protection plus extra
capacity
 Water re-circulating systems - the storage reservoir should hold 30 minutes supply without
recirculation
 Power failure - Plans should be prepared for what should happen in the event of a local
power failure during fire-fighting efforts
 Drainage – The drainage on site should be capable of handling the likely flow of water
during firefighting or fire protection, and install water-sealed interceptors where necessary
to prevent LPG entering storm drains and sewers
 Control of water flow – The design of fixed drench and hydrant systems should allow
control of water flow from the safety of distances greater than specified in Table 1 for the
distance to a public place. Additionally, the water supply to fixed drench systems should
incorporate connections for firefighting use, at safe locations agreed with the local fire
authority
9.2.4 Fire Protection Equipment
The need for fire protection equipment at LPG storage sites depends on:
 The size of individual tanks
 The site’s maximum storage capacity

 The frequency of tanker deliveries
 The calculated fire risk according to site conditions (e.g. higher for a cylinder filling
facility)
See 9.2.5 to 9.2.8 for standards generally demanded by enforcing authorities. Additional
precautions may be necessary under certain conditions such as slow fire brigade response times,
remotely located water supplies or high fire risks in adjacent sites.
9.2.5 Tanks up to 56,250 Litres Water Capacity (25 MT of LPG)
Domestic and small commercial and industrial installations may be required to have a water supply
sufficient for use by the fire brigade, easily accessible and no more than 100 metres from the tank;
e.g. hydrants, rivers, canals, ponds, except for liquid offtake tanks with a water capacity greater
than 15,750 litres (7 MT of LPG) (See 9.2.7); however, balance this with other advice in this guide
plus the likely fire brigade response and area evacuation times.
9.2.6 Remote Sites with Low, Easily Evacuated Adjacent Population
Distance from the water supply to the tanks may be over 100 metres, subject to agreement with
the local fire authority and the existence of a detailed, fully publicised (i.e. to local residents) and
a tested evacuation plan.
9.2.7 Liquid Offtake Tanks Greater than 15,750 Litres Water Capacity (7 MT of LPG)
Minimum fire protection should be an appropriate firefighting water supply plus, where liquid
outlet connections have no remotely operated emergency valves, some form of tank radiation
protection e.g. fixed/portable monitors or intumescent coating
9.2.8 Total Tank Inventory of 56,250 Litres Water Capacity (25 MT of LPG) but less than 112,500 Litres
Water Capacity (50 MT of LPG)
Minimum fire protection should be an appropriate firefighting water supply plus some form of tank
radiation protection, e.g. fixed /portable monitors or intumescent coating
9.2.9 Total Tank Inventory of more than 112,500 Litres Water Capacity (50 MT of LPG)
Minimum fire protection should be an appropriate firefighting water supply plus fully automatic
water delivery system triggered by a fire detector capable of detecting a fire threatening the tanks
(i.e. not just an excess tank pressure sensor). Manual systems are only acceptable where there is
24-hour supervision, and these may be configured to target individual rather than all tanks;
however, such systems should be activated remotely (See 9.2.2).

9.3 Other Facilities where Fire Protection is Needed
9.3.1 Cylinder Filling Sites
Tanks at these, and similar sites (e.g. aerosol filling sites), should be protected by fixed monitor
systems or intumescent coating, unless the operation is very small (e.g. cylinder filling only for
forklift trucks). The filling area should also be protected by suitable fixed water sprays and/or water
monitor.
9.3.2 Road Tanker Gantries
Road tanker gantries should have fire protection equal to that of the storage tanks if:
 Storage tank capacity exceeds 56,250 litres water capacity (25 MT of LPG)
 Road tanker loading/unloading averages twice or more per week (i.e. averaged over 6
months, including winter)
9.3.3 Rail Loading/Unloading Gantries
Fixed monitors or comparable fire protection should be provided.
9.3.4 Individual Versus Group of Tanks
In sections 9.2.5 to 9.3.2 tanks may be treated individually if they are spaced apart by a distance
equal to the sum of the separation distances in Table 1 to a public place.
9.4 Portable Firefighting Equipment

9.4.1 General
All LPG storage sites should have enough of the correct portable firefighting equipment to
extinguish fires next to LPG tanks and prevent escalation of any incident. The ‘correct’ equipment
comprising fire extinguishers and access to water will be defined by local or national fire protection
standards or codes of practice, which will also specify an appropriate ‘mix’ of equipment, plus
location, maintenance and levels of capability.
9.4.2 Requirement
 The fire extinguishers provided at all fixed LPG storage sites storing more than 4,000 litres
water capacity (2 MT of LPG) should consist of at least two LPG-compatible fire extinguishers
of 9 kg capacity dry powder each.
 Fire extinguishers are not required at domestic installations since users are usually untrained
in LPG firefighting.

