LP-GAS SERVICEMAN'S

HANDBOOK

LP-10

The Fisher Controls LP-Gas Serviceman's Handbookserves as a general reference of information on LP-Gasand for the installation, operation and maintenance ofLP-Gas equipment. It provides key data and answersimportant questions that are relevant to managementand field servicemen in the LP-Gas industry.

Users of this handbook should consult applicable federal,state and local laws as well as pertinent industry regula-tions, including National Fire Protection Association (NFPA)Pamphlets No. 54 and 58.

Fisher Controls shall have no responsibility for any misin-terpretation of the information contained in this handbookor any improper installation or repair work or other devia-tion from the procedures recommended in this handbook.

For additional copies of this handbook please contactyour local Fisher Distributor, or call 1-800-558-5853.

1

Table of Contents

PROPERTIES OF LP-GASES .................................... 2

VAPOR PRESSURE OF LP-GASES .......................... 4

DETERMINING TOTAL LOAD..................................... 5

VAPORIZATION RATE ................................................ 6

CYLINDER AND TANK MANIFOLDING ..................... 9

CONTAINER LOCATION AND INSTALLATION ........ 11Container Preparation .................................................... 15

PIPE AND TUBING SIZING ...................................... 18Sizing between 1st Stage and 2nd Stage Regulators ... 23

Sizing between 2nd Stage Regulator and Appliance .... 26

Maximum Capacity of CSST .......................................... 27

LP-GAS REGULATOR INFORMATIONRegulator Selection ........................................................ 29

Two-Stage Regulation .................................................... 32

Regulator Installation ..................................................... 33

Leak Testing Methods .................................................... 36

Regulator Inspection ...................................................... 38

Troubleshooting Domestic Tank Fittings ........................ 40

LP-Gas Orifice Capacities .............................................. 42

Line Sizing Chart for Liquid Propane ............................. 43

CONVERSION FACTORS ........................................ 44

FLOW EQUIVALENT CONVERSIONS ..................... 46

TEMPERATURE CONVERSIONS ............................ 46

© Fisher Controls, 1998

2

APPROXIMATE PROPERTIES OF LP-GASES

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APPROXIMATE PROPERTIES OF LP-GASES

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4

VAPOR PRESSURE OF LP-GASESVapor pressure can be defined as the force exerted by agas or liquid attempting to escape from a container. Thispressure moves gas along the pipe or tubing to the appli-ance burner.

Outside temperature greatly affects container pressure.Lower temperature means lower container pressure. Toolow a container pressure means that not enough gas isable to get to the appliance.

The Table below shows vapor pressures for propane andbutane at various outside temperatures.

-AREPMETERUT

ROPAVETAMIXORPPA2ELBATGISP,ERUSSERP

ENATUBOTENAPORP

F° C° 001 % 02/08 04/06 05/05 06/04 08/02 %001

04- 04- 6.3 — — — — — —

03- 4.43- 8 5.4 — — — — —

02- 9.82- 5.31 2.9 9.4 9.1 — — —

01- 3.32- 02 61 9 6 5.3 — —

0 8.71- 82 22 51 11 3.7 — —

01 2.21- 73 92 02 71 31 4.3 —

02 7.6- 74 63 82 32 81 4.7 —

03 1.1- 85 54 53 92 42 31 —

04 4.4 27 85 44 73 23 81 3

05 01 68 96 35 64 04 42 9.6

06 6.51 201 08 56 65 94 03 21

07 1.12 721 59 87 86 95 83 71

08 7.62 041 521 09 08 07 64 32

09 2.23 561 041 211 59 28 65 92

001 8.73 691 861 731 321 001 96 63

011 3.34 022 581 561 841 031 08 54

5

DETERMINING TOTAL LOADThe best way to determine BTU input is from the appliancenameplate or from the manufacturer’s catalog. Add theinput of all the appliances for the total load. If specific ap-pliance capacity information is not available, the Table be-low will be useful. Remember to allow for appliances whichmay be installed at a later date.

If the propane load in standard cubic feet per hour (SCFH)is desired, divide the BTU/HR load by 2488 to get SCFH.Conversely, the BTU/HR capacity can be obtained fromSCFH by multiplying the SCFH figure by 2488.

Figuring the total load accurately is most important becauseof the size of the pipe and tubing, the tank (or the numberof cylinders), and the regulator will be based on the capac-ity of the system to be served.

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6

VAPORIZATION RATEThe rate of vaporization of a container is dependent uponthe temperature of the liquid and the amount of “wettedsurface” area of the container.

