Gu i d e l i n e f o r I n s sp pec ctt i o n o f L i q u e f i e d P e t r o l e u m Ga s F i l l i n g St a t i o n s
Guideline for Inspection of LPG Filling Stations
May 2007
FOREWORD
In Hong Kong, a num number ber of Liquefied iquef ied Petro Petroleum leum Gas (LP (LPG) filling fill ing st ations atio ns have have been been built buil t t o support the LPG vehicle scheme. This Guideline delineates the safety aspects of an LPG filling station and provides guideline to the owner and competent person for annual / periodic inspection of the filling station. This Guideline shall be read in conjunction with the Code of Practice for Hong Kong LPG Industry Module 1 on LPG Compounds and Cylinder Stores, Code of Practice for LPG filling st ations atio ns in Hong Kong, t he Gas Safet afety y Ordinance (Ca (Cap. p. 51) and it i t s subsidiary subsidiary regulations regulatio ns.. Station owner and competent person should consult the LPG equipment manufacturer for specific operation and maintenance requirements of the equipment, if necessary. Enquiry on this document should be addressed to the Gas Standards Office of Electrical and Mechanical Services Department.
Guideline for Inspection of LPG Filling Stations
May 2007
CONTENTS
1.1 1.2
Introduction Scope
1 1
2.1 2.2
Owner’s Responsibilit y Inspection and Submission
1 1
3.1 3.2 3.3
General Process Flow of the LPG Filling Station Separation Distance Betw een LPG and Petrol/Diesel Filling Facilit ies
2 2 2
4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12
General Facilit ies Common to LPG Compound LPG Storage Tank with Submersible Pump LPG Dispenser Dispenser Nozzle Breakaway Coupling Remote Emergency Shut -down System Water Spray and Sprinkler System Gas Detection System Drain and Pit Crash Barrier Electrical Installation
3 3 3 3 4 4 4 4 4 5 5 5
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13
General Station Housekeeping Separation Distance LPG Storage Tank and Submersible Pump LPG Dispenser Dispensing Hose and Breakaway Coupling Dispensing Nozzle Remote Emergency Shut -down System Fire Services Installation Gas Detection System Drains and Pits Crash Barrier Electrical and Instrumentation Installation
6 7 7 7 8 8 9 9 9 9 9 10 10
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Guideline for Inspection of LPG Filling Stations
May 2007
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Guideline for Inspection of LPG Filling Stations
May 2007
GUIDELINE FOR INSPECTION OF LIQUEFIED PETROLEUM GA S FILL ING ST A T IONS
SECTION 1. INTRODUCTION AND SCOPE
This Guideline is prepared by the Gas Standards Office of Electrical & Mechanical Services Department giving guidance on the periodic inspection of liquefied petroleum gas (LPG) filling station for dispensing LPG as a vehicle fuel.
This Guideline describes the special features of an LPG filling station, provides a brief account of owner’s maintenance responsibilities and also stipulates the minimum inspection requirements so as to f acilitate the competent person in carrying out annual inspection of those facilities installed in the station.
SECT ION 2. STA T UTORY REQUIREM ENT S
Pursuant to Regulation 6B of the Gas Safety (Gas Supply) Regulations, the owner of a “ notifiable gas installation” (NGI) shall maintain and operate the installation in a safe condition for the prevention of fire, explosion or ot her danger arising from the installation. According to paragraph (f) of “ notifiable gas installation” as defined under section 2 of the Gas Safety Ordinance (Chapter 51), an LPG filling station is a NGI. The owner of an LPG filling station is therefore obliged to ensure that the station and all equipment therein shall be maintained and operated in a safe manner.
Pursuant to Regulation 6C of the Gas Safety (Gas Supply) Regulations, the owner of an LPG filling station shall employ a competent person to carry out inspections on the installation to ascertain whether the installation is maintained and operated in accordance with Regulation 6B of the aforementioned Regulations. The inspections shall be carried out at intervals of not less than once every year. The inspection reports of the station shall be kept by the owner for the service life of the installation. A copy of the inspection report shall be submitted to the Gas Authority (i.e. The Director of Electrical and Mechanical Services) by the owner within four weeks after an inspection.
