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The storage and handling of LPG

New or modified equipment proceduresAS 1596 10.6.1

10.6.1 Commissioning new or modified equipment

No installation or part thereof shall be brought into service until operating and emergency procedures and associated equipment are available, appropriate to the facility being brought into service, and adequate personnel are available to cope with any likely fault condition.

Tank placard (24 hour phone number)AS 1596 D2.2, 2.3

D2.2 Tank or tank storage area placarding

An above-ground tank or tank storage area shall be provided with a placard in accordance with Paragraph D2.3. Where the tank and pump are underground, the placard shall be in accordance with Figure D1 and Clause 5.3.

D2.3 Placard

The placard shall display the following information:

Phone number of the organization having ownership of the equipment. The nominated phone number shall provide contact with 24-hour specialist advice via the supply company or a contractor.
Standard symbols of at least 100 mm diameter for ‘flammable gas’ and ‘no smoking’ or a warning notice in letters not less than 50 mm high prohibiting smoking and ignition sources. Where the area is isolated by a fence, the sign shall be visible from outside the fence and also from points of access.
Emergency information panel complying with the requirements of the ADG Code.
NOTE: Suitable wording for such signs would be as follows:
1. NO SMOKING, NO FLAME.
2. NO SMOKING, KEEP FIRE AWAY.
3. FLAMMABLE GAS, NO SMOKING.

Emergency shut down marked in redAS 1596 D2.1

D2 TANK INSTALLATIONS

D2.1 Emergency shut-down system marking

Every actuation point for the emergency shutdown system except the provision on the valve itself shall be provided with a sign—

marked ‘LP GAS EMERGENCY STOP’ in red letters not less than 40 mm high on a white background; and
giving instructions on how to actuate the system, in red or dark lettering not less than 20 mm high on a white or light contrasting background.

Open and closed positions of valves clearly markedAS 1596 D1

D1 TANK SYSTEMS

D1.1 Valve indicators and marking

A quarter-turn valve shall be provided with indicators and marking in accordance with the following requirements:

A means for indicating clearly the open and closed position shall be provided. Where a lever valve is fitted with a fixed handle, the valve shall be open when the handle is in the direction of the pipe. Where a valve handle is removable, a separate metal plate shall be provided, and this plate shall be clearly and indelibly marked to indicate the open and closed positions of the valve.
Globe and angle valves shall have handwheels permanently marked with the direction to open.
Any valve other than for a safety valve, pressure gauge or fixed liquid level gauge shall be marked to indicate whether it connects to liquid or vapour space.

D1.2 Direction of flow

A manual isolating valve that is subject to tank pressure shall be installed so that the valve gland is not subject to direct tank pressure when the valve is shut.

NOTE: Compliance with this requirement necessitates the mounting of valves in certain locations such as a tank inlet isolating valve contrary to any direction-of-flow marking on the valve.

D1.3 Vaporizer marking

A vaporizer shall be marked with the following information:

Manufacturer’s name or identification mark.
The number of the Standard to which the vaporizer is constructed.
Design pressure, in kilopascals.
Design temperature, in degrees Celsius.
The maximum vaporizing capacity in litres per hour.
The surface area of the heat exchanger in square metres, as detailed in Paragraph E2 of Appendix E.
If direct-fired—
1. the rated input of the heat source; and
2. the outside surface area of the vaporizer in square metres, as detailed in Paragraph E2, Appendix E.

Elbow length thermal resistant gloves (check with attendant)AS 1596 10.9.5, 10.12.6

10.9.5 Use of gloves

Protective gloves shall be worn when handling equipment which could involve contact with LP Gas.

10.12.6 Decanting

The filling of cylinders by decanting shall be carried out in accordance with Clauses 10.12.1, 10.12.2, 10.12.3 and the following requirements:

Protective gloves shall be worn.

Acme caps provided x 2 (check with attendant)AS 1596 9.3.5

At least two spare standard metal automotive filler caps shall be kept on site for use in the event of a leak at a vehicle-filling connection.

Latching device (prohibited)AS 1596 9.3.4

9.3.4 Dispensing nozzle

The dispensing nozzle shall comply with the following requirements:

The connection provision shall mate with the filler connection specified in AS/NZS 1425.
A provision to start and stop gas flow shall be incorporated and shall be quick-acting (i.e. not a screw-down valve).
Where the nozzle is self-sealing, —
1. it shall not be possible to discharge fuel unless the nozzle is connected and fully sealed to the vehicle’s filler connection;
2. upon disconnection, the amount of liquid released shall not exceed 15 mL.
Where a self-sealing nozzle is fitted to a Style A dispenser and is intended for public use, the nozzle lever shall be fitted with a latching device only if one of the following safety features is in place:
1. The nozzle cannot be sufficiently disconnected to cause a leak while the lever is attached.
2. The dispenser system incorporates an additional device that has to be activated by the person operating the dispenser, and that requires constant actuation by the operator to maintain the flow of fuel. When the device is released, the flow of fuel is stopped.
3. A device is provided that achieves an equivalent level of safety as Items (i) and (ii) above.

