What is the maximum fill capacity of an LPG cylinder and what is reason for it?

LPG is stored as a liquid under pressure in purpose-built cylinders. Gas appliances burn the vapour that is released from the cylinder to produce heat. It's important to check your cylinders and fittings are safe to prevent injury to people, fires and damage to property.

LPG cylinders should be safety tested or replaced every 10 years.

The connection fittings found on LPG gas cylinders for BBQs and other outdoor appliances are changing to a new fitting type. The old fittings (called POL or Type 27) have been replaced by new LCC27 type fittings which are safer and easier to use.

The new valves only allow gas to flow when an appliance is connected and will stop the flow of gas in the event of a fire.

Existing appliances

There’s no need to alter existing appliances or to purchase adaptors. The new LCC27 cylinder fittings are designed to connect to both the new LCC27 and the old POL fittings. Appliances with the new LCC27 will not be able to connect to older cylinders with POL fittings.

• LCC27 Cylinder to LCC27 Appliance: Compatible
• LCC27 Cylinder to POL Appliance: Compatible
• POL cylinder to POL appliance: Compatible
• POL cylinder to LCC27 Appliance: Not compatible

Visit the Gas Energy Australia website to find out more about the change to LCC27 fittings.

All LPG cylinders sold in Australia must meet strict specifications before they can be certified as safe to use for ten years.

Portable cylinders can only be refilled legally if they have a valid ten-year stamp on the collar, neck or foot ring. The stamp indicates the last time the cylinder was tested and shows the letter T followed by the month and year.

If they are out of date they must be tested at an authorised test station or swapped for a newer cylinder. Tested cylinders will either be restamped for another ten years of use or be destroyed.

You should also check that hoses and regulators are certified to Australian Standards and have a certification number printed on them from a recognised certifying body. It's recommended that hoses are replaced every five years.

Storing LPG cylinders:

• Always store cylinders upright and in a well ventilated outdoor area. If stored incorrectly, they may release liquid gas that can ignite and flare up uncontrollably, creating a major safety hazard.
• Make sure cylinders are protected from excess heat and potential ignition sources.
• When the cylinder isn’t connected to a gas appliance, put a sealing plug in the cylinder valve.

Using LPG cylinders:

• Only use LPG cylinders with LPG appliances – it’s not safe to connect LPG cylinders to appliances designed to use natural gas.
• Make sure any appliance or hose connected to the cylinder is done up tightly so there are no leaks. Using a soapy water solution, spray the connection joint. If bubbles appear, there is a leak. Tighten the connection and then retest. If bubbles still appear, immediately isolate the gas and have the fault repaired by a licensed gas fitter, or replace the faulty component.
• Never tamper with the safety valve, cylinder fittings or apply excessive force to the cylinder valve.
• Always shut off the cylinder valve before disconnecting the cylinder.
• If you are replacing a portable cylinder, such as on a barbecue, ensure the gas appliance is turned off.
• If you are replacing one cylinder from a pair of cylinders in a permanent installation, turn off all LPG appliances, unless an automatic changeover valve is fitted to the installation.
• A dew line that forms around the cylinder when an appliance is operating is not uncommon or dangerous and indicates the level of liquid inside.
• An ice build-up around the cylinder may occur in exceptional circumstances and indicates the demand for gas is exceeding the supply available. The cylinder will need to be refilled or replaced with a larger one.

Most retailers will swap empty cylinders for full ones. This ensures you receive a cylinder that is within the ten-year certification and has been filled appropriately.

Never fill portable LPG cylinders from autogas dispensers – this is both illegal and dangerous. Autogas is a mixture of propane and butane. Australian LPG appliances are designed only for use with commercial LPG, which is predominantly propane.

The maximum fill level for portable cylinders is 80%. This allows expansion room if the temperature of the cylinder increases. The empty weight is stamped on the cylinder so the amount of gas left can be estimated by weight. Some cylinders have a contents gauge fitted.

When transporting an LPG cylinder:

• secure it in an upright position
• use a sealing plug to prevent accidental gas leakage
• keep the cylinder cool
• don't carry it in the passenger compartment of your vehicle.

Don’t keep LPG cylinders in your car, especially in hot weather. If the cylinder overheats and exceeds its maximum pressure, the safety relief valve will release and fill the car with vapour. If you need to transport a portable cylinder during hot weather, secure it upright and wrap it in a wet towel to keep it cool.

If an LPG cylinder has been affected by fire or heat, has rust on it, or has any other obvious physical damage, it should be inspected at an authorised test station before your use or refill it.

Never dispose of old cylinders at the rubbish dump or in the rubbish collection. They need to be disposed of through an authorised test station, LPG supplier or filler.

Visit Which Bin to find your closest hazardous waste drop-off centre to help you dispose of your unwanted chemicals in an environmentally safe way. Your local council may also offer disposal services.

Search online or check your local business directory (eg Yellow Pages) for 'gas cylinder testing' to find a test station near you. Alternatively, ask your LPG supplier or retailer about where you can find an authorised LPG cylinder test station.

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Unit Of competency

Not applicable.

Application

This unit describes the performance outcomes, skills and knowledge required to safely fill liquefied petroleum gas (LPG) cylinders up to a maximum of 9kg. It requires sound knowledge of working with volatile and hazardous gas and how to respond to an emergency.

The unit is relevant to holiday parks and resorts and other associated hospitality or retail workplaces that provide LPG cylinder filling services.

It applies to frontline service or supervisory personnel who operate with a level of independence. Work is undertaken according to organisational policy and procedures and relevant legislative requirements.

No occupational licensing, certification or specific legislative requirements apply to this unit at the time of publication.