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Guideline for Inspection of LPG Filling Stations
May 2007
SECT ION 3. FEA T URES OF LP G FILL IN G STA T ION
This section sets out the special features of LPG filling facilities and minimum separation distance requirements of LPG filling facilities.
Typical schematic and layout diagrams of an LPG filling station are shown in Appendices A and B respectively. An LPG filling station mainly consists of LPG unloading, storage and dispensing facilities. The LPG unloading process is similar to those of an LPG compound in which a road tanker parks at a dedicated unloading area and unloads the LPG to an underground storage tank. A submersible pump inside the storage tank is used to deliver LPG to the dispensers. The LPG vapour is separated and returned to the storage tank where as the liquid LPG is metered and delivered to the vehicle fuel tank through the dispensing hose and nozzle.
The following table lists out the minimum separation distance requirements between LPG and petrol/diesel filling facilities, in addition to the separation distances used in LPG compound.
-
-
3m
3m
-
-
3m
3m
3m
3m
-
-
3m
3m
-
-
1.5m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
3m
7.6m
7.6m
4.25m
4.25m
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Guideline for Inspection of LPG Filling Stations
May 2007
If a radiation wall constructed of non-combustible material and with 2-hour fire resistance rating is provided, the separation distances can be suitably reduced by measuring round the edge of the wall. A typical layout of LPG filling station with separation distances is shown in Appendix B.
SECTION 4. FACILITIES OF LPG FILLING STATION
This section lists out the facilities specific to LPG filling station, in addition to those used in LPG compound.
There are similarities between an LPG filling station and an LPG compound, e.g. tanker loading bay, fill-connection, LPG storage tank (except the submersible pump well), pressure relief valve, vessel chamber, cathodic protection system, pipework & fitting and electrical equipment. The following items however are specific to LPG filling facilities.
4.3.1
The LPG storage tank is provided wit h a pump well for installing a submersible pump. The pump well is designed in such a way that it can be isolated from the storage tank in case the cover flange is removed and the tank is filled with LPG.
4.3.2
Each LPG storage tank is provided with the following valves and fittings in addition to those for LPG compound: i. shut-off valve with closing mechanism and excess flow valve for pump well inlet; ii. shut-off valve and excess flow valve for pump bypass and dispenser return; and iii. vapour balance valve between the pump well and storage tank complete with closing mechanism.
4.3.3
The submersible LPG pump of appropriate design to meet the operating characteristics of t he filling system and suitable for Zone 0 application is installed in the pump well of the LPG storage tank so as to reduce the amount of space required, the chance of tampering and impact by vehicles.
4.3.4
A by-pass valve is installed in the by-pass line immediately aft er the discharge valve of submersible pump to control and maintain the differential pressure generated by the pump. The discharge is piped back to the LPG storage tank at a pre-determined pressure selected in relation with the pump curve. The function of the by-pass line is to prevent excessive pressure and overheat of the pump.
4.4.1
Typical schematic and layout diagram of a LPG dispenser is shown in Appendix C for reference. The LPG dispenser is of flameproof type and all components comply with the requirements of applicable standards.
4.4.2
The dispenser is equipped with automatic temperature compensation device to ensure that the quantit y of Auto-LPG sold t o customers is not affected by variation of ambient temperature.
4.4.3
A LPG return line leading to the vapour space of the LPG storage tank is provided for the dispenser.
4.4.4
Remote operated shut-off valve is provided for the LPG return line of the dispenser. -3-
Guideline for Inspection of LPG Filling Stations
May 2007
4.4.5
A pump control mechanism is provided in the dispenser such that the submersible pump of t he filling system can be switched on/off automatically when the dispensing nozzle is in and out of its receptacle.
4.4.6
Protective shearing device (e.g. breakable glass tube) is provided in the dispenser such that upon rupt ure of the shear provision as in t he case of vehicular collision onto dispenser, the whole LPG filling system will be shut down and the remotely-operated shut off valves in the dispenser will actuate automatically to cut off the LPG supply.