The temperature of the liquid is proportional to the outsideair temperature and the wetted surface area is the tanksurface area in contact with the liquid. Therefore, whenthe outside air temperature is lower or the container hasless liquid in it, the vaporization rate of the container is alower value.

To determine the proper size of ASME storage tanks or theproper number of DOT cylinders for various loads, it is im-portant to consider the lowest winter temperature at thelocation.

Multiple cylinders or tanks may be manifolded to give therequired vaporization capacity. Withdrawal of gas from oneor two containers can lower the container pressure sub-stantially due to the refrigeration of the vaporization gas.Regulator capacity is then reduced because of the lowerinlet pressure. Where any reasonably heavy gas load isexpected, put sufficient cylinders on each side of an auto-matic changeover system.

See pages 7 and 8 for more information.

7

VAPORIZATION RATES FORASME STORAGE TANKSA number of assumptions were made in calculating theBTU figures listed in the Table below:

1) The tank is one-half full.

2) Relative humidity is 70%.

3) The tank is under intermittent loading.

Although none of these conditions may apply, the Tablecan still serve as a good rule-of-thumb in estimating whata particular tank size will provide under various tempera-tures. Continuous loading is not a very common occur-rence on domestic installations, but under continuous load-ing the withdrawal rates in the Table should be multipliedby 0.25.

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F°01- 004,231 004,771 008,492 004,525

F°02- 008,801 008,541 003,242 006,134

F°03- 001,701 005,341 006,832 000,524

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8

Vaporization Rates for 100 PoundDOT Cylinders“Rule of Thumb” Guide

For continuous draws, where temperatures may reach 0°F,assume the vaporization rate of a 100 lb. cylinder to beapproximately 50,000 BTU/HR Therefore the:

Number of cylinders per side = total load in BTU/HR / 50,000

Example:

If a total load requirement of 200,000 BTU/HR is to be sup-plied from 100 pound DOT cylinders and winter tempera-tures may drop to 0°F, then how many cylinders are neededper side?

Number of cylinders per side = 200,000/50,000 = 4

* When using a changeover regulator, 4 cylinders perside are required.

Vaporization Rate Table for 100 Lb. DOT Cylinders

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F°02- F°0 F°02 F°04

001 000,56 000,17 000,97 000,49

09 000,06 000,56 000,27 000,58

08 000,45 000,95 000,66 000,77

07 000,84 000,25 000,95 000,96

06 000,34 000,64 000,25 000,16

05 000,73 000,04 000,54 000,35

04 000,13 000,43 000,83 000,54

03 000,62 000,82 000,13 000,73

02 000,02 000,22 000,52 000,92

01 000,51 000,61 000,81 000,12

9

CYLINDER AND TANKMANIFOLDINGOften it is necessary to manifold cylinders or tanks to ob-tain the required capacity needed for the installation. Mul-tiple cylinder hookups are most frequently used on com-mercial applications and at many residential jobs, eventhough tank manifolding is common in certain areas.

On certain multi-cylinder or tank installations, an automaticchangeover regulator can be used. These regulatorschange from the supply cylinder (when the gas is ex-hausted) to the reserve cylinder automatically without hav-ing to shutdown the system to refill.

A typical cylinder manifold using an automatic changeoverregulator can be installed in line with multiple cylinders.(See Figure 1 below.)

Figure 1

AUTOMATIC CHANGEOVERREGULATOR TYPE R422-CDFPA

SCH 80 1/2-IN PIPE MANIFOLD

COPPER PIGTAIL

10

CYLINDER AND TANKMANIFOLDINGWhen manifolding cylinders or tanks, do not use a regula-tor at each container. When this is done, the required ca-pacity for the particular installation may not be obtained. Itis impossible to set all of the regulators at the same outletpressure. The regulator delivering the highest outlet pres-sure will backpressure the other regulators, keeping themfrom operating. In effect, only one container would be sup-plying gas in this sort of situation.

The answer on manifold installations is to run high pres-sure piping from the containers into a common line, asshown in the Figure below. Then, install a regulator thatcan handle the required capacity. Two-stage regulation isthe most effective system on tank manifold installations.

Figure 2

1st STAGEREGULATOR

2nd STAGEREGULATOR

Schematic of atank manifoldinstallation

11

CONTAINER LOCATION ANDINSTALLATIONOnce the proper size of ASME storage tank or the propernumber of DOT cylinders has been determined, carefulattention must be given to the most convenient, yet safe,place for their location on the customer’s property.