Dispensing nozzle (self sealing type)AS 1596 9.3.4

9.3.4 Dispensing nozzle

The dispensing nozzle shall comply with the following requirements:

The connection provision shall mate with the filler connection specified in AS/NZS 1425.
A provision to start and stop gas flow shall be incorporated and shall be quick-acting (i.e. not a screw-down valve).
Where the nozzle is self-sealing, —
1. it shall not be possible to discharge fuel unless the nozzle is connected and fully sealed to the vehicle’s filler connection;
2. upon disconnection, the amount of liquid released shall not exceed 15 mL.
Where a self-sealing nozzle is fitted to a Style A dispenser and is intended for public use, the nozzle lever shall be fitted with a latching device only if one of the following safety features is in place:
1. The nozzle cannot be sufficiently disconnected to cause a leak while the lever is attached.
2. The dispenser system incorporates an additional device that has to be activated by the person operating the dispenser, and that requires constant actuation by the operator to maintain the flow of fuel. When the device is released, the flow of fuel is stopped.
3. A device is provided that achieves an equivalent level of safety as Items (i) and (ii) above.

Dispensing hose (self sealing break away coupling)AS 1596 9.3.3

9.3.3 Dispensing hose

The dispensing hose assembly shall comply with Clause 3.6.5 and shall incorporate a selfsealing hose break coupling which complies with the following requirements:

The coupling shall disconnect in the event of undue force being applied to the hose, such as a vehicle moving off with the hose connected.
NOTE: The coupling should be capable of being re-assembled after separation, preferably without the need for draining the hose, the use of special tools, or the replacement of parts.
The force required to separate the coupling shall be less than 600 N for internal hose pressures of 700 kPa to 2500 kPa.
The coupling shall retain the liquid within each section of the hose after separation when pressures of 700 kPa to 2500 kPa are maintained in the hose. The volume of liquid lost as a result of parting shall not exceed 15 mL, and the coupling shall not leak after disconnection.

Test shut down (at the dispenser, let their operator activate button)AS 1596 9.3.2

Where a Style A dispenser system is required by Figure 9.2, it shall include a dispenser which complies with AS 2229.2/NZS 6109.2 and which is provided with an excess-flow valve, a remote-operated shut-off valve, and a pipe-shear provision, in that order, in all LP Gas pipes attached to the cabinet. The valves shall be below or as close as possible to ground level, with the shear provision above them. Where the remote-operated valve can be relied upon to shut off automatically in the event of pipe shear the excess-flow valve may be omitted. (Additional requirements for service station dispensers are provided in Clause 9.5.16). In addition, the system shall incorporate the following:

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Pump control (switch inside can shut down remote pump)AS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Overspeed sensor providedAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Manually operated + VE shut off valveAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Emergency information panel (as per ADG Code)AS 1596 D2.2, 2.3

D2.2 Tank or tank storage area placarding

D2.3 Placard

The placard shall display the following information:

Phone number of the organization having ownership of the equipment. The nominated phone number shall provide contact with 24-hour specialist advice via the supply company or a contractor.
Standard symbols of at least 100 mm diameter for ‘flammable gas’ and ‘no smoking’ or a warning notice in letters not less than 50 mm high prohibiting smoking and ignition sources. Where the area is isolated by a fence, the sign shall be visible from outside the fence and also from points of access.
Emergency information panel complying with the requirements of the ADG Code.
NOTE: Suitable wording for such signs would be as follows:
1. NO SMOKING, NO FLAME.
2. NO SMOKING, KEEP FIRE AWAY.
3. FLAMMABLE GAS, NO SMOKING.

Flammable gas, no smokingAS 1596 D2.3, 2.4

D2 TANK INSTALLATIONS

2.3 Placard

The placard shall display the following information:

Phone number of the organization having ownership of the equipment. The nominated phone number shall provide contact with 24-hour specialist advice via the supply company or a contractor.
Standard symbols of at least 100 mm diameter for ‘flammable gas’ and ‘no smoking’ or a warning notice in letters not less than 50 mm high prohibiting smoking and ignition sources. Where the area is isolated by a fence, the sign shall be visible from outside the fence and also from points of access.
Emergency information panel complying with the requirements of the ADG Code.
NOTE: Suitable wording for such signs would be as follows:
1. NO SMOKING, NO FLAME.
2. NO SMOKING, KEEP FIRE AWAY.
3. FLAMMABLE GAS, NO SMOKING.

D2.4 Construction of signs

Signs shall be constructed in accordance with AS 1319. Class labels shall be a minimum of 250 mm square unless permitted to be reduced by the ADG Code.