4.4.7
A manually operated shut-off valve and excess flow valve are provided in the dispenser and as near to the inlet of dispensing hose as practicable between the dispenser cabinet and the breakaway coupling for prevention of leakage of LPG liquid under abnormal conditions, e.g. dispensing hose rupture.
4.4.8
Hose retaining or retrieving mechanism is incorporated to protect the hose from touching the ground when not in use.
4.4.9
Other essential components in the dispenser include vapour eliminator to separate vapour from the liquid prior to metering, meter unit, differential valve and hydrostatic pressure relief valve.
4.5.1
The dispensing nozzle is of low emission type, i.e. when the nozzle is uncoupled following a transfer, not more than 4 c.c. of product will be released to the atmosphere.
4.5.2
Adequate mechanism is incorporated in the design of t he nozzle such that it cannot be disengaged inadvertently or deliberately during the dispensing operation.
4.5.3
A double-check arrangement or one with single check and dynamic pressure sealing arrangement is provided at the dispensing nozzle.
A breakaway coupling is provided between the excess flow valve in the dispenser and the outgoing flexible dispensing hose to prot ect against excessive leakage of LPG liquid in the event the driver drives away the LPG vehicle when the dispensing nozzle is still engaged to the vehicle.
Remote emergency shutdown buttons are provided at the extended fill connection, LPG storage tank, dispensing area and sales office for shutting down the whole LPG dispensing system in the event of emergency.
Automatic water spray and sprinkler systems are installed to cover the fill connection at road tanker unloading point and the floor area (petrol-cum-LPG filling stations) or surface area (dedicated LPG filling station) of LPG dispensers to provide automatic fire fighting in case of gas leakage or fire
A gas detection system with detector heads at different locations is provided for the LPG filling station. The system will give audible alarm when detecting LPG at a concentration 20% of the Lower Flammable Limit and give direct signal to Fire Services Communication Centre when detecting LPG at a concentration 40% of the Lower Flammable Limit. -4-
Guideline for Inspection of LPG Filling Stations
May 2007
Drains and pits are avoided in the immediate vicinity of 3 m of the LPG storage tank, dispenser or extended fill-connection of the LPG tank. Where the drains and pits are unavoidable wit hin t his distance, the openings are either securely covered or suitably sealed.
Crash barriers are provided at appropriate locations to prevent the above-ground connections of the LPG storage tank and dispenser from collision by vehicles.
4.12.1 All electrical equipments are properly installed in accordance with manufacturers’ instructions and in compliance with statutory regulations. 4.12.2 Electrical equipments for use in classified zones are certified by approval bodies such as BASEEFA in accordance with BS EN 60079 or equivalent. 4.12.3 All electrical connections in the dispenser should be made in accordance with the manufacturer’s instructions without negating the integrity of the explosion protection. 4.12.4 The area classifications for LPG filling facilities at the filling station are listed below: -.
(a) Within 1.5m in all directions from the tank connections or shell (b) Up to 1.5m above ground level and within 3m from valve assembly and fill connection
(a) Within direct path of discharge. (b) Within 1.5m in all other directions from point of discharge (c) Beyond 1.5m but within 4.5m in all directions from point of discharge.
(a) Within 1.5m in all directions from a point where connections are regularly made or disconnected for product transfer.
Zone 1 Zone 2
No fixed electrical equipment Zone 1 Zone 2
Zone 1
(b) Beyond 1.5m but within 4.5m from point of connection or disconnection. Zone 2 (a) Cylindrical zone with height up to 250mm above ground level, the enclosure housing the hydraulic -5-
Zone 1
Guideline for Inspection of LPG Filling Stations
May 2007
component of dispenser and radius 4.25m measured at dispenser. (b) Conical zone immediately above Zone 1 with vertex 1m above the highest liquid joint of dispenser and base radius 4.25m measured at dispenser.
Zone 2
(Diagram shown in Appendix D)
Where Zone 0 - Area in which an explosive gas-air mixture is continuously present or present for long periods. Zone 1 - Area in which an explosive gas-air mixture is likely to occur in normal operation. Zone 2 - Area in which an explosive gas-air mixture is not likely to occur in normal operation and if occurs will only exist for a short time.