Containers should be placed in a location pleasing to thecustomer that does not conflict with state and local regula-tions or NFPA Pamphlet No. 58, Storage and Handling ofLiquefied Petroleum Gases. Refer to this standard to de-termine the appropriate placement of LP-gas containers.

In general, storage tanks should be placed in an acces-sible location for filling, supported by concrete blocks ofappropriate size and reinforcement, and located away fromvehicular traffic.

Cylinders should be placed with ease of replacement orrefilling in mind, secured on a firm base, and protectedfrom vehicular traffic, animals and the elements.

For both ASME and DOT containers, the distance from anybuilding openings, external sources of ignition, and intakesto direct vented gas appliances or mechanical ventilationsystems are a critical consideration. See Figures 3, 4 and5 on pages 12, 13 and 14.

Refer to NFPA No. 58 for the minimum distances that thesecontainers must be placed from the building or other ob-jects.

12 CO

NTA

INE

R LO

CAT

ION

(cont)

DOT Cylindersnot filled on site

3-ftMin.

Intake to directvent appliance

Crawl space opening,windows, or exhaust fan

DOT Cylinder filled onsite from bulk truck

10-ft Min.(Note 2)Central A/C

compressor (source ofignition)

3-ftMin.

5-ftMin.

(Note 1)

Window air conditioner(source of ignition)

Note 1: 5-ft minimum from relief valvein any direction away from anyexterior source of ignition, openingsinto direct vent appliances, ormechanical ventilation air intakes.

Note 2: If the DOT cylinder is filled on site from abulk truck, the filling connection and vent valvemust be at least 10-ft from any exterior source ofignition, openings into direct-vent appliances, ormechanical ventilation air intakes.

Figure 3 D

OT

Cylinders

Reprinted from NFPA 58-1995

13

CO

NTA

INE

R LO

CAT

ION

(cont)

Reprinted from NFPA 58-1995

Figure 4 A

bove Ground A

SM

E C

ontainers

5-ftMin.

25-ftMin.

(Note 2)

10-ftMin.

10-ftMin.

Central A/Ccompressor

(source ofignition)

Crawl spaceopening, windows,or exhaust fan

10-ft Min.(Note 1)

5-ftMin.

125-500 Gal. w.c.

Under 125Gal. w.c.

Intake to directvent appliance

10-ftMin.(Note 1)

10-ft Min.(Note 1)

25-ftMin.

(Note 2)

Under 125 Gal. w.c.

Window air conditioner(source of ignition)

Nearest line ofadjoining property that

may be built upon

(1 ft = 0.3048 m)

Note 1: Regardless of its size, any ASME tank filled on site must be located so thatthe filling connection and fixed liquid level gauge are at least 10 ft. away from anyexternal source of ignition (i.e., open flame, window A/C, compressor, etc.). Intake todirect vented gas appliance or intake to a mechanical ventilation system.

Note 2: This distance may be reduced to no less than10 ft. (3 m) for a single container of 1,200-gal (4.5-m3)water capacity or less provided such container is at least25 ft (7.6 m) from any other LP-Gas container of morethan 125-gal (0.5-m3) water capacity.

501-2000 Gal. w.c.

14

Central A/Ccompressor (source ofignition)

(1 ft = =0.3048 m)

Crawl space opening,windows, or exhaust fan

10-ftMin.

(Note 2)

Crawl space opening

10-ftMin.(Note 2)

10-ft Min.(Note 1)

10-ftMin.

(Note 1)

Intake to direct ventappliance Window air conditioner

(source of ignition)

10-ftMin. (Note 1)

2000 Gal. w.c. or less

Nearest line of adjoiningproperty that may be built upon

CO

NTA

INE

R LO

CAT

ION

(cont)

Reprinted from NFPA 58-1995

Figure 5 B

elow G

round AS

ME

Containers

Note 2: No part of an underground container shallbe less than 10 ft. from an important building or lineof adjoining property that may be build upon.

Note 1: The relief valve, filling connection, and liquidlevel gauge vent connection at the container must be atleast 10 ft. from any exterior source of ignition, openingsinto direct-vent appliances, or mechanical ventilation airintakes.

15

CONTAINER PREPARATION FORREMOVAL OF WATER AND AIRCONTAMINANTSBoth water and air are contaminants that can seriouslyhinder the proper operation of the LP-Gas system and theconnected appliances if not effectively removed. The fol-lowing procedures will help increase system performanceand decrease the number of service calls.

REMOVING WATER FROM CONTAINERSWater in LP-Gas cylinders and tanks can contaminate thegas, causing regulator freezeups and erratic applianceperformance. Neutralize any moisture in the container byadding anhydrous methanol (99.85% pure) according tothe amount shown in the Table below.