Testing and inspection proceduresAS 1596 10.5.1- 10.5.12

10.5 CONSTRUCTION, INSPECTION, TESTING AND MAINTENANCE

10.5.1 Installation certification

Before an installation is put into service, it shall be certified in writing that the complete installation was installed, tested and proved to be leak-free and in accordance with the installation specifications and the provisions of this Standard.

10.5.2 Scheduled checks

A routine check procedure shall be prepared for each installation appropriate to that installation. Such a procedure shall cover all operating valves and systems, instruments, emergency shut-down systems, safety valve protective caps and discharge provisions, and fire protection equipment. Tank-emptying provisions are excluded. In particular, emergency shut-off valves shall be operated at intervals not exceeding 1 month, from each available operation point. A pumping and supplementary fire protection system shall be tested in accordance with the relevant Parts of AS 1851. A record of tests and inspections shall be kept.

NOTE: Where an emergency system installation can be actuated from any of a number of points, it is not necessary to test all such points on the same day, i.e. operation may be tested from the various points in rotation, provided that each has been checked within the stated time.

10.5.3 Tanks

Tanks shall be inspected according to regulatory requirements. The following additional requirements apply to underground tanks:

Where tests prove the effectiveness of the corrosion-resistant system, periodic external inspection of a tank need not be made. Inspection of test plates or probes buried close to a tank and connected to it may be used as evidence of satisfactory cathodic protection.
Tanks shall be inspected at the end of the effective life of sacrificial anodes or when tests indicate the permanent loss of effectiveness of the cathodic protection system or coating.
When any fault is found in the protective coating, it shall be stripped in the immediate vicinity of the fault and the underlying metal surface examined. Such defective coating shall be repaired and tested to ensure compliance with Clause 5.2.
Cathodic protection systems shall be tested at intervals not exceeding 6 months and record of these tests shall be kept and shall be available for 10 years.

NOTE: AS 2832.2 provides guidelines for operation and maintenance of cathodic protection systems.

10.5.4 Piping

Piping for LP Gas, whether it is new, modified, or added piping, shall be tested in accordance with the relevant procedures detailed in Appendix H.

10.5.5 Hoses

Transfer hoses other than decanting hoses shall be periodically inspected and tested as follows:

Visually inspected for damage over the whole length in use at intervals not exceeding 1 month.
Hoses and couplings which are assembled and tested in accordance with the manufacturers’ guidelines, and in compliance with AS/NZS 1869, shall, at the end of five years’ service, be either––
1. replaced; or
2. tested at a pressure of 2.4 MPa at intervals not exceeding one year thereafter.
Electrical continuity check of hoses containing electrical continuous wiring at intervals not exceeding 1 year in accordance with AS/NZS 1869. Delivery hose for in-situ filling shall be inspected visually over its entire length weekly. Hoses which fail inspection or testing shall be discarded or repaired.

10.5.6 Flexible connections

Metal flexible connections shall be inspected visually at intervals not exceeding 1 year and shall be hydrostatically tested to 3.6 MPa at intervals not exceeding 5 years. Elastomeric flexible connections shall be inspected and tested as for transfer hose. Metal flexible connections which fail inspection or test shall be replaced.

10.5.7 Protective flow-control valves

Excess-flow valves and non-return valves shall be checked immediately after installation to ensure correct functioning. Hydrosttic relief valves shall be checked in accordance with AS/NZS 3788.

NOTE: AS/NZS 3788 requires that pressure relief valves for LP Gas be tested at intervals not exceeding the internal inspection interval for the vessel, provided that weatherproof external protection prevents dust, rain or other contamination from affecting the valve’s performance.

10.5.8 Authorization of work

No work shall be carried out on any LP Gas installation without authorization in one of the following forms:

A verbal instruction, which shall be limited to non-hazardous actions or to work for which the person has been trained.
Procedures in accordance with Clause 10.5.10 for which the person has been trained.

10.5.9 Safe procedures

Work on or near any components containing LP Gas shall be undertaken only after necessary steps have been taken to ensure safety. Safe work procedures shall be followed. These may be in the form of compliance with the following:

AS/NZS 2865.
A recognized safe work system.
A recognized work permit system including a hot work permit in accordance with AS 1674.1.
Clause 10.5.10.

10.5.10 Work preparation

Appropriate procedures shall be adopted and responsibilities assigned to ensure that the relevant site area and plant are properly prepared to prevent injury to people, damage, fire or explosion. Particular attention shall be paid to the following, as appropriate:

Observance of any written safety procedures.
Liaison with site operator.
Testing for flammable gas and oxygen levels, particularly for any confined spaces, pits, trenches and other potentially hazardous areas.
Removal of protective devices unless substitute protection has been provided.
Prevention of inadvertent operation during maintenance.
Prevention of contamination of equipment by water, dirt, foreign matter, or other materials.
Identification of both the equipment to be worked on and all other equipment affected, including underground piping or equipment.
Depressurization and disconnection.
Isolation from other equipment.
Blanking or capping opened connections.
Purging of the equipment.
Removal of combustible materials.
Sealing off of sewers, drains and gutters.
Provision of additional protection, fireguards, and firefighting equipment.
Tagging where required.