SECTION 5. SCOPE OF INSPECTION
5.1.1
This section lists out t he inspection requirements specific to LPG filling station, in addit ion to those for LPG compound. Inspection requirements in t he relevant portions of the Module 1 (LPG Compounds and Cylinder Stores) of Code of Practice for Hong Kong LPG Industry will not be repeated in this section.
5.1.2
The owner of an LPG installation shall have a duty to operate and maintain the installation in a safe condition in accordance with relevant Ordinances, Regulations and manufacturers’ recommendations and shall employ a competent person to inspect the installation annually. The owner shall also ensure, or cause to ensure, the compliance of the key maintenance / periodic inspection requirements in relation to the LPG facilities installed in the LPG filling station as highlighted in Sections 5.2 to 5.13.
5.1.3
Activities such as annual inspection and preparation of inspection report of the LPG installation shall be undertaken by a competent person. The minimum scope of the annual inspection shall include, but not be limited to, the checking of records of key maintenance / periodic inspection as highlighted in Sections 5.2 to 5.13 and those inspections specifically assigned to be carried out by the competent person as stipulated in Sections 5.2 to 5.13 to verify that the LPG installation is maintained and operated in accordance with the requirements under the Gas Safety Ordinance and relevant codes of practice. The competent person shall make reference to the operation, maintenance, inspection and testing requirements as stipulated in manufacturers’ manuals, if necessary.
5.1.4
A logbook detailing all maintenance, repair and alteration works that have been carried out shall be kept by the owner for the service life of the installation.
5.1.5
Relevant tests on the LPG storage tanks and associated piping systems shall be supervised and certified by a competent person.
5.1.6
An annual inspection report on the safety conditions and housekeeping of the LPG filling station shall be prepared by a competent person and submitted to the Gas Authority for review by the owner. -6-
Guideline for Inspection of LPG Filling Stations
May 2007
5.1.7
All test records and certif icates shall be maintained by the owner for the service life of the system.
5.1.8
Appropriate personal prot ective clothing and safety equipment including flammable gas detectors shall be used by people involved in LPG work. Traffic safety should be taken into account when carrying out inspection and testing in filling station.
5.1.9
The competent person shall check the GSO approved plans to ensure that all LPG facilities have not been altered unless approval from the Gas Authority for the alteration has been obtained.
5.2.1
Good housekeeping procedures, which shall include but not be limited to the daily att ention of the following activities, should be established by the owner. The competent person shall check the housekeeping records and carry out an inspection for the following items: i.
The gas detection, LPG vehicle filling and fire fighting systems are under normal operation.
ii.
No visual damage to the fill-connection, above-ground pipework and fittings, manhole covers of underground LPG storage tanks, valve pits and the associated instrumentation such as gas detector heads, remote emergency shut-down buttons, etc. are found.
iii.
No visible damage to the dispensers, dispensing hoses, breakaway couplings and dispensing nozzles are found.
iv.
Portable fire extinguishers for the filling station are kept in place and charged in particular around the LPG tanks and dispensers.
v.
Warning signs are kept in a legible condition and in place.
vi.
Rain caps for the vent pipes of pressure relief valves remain in place.
vii.
Any accumulation of flammable or combustible materials especially around the road tanker unloading area, the storage tank area and the fill-connection, are removed.
viii. Illumination is kept operational and effective especially at the filling point and around the dispensing area. ix.
Identification labels are in place and legible.
x.
Vegetation, if any, which might become a fire hazard are removed.
5.3.1
The owner shall maintain the separation distance requirements of the LPG filling facilities as specified in Section 3.3. No change or modification of the filling station which affects the compliance of the separation distance requirements shall be carried out unless prior approval has been given by the Gas Authority. The competent person shall check the GSO approved plans to ensure the compliance of these requirements.
5.4.1
The LPG submersible pump and t he associated control equipment shall be inspected, tested, replaced or maintained at regular intervals as recommended by the equipment manufacturer.