This will minimize freezeup problems for normal amountsof water in a container. However, this water may still causecorrosion or sediment problems. Large amounts of watershould be drained from the tank.

Warning: Do not substitute other alcohols in place ofmethanol.

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16

PURGING AIR FROM CONTAINERSAir in the LP-Gas can cause appliance pilot lights to beextinguished easily. It can also lead to excessive containerpressure, making the safety relief valve open. Since nearlyall containers are shipped from the fabricator under air pres-sure, it is extremely important to get rid of the air beforethe container is put in service.

DOT Cylinders

First, open the cylinder or service valves for several min-utes to allow air to bleed to atmosphere. Then, pressurethe cylinder with LP-Gas vapor and again open the cylin-der or service valve (repeat this step at least two times).

ASME Storage Tanks

Depending on the type of valves in the tank, (see Figure 6on page 17), purge the container as follows:

1) Bleed the air to atmosphere by opening the multi-pur-pose valve or the service valve for several minutes untilair pressure is exhausted. Close the valve.

2) If a pressure gauge has not been installed in the multi-purpose valve side outlet, install a 0-300 psig gauge(Fisher Type J506). On tanks with service valves, in-stall a POL x 1/4” FNPT pipe coupling and 0-300 psiggauge in the service valve outlet.

3) Attach the truck vapor equalizing hose to the multi-pur-pose valve’s vapor equalizing valve or the separate va-por-equalizing valve.

4) Slowly open the shutoff valve on the end of the hose sothat the truck excess flow check valve does not slamshut.

17

PURGING AIR FROM CONTAINERS (Cont.)ASME Storage Tanks (cont.)

(5) Closely watch the pressure, and when the gaugereaches 15 psig, close the shutoff valve.

(6) Open the vapor service valve on the multi-purpose valve(or the separate service valve, after removing theadapter). Allow all pressure to be exhausted beforeclosing the multi-purpose valve or the service valve.

(7) Repeat steps 4 through 6 at least three more times tomake certain air has been purged from the tank.

Note: Do not purge tanks in this way on the customer’sproperty. Purge them in a safe place at the bulk plant site.

VAPOREQUALIZING

VALVE

SHUTOFF VALVE

PRESSURE GUAGE

SHUTOFFVALVE

SERVICE VALVE

PIPECOUPLING

PRESSUREGUAGE

SERVICE VALVEOUTLET

TO TRUCK VAPOREQUALIZING VALVE

TO TRUCK VAPOREQUALIZING VALVE

PURGING METHOD WITH SEPARATE VALVES

MULTI-PURPOSEVALVE

PURGING METHOD WITH MULTI-PURPOSE VALVE

Figure 6

18

PIPE AND TUBING SIZINGThe proper selection of pipe and tubing sizes is essentialfor the efficient operation of the LP-Gas appliance. Gen-eral consideration must be given to the maximum gas de-mand requirements of the system and the allowable pres-sure loss from the point of delivery to the inlet connectionof the gas appliance.

Four different areas of sizing requirements must be ad-dressed:

1) Sizing between First-Stage and Second-StageRegulators

2) Sizing between Second-Stage Regulator and Appliance

3) Sizing between 2 PSI Service and Line Pressure Regulators

4) Sizing between Line Pressure Regulator and Appliance

The following directions and examples, as well as tables 7-10 starting on page 23, will assist you in determining theproper selection of pipe and tubing sizing for these differ-ent areas. All data in the tables are calculated per NFPAPamphlet Nos. 54 and 58.

19

PIPE AND TUBING SIZING (Cont.)Directions for Sizing between First-Stage and Second-Stage Regulators1) Measure the required length of pipe or tubing from the

outlet of the first-stage regulator to the inlet of the sec-ond-stage regulator.

2) Determine the maximum gas demand requirements ofthe system by adding the BTU/HR inputs from the name-plates of all the appliances or by referring to Table 3 onpage 5.

3) Select the pipe or tubing required from Tables 7a, b,and c on pages 23-26.

Directions for Sizing Between Second-Stage Regulator and Appliance1) Measure the length of pipe or tubing from the outlet of

the second-stage regulator to the most remote appli-ance. (Note: This is the only length needed to size thesecond-stage system.)

2) For each outlet and section of pipe, determine the spe-cific gas demand requirements by adding the BTU/HRinputs from the nameplates of each appliance or by re-ferring to Table 3 on page 5.

3) Select the pipe or tubing required for each section fromTable 8 on page 27.