10.5.11 Completion of work

Upon completion of work, a check shall be made to ensure that—

any written safety procedures have been followed;
the work has, in fact, been completed;
any temporary arrangements have been discontinued, e.g. bypass lines or blank flanges have been removed or fuses replaced;
all personnel and equipment are accounted for;
relevant work permits or other documentation have been signed off; and
the site operator is notified of status.

10.5.12 Site upkeep

The area around any storage and handling facility and the installation itself shall be maintained in a safe condition. In particular––

any accumulation of flammable or combustible materials, of a type and quantity sufficient to constitute a significant heat radiation hazard to the installation in the event of fire in those materials, shall be removed;
specified clearance distances shall be maintained;
vegetation that could become a fire hazard shall be kept short;
the area shall be kept clear of all extraneous material;
lighting shall be kept operational and effective;
the surface coating of any tanks shall be maintained in good condition; and
signs and notices shall be legible.

Supervision and recordsAS 1596 10.4.2 and 10.4.3

10.4.2 Supervision

All operational and maintenance work shall be planned and supervised. All necessary precautions shall be observed.

10.4.3 Records

Records shall be kept of the following:

Training and retraining (permanent record).
Routine testing of safety equipment and fire protection equipment (as required by this Standard and other referenced Standards).
In-service inspections (life of installation).
Training drills (six years).
Maintenance and repairs, and equipment deficiencies (life of equipment).
Abnormal incidents, including ‘near-miss’ occurrences (life of installation).

The suggested periods for retention of records are indicated in parenthesis.

Contractor proceduresAS 1596 10.3.7.2

10.3.7.2 Contractors

Contractors and their staff shall be trained in the following as appropriate to the site:

Properties, characteristics and hazards of any materials likely to be encountered and appropriate for the site.
Correct use of any necessary personal protective equipment provided.
Hazards likely to be encountered.
Procedures to be followed in the event of an incident (spillage, accident, fire).
Layout of the installation.
Location of firefighting equipment.
Basic principles of first aid firefighting, and the use of fire hose reels and fire extinguishers.
Any regulations relevant to their tasks.
Area housekeeping.
Safety rules of the installation.
Conditions and obligations associated with work permits and confined-space entry permits.

Training proceduresAS 1596 10.3.7.1

10.3.7.1 Employees

Each employee shall be trained in such duties as have been individually assigned to that person in connection with LP Gas. In addition, the training shall include the following, as appropriate:

Procedures to be followed in the event of an incident (accident, fire).
Layout of the installation.
Location of firefighting equipment.
Basic principles of first aid firefighting, and the use of fire hose reels and fireextinguishers.
Regulations relevant to the employee’s tasks.
Properties, characteristics and hazards of any materials kept or handled.
Correct use of any personal protective equipment provided.
Area housekeeping.

NOTE: Procedures and precautions for motor vehicle refuelling are provided in Appendix N.

Emergency proceduresAS 1596 10.3.6

10.3.6 Emergency procedures

The emergency procedures shall be appropriate to the particular installation and shall take into account, amongst other things, the following:

List of contacts, emergency services, phone numbers.
Chain of command.
List of duties.
Any mutual aid (inter-company) arrangements.
Cooperation with relevant authorities, and compatibility with equipment.
Fire teams (initial response).
Fire drills.
Evacuation provisions.
Assembly points.
First aid.
Debriefing and reporting.
Vehicles on site.
Contractors.
Access control.
Site plan.

For large sites storing dangerous goods in addition to LP Gas the total site shall be considered when preparing on-site and off-site emergency plans.

NOTE: Appendix M provides relevant information on on-site and off-site emergency plans.

Maintenance proceduresAS 1596 10.3.5

10.3.5 Construction and maintenance procedures

The construction and maintenance procedures shall be appropriate to the particular installation and shall take into account, amongst other things, the following:

Periodic testing of protective devices, alarms, and personal protective equipment.
Regular testing of hoses.
Establishment of safe areas.
LP Gas purging.
Isolation and tagging.
Control of contractors.
Work authorization.
Confined spaces.
Hot work permits
Firefighting equipment.
Pipelines and equipment.
Storage tanks.
Electrical equipment.
Fences and security measures, signs, notices.
Lighting.
The needs of any other individual item or plant components, e.g. pumps, equipment.