5.4.2
Insulation test of the LPG submersible pump motor shall be carried out annually.
5.4.3
The operating conditions of the submersible pump such as electric current, pumping head, noise and vibration shall be checked at intervals as recommended by the equipment manufacturers to ensure its proper function. The competent person shall visually check the operation conditions of the submersible pump during the annual inspection.
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Guideline for Inspection of LPG Filling Stations
May 2007
5.4.4
The underground LPG tank concrete chamber, underground LPG tank turret and valve manifold pit shall be inspected for any accumulation of gas and water monthly and the inspection record shall be checked by the competent person. In rainy season, the inspection shall be carried out more frequently. This inspection shall also be carried out by the competent person during the annual inspection.
5.4.5
The piping and fit tings inside the underground LPG tank turret shall be subject to visual examination and leak test carried out by the competent person under operating pressure using soap solution during the annual inspection.
5.5.1
The dispenser shall be calibrated, inspected, tested and maintained at regular intervals as recommended by the equipment manufacturer.
5.5.2
All seals (e.g. mechanical seal, lip seal, O ring and seal ring) of the dispener shall be replaced at regular intervals as recommended by the equipment manufacturer.
5.5.3
The metering unit and excess flow valve shall be properly maintained at regular intervals as recommended by the equipment manufacturer.
5.5.4
The dispenser shall be inspected monthly to ensure that the internal and external parts being free from damage and corrosion. The hydrostatic pressure relief valve shall be free from debris, damage, corrosion and missing caps.
5.5.5
The dispensing nozzle receptacle switch shall be checked monthly for its proper function.
5.5.6
The competent person shall visually check the general condition of dispenser.
5.5.7
All connections, pipe joint s, seals and associated fittings inside the dispenser cabinet shall be subject to visual examination and leak test carried out by the competent person under operating pressure using soap solution during the annual inspection.
5.5.8
The competent person shall inspect the prot ective shearing device of t he dispenser.
5.5.9
The comeptent person shall inspect the backfill material and the void space underneath the dispenser to avoid accumulation of gas and water.
5.6.1
The dispensing hose of the dispener shall be replaced at regular int ervals as recommended by the equipment manufacturer.
5.6.2
The dispensing hose and breakaway coupling of t he dispenser shall be visually inspected monthly.
5.6.3
The dispensing hose supporting mast or recoil wire shall be inspected for damage, corrosion, tension and abnormality monthly.
5.6.4
All seals (e.g. lip seal, O ring and seal ring) of the breakaway coupling shall be replaced at regular intervals as recommended by the equipment manufacturer.
5.6.5
The breakaway coupling shall be manually separated for functional test monthly. Safety precautions such as isolation of the relevant dispensing hose and provision of fire extinguisher should be adopted before the test.
5.6.6
The competent person shall visually check the general condit ion of dispensing hose and breakaway coupling.
5.6.7
The dispensing hose joints and breakaway coupling shall be subject t o visual examination and leak test carried out by the competent person under operating pressure using soap solution during the annual inspection. -8-
Guideline for Inspection of LPG Filling Stations
May 2007
5.6.8
The competent person shall check that the dispensing hose is properly supported and that it w ill not t ouch the ground.
5.7.1
All seals (e.g. lip seal, O ring and seal ring) of the dispensing nozzle shall be replaced at regular intervals as recommended by the equipment manufacturer.
5.7.2
The dispensing nozzle shall be checked for wear and abnormality mont hly.
5.7.3
The dispensing nozzle hold-open latch shall be inspected for proper functioning mont hly.
5.7.4
The swivel nut and its “ ratchet” type locking system shall be checked for damage and proper functioning monthly.
5.7.5
The competent person shall visually check the general condition of dispensing nozzle.
5.7.6
The dispensing nozzle shall be subject to visual examination and leak test carried out by the competent person under operating pressure using soap solution during the annual inspection.
5.8.1
The remote emergency shut-down system including the butt ons and valves shall be tested annually.
5.8.2
The emergency shut-down butt ons shall be visually checked for integrity and free from debris monthly.