INSTALLATION CAPACITY PRECAUTIONS Ref
Water Capacity Nominal LPG Capacity

(litres) (MT)
Less than 150-2,500 (domestic tank Less than 1.1 - Water supply for fire brigade use up to 100 m 9.2.2
capacity) away 9.2.3
Less than 150-2,500 (commercial and Less than 1.1 - Water supply for fire brigade use up to 100 m
Industrial tank capacity) away
- Two 9kg dry powder extinguishers
Greater than 2,500 to 56,250 Greater than 1.1 to 25 - Water supply for fire brigade use up to 100 m 9.2.1
away 9.2.3
- Two 9kg dry powder extinguishers 9.4.2
Greater than 15,750 Greater than 7 - Water suppy 9.2.1
(liquid offtake tank capacity with -Two 9kg dry powder extinguishers 9.4.2
remotely operated shutoff)
Greater than 15,750 Greater than 7 - Water suppy 9.2.1
(liquid offtake tank capacity without - Fixed and/or portable monitors 9.2.7
remotely operated shutoff) - Two 9kg dry powder extinguishers 9.4.2
56,250 to less than 112,500 25 to less than 50 - Water suppy 9.2.1
- Fixed and/or portable monitors 9.2.8
112,500 or more 50 or more - Water suppy 9.2.1
- Fixed and/or portable monitors 9.2.9
Cylinder filling - Water supply 9.2.1
- Automatic fixed water sprays 9.3.1
Table 9 Fire Precautions Summary
Note: In all tank protection cases above, the water requirement for tank cooling may be replaced with
intumescent coating of the tank with a coating certified for one hour and applied and maintained in accordance
with the manufacturer’s instructions

10.0 Tank Commissioning and Decommissioning
10.1 General
 Only fully competent and trained staff familiar with LPG tank commissioning and
decommissioning should be assigned to carry out these procedures.
 For tanks up to 5,000 litres water capacity, the preferred approach is for most commissioning
and decommissioning procedures to be carried out under controlled conditions at the LPG
company (or contractor) depot, using appropriate handling/transportation systems and
methods, rather than at the customer’s premises. Tanks above 5,000 litres water capacity
would normally be dealt with at the customer’s premises using specialised equipment and
personnel.
10.2 Commissioning
10.2.1 Leak Testing/Purging Conditions
 Tanks, associated fittings, and equipment should have all the connections leak tested to a
pressure not less than 3 bar gauge for butane, and 6 bar gauge for propane but no more than
90 per cent of the tank design pressure
 During leak testing and purging care should be taken to ensure the tank is not subjected to
pressures, temperature or vacuum conditions outside its design criteria
10.2.2 Testing
All tanks and associated equipment should be tested and certified fit for purpose prior to filling.
10.2.3 Purging
All tanks and associated fittings should be purged until there is insufficient oxygen inside to support
combustion. To do so, the air should be either evacuated or replaced with inert gas, water or LPG.
 Inert gas purging - If inert gas is used (e.g. gaseous nitrogen or carbon dioxide), this needs
to be removed from the tank with LPG, taking care to direct the purged gas/LPG mixture
safely away from other tanks, ignition sources, boundaries, buildings or public places or to
a flare stack. Care should be taken during purging to ensure the safe dispersion of unignited
purge gases. If purge gases are flared this should be done outside the normal separation
distances
 LPG vapour purging - When LPG vapour is used to replace air, the tank and fittings will for
a period of time contain a flammable mixture. A competent person should vent this to
atmosphere in a safe manner. A flame arrestor should be fitted in the vent line to prevent
flashback should the LPG/air mixture ignite
 Water purging - If using water as a purge medium, check before starting that the tank and
its supports will be capable of holding the full weight of water. After purging, ensure that
all the water is removed from the tank

 Evacuation - If using evacuation as the purge method, check before starting that the tank
is designed to sustain full vacuum conditions
10.2.4 Initial Fill
 A responsible person should be present and in control throughout the initial fill. Care
should be taken to limit flash vapourisation on initial fill. This can be achieved by
pressurising the tank with vapour before introducing liquid LPG
 During initial fill, any inert gas should be safely vented from the tank
 Contents gauges should be checked for freedom of action/movement by internal

inspection, where practicable, or otherwise by observation during the initial fill
10.3 Decommissioning
10.3.1 Isolation
Tanks and fittings to be decommissioned should be isolated from any process, tank or equipment,
usually by disconnecting and removing adjoining pipework or blocking it off with spades or blanks.
Closing shut-off valves is not enough
10.3.2 Preparation
Prior to de-commissioning:
 Remove as much liquid LPG from the tank as possible via normal use or through controlled
transfer to other tanks, or by flaring. If it is necessary to vent residual vapour this should
be kept to the absolute minimum possible
 Purge with inert gas until the LPG content remains less than 4%
 Purge by displacement with water or other suitable methods
 Care should be taken to ensure that no flammable vapours are generated from residual
heavy ends

11.0 Transfer Operations
11.1 General
11.1.1 Operating Procedures
All staff who take part in loading/unloading should be issued with written procedures that clearly
specify their responsibilities and actions to take in case of emergency.
11.1.2 Supervision/Staffing
A competent person should remain in control throughout all transfer operations, and there should
be adequate supervision throughout the transfer operation.
Whilst staffing on LPG loading /unloading will depend on site size or type, there should never be
less than two trained people involved, e.g. a site employee plus the road tanker driver/rail tanker
operator/ship master or his representative. The only exceptions to this rule are:
 Domestic or very small sites, where having any additional staff would be impractical
 Automated depots designed for one-man operation
11.1.3 Personal Protection Equipment (PPE)
Staff involved in LPG transfer operations where there is a likelihood of contact with liquid LPG
should be provided with suitable personal protection equipment (PPE), e.g. gloves, eye protection,
apron, etc.
11.1.4 Pre-Transfer Check
 The quantity and type of LPG should be checked by someone in authority to confirm its
suitability for transfer to the receiving tank. Checks should also be made to ensure that the
receiving tank is in safe working condition
 The interconnection system, i.e. pipework, fittings, valves, hoses, etc. should be visually
inspected to ensure that it is in a safe working condition and that the tanker hose coupling is
compatible with the storage tank fill coupling
11.1.5 Other Safety precautions
 The driving unit and any electrical equipment not required and not specifically designed for the
transfer operation should be stopped and isolated.
 Fire extinguishers should be located in easily accessible positions and temporary warning
notices prominently displayed before product transfer commences
11.1.6 Prevention of Overfilling
 During LPG transfers, a constant check should be kept on the receiving tank to ensure that
overfilling or other hazardous conditions do not occur. On completion of the transfer, the
receiving tank should be checked to ensure that it has not been overfilled