Operating proceduresAS 1596 10.3.4

10.3.4 Operating procedures

The operating procedures shall be appropriate to the particular installation and shall take into account, amongst other things, the following:

Identification of safe areas.
Initial commissioning procedures.
Normal handling procedures.
Monitoring of essential functions and equipment.
Recognition of fault conditions.
Product transfer.
Housekeeping and site upkeep.
Any manufacturer’s operating instructions for equipment.
Equipment not in use (i.e. isolation, deactivation, identification).
Maintaining clear spaces for access.
Personnel safety.
Personal protective equipment.
Control of ignition sources.
Earthing and bonding.
Control of access, security and lock-up.
Vehicle movement.

Safety Management System ( LPG Auto Retail Outlets COP )AS 1596 9.8

9.8 SAFETY MANAGEMENT SYSTEM

A safety management system shall be prepared and implemented. Compliance with the ALPGA publication LP Gas Automotive Retail Outlets––Code of Practice for Safe Operation is deemed to constitute a means of compliance with this requirement and Clause 10.2.

Ignition sources in hazardous area (as per AS 2430 )AS 1596 9.2.1

9.2.1 Ignition sources

The design of the installation shall be such that ignition sources are not located in and are not permitted in a hazardous area as described in the relevant Parts of AS/NZS 2430 (see Clause 1.4.28). A vehicle is not regarded as being an ignition source while it is entering or leaving the hazardous zone surrounding a LP Gas dispenser or a bulk LP Gas filling connection. However, it is treated as a potential ignition source during the period of bulk liquid transfer, and precautionary measures need to be taken (see Clause 10.11).

Remote shut down system (RSDS) x 2AS 1596 9.5.14

9.5.14 Remote shut-down system

A remote shut-down system shall be fitted and shall be as follows:

Capable of initiation at the following locations as a minimum, with at least one actuation point being accessible at all hours: (i) Within 10 m from the tank filling point. (ii) For self-service sites, at a point easily accessible and visible from the console. (iii) For attendant-operated sites, either at the dispenser or at a point which is easily accessible to the attendant. (iv) At a remote location external to any building and distant from the tank filling point and console, in a direction to allow ready egress from the site.
Of a fail-safe design which will close all liquid supply, pump bypass and vapour return tank connections and shut down the pump systems as quickly as possible with a response time of no more than 10 s when operated from any point.
Checked in accordance with the requirements of the site safety management system (see Clause 9.8) with test results recorded and the records retained on site. If any defect compromising safety is identified, the tank shall be manually isolated until such time as the system is returned to full function.
Designed and installed so that manual action is required to re-open the valves to resume operation.
Designed and installed so that it achieves a high degree of reliability.
Provided with instructions on how to actuate it and marked in accordance with Paragraph D2.1(a).
Provided with clear access to the actuation points and with such access being maintained.
NOTE: The remote shutdown system and the emergency shutdown system (see Clause 4.8) may use common componentry provided the function of each system is satisfied.

Emergency procedures displayedAS 1596 fig D1

Click image to enlarge

Cylinder filling instructionsAS 1596 D4

D4 CYLINDER FILLING

D4.1 Decanting cylinder notices

The following notices shall be prominently displayed as closely as possible to the decanting point:

Standard symbols of at least 100 mm diameter for ‘flammable gas’ and ‘no smoking’ or a warning notice in letters not less than 50 mm high, reading—
FLAMMABLE GAS, NO SMOKING
Instructions for decanting procedure, including a warning to stop filling as soon as the fixed liquid level gauge indicates that the maximum permitted liquid level has been reached.

D4.2 Cylinder filling installations

A notice shall be displayed near the cylinder-filling point indicating ‘NO SMOKING, NO FLAME’ in letters not less than 50 mm high.

Control valve inside cabinetAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Pipe-shear provision providedAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Remote shut off valve providedAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Filler Valve (manual shut off wheel or compound valve)AS 1596 3.3.5

3.3.5 Secondary shut-down system

Where the primary shut-down provision is a non-return valve, the secondary system shall comprise at least a manual positive shut-off valve, or, if the tank is 8 kL or less and the entry is for filling into the vapour space, another non-return valve that is gastight. Where the primary shut-down provision is an excess-flow valve, the secondary system shall comprise—

for vapour connections . . . at least a manual positive shut-off valve; or
for liquid connections . . . an emergency shut-down system, except that for an opening into a tank that is not larger than 3/4 NPT and that is used only for decanting into cylinders, a manual positive shut-off valve is permissible.

NOTE: Clauses 3.3.4 and 3.3.5 should be read as specifying functions and not necessarily selfcontained and independent valves. The primary and the secondary functions may be incorporated in a single compound valve provided that all the functional requirements are incorporated.