20

Example (cont.)Determine the sizes of pipe or tubing required for this two-stage LP-Gas installation.For First-Stage:1) Length of first-stage piping = 25 feet (round up to 30 ft.

for use in Table 7a, b, c.).2) Total gas demand = 40,000 + 75,000 + 120,000 =

235,000 BTU/HR.3) From Tables 7a, b, c, use 1/2” iron pipe, 3/8” copper

tubing or 1/2” plastic tubing. (Assume a 10 psig first-stage regulator setting and 1 psig pressure drop.)

For Second-Stage:1) Total second-stage piping length = 30 + 10 + 15 = 55

feet (round up to 60 ft. for use in Table 8).2) Gas demand requirements and pipe selection from Table

8 (Assume a 11” w.c. setting and 1/2 psig pressuredrop):

For Outlet A, demand = 40,000 BTU/HR, use 1/2” iron pipeFor Outlet B, demand = 75,000 BTU/HR, use 1/2” iron pipeFor Outlet C, demand = 120,000 BTU/HR, use 3/4” iron

pipeFor Section 1, demand = 40,000 + 75,000 = 115,000 BTU/HR, use 3/4” iron pipeFor Section 2, demand = 40,000 + 75,000 + 120,000 =235,000 BTU/HR, use 1” iron pipe

Example:A private home is to be supplied with a propane systemserving a central furnace, range and water heater. Thegas demand and piping lengths are shown on the sketchbelow.

Figure 7Fisher 1st

Stage Regulator

Fisher 2nd StageRegulator

12’ 10’

10’ 30’15’

Section 1 Section 2

CFURNACE

120,000 BTU/HR

BRANGE 75,000

BTU/HR

AWATERHEATER40,000

BTU/HR

25’

21

PIPE AND TUBING SIZINGDirections for Sizing Between 2 PSI ServiceRegulator and Line Pressure Regulator1) Measure the length of CSST tubing from the outlet of

the 2 PSI service regulator to the inlet of the line pres-sure regulator.

2) Determine the maximum gas demand requirements ofthe system by adding the BTU/HR inputs from the name-plates of all the appliances or by referring to Table 3 onpage 5.

3) Use the correct footage column, or next higher columnin Table 9. Select CSST tubing size when capacity incolumn exceeds gas demand.

Directions for Sizing Between LinePressure Regulator and Appliance1) Measure the length of CSST tubing from the outlet of

the line pressure regulator to each of the appliances.

2) For each outlet and section of CSST tubing, determinethe specific gas demand requirements by adding theBTU/HR inputs from the nameplates of each applianceor by referring to Table 3 on page 5.

3) Use the correct footage column, or next higher columnin Table 10. Select CSST tubing size when capacity incolumn exceeds gas demand.

Example:

A typical single family home with four appliances is to besupplied with a propane system. The piping is arranged inparallel with a distribution manifold branching CSST runsto the appliances. The supply pressure (downstream ofthe service regulator) is 2 psig and the outlet pressure ofthe line pressure regulator is set to 11” w.c. (see next page).

22

PIPE AND TUBING SIZINGDetermine the sizes of pipe or tubing required for this in-house LP-Gas installation.

From 2 PSI Service Regulator to Line Regulator:

1) Length of section A tubing = 20 feet

2) Total gas demand = 80,000 + 36,000 + 28,000 + 52,000= 196,000 BTU/HR

3) From Table 9, use 25’ column. Select 3/8” CSST for runA, as it has capacity over 196,000 BTU/HR (262,000).(Assume a 2 psig second-stage regulator setting and 1psig pressure drop)

From Line Pressure Regulator to Each Appliance:

1) For line B, length= 10 feet; gas demand = 80,000 BTUFor line C, length= 10 feet; gas demand = 36,000 BTUFor line D, length= 30 feet; gas demand = 28,000 BTUFor line E, length= 35 feet; gas demand = 52,000 BTU

2) CSST Tubing selection from Table 10 (Assume a 11”w.c. setting and 0.5” w.c. pressure drop):

Figure 8

2 PSIService

RegulatorREGULATOR

MANIFOLD

xxxxx

A = 20ft

FURNACE80,000 BTU/

HR

B = 10ft C = 10ftWATER HEATER36,000 BTU/HR

DRYER28,000 BTU/

HR

RANGE 52,000 BTU/HR

E = 35ft

D = 30ft

xxx

xxx

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23

PIP

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24

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29

SELECTING THE REGULATORRegulator performance curves show the capacity of a regu-lator at different inlet pressures, given the factory settingfor outlet pressure.