 In the event of overfilling, excess LPG should be immediately removed from overfilled tanks or
tankers in a safe way. Failure to do so may contribute to a serious incident
Flexible hoses used for transfer operation should be:
 Properly identified
 Protected from damage to, or intake of, foreign matter through their end fittings
 Protected against external damage (where this is likely)
 Protected in transit, storage or when not in use from weathering or other physical damage
 Inspected and tested regularly to confirm their fitness to use (see 14.4.5)
 Kept to absolute minimum the length to avoid hoses having to be dragged long distances
11.1.8 Static Electricity Protection
The transfer procedure should include the following as a minimum:
 Discharge to earth of any accumulated static electricity from the road/rail tanker before
connecting the transfer hose, by bonding the tanker to an earthing point or to the tank to
be filled
 Bonding the tanker to the tank being filled before connecting the hose coupling and
maintaining this bond throughout the transfer
 Detachment of the electrical bond only after the liquid, and where used the vapour,
balance connection has been disconnected
11.2 Road Tanker Loading/Unloading

11.2.1 Siting
The following precautions against accidental road tanker movement during transfer operations
should be taken:
 Siting of transfer points on well-drained essentially level ground, preferably with a slight
slope or camber in one direction to take any spillage away from the tanker and prevent it
from flowing and collecting under any fixed LPG tanks or pipework
 Place wheel chocks against all wheels (or provide other means to prevent vehicle
movement) before transfer begins and remove only after transfer ends
11.2.2 Road Tanker Position
The following criteria should be applied during transfer operations:

 Road tanker should preferably be positioned off the public highway whilst unloading
 Where off-road parking is impossible (e.g. at domestic sites), clear guidance should be
provided on parking procedures to avoid causing obstruction to other road users,
pedestrians etc. and to comply with legal requirements
 Tanker access to the discharge position should avoid the need for reversing. If necessary,
arrangements should be made for the tanker to be reversed in and driven out in the
forward direction
 During the unloading, the tanker should be positioned a minimum of 2 metres from the
storage tank at customers’ premises to provide an adequate working space. At cylinder
filling plants and bulk distribution depots this should be increased to 15 metres. Wherever
possible the tanker parking position should not be within the separation distances set out
in Table 1.
 All shut-off valves on both the tanker and the storage tank should be readily accessible
during transfer operations. Tanker access to the discharge position should avoid the need
for reversing. If necessary, arrangements should be made for the tanker to be reversed in
and driven out in the forward direction
 During transfer operations the tanker should be positioned so that it can be readily and
quickly driven away in an emergency
 There should be a clear line of sight between the tanker and the storage tank being filled.
At all times during the operation the driver should be able to immediately stop the transfer,
either normally when the tank is full or in an emergency. If there is no clear line of sight, a
second trained person should assist during the transfer operation or a remote tanker
control system capable of shutting down the pump and foot-valve on the road tanker
should be used
11.2.3 Drive-Away Protection/Prevention
One or more drive-away protection/prevention measures such as the following should be used:
 A system of simultaneously activating emergency isolation valves on both tanker and

tank
 A self-seal breakaway coupling
 Brake flaps that lock on the vehicle brakes when moved aside to access the filling
connection
 A trip switch that locks on the vehicle brakes when the flexible hose is unloaded from its
normal stowage position
 Interlocked physical barrier or similar system on either road tanker or fixed installation

11.2.4 Operating Restrictions
 Loading/unloading operations should only be carried out when safe to do so and preferably be
separated from other traffic movement. Diversions for passing vehicles and pedestrians (e.g.
barriers, warning signs) should be used
 Operations should not be carried out during the hours of darkness unless adequate artificial
lighting suitable for hazardous area is used
11.2.5 Remote Power Shut-Off
A remote switch should be fitted to tankers that relies on engine power to drive pumps or other
equipment, allowing emergency engine shut-down from outside the cab.
11.2.6 Hose Routing
Hoses should not be routed across public areas such as pavements or footpaths unless it clearly
will not endanger the public or there is absolutely no alternative, in which case warning notices
should be placed on both sides of the hose. These should be readable from 6 metres and carry
warnings such as:
DANGER - NO SMOKING OR NAKED FLAMES
WARNING – LPG TRANSFER IN PROGRESS
11.3 Rail Tanker Loading/Unloading

11.3.1 Location of Transfer Point
 All rail loading/unloading activities should be done well clear of other rail traffic (e.g. in a
siding), at least 15 metres away from other fixed tanks, ignition sources, boundaries and
buildings, and in a location with good ventilation. Wherever possible the rail tanker parking
position should not be within the separation distances set out in Table1
 Transfer points should be sited on well-drained essentially level ground to minimise risk of
accidental rail tanker movement. A slight gradient of less than 1:250 is permissible so long as
this is away from the main line or towards the buffers, to take any spillage away from the tanker
and prevent it from flowing and collecting under any fixed LPG tanks or pipework
11.3.2 Rail Operations
The following should be observed:
 Rail tankers containing LPG should not be shunted when separated from the locomotive or
train
 Physical barriers should be provided where there is the risk of a rail tanker being damaged
by a road vehicle