Filler valve (primary shut down - check non return valve is working)AS 1596 3.3.4

3.3.4 Primary shut-down system

The primary shut-down provision shall consist of a non-return valve, except that where outward flow is necessary an excess-flow valve may be used. The design and installation of the valve shall be such that it will continue to function as a shut-down device should impact or shear-off occur to any external portion or attachment. Where a multiple function valve which complies with Clause 3.3.1(e) is used, a primary shut-down system is not required.

Safety valve (protected from physical damage)AS 1596 3.4.1- 3.4.3

3.4.1 Provision of safety valves

Safety valves shall be provided as required by the pressure vessel design code, with the following qualifications:

A safety valve shall communicate with the vapour space in the tank.
Safety valves shall be arranged so that the possibility of tampering is minimized. Any externally located pressure-setting adjustment shall be provided with a means of sealing or locking after setting.
Safety valves shall comply with AS 1271 or UL132 or other recognized Standard. NOTE: Care is necessary in determining the setting and capacity of safety valves for tanks with provisions for controlling the service temperature (see Clause 3.2.1(b)(iii)) if the temperature of the LP Gas delivered is likely to be higher than the controlled design temperature).
In Australia only, the aggregate discharge capacity of the safety valve(s) shall be not less than that determined in accordance with Appendix E. NOTE: Appendix E has been derived from the general formula of AS 1210, simplified to suit the particular case of LP Gas.

3.4.2 Discharge provisions

A safety valve and any discharge piping shall comply with the following requirements when installed:

The size of any discharge piping shall be sufficient to ensure that the required discharge capacity of a safety valve is achieved. The effect of back pressure shall be taken into account in the case of changes of direction or excessive length.
The direction of discharge shall be vertically upwards.
Except for measures necessary to prevent ingress of rainwater or blockage, venting shall be direct to atmosphere.
The direction of discharge shall not permit escaping vapour to impinge on any tank, fitting, structure or piping.
It shall not be possible to render a safety valve inoperative except under the conditions permitted in Clause 3.4.3.
The discharge for a tank of more than 8 kL capacity shall terminate not less than 2 m above the tank.
Where a lockable dome or cage is provided, the arrangement shall continue to comply with the requirements relating to free dispersal or impingement of discharge.
The outlet shall be protected as far as practicable from physical damage.
A cap shall be provided to prevent the accumulation of rain, dew or foreign matter within the safety valve in such a manner as to render the valve defective. Where a discharge pipe is fitted, the cap shall be fitted at the point of discharge. The cap shall not prevent the safety valve from operating effectively and shall not prevent the effective discharge, in a safe manner, of any release of LP Gas. Where a weep hole or drain is provided in order to comply with this requirement, the overall design shall be such that any ignited LP Gas discharge cannot impinge on the tank, adjacent tanks, piping, or equipment. NOTE: A deflector or a drainage discharge pipe is permissible, provided that piping does not incorporate a valve.
A means shall be provided to protect the safety relief valve from impact or high wind loading on the discharge piping which could damage the valve.

3.4.3 Reserve safety valves

Where additional safety valves are provided to permit servicing without depressurizing, the valve system used to isolate any individual safety valve shall be designed so that it is not at any time possible to operate the system with less aggregate pressure-relief capacity than that required under Clause 3.4.1(c).

Lockable domeAS 1596 3.4.1- 3.4.3

3.4.1 Provision of safety valves

Safety valves shall be provided as required by the pressure vessel design code, with the following qualifications:

A safety valve shall communicate with the vapour space in the tank.
Safety valves shall be arranged so that the possibility of tampering is minimized. Any externally located pressure-setting adjustment shall be provided with a means of sealing or locking after setting.
Safety valves shall comply with AS 1271 or UL132 or other recognized Standard. NOTE: Care is necessary in determining the setting and capacity of safety valves for tanks with provisions for controlling the service temperature (see Clause 3.2.1(b)(iii)) if the temperature of the LP Gas delivered is likely to be higher than the controlled design temperature).
In Australia only, the aggregate discharge capacity of the safety valve(s) shall be not less than that determined in accordance with Appendix E. NOTE: Appendix E has been derived from the general formula of AS 1210, simplified to suit the particular case of LP Gas.

3.4.2 Discharge provisions

A safety valve and any discharge piping shall comply with the following requirements when installed:

The size of any discharge piping shall be sufficient to ensure that the required discharge capacity of a safety valve is achieved. The effect of back pressure shall be taken into account in the case of changes of direction or excessive length.
The direction of discharge shall be vertically upwards.
Except for measures necessary to prevent ingress of rainwater or blockage, venting shall be direct to atmosphere.
The direction of discharge shall not permit escaping vapour to impinge on any tank, fitting, structure or piping.
It shall not be possible to render a safety valve inoperative except under the conditions permitted in Clause 3.4.3.
The discharge for a tank of more than 8 kL capacity shall terminate not less than 2 m above the tank.
Where a lockable dome or cage is provided, the arrangement shall continue to comply with the requirements relating to free dispersal or impingement of discharge.
The outlet shall be protected as far as practicable from physical damage.
A cap shall be provided to prevent the accumulation of rain, dew or foreign matter within the safety valve in such a manner as to render the valve defective. Where a discharge pipe is fitted, the cap shall be fitted at the point of discharge. The cap shall not prevent the safety valve from operating effectively and shall not prevent the effective discharge, in a safe manner, of any release of LP Gas. Where a weep hole or drain is provided in order to comply with this requirement, the overall design shall be such that any ignited LP Gas discharge cannot impinge on the tank, adjacent tanks, piping, or equipment. NOTE: A deflector or a drainage discharge pipe is permissible, provided that piping does not incorporate a valve.
A means shall be provided to protect the safety relief valve from impact or high wind loading on the discharge piping which could damage the valve.

3.4.3 Reserve safety valves

To above ground LPG bullet: 5mAS 1596 9.5.19

9.5.19 Decanting cylinders

Any LP Gas cylinder provided for the filling of other LP Gas cylinders by decanting shall be located not less than 5 m from any above-ground LP Gas storage tank, unless the tank is protected from a fire at the decanting cylinder. A firewall constructed in accordance with Clause 4.4 is deemed to provide suitable protection. The outlet and safety relief valves of the decant cylinder shall be directed away from the storage tank.Apart from the provisions of this Clause (Clause 9.5.19), all provisions of the relevant Sections of this Standard shall apply to the operation of decanting cylinders.

To any structure limiting egress: 2mAS 1596 7.4.3

7.4.3 Location

A decanting cylinder shall not be stored indoors, used indoors or used in a portable application and shall be located on the ground in a static position. Whether decanting froma tank or a cylinder, the design of the installation shall be such that the point of connection to the cylinder being filled cannot lie within the following separation distance:

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To a drain, pit or basement: 3mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To dispenser of any type of fuel: 3mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To D/G storage tank: 3mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To public places: 3mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To a neighbouring property or combustible materials: 5mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

To an opening into a building: 2mAS 1596 7.4.3

7.4.3 Location

To an opening into a building: 2 m.
To buildings on neighbouring property or to any combustible materials stored above ground : 5 m.
To public places: 3 m.
To any above-ground tank containing dangerous goods : 3 m.
To dispensers for any type of fuel: 3 m.
To the entrance to a drain, pit, or basement: 3 m.
To any structure limiting egress past the point of connection to the cylinder: 2 m.

NOTES:

The point of connection implies hose reach if flexible decanting hoses are used. Except where LP Gas decanting is carried out on a dedicated area clearly marked on the ground or on a cylinder stand, the separation distances may be taken from the marked area or stand.
The above requirements are displayed in Figure 7.1.

Fixed liquid level gauge providedAS 1596 3.5.4

3.5.4 Liquid level and contents

A tank shall be fitted with the following:

A separate fixed liquid level gauge arranged to indicate the standard filling level, which shall be determined in accordance with Appendix C.
A means for monitoring the whole range of the liquid contents of the tank.

NOTE: A tank may be fitted with the following:
Additional fixed liquid level gauges located to indicate the standard filling level for different LP Gas compositions.
A variable liquid level gauge to permit the use of the temperature-correction method of filling to the maximum filling level. (e) A contents gauge to indicate the liquid contents or surface level as it varies with consumption and replenishment.

Pressure gauge providedAS 1596 3.5.5

Each tank shall be fitted with a pressure gauge complying with AS 1349/NZS/AS 1349.

Excess flow valve providedAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Style A Dispenser SystemAS 1596 9.3.2

Control valves
The following control valves shall be provided inside the dispenser cabinet and as close as practicable to the flexible hose between the dispenser cabinet and the breakaway coupling:
1. A manually operated positive shut-off valve.
2. An excess-flow valve.
Overspeed sensor
A device shall be fitted to the dispensing equipment which has the ability to detect an abnormal flow of fuel, e.g. caused by a hose rupture, and which will shut down the dispenser and the remote pump.
Pump control
A switch shall be fitted inside the dispensing cabinet which can shut down the remote pump. NOTE: This switching action may be performed automatically by the positioning of the hose nozzle in and out of its receptacle.
Return line
In Australia, a return line from a dispenser shall comply with the requirements of Table 3.2 for liquid withdrawal or two-way flow. In New Zealand, the return line shall comply with the requirements for vapour return and balancing lines. A continuous liquid bypass in the dispenser shall be limited to a flow area of less than 4 mm2. NOTE: Use of bollards or guardrails to protect the dispenser from minor impact is considered good practice but is not mandatory.

