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Hot work repairs to cylinders, including shot or grit blasting, zinc metal spraying and the use of machinery, e.g. shroud and base ring straightening (although there is equipment available to undertake straightening without heat), which does not comply with the hazard zone safety requirements, must not be carried out in cylinder filling areas or within other hazardous zones.

Sites where hot work is carried out must be located outside hazardous areas.

When performing maintenance, repair and requalification on composite LPG cylinders, the instructions and manuals from the manufacturer must be observed and followed.

6.2.7 LPG piping and fittings

Any LPG piping within plants must comply with the local or regional requirements.

All product piping shall be colour coded and fire-fighting water and other services installed against appropriate standards.

All valves must be marked or labelled to indicate their service and function.

All piping must be protected from accidental damage by appropriately locating it or by installing mechanical protective means.

The liquid piping system should include a liquid return to the main storage tank(s) with an automatic pressure control valve fitted in the return line from the filling machines to prevent vaporisation of LPG in the fill line.

A shut-off valve and non-return valve should be fitted in the liquid return.

A remotely controlled fire-safe and fail-safe emergency shut-

off valve must be located in the liquid supply pipeline or close

to the point of entry into the cylinder filling building/structure with actuation points positioned at strategic locations, e.g. locations which are usually manned, throughout the plant.

locations which are usually manned, throughout the plant. LPG bulk storage facility Consideration should be given

LPG bulk storage facility

Consideration should be given to inter-connecting the emergency valve’s actuation system into the fire alarm and general emergency shut-down system of the plant.

An appropriate filter should be fitted in an easily accessible location in the liquid pipeline upstream of the filling machines.

The overall filtration system of the plant, from product receipt via main storage tank(s) to cylinder filling, should be assessed at the design stage to ensure satisfactory product quality when filling cylinders.

It is recommended to install a drive-away protection system with bulk trucks that prevents a major leak that would follow an unplanned departure of the vehicle.

Drive-away couplings result in the breakage of the coupling instead of rupturing the hose.

6.2.8 Cylinder handling systems

The best method of handling filled and empty cylinders from the filling area to the transport loading bays and storage areas should be assessed taking into consideration traffic flow in the plant, the means and size of the transport units used, the planned distribution system, the possible use of pallets, (refer 8.4), the possible use of ground level and overhead conveyor systems, etc.

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