 A barrier gate and other positive isolation means should be provided to protect against the
risk of the train being accidentally moved whilst the rail tank wagons are still connected to
the LPG reception facilities. Such measures could include removal of the locomotive,
application of rail tank wagon hand brakes, locked points, removal of the towing cable or
isolation of the capstan motor etc.
 Positive interlocks incorporating the product transfer pumps or compressors, isolation

valves, etc. should be considered to ensure the rail tank wagons have been correctly
positioned before transfer operations are commenced
 A simple communication system similar to a Permit to Work should be in place between

the rail service operator and the LPG storage operator, to ensure a clear handover and
hand-back of the tank wagons and to prevent entry of a locomotive into the tank area while
discharge or filling is taking place
 Signals may provide additional protection
11.3.3 Emergency Shutdown Valve Protection
The following protection should be used for transfer points:
 Remotely operated, fail safe, fire safe emergency shutdown valves on the reception
facilities and, where appropriate, for vapour lines
 Manual shut-off valves on every liquid LPG branch pipe, fitted with dedicated handles/keys
for quick use
 Non-return valves on common manifolds to prevent liquid back flow during transfer
11.3.4 Extra Pull-Away Protection
Additional measures against pull-away incidents and to prevent the resultant leakage should be
provided. This may be in the form of self-sealing break away couplings, isolation valves/rail tanker
wagon movement interlock systems or other comparable systems.
11.4 Completion of Transfer
On completion of the transfer, all transfer hose connections should be disconnected before
removing the electrical bonding. The immediate surroundings should be checked to ensure it is
safe before any vehicle involved in the transfer operation is allowed to drive away.
11.5 Ship Loading/Unloading
11.5.1 Design and Construction
 All jetties, piers, docks and wharves used for LPG product transfer operations should be
designed and constructed in accordance to local laws and regulations

 All transfer equipment should be suitable for use with LPG, meeting recognised standards and
be suitable for operating in all conditions that the equipment is likely to encounter during its
service life.
 Pipelines on the jetty should be located so that they are not exposed to physical damage from
vehicular traffic or other possible sources of physical damage. Pipelines underwater should be
located or protected against damage from marine traffic and their location should be clearly
identified.
 Isolation valves and bleed connections should be provided at the loading/unloading manifolds
for both liquid and vapour return lines so that the hoses and arms can be blocked off, drained
or pumped out and depressurised before disconnecting.
 Insulating flanges should be installed on the pipeline to provide effective electrical isolation
between ship and shore. These should be tested annually to ensure their effectiveness.
 Electrical equipment and wiring at the jetty should be installed in accordance with the
requirements of the zone classification defined by local regulations.
 Adequate fire protection equipment, including fixed and portable equipment for first and
major event response, should be made available on site.
 Adequate lighting should be provided at the jetty if the transfer operation occurs at night.
Lighting should be located or shielded so that it is not confused with any aids to navigation and
does not interfere with navigation on the adjacent waterway.
11.5.2 Jetty Transfer Operation
 Flammable liquids and/or compressed gases should not be handled within 30 metres of the point
of transfer connection while LPG or other flammable liquids are being transferred.
 Trucks and other motorised vehicles should be prohibited within 30 metres of the transfer
connection while transfer operations are in progress
 Unauthorised individuals should not be allowed access to the waterfront area while the LPG vessel
is alongside the pier or dock
 Storage tanks, pipelines, and other jetty equipment to be used in the unloading operation should
be inspected to ensure they are in a sound, leak-free condition. Shore hoses being used for the
operation should be checked for soundness and electrical continuity.
 Emergency Shutdown Valves should be tested to ensure they are in good working condition
 Portable electrical equipment used within 30 metres of the transfer connection while transfer
operations are in progress should be suitable for the hazard area classification.
 Life-saving equipment should be made available and ready for use while personnel are working on
the jetty.

 The jetty and the storage tank should be continuously manned while the transfer operation is
ongoing. The pipeline/hose system and tanks should be checked before and during use for any
signs of leakage.
 Upon completion of the transfer operation, liquid hoses should be cleared and depressurised if
used, shore valves closed and protective caps fitted on hoses or loading arms.
11.6 Draining
 Draining of LPG tanks is a critical operation and should be carried out with special care to minimise
the risk of escape of LPG into the surroundings. Where this is carried out after product receiving
for quality control purposes i.e. tests for water, it should only be undertaken by competent
personnel under a written operational procedure
 At no time should both drain valves described in section 5.3.1 be opened simultaneously in order
to prevent possible freezing. One procedure that will ensure safe draining is as follows:
o Fully open the drain valve closest to the tank first and allow pipe to fill
o Close the valve
o Then control draining by gradually opening the second valve. If no draining occurs, close the
valve immediately and investigate
o Repeat this procedure until all the water and any other contamination has been drained
 Suitable protective clothing should be worn by personnel carrying out draining
 Draining of customer installations may not be necessary and should be discouraged unless the
operation is carried out by a competent person under a written operational procedure