Tank to protected place 6mAS 1596

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Tank to adjacent property 6mAS 1596

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Tank to public place 3mAS 1596

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Tank to adjacent tank 1mAS 1596

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8 kl LPG tank to flammable liquids store > 6mAS 1596 4.2.6

4.2.6 On-site storages and flammable and combustible materials

LP Gas tanks shall be separated from stores of flammable or combustible materials as follows:

At least 6 m from any above-ground tank, package store or filling area for flammable or combustible materials.
At least 3 m from the top of the bund of a compound in which flammable liquids are stored.
At least 2 m from any vent outlet of flammable liquids store (measured horizontally).
For stores of flammable liquids, as determined by AS 1940 or this Standard, whichever is greater.

8 kl LPG tank to protected place > 10mAS 1596

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8 kl LPG tank to public place > 6mAS 1596

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Above ground LPG tanks - separation distances

4.2.1 General location and spacing

Above-ground storage tanks shall be located in accordance with the distances shown in Table 4.1, with the following qualifications:

An above-ground tank shall not be installed in a building.
Where the site is used primarily for LP Gas storage and handling, or where the LP Gas facility is within a petroleum terminal, the separation distance to buildings on the same site as the LP Gas storage may be halved, provided that in no case shall a tank having a total capacity exceeding 2.5 kL be located closer than 3 m to such a building.
A tank exceeding 0.5 kL capacity shall be not less than 1 m from a boundary.
Where a tank under 0.5 kL capacity is permitted with zero distance to public places or protected places, the space in the opposite direction shall be clear for a minimum distance of 3 m. No more than five such tanks shall be installed in a group with 1.5 m to a public place and zero to a protected place (see Appendix F for an illustration of the application of separation distances).

Electrical equipment and wiring complies with AS 3000AS 1596 3.5.9

Electrical equipment and wiring shall comply with AS/NZS 3000/New Zealand Electricity Regulations 1993.

Provision for emptying tank (shut off valve and excess flow valve)AS 1596 3.5.8

3.5.8 Provision for emptying tank

Every tank shall have a means for removing liquid LP Gas from the tank should an emergency arise. Where the piping system cannot perform this function, an additional provision shall be made in the form of a drain or an eductor tube, fitted with an excess flow and shut-off valve. The shut-off valve outlet shall be capped or plugged, when not in use, with a metal fitting, and Table 3.2 shall apply. The outlet shall be directed so as to avoid impingement on the tank and fittings, supports, or other tanks.

NOTES:

Because bottom drain fittings on small tanks may be difficult to access and vulnerable to damage, eductor tubes may be preferable.
Devices which are plugged when not in use and incorporate a check valve with an excessflow function that is enabled by the insertion of a screw-in fitting are acceptable as primary and secondary protection for tanks up to 8 kL capacity and may serve as a means of emptying the tank.

Decanting procedureAppendix L

The following procedure should be followed when filling cylinders by decanting:

Inspect the customer’s cylinder for corrosion and dents, paying particular attention to the underside of the cylinder. If significant corrosion is present, do not fill the cylinder and refer the customer to a registered cylinder test station.
Unlock the decant vessel cover/valve. Ensure that the dead-man’s valve on the filling assembly is closed and the assembly is tightly connected to the storage vessel. Gloves should be worn when decanting.
Connect filling assembly (hose) to customer’s cylinder.
Open the main valve on customer’s cylinder.
Check that the bleed valve on the customer’s cylinder is directed away from the operator and towards a well-ventilated area before opening the bleed valve one half turn using the correct tool. This will reduce the pressure in the customer’s cylinder to be filled.
Open the main valve on the decant vessel.
Activate the dead-man’s valve on the filling assembly to start the filling process.
Stay in attendance during the entire process of filling. Do not use any device (i.e. clamps, rubber bands) to hold the dead-man’s valve open. Observe the hose and all connections during filling for possible leaks.
Allow the filling to continue until white cloud/mist emerges from the customer’s cylinder bleed valve, which indicates that the cylinder is full (the maximum fill level has been reached).
Immediately release the dead-man’s valve to stop filling.
Remove a glove and touch the main decant vessel with bare hands (to discharge any static electricity from the body of the person decanting). Replace the glove and continue.
Close the main valve on the customer’s cylinder.
After white cloud/mist disappears, close the bleed valve on the customer’s cylinder. Do not close the bleed valve while white cloud/mist is still emerging.
Close the main valve on the decant vessel.
Carefully disconnect the filling assembly hose from the customer’s cylinder. When breaking the connection, a small amount of vapour trapped between the two valves will escape.
Confirm the customer’s cylinder is leak free by applying soapy water with a small paint brush or spray bottle to the following:
1. Outlet of the main valve.
2. Thread where the main valve is attached to the customer’s cylinder.
3. Bleed valve opening.
Lock the cover/valve of the decant vessel.
If LP Gas in liquid form comes in contact with the bare skin or eyes, wash the affected areas with water for at least 10 min and see a doctor.