5.8.3
The competent person shall visually check the general condition of emergency shut-down buttons and valves.
5.9.1
The fire services installation of t he filling station shall be regularly inspected and tested by relevant competent personel / contractor in accordance with the relevant statutory regulations.
5.9.2
The competent person shall visually check the general condition of f ire services installation.
5.10.1 The gas detection system shall be inspected, tested and maintained by relevant competent personnel/contractor at regular intervals as recommended by the equipment manufacturer. 5.10.2 All gas detectors shall be calibrated by relevant competent person/contractor to ensure satisfactory condition and proper functioning in accordance with manufacturer instructions at intervals not exceeding one year. 5.10.3 The gas detector shall be checked for int egrity and cleanliness mont hly. 5.10.4 The competent person shall visually check the general condit ion of gas detection system.
5.11.1 Any drain near to t he tanker loading area and dispensing area, LPG gas trap and oil interceptor shall be checked at monthly intervals for the presence of LPG accumlated. The competent person shall also check for the presence of LPG accumlated during t he annual inspection.
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Guideline for Inspection of LPG Filling Stations
May 2007
5.12.1 The competent person shall check the crash barrier protecting t he above ground LPG facilities for integrity and whether it is properly maintained.
5.13.1 The electrical installation of the filling station shall be annually inspected and tested by relevant competent personnel in compliance with the statutory regulations. The competent person shall check the relevant record during the annual inspection and report the findings. 5.13.2 All instrumentation such as content gauge, pressure gauge and switch etc. shall be checked and maintained to ensure satisfactory condition and proper function in accordance with manufacturer instructions at intervals not exceeding one year and replaced with new or reconditioned units as necessary. 5.13.3 The earthing/bonding connection, insulation joints and lightning protection shall be checked and maintained by relevant registered electrical worker at intervals not exceeding one year to ensure its proper f unctioning. 5.13.4 Each electrical equipment and cable connection shall be inspected and properly maintained by registered electrical worker at intervals not exceeding one year to ensure satisfactory condition in accordance with manufacturer instructions. 5.13.5 The competent pseron shall check that all electrical equipments used in classified zones shall be certified by approval bodies such as BASEEFA in accordance with BS EN 60079 or equivalent.
SECT ION 6 . SUBM ISSION FORM A T An LPG filling station shall be inspected annually by a compt ent person (Class 2) to ascertain whether the installation is maintained and operated in a safe manner in accordance with relevant sections in this guideline. The owner of the LPG station shall submit such inspection reports to the Gas Authority within 4 weeks after the inspection. The inspection report shall include a checklist, Form 109A as attached in Appendix E, specifically for LPG filling station.
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Sch e m a t i c Di a g r a m f o r L P G Fi l l i n g St a t i o n
Breakaway Coupling
Dispensing Hose
Vent Pipe
LPG Road Tanker
LPG Dispenser LPG Vehicle Safety Relief Valve
Non Return Valve
LPG Cylinder on Vehicle
Double Check Fiil Connection for Road Tanker
Submersible Pump
Under round LPG Stora e
Excess Flow Valve
A P P EN D I X B T y p i c al L a y o u t o f L P G Fi l l i n g St a t i o n (2 U n d er g r o u n d T a n k s w i t h Su b m e r si b l e P u m p s)
approx.50 m Radiation Wall with 2 hour fire resistance
Boundary wall Underground Water Tank
Sales Room
Extended LPG Fill-connection >3m LPG Dispensers
Sun Roof Filling Hose
> 4.25 m
6m
Vehicle Fill Connection
Size of LPG Filling Station with 8 Dispensing Hoses : approx. 750m 2
2 x 10 tonne U/G LPG tanks with submersible pumps (approx. 5.5m x 2.1m each)
> 7.6 m >3m