12.0 Training
12.1 General
 Training is an essential element of an effective Health, Safety, Security and Environment (HSSE)
management system. All those that work in HSSE critical activities should be properly trained and
competent for the activities undertaken
 A sufficient number of people should be appointed and trained to carry out and supervise
procedures and operations. Staff that have not acquired the necessary experience or competency
requirement for their role should not go on duty without close supervision
12.2 Training Program
It is the responsibility of management to make sure that all staff involved in LPG operations clearly
understand the characteristics of LPG and its associated risks. Staff should be regularly trained and
assessed in the knowledge and practice of normal operations, including as appropriate:
 Company safety policy, drugs and alcohol policy
 LPG product knowledge
 Safety in day to day operations
 Use of personal protective equipment (PPE)
 First aid
 Loading/unloading
 Emergency procedures and shutdown
 Firefighting
 Inspection and maintenance
To be effective, training should be continuous, with refresher courses every 3 years and where
appropriate at least an annual emergency procedure practice.
12.3 Change Control
Any changes to plant, fittings or equipment, or changes to operating procedures, should be correctly
assessed for risks, authorised and communicated to those affected. If necessary, retraining of personnel
may be required.
12.4 Training Record
Individual staff training records, giving details of initial induction training and periodic refresher training,
should be kept.
12.5 Fire Instruction and Training
All staff involved in LPG operations should clearly understand the fire/leakage precautions and emergency
procedures. Staff at operational sites should be regularly trained and assessed to ensure their knowledge
and practice of actions to be taken in an emergency, including:
 Emergency shut-down procedures
 Dealing with LPG releases
 The nature of LPG fires
 Firefighting

13.0 Written Operating and Emergency procedures
13.1 General
 Documenting the operating and emergency procedures is important because it ensures that the
procedures are clear and consistent throughout the organisation and that the procedures are not
lost when experienced staff leave or move to a different role
 All staff and contractors should be instructed to familiarise themselves with the relevant
procedures required by their roles. Any deviations from the written procedures should be
supported by written authority, which may include a work permit from the relevant responsible
person
13.1.1. Scope
LPG storage sites with individual tank water capacity of 4,500 litres or more and aggregate
capacity greater than 22,700 litres should have a set of written operating procedures that:
 Clearly detail the tasks of each employee involved with LPG on site
 Cover both normal and emergency activities
 Are issued in part or in full to site staff, as well as visiting contractors
 Are regularly reviewed to check that they reflect current operating methods
 Are amended to reflect changes or alterations to the plant or site
Sites with multiple tanks in vapour service with individual water capacity of not more than 4,500
litres and aggregate capacity of not more than 22,700 litres are not required to have written
operating procedures.
13.1.2 Specifics
Activities that should be covered in detail by written procedures include:
 LPG transfers to or from the site
 LPG deliveries to customer sites or other locations
 Emergency procedures
 Plant maintenance and modification, including electrical equipment
 Permit to work system
 Drainage of storage tanks

13.2 Customer Sites
 All bulk customers should be provided with bold and clear emergency procedure notices
displayed near all storage tanks. The user should be provided with full documentation including
information on the actions to be taken in an emergency. This should include procedures in the
event of gas leakage, or suspected leakage, and in the event of fire
 Emergency instructions should include also:
o 24-hour emergency service contact telephone number

o Local fire service contact telephone number
 Industrial/commercial customers should be encouraged to incorporate plans for dealing with

LPG incidents into their overall emergency plans

14.0 Maintenance and Examination
14.1 General
 LPG tanks, equipment, pipework and associated systems should be kept in good working order by a
combination of routine inspection, periodic examination and regular maintenance. Such work should
be carried out to a written scheme of examination which has been prepared by a competent person
 The maintenance scheme should emphasise elements of the system that affect the integrity of the
tanks and equipment, and the ability to react in an emergency
 Only trained and experience personnel under the appropriate supervision of a competent person
should be allowed to carry out all maintenance work on a LPG installation
 A detailed report should be issued after an examination and kept on record (see 14.7)
14.2 Maintenance Scheme
Each LPG storage installation should have a maintenance scheme, which includes the protective equipment
and instrumentation relevant to the scale and complexity of the installation. For a depot or large installation
this will be a site-specific written scheme of examination (see Appendix 1 for more details) prepared and
authorised by a competent person. For smaller customer installations a generic scheme may be applied.
Dependent upon the equipment on site the maintenance scheme should include:
 Frequency of periodic tank and fittings inspection
 Inspection of tank supports, foundations and holding down arrangements
 Inspection of vapourisers in accordance to manufacturer’s recommendation
 Integrity and corrosion inspections of aboveground and underground LPG pipework
14.3 Frequency of Periodic Examination
In many countries the scope and period of examination and testing of the LPG system will be defined in
local legislation. For those countries where this is not the case, Table 10 provides guidance on frequency
and scope of inspection for LPG equipment. Table 10 assumes routine inspections are carried out in
accordance to section 14.6. This frequency may be adjusted by the Competent Person based on a
combination of experience, statistical data or equipment manufacturer’s recommendation.