Figure 9 on page 30 shows a performance curve for a FisherR522 Second-Stage Regulator. Gas flow rate is plottedhorizontally and regulator outlet pressure vertically. Thecurved line represents an inlet pressure of 10 psig. For theappliance to operate efficiently, the regulator outlet pres-sure must not fall below 9” w.c.

Fisher rates this particular regulator at the point the 10-psig-inlet curve crosses the 9” w.c. horizontal line. Thus,the Fisher catalog literature would rate this regulator at1,375,000 BTU/HR. or more - if the inlet pressure staysabove 10 psig.

What you must know to select a regulator:1. Appliance Load

2. Pipe Size

3. Inlet Pressure

4. Outlet Pressure

5. Gas Used (Propane/Butane)

6. Select From Manufacturer Catalog

30

OU

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T P

RE

SS

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100250,000

200500,000

9

10

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13

12

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6001,500,000

10 PSIG

Figure 9

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PIC

AL C

APA

CIT

Y C

UR

VE

31

REGULATOR SELECTION

1 Based on 30 psig inlet pressure and 20% droop2 Based on 10 psig inlet pressure and 20% droop3 Based on inlet pressure 20 psig greater than outlet pressure with 20% droop.

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NOTE: The capacity BTU/HR column should be used forreference purposes only. The capacity will vary dependingon the pipe size, orifice size and outlet pressure setting.

32

TWO-STAGE REGULATIONAdvantages of Two-Stage RegulationUniform Appliance Pressure - Two-staging lets the first-stage regulator supply a nearly constant inlet pressure tothe second-stage regulator at the house. This means thesecond-stage regulator has an easier time of maintainingappliance pressure at 11” w.c., thus improving the systemefficiency.

Lower Installation Costs - Smaller pipe or tubing can beused between the first and second-stage regulators due tothe higher pressure, thus reducing installation and pipingmaterial costs.

Freezeups - Two-stage systems reduce problems due toregulator freezeups caused by excessive water in gas.Larger orifices make it more difficult for ice to form andblock the passage area. The expansion of gas at two dif-ferent orifices in a two-stage system greatly reduces the“refrigeration effect” that causes freezeups. See FisherBulletins LP-18 and LP-24 for more detailed informationon freezing regulators.

Flexibility of Installation - A high pressure regulator canfeed a number of low pressure regulators, thus enablingthe addition of appliances in the future to the same pres-sure line without affecting their individual performance.

Fewer Trouble Calls - With two-stage regulation, you canexpect fewer trouble calls due to pilot outage or burneradjustment. This means higher appliance efficiency, lowerservice costs and better customer relations.

33

REGULATOR INSTALLATION

A two-stage regulator system or an integral two-stage regu-lator shall be required on all fixed piping systems that serveappliance systems at 11” w.c. This includes R.V., manu-factured housing and food service installations. (Excep-tions: Small portable appliances and outdoor cooking ap-pliances with input ratings of 100,000 BTU/HR or less, cer-tain gas distribution systems utilizing multiple second-stageregulators and systems that provide an equivalent level ofoverpressure protection).

This standard along with changes in UL 144 requiring in-creased regulator relief valve capacity or an overprotec-tion shutoff device, results in the maximum pressure down-stream of the second-stage regulator being limited to 2 psigeven with a regulator seat failure.

See Fisher Bulletin LP-15 for more detailed informationon regulator operation, installation and maintenance.

TWO-STAGE REGULATIONTwo Regulators, one at tank and one at building,

reduce pressure down to burner pressure (11” w.c.)

Figure 10

34

REGULATOR INSTALLATIONRegulator VentsRegulators should be installed in accordance with NFPA58 and any other applicable regulations, as well as themanufacturer’s instructions. The following guidelines shallbe followed:

Outdoor Installations - A regulator installed outdoors with-out a protective hood must have its vent pointed verticallydown, as shown in the drawing.

The regulator should be at least 18 inches above ground.Do not install the regulator where there can be excessivewater accumulation or ice formation, such as directly be-neath a downspout, gutter or roofline. All vent openingsmust be at least three horizontal feet from any buildingopening and no less than five feet in any direction from anysource of ignition, openings into direct vent appliances ormechanical ventilation intakes.

Horizontally mounted regulators, such as on single cylin-der installations, must be installed underneath a protectivecover. On ASME tank installations with the regulator in-stalled under the tank dome, the regulator vent should slopeslightly down enough to allow any condensation to drainfrom the spring case. The regulator vent should be posi-tioned far enough back from the tank dome slot so that it isprotected from the weather. The hood should be keptclosed.