approx. 15 m
> 1.5 m
> 4.25 m Main Road
> 7.6 m
9 tonne LPG Road Tanker (approx. 10.5m x 2.5m)
A P P EN D I X B T y p i c al L a y o u t o f L P G Fi l l i n g St a t i o n (2 U n d er g r o u n d T a n k s w i t h Su b m e r si b l e P u m p s)
approx.50 m Radiation Wall with 2 hour fire resistance
Boundary wall Underground Water Tank
Sales Room
Extended LPG Fill-connection >3m LPG Dispensers
Sun Roof Filling Hose
> 4.25 m
6m
Vehicle Fill Connection
2 x 10 tonne U/G LPG tanks with submersible pumps (approx. 5.5m x 2.1m each)
> 7.6 m >3m
approx. 15 m
> 1.5 m
> 7.6 m
9 tonne LPG Road Tanker (approx. 10.5m x 2.5m)
> 4.25 m Main Road
Size of LPG Filling Station with 8 Dispensing Hoses : approx. 750m 2
A P P EN D I X C
LPG Dispen ser
Breakaway Coupling
Nozzle Computer
Isolating valve
A P P EN D I X C
LPG Dispen ser
Breakaway Coupling
Nozzle Computer
Isolating valve Excess flow Meter Vapour Separator
Ground
Breakable glass rod to trigger automatic
Pneumatic controlled
shutdown of LPG
shut-off valve
supply when sheared upon LPG liquid
LPG vapour
inlet f rom
return to LPG
LPG storage
storage tank
valve
A P P EN D I X D
H a z a r d o u s Z o n e Cl a s si f i c a t i o n f o r L P G D i s p e n s er Installation
Zon e 2 1 m etre above high est liqu id
Zon e 1
joint
LPG D ispen ser c/w Hydraulic Com ponent s 250 mm Ground
4.25 m
4.25 m
A P P EN D I X E THE GOVERNMENT OF THE HONG KONG SPECIAL ADMINISTRATIVE REGION FORM 109A GAS SAFETY (GAS SUPPLY) REGULATIONS (Chapter 51) ANNUAL INSPECTION REPORT OF LPG FILLING STATION
To：The Gas Authority GasSO Ref: GSO/GPS/S/ Section I - Particulars of LPG Installation Location Owner Gas Supply Company Maintenance Contractor Type of Installation
LPG Dedicated Filling Station/ LPG cum Petrol Filling Station *
Storage Quantity
x
kL
Section IIa - Inspection Checklist A
Site Condition
E
Pipework/Equipment
1
Structures/fitments* within safety distance
1
2
Condition of fence/boundary walls/gates*
2
Condition of pipework/pressure regulators/valves/ gauges/fittings* Identification markings of pipework/valves/ fittings*
3
Condition of catchment pits/drains/gully covers*
3
Identification and functional markings of main control valve
4
Type and number of certified unexpired fire extinguishers
4
Visual examination and leak test of pipes and fittings
5
Condition of warning signs/emergency notices*
5
All HPRV within valid period
6
Others
6
Others
B
Housekeeping
F
Bulk Tanks & Tanker Bay
1
General condition of the filling station
1
Condition of valve chambers
2
Visual examination and leak test of pipes and fittings inside turret
C
Record of Maintenance
3
Provision of rain caps, valve chamber covers, etc.
1
General maintenance records
4
Condition of PRVs and vent pipes
2
Insulation test of LPG pump motor (The last test date: ) Emergency shut-down system test (The last test date: ) Record of routine test of fire services installation (The last test date: ) Gas detection system test (The last test date: ) Periodic test of fixed electrical installation-Form WR2 (The last test date: ) Content/Pressure gauge/switch test (The last test date: ) Test of earthing/bonding connection, insulation joints and lightning protection (The last test date: ) Others
5
Condition of earthing/bonding connection*
6
Date of tank revalidation
D
7
Record of cathodic protection test
D
8
Others
G
LPG Dispenser and associated equipment
1
General condition of dispenser, dispensing hose, breakaway coupling and nozzle
2
3 4 5
6 7 8
9
D
Alteration, Separation Distance and Crash Barriers
4
Visual examination and leak test of internal pipes and fittings of dispenser Visual examination and leak test of dispensing hose joint and breakaway coupling Visual examination and leak test of dispensing nozzle
1
Alteration
5
Protective shearing device
2
Maintenance of separation distance
6
Support of dispensing hose
3
Maintenance of crash barriers
7
Others
4
Others
3
Note:
tick if satisfactory; 〈 NA〉if not applicable; * delete as appropriate; 〈 X 〉cross if equipment is unsafe/in adverse condition; 〈 〉 O if Owner has not made the maintenance record available for inspection; 〈 〉 〈 D〉 Information to be provided in Section IIb – Maintenance Record Summary.