Ref.
ITEM INTERVAL
Aboveground tanks 10 yrs 14.4.1
Underground tanks
w/ Cathodic Protection 10 yrs 14.4.2
w/out Cathodic Protection 5 yrs 14.4.2
Pipeworks
Aboveground pipeworks 10 yrs 14.4.3
Underground pipeworks 5 yrs 14.4.4
Vaporisers
Direct heated Annual 14.5.2
Indirectly heated 5 yrs 14.5.2
Table 10 - Frequency of Periodic Examination
14.4 Periodic Examination of Tanks and Pipework

14.4.1 Aboveground Tanks
Periodic examination of above ground tanks should include:
 Visual examination of external surfaces and all welds for signs of defects such as damage,
corrosion, cracking, erosion, deformation, leakage etc.
 A check of wall thickness by internal visual examination or a wall thickness survey (e.g.
using an ultrasonic thickness gauge)
 Replacement of pressure relief valves with new or reconditioned units set at a pressure not
less than the tank maximum working pressure but not above the tank design pressure.
Capacity of the pressure relief valve should meet design requirements
 Inspection of shut off valves, including remotely operated types and other tank fittings for
effective operation, corrosion or damage or replacement. Shut off valves and other tank
fittings should be replaced when they reached 20 years of service regardless of condition
14.4.2 Mounded or Underground Tanks
Periodic examination of mounded/underground tanks should include:
 A visual check of exposed surfaces for signs of corrosion, damage, leakage, etc.
 Replacement of pressure relief valves with new or reconditioned units set at a pressure not
less than the tank maximum working pressure but not above the tank design pressure.
Capacity of the pressure relief valve should meet design requirements

 Where cathodic protection is provided, the operation of sacrificial anodes or impressed
current systems should be checked in accordance with a written procedure and replaced
as necessary. Records should be maintained to allow comparisons of the readings obtained
to allow investigation of any anomalous readings (see also 14.7.1)
 Where cathodic protection is not provided, an internal visual examination should be

conducted and either a wall thickness check or a hydraulic test. Where internal
examination is not reasonably practicable the external surfaces of the tank should be
exposed for examination as directed by the competent person
 Inspection of shut off valves, including remotely operated types and other tank fittings for
effective operation, corrosion or damage or replacement. Shut off valves and other tank
fittings should be replaced when they reach 20 years of service regardless of condition
14.4.3 Aboveground Pipework
Periodic examination of aboveground pipework should include:
 Checking for corrosion and damage particularly on sections where the pipe passes
through supports
 Checking for satisfactory condition of pipe supports
 Inspecting thermal insulation for damage if used. Any suspect areas should be removed
to allow inspection of the pipe
 Pressure testing of pipework and checking end to end electrical continuity for terminal
and depot pipework except for cathodically protected sections
 Replacement of hydrostatic valves every 10 years with new units set at a pressure not
less than the maximum working pressure but not more than the more than the design
pressure of the equipment they are protecting
14.4.4 Underground Pipework
Periodic examination for vapour pipework operating below pressure of 5 bar should include:
 Checking for leakage by appropriate means such as pressure testing, gas detection etc. at
a frequency dictated by the risks associated with its location, pressure of operation and
aggressiveness of their environment
Periodic examination for liquid pipework and vapour pipework operating at pressure of 5 bar or
above should include:
 Check for leakage by appropriate means such as pressure testing, gas detection etc. at a
frequency dictated by the risks associated with its location, pressure of operation and
aggressiveness of their environment. Pipework may be subjected to same pressure test
done during installation where practicable. No further testing is necessary if the system is
constantly monitored e.g. by gas detection

 Pipework should be pressure tested, excavated for visual inspection and leak tested under
operating pressure when it incorporates buried screwed or flanged joints, or where there
is any doubt of the effectiveness of the corrosion protection system
 Each hose should be subjected to formal external visual inspections by a competent person
at the following intervals. Results of these formal inspections should be recorded.
Road tanker/rail/jetty hoses - 6 months

Autogas dispenser hoses - 6 months
Cylinder filling hoses - 12 months
 A hose should be inspected for defects such as leakage, cuts, soft spots, kinks, twists,
flattening or blistering. Hoses with defects should be rejected for LPG service
 In addition, jetty hoses should also be tested hydraulically to its maximum working
pressure at least every year
 Hose end couplings should be checked using appropriate gauges i.e. Go/No Go thread
gauges for ACME couplings
 Hoses should be checked at least every year for electrical continuity
14.5 Periodic Examination of Other Equipment

14.5.1 Product Transfer System
Pumps, compressors and other associated equipment should be checked in accordance to the
manufacturer’s instructions or other procedures prepared by a competent person. Seals and
lubrication should be given particular attention.
14.5.2 Vapourisers
Periodic examination of vapourisers should include:
 Check for satisfactory operation of items such as level control, heat input controls,
emergency valves (other than pressure relief valves), flame control devices, pressure
controllers, etc. Safety devices such as solenoid valves and similar items should be given
particular attention
 Check for corrosion and damage and hydraulic test
 Check for LPG leakage under operating pressure
14.5.3 Regulator
Pressure regulators should be replaced with new units every 10 years.

14.5.4 Electrostatic Protection
Earthing and bonding connections should be inspected visually, and the electrical resistance should
be checked to ensure it is not more than 106 ohms.
14.5.5 Electrical Equipment
Ancillary electrical equipment such as cables and connections, particularly flameproof connections,
switches etc. should be inspected to ensure they are in satisfactory condition in accordance with
manufacturers/installers instructions or other schedule prepared by a person competent in
electrical installations.
14.5.6 Firefighting/Emergency System
 Firewater, gas detection, over-fill prevention and alarm systems and other safety critical
equipment should be checked for correct operation in accordance with the manufacturer’s
instructions or other schedules prepared by a competent person. If stand by power generation
is part of the firefighting/emergency response system, it should be tested under load.
 Maintenance on fire protection equipment should be scheduled so that a minimum of

equipment is taken out of service at any time and is returned to service in a reasonable period
of time
 Fire extinguishers should be inspected and maintained at regular intervals according to the
manufacturer’s instructions, or other schedule prepared by a competent person.
14.6 Routine Examination