Regulators without “drip lip” vents must be installed undera protective cover.

VENT POINTEDDOWN

Figure 11

35

REGULATOR INSTALLATIONRegulator Vents (cont.)Indoor Installations - In a fixed pipe system, regulators in-stalled indoors require a vent line to the outside air. Ascreened vent assembly (Fisher Type Y602 series or equiva-lent) must be used at the end of the vent line. The ventassembly position and location precautions are the sameas for regulator vents. The vent line must be the same sizeas the regulator vent and adequately supported. See Fig-ure below.

Underground Tanks - A vent tube is required on these in-stallations to prevent water from entering the regulator’sspring case. The vent tube connects to the regulator ventand terminates above any possible water level, see Figurebelow. Be sure that the ground slopes away from the tankdome as illustrated. See Figure below.

Moderately crown surfacearound dome. This preventswater collecting and runninginto dome or standingaround dome.

End of regulator venttube located at topinside dome cover.

Water mark in domeat level above vent or

end of vent tuberequires replacement

of regulatorand correcting

installation.

Regulatorbonnet

closure capmust be tight.

FROMFIRST-STAGEREGULATOR

TOAPPLIANCE

VENT ASSEMBLY

DISCHARGEOPENING MUSTBE AT LEAST 3FT FROM ANYOPENINGBELOW IT

VENTLINE

BASEMENT

Figure 12

Figure 13

2” Minimum

36

LEAK TESTING METHODSThere are two primary methods for testing leaks in installa-tions:

Low Pressure Method

1) Inspect all connections and appliance valves to be surethey are tight or closed. This includes pilot valves.

2) Connect a low pressure gauge (Fisher Type 50P-2 orequivalent) to the burner orifice and open the valve.

3) Open the service valve at the tank to pressure the sys-tem. Close the service valve tightly.

4) The low pressure gauge should read at least 11” w.c.Slowly bleed off pressure by opening burner valve onthe appliance to vent enough gas to reduce the pres-sure to exactly 9” w.c.

5) If the pressure remains at 9” w.c. for 3 minutes, you canassume the system is leak tight. If the pressure drops,refer to the leak detection procedures on the next page.

6) After the leak is repaired, repeat steps 3, 4, and 5.

High Pressure Method

1) Inspect all connections and appliance valves to be surethey are tight or closed. This includes pilot valves.

2) Connect a test block . (Fisher Type J600 or equivalentin the service valve outlet at the tank, between thevalve’s outlet and the first regulator in the system.)

37

LEAK TESTING METHODSHigh Pressure Method (cont.)

3) Open the service valve at the tank to pressure the sys-tem. Close the service valve tightly.

4) Open an appliance valve until the test block’s pressuregauge drops to 10 psig.

5) The system should stand for 3 minutes without an in-crease or decrease in the 10-psig reading. If pressuredrops, refer to the leak detection procedure section. Ifpressure increases, then the service valve is leaking.

6) After any leaks are repaired, repeat steps 2, 3 and 4.

Leak Detection and Correction Procedures

1) Use a bubble leak detection solution, or mechanicalleak detector, (never a match or an open flame) whenchecking for leaks.

2) Apply the solution over every pipe or tubing joint andobserve carefully to see if the bubbles expand, indicat-ing a leak is present. A large leak can blow the solutionaway before bubbles have a chance to form.

3) To correct a leak on flaring tubing, first try to tighten theconnection. If this doesn’t work, reflare.

4) On threaded piping, try tightening or redoping first. Ifthe leak continues, take the connection apart and in-spect the threads. Cut new threads if necessary.

5) If steps 3 and 4 fail to correct the problem, look forsandholes in the pipe or fittings and check for splits inthe tubing. Replace whatever material is defective.

Note: Leaks caused by equipment such as gas cocks,appliances, valves, etc., will require repair of the faultypart or replacement of the entire device.

38

REGULATOR INSPECTIONThe following items should be checked at each gas deliv-ery and at regularly scheduled testing and maintenanceprogram intervals.

The customer should be instructed to turn off the tank ser-vice valve if gas can be smelled, pilot lights fail to stay on,or any other abnormal situation takes place.

Improper Installation

The regulator ventmust be pointeddown or under aprotective cover.Regulators without“drip lip” vents mustbe under a protec-tive cover. Properinstallation alsominimizes weatherrelated vent blockage and internal corrosion.

Vent Blockage

Make sure the regulator vent, vent assembly, or vent tubeis not blocked with mud, insect nests, ice, snow, paint, etc.The screen should be clean and properly installed.