EMSD/GSO/109A (5/07)
H LPG Submersible Pump
K
Fire Services System
1
Operation condition, sound and vibration
1
General condition of fire services installation
2
Others
2
Others
I
Accumulation of Gas and Water
L
Gas Detection System
1
1
General condition of gas detection system
2
Underground tank concrete chamber, turret and valve manifold pit Void space underneath the dispenser
2
Others
3
Drain and pit
4
Others
M Electrical and Instrumentation Installation
1
Appropriate electrical equipment in classified zones
J
Emergency Shut Down System
2
Others
1
General condition of emergency shut-down button and valve Others
N
Remarks/Other Information
2
(See Section IIb)
Section IIb - Maintenance Record Summary For Item F7-Date of Tank Revalidation and F8-Record of Cathodic Protection Test Tank Serial no.
Tank Last test date (dd/mm/yyyy)
Tank PRV Manufactured date/re-test date* (dd//mm/yyyy)
Overdue for revalidation (Yes/No)
Remarks
Tank Serial no.
U/G tank Cathodic protection system Last test date (dd/mm/yyyy)
U/G tank Cathodic protection system second Last test date (dd/mm/yyyy)
Comply with statutory requirements (Yes/No)
Remarks
For Item N-Remarks/Other Information
Note:
tick if satisfactory; 〈 〈 X 〉cross if equipment is unsafe/in adverse condition; 〈 〉 NA〉if not applicable; * delete as appropriate; 〈 O〉if Owner has not made the maintenance record available for inspection; 〈 D〉 Information to be provided in Section IIb – Maintenance Record Summary.
EMSD/GSO/109A (5/07)
Section III - Recommendations and Remedial Work (A) Recommendations by Competent Person Checklist Item
(B) Remedial work done by Owner Tick if Completed
Description
Planned Completion Date
1. I am of the opinion that at the time of inspection the general condition of the Remark: The owner of LPG Installation Overall LPG installation was/ was not* satisfactory. Comments should inform the Gas Standards Office in writing upon completion of the remedial 2. I recommend work.
Note: Please use additional sheets if necessary.
Section IV - Declaration (A) Competent Person This is to certify that the above installation was inspected on
by (Date)
of (Competent Person)
(Company Name)
and the foregoing is a correct report of the results of the inspection. Signature：
Company Chop：
(B) Owner I/We hereby submit an inspection report of the above installation in accordance with Regulation 6C of Part IIA of the Gas Safety (Gas Supply) Regulations, Cap. 51. Date of Submission：
Signature： (Name:
)
Contact Telephone No.:
Explanatory Notes: 1. This report is to be used for annual inspection of LPG installation referred to in paragraph (f) of ‘notifiable gas installation’ interpretation, as stated under Part I Section 2 of th e Gas Safety Ordinance, Chapter 51. 2. The owner shall employ a competent person to inspect the LPG installation annually. The competent person should complete appropriate Sections I, II, III(A) & IV(A) of the report and the owner should complete Sections III(B) & IV(B) of the report. The report shall be kept by the owner for the service life of the installation. 3. The owner shall submit a copy of the report to Gas Standards Office, Electrical & Mechanical Services Department, 3 Kai Shing Street, Kowloon, Hong Kong by mail or by fax (2576 5945) within 4 weeks after the inspection. 4. The owner shall carry out the necessary remedial work on the LPG installation as recommended in the inspection report. 5. Failure to comply with the requirements of inspection by a competent person and/or the requirement of submission of inspection report is an offence and the owner is liable on conviction to a fine of $5 ,000. EMSD/GSO/109A (5/07)