14.6.1 General
Routine examination of tanks and other equipment in an LPG installation should be carried out at
least annually but, in many sites, this may be done conveniently as part of the routine filling
operation. Routine examination should be done in accordance to a written procedure with
appropriate remedial action plans for defects observed.
14.6.2 Scope
Routine examination should include:
 Full visual inspection for corrosion, damage and leakage for tanks, equipment and pipework.
Particular emphasis on undersides of pipe and areas in contact with supports
 Inspection of the storage site for any flammable material stored around the tank and whether
there is adequate ventilation
 Checking the concrete pads and piers to ensure they are in satisfactory condition and that there
are no signs of differential settlement
 Checking the pressure relief valves to ensure they are free from corrosion and drain holes are
not blocked to prevent water being retained in the pressure relief valves
 Visual inspection of flexible hoses each time they are used or, in the case of hoses in daily use
e.g. cylinder filling and Autogas dispenser hoses, every day prior to start up
 Thread gauging with the use of Go/No Go gauges of all depot and terminal ACME couplings
and replacement if worn
 Recording of the cathodic protection voltage for protected underground tanks and/or
pipework to confirm it is within specifications
 Checking that insulating flanges and couplings are not bridged and that they are providing
isolation of cathodically protected parts of the system from above ground parts
 Checking that the earthing rod is securely connected to the tank and earthing/bonding
connections are in good condition
14.7 Records
Detailed records should be maintained of all inspections, tests, and repairs or replacement of tanks,
equipment or fittings.
14.7.1 Inspection Reports
Where inspections reveal defects or significant deterioration, these should be recorded and the
inspection methods used plus any remedial action taken should be detailed. The competent person
should also assess the effects of such deterioration, defect or repair and either endorse or revise
the safe working limits of the tank or equipment. Specifically, the following should be recorded:
 Minimum safe operating temperature
 Minimum safe operating pressure
 Maximum safe operating pressure
 Maximum permissible loading on supports
 Date of next inspection
14.7.2 Repair Standards
The standard of any modifications or repair work should be at least equivalent to the original design
and manufacturing standard. If installation integrity may be affected by such work, it should be
supervised and certified by a competent person, who should endorse or revise the safe operating
limits.

Appendix 1: Written Scheme of Examination
A Written Scheme of Examination (WSE) should be prepared prior to commissioning of any LPG installation. The
scheme for customer installations may be generic, i.e. one WSE may describe the method of assuring the integrity for
all of this class of installation. At depots, terminals and plants a specific written scheme of examination should be
prepared which covers the following:
 Identification of the items of plant or equipment within the system
 Those parts of the system which are to be examined
 The nature of the examination required, including the inspection and testing to be carried out on any
protective devices
 The preparatory work needed for the item to be examined safely
 Where appropriate, the nature of any examination needed before the system is first used
 The maximum interval between examinations
 The critical parts of the system which, if modified or repaired, should be examined by a competent person
before the system is used again
 The name of the competent person certifying the written scheme of examination
 The date of certification
In order to prepare a WSE:

 The system design criteria should be established, i.e. what pressure should each part withstand.
 A drawing of the system should show the items of equipment that are under pressure and number them for
reference in an equipment list.
 The list of equipment should show the pressure ratings of the equipment and test certificates for each item
should be held on a system integrity file.
 Where the history of the installation has led to the loss of certificates for components of the LPG system, the
integrity can be verified by reference to markings on the items and by a pressure test at which point the
integrity of the system can be certified.
A competent person should decide:

 Which parts of the system are going to be inspected and /or tested,
 What inspection/testing is to be done
 How the system is to be safe while the inspection/testing is done
 How often the parts of the system are to be inspected/tested and how it is to be done
 What independent inspection is required from a notified body
A defined person should be responsible for each LPG system and for ensuring that the WSE is applied and that records
are kept for the design, and maintenance of the system integrity. He should appoint or may be the competent person
who creates the WSE. A competent person should have the necessary knowledge, experience and independence to
undertake the functions required of them.
The WSE should be periodically reviewed for suitability by a competent person.

Appendix 2: Definitions
Braided - A layer (or layers) of cylindrically woven wires covering the hose and attached to the hose ends
and fittings, serving the functions of:
a) restraining the hose against elongation; and
b) damping vibration of the hose.
Competent person - A person with knowledge, training and ability to carry out their work safely and with
the necessary proficiency to ensure the subsequent safe operation of the equipment.
Enforcing authority - The authority responsible for enforcing national and local health and safety
legislation and other relevant statutory requirements. (Can either be a national body or a local authority).
Evaporation area - Safe ground adjacent to LPG storage tank(s) where LPG can evaporate and disperse
safely.
Fire wall - A screen, wall, or dividing partition set up in open air to protect LPG tanks, pipes or equipment
from radiated heat and to ensure enough dispersion distance in the event of a leak from a protected
tank.
Fire resisting - The ability of materials to resist a fire for specific periods of time, if tested from either side,
whilst still retaining properties of insulation, integrity and stability.
Mounded tank - A storage tank partly buried or above ground and covered by a mound of earth or other
inert material.
Non-combustible - Material which will not support combustion when tested in accordance with
recognised standards.
Point of liquid transfer - The point at which liquid transfer connections and disconnections are made.
Remotely operated emergency shutdown valve - A shut-off valve that can be activated remotely to
automatically shut when engulfed by fire, deprived of actuating power or some other hazardous
condition is detected.
Separation distance - The horizontal distance between a specified feature and the nearest part of a
storage tank.
Tank - A container or vessel of over 150 litres water capacity, designed and manufactured to a recognised
pressure vessel code.
Water capacity - The water volume (in litres of water) that will completely fill a tank.
Underground tank - A storage tank buried below ground level.