Internal & External Corrosion

Replace any regulator that has had water in the spring caseor shows evidence of external or internal corrosion. Regu-lators that have been flooded or that have been installedhorizontally which minimizes moisture drainage, or on un-derground tanks, or in coastal areas are more susceptibleto internal corrosion.

To inspect for internal corrosion:

1) Remove the regulator’s closing cap and look down intothe spring case (a flashlight may be needed).

2) On some regulators it may be necessary to shut downthe system and remove the adjusting screw and mainspring to adequately see any internal corrosion.

Drip Lip

Figure 14

39

REGULATOR INSPECTION (cont.)Internal & External Corrosion (cont.)

3) Look for visible corrosion or water marks on the reliefvalve area and chimney (shaded area in the picturebelow).

4) Replace the regulator if corrosion is present.

Regulator Age

Locate and replace old regulators. Replace regulators thatare over 15 years of age or that have experienced condi-tions (corrosion, underground systems, flooding, etc.) thatwould shorten their service life. Older regulators are morelikely to fail because of worn or corroded parts. Replacewith a two stage regulator system.

Abnormal Pressure

Regulator disc wear (especially on older regulators) or for-eign material (dirt, pipe scale, etc.) lodged between theregulator disc and orifice can cause higher than normaloutlet pressure to the appliances at lock up or extremelylow flows. A pressure test of the system will be required toverify the outlet pressure under these conditions. Replacethe regulator if pressure is high. Check the system for for-eign material and clean out or replace pigtails as needed.

Always retest the system after replacing a regulator.

See Fisher Bulletin LP-32 and the instruction manual formore detailed information on inspecting LP-Gas regula-tors.

Shaded area indicatesspot to examine forinternal corrosion.

Figure 15

40

TROUBLESHOOTING DOMESTICTANK FITTINGSA periodic inspection and maintenance program is recom-mended for domestic tank fittings. The following briefly dis-cusses ways to avoid and correct potential safety prob-lems with the most common domestic fittings.A more complete examination of this subject can be foundin Fisher’s Bulletin LP-26 , applicable Fisher instructionmanuals and NPGA Safety Bulletin 306.Filler ValvesAlways use a filling hose adapter on the end of the hoseend valve during the filling process. After filling the tank,do not disconnect the Acme coupling from the filler valveuntil the Fill valve is closed and all pressure between thehose end valve and the Fill valve has been bled off. Ifpressure discharge continues, the filler valve may havemalfunctioned. DO NOT REMOVE THE FILL HOSE ASTHE INTERNAL PARTS MAY BE BLOWN OUT. If lighttapping does not close the Fill valve, disconnect the FillingHose Adapter from the Hose End Valve, leaving the FillingHose Adapter on the Fill valve. The tank will probably haveto be emptied to replace the Fill valve.Some Fill valve designs allow the seat disc to be replacedwhile the tank is pressurized. On these designs, makesure the lower back check is still functioning by forcing openthe upper back check with an adapter. Take care to dis-lodge only the upper back check and not both back checks.If there is little leakage with the upper back check open,then the lower back check is in place and the disc can bereplaced by following the manufacturer’s instructions.Relief ValvesDO NOT STAND OVER A RELIEF VALVE WHEN TANKPRESSURE IS HIGH. A relief valve’s purpose is to relieveexcessive tank pressure which can be caused by overfill-ing, improper purging of air from the container, overheat-ing of the tank, improper paint color, or high vapor pres-sure, to list just a few reasons. Check the tank pressuregauge if the relief valve is leaking. On a 250 psi design

41

TROUBLESHOOTING DOMESTICTANK FITTINGS (cont.)Relief Valves (cont.)pressure tank for example, if the relief valve is dischargingbetween the 240 to 260 psig range, the relief valve is work-ing properly as long as it reseats.A relief valve that discharges substantially below 240 psigor that does not reseat when the tank pressure is lowered,will have to be replaced. Do not attempt to force the valveclosed. Lower the tank pressure by withdrawing gas orcooling the outside of the tank.Always keep a rain cap on the relief valve to help keep outdirt, debris and moisture.Relief valves, like other pieces of equipment, will not lastforever. Fisher recommends that a relief valve not be usedfor over 15 years. Earlier replacement may be requiredbecause of severe service conditions or applicable federal,state, or local codes.Liquid Withdrawal ValvesA damaged seat or missing internal parts may allow anexcessive amount of liquid discharge when the closing capis loosened. These valves have a bleed hole