Pre-requisite Unit

Nil

Competency Field

Venue and Facility Operations

Unit Sector

Tourism

Elements and Performance Criteria

Foundation Skills

Unit Mapping Information

No equivalent unit.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=68c40a93-e51d-4e0f-bc06-899dff092694

Assessment requirements

Not applicable.

Performance Evidence

Evidence of the ability to complete tasks outlined in elements and performance criteria of this unit in the context of the job role, and:

• demonstrate the liquefied petroleum gas (LPG) decanting process safely for at least three LPG cylinders following organisational policy and procedures for:

• storage of tools, equipment and cylinders
• correct positioning of LPG decanting cylinder
• handling and transportation of full and empty LPG cylinders
• filling cylinders
• testing newly filled cylinders for leaks

• explain procedure to identify a hazardous cylinder and explain organisational policy and procedures for:

• notifying customers of hazards and offering alternatives
• retention and safe storage of hazardous cylinders
• emptying hazardous cylinders as required
• making cylinders safe
• reporting and recording the identified hazard or potential hazard

• explain procedure for responding to each of the following emergency situations:

• leaking decanting cylinder
• leaking customer cylinder
• LPG cylinder on fire
• fire in location of LPG cylinders
• vehicle driving into decanting cylinder
• naked flame in proximity of decanting process
• decanting cylinder leak into drainage system
• LPG explosion

• explain procedure to complete incident reports for three of the emergency situations listed above.

Knowledge Evidence

Demonstrated knowledge required to complete the tasks outlined in elements and performance criteria of this unit:

• properties of LPG and its potentially highly volatile and dangerous nature
• potential hazards associated with LPG gas and methods of control
• unsafe conditions or environment when working with LPG:

• damage to plant equipment
• breaches in procedures

• required warning notices and their correct positioning
• HAZCHEM/HAZMAT symbols associated with LPG
• current legislation relating to filling LPG cylinders:

• Australian New Zealand Standards AS/NZS1596 The storage and handling of LP gas
• Dangerous Goods Act
• Work Health and Safety Act

• employer responsibilities under the WHS Act to provide a safe workplace
• safe location of LPG decanting cylinder
• regulatory firefighting equipment for LPG and audit timeframe
• tools and equipment required to fill LPG cylinders
• appropriate safe environment to decant LPG
• safe standards for LPG cylinders:

• capacity greater than 10kg
• test pressure greater than 3.3 MPa
• test date less than 10 years old
• bleed valve fitted that can be easily operated
• no rust or other damage
• no leaking fittings

• personal protective equipment (PPE) for decanting LPG and the reason for wearing each:

• heavy duty gloves
• eye protection
• work boots

• safety procedures for controlling static electricity:

• earthing of cylinders
• discharging body build-up of static electricity

• manual handling techniques
• operation and purpose of ‘dead man’s handle’
• safe capacity of LPG cylinders and how to identify when cylinders are at capacity
• outcomes of over filling cylinders
• how a ‘cold burn’ occurs and appropriate first aid
• emergency procedures for:

• leaking decanting or customer cylinder
• LPG cylinder on fire
• fire in location of LPG cylinders
• vehicle driving into the LPG decanting cylinder
• naked flame in proximity of decanting process
• decanting cylinder leak into drainage system
• LPG explosion

• environmental standards and safe release procedures for emptying LPG cylinders
• potential impact of LPG leaks to environment, workplace, customers and personnel
• alternative options for customers in the event their LPG gas cylinder must be retained
• organisational policies and procedures for:

• preparing for decanting LPG
• decanting LPG
• finalizing cylinders
• testing filled cylinders for leaks
• risk management and workplace safety
• safe storage and delivery of LPG
• retention of hazardous cylinders
• ‘making safe’ a hazardous cylinder
• reporting of hazards and incidents or potential hazards and incidents

• reportable unsafe practices:

• being asked to participate in unsafe work practices
• failing to replace unsafe damaged property or fittings
• ignoring direction of safety signage, supervisors, or managers
• lack of required safety signage
• lack of training in health and safety procedures and safe work practices
• seeing others using unsafe work practices
• broken or malfunctioning equipment.

Assessment Conditions

Skills must be demonstrated in an operational business or activity where LPG cylinder filling is required and safe working practices must be maintained, this can be:

• an industry workplace
• a simulated environment set up for the purpose of skills assessment.

Assessment must ensure use of:

• current plain English regulatory documents distributed by the LPG supplier and local work health and safety government regulator
• policies, procedures, codes of practice and standards issued by government regulators or industry groups
• LPG safe handling and decanting manuals
• current organisational policies, procedures and template documents
• LPG incident and hazard report identifying:

• cause of emergency
• outcome
• recommendation for prevention of reoccurrence

• safety equipment for decanting LPG:

• PPE
• 9kg dry chemical powder fire extinguisher
• hose attached permanently to a water tap

• tools and equipment for decanting LPG:

• set spanner or adjustable spanner to fit plug and connection
• screwdrivers to meet size of bleed valves on different size cylinders
• lockable padlock on decanting bottle
• filling hose

• drill and drill bits for making a hazardous cylinder safe
• LPG gas cylinders requiring filling
• LPG decanting cylinder
• required warning notices positioned correctly
• customers and colleagues with whom the individual can interact; these can be:

• customers or colleagues in an industry workplace; or
• individuals who participate in role plays or simulated activities, set up for the purpose of assessment, in a simulated industry environment operated within a training organisation.

Assessors must satisfy the Standards for Registered Training Organisations’ requirements for assessors; and;

• have worked in industry for at least three years where that have applied the skills and knowledge of this unit of competency.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=68c40a93-e51d-4e0f-bc06-899dff092694