References
NFPA 58: - Liquefied Petroleum Gas Code 2020 Edition.
NFPA 54: - National Fuel Gas Code 2018 Edition
UK LPG Association: – Code of Practice 1 Part 1: Design, Installation and Operation of Vessels Located above Ground
UK LPGA Code of Practice 1: - Bulk LPG Storage at Fixed Installation Part 3: 2000 Examination and Inspection
UK LPGA Code of Practice 1: - Bulk LPG Storage at Fixed Installation Part 4: 2000 Buried/Mounded LPG Storage Vessels
UK LPGA Code of Practice 20: - 2001 Automotive LPG Refuelling facilities
UK LPGA Code of Practice14: - 2002 Hoses for the transfer of LPG in bulk - Installation, Inspection, Testing and Maintenance
ASME boiler and pressure vessel code Section VIII: - Pressure Vessels, American Society of Mechanical Engineers.
EN 60079-10: - 2003. (IEC 60079-10:2002), Electrical apparatus for explosive gas atmospheres- Part 10: Classification
of hazardous areas.
EN 1762: - 2003 Rubber hoses and hose assemblies for liquefied petroleum gas, LPG (liquid or gaseous phase), and
natural gas up to 25 bar (2.5Mpa) – Specification
BS 4089: - 1999 Metallic hose assemblies for liquid petroleum gases and liquefied natural gases
BS EN 13766: - 2003 thermoplastic multi-layer (non-vulcanised) hoses and hose assemblies for the transfer of liquid
petroleum gas and liquefied natural gas specification
IP Model Code of Safe Practice Part 15: - Area Classification Code for Installations Handling Flammable Fluids.
Calculations in Support of IP15: - The Area Classification Code for Petroleum Installations, November 2001, by P T
Roberts, Shell Global Solutions (UK), published by The Institute of Petroleum, London
IP Publication, A risk-based approach to hazardous area classification, November 1998.

Disclaimer
While the WLPGA has made efforts in good faith to ensure that the information and advice contained in
this Guide is accurate, WLPGA offers no implied warranty of merchantability or fitness for any particular
purpose, nor accepts any responsibility whatsoever for any damages arising from the use of the information
contained in this Guide.


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Guide to Good Industry Practices

Bulk LPG Installations

2.0 Good Practice Guidelines for Bulk LPG Installations 6

3.0 Tank Location and Layout 7

4.0 Tank Design 17

5.0 Tank Fittings 24

Guide to Good Industry Practices – Bulk LPG Installations Page 1

7.0 Pipework and Regulators 37

8.0 Electrostatic and Electrical Precautions 44

9.0 Fire Precautions 48

10.0 Tank Commissioning and Decommissioning 54

11.0 Transfer Operations 56

14.0 Maintenance and Examination 67

Appendix 1: Written Scheme of Examination 73

Guide to Good Industry Practices – Bulk LPG Installations Page 3

Steve Reynolds Elgas

Guide to Good Industry Practices – Bulk LPG Installations Page 4

Guide to Good Industry Practices – Bulk LPG Installations Page 5

An example of a Bulk LPG facility

Guide to Good Industry Practices – Bulk LPG Installations Page 6

 The size of the trees/shrubs when fully grown

 Access needs for maintenance purposes

3.1.3 Flammable Materials

3.1.4 Horizontal Direction

3.1.5 Multiple Tanks

3.1.6 Overhead Electric Cables

Guide to Good Industry Practices – Bulk LPG Installations Page 8

 At least 7.5 m away if the cable is carrying 1 kV or more

3.1.7 Bunded Enclosures

 Any flammable liquid

 Heated liquids such as heavy fuel oil or bitumen

 Liquid oxygen or cryogenic substances

 Any other hazardous substances

3.1.8 Spillage Planning

LPG spillage containment (e.g. evaporation areas) should be installed for:

3.1.9 Siting Near Cylinders

 Less than 50 kg may be stored adjacent to the tank

Guide to Good Industry Practices – Bulk LPG Installations Page 9

3.1.10 Natural Phenomenon

Local rules should be applied to safeguard against natural phenomena, including:

 Hurricanes or Cyclones – Where prevalent, consideration should be given to the effect of

3.2 Separation Distances

Guide to Good Industry Practices – Bulk LPG Installations Page 10

3.2.2 Flammable Liquids

Up to 265,000 Up to 60 Up to 566,000 6.0

Guide to Good Industry Practices – Bulk LPG Installations Page 11

Up to 265,000 Up to 60 Up to 566,000 6.0

3.2.4 Separation Distances from Cylinder Filling Plant

Tank Capacity Minimum Distance

Table 4 - Separation Distances – Cylinder Filling Plant to LPG tanks

3.2.5 Separation Distance from Cylinder Stacks

3.2.6 Separation Distances in Automotive Retail Sites

Guide to Good Industry Practices – Bulk LPG Installations Page 12

Liquid fuel dispenser 3

Motor vehicle LPG filling connection 3

Buried tank (Flammable liquid) manway 3

LPG cylinder storage area 8

Site boundary, buildings, fixed sources of Refer to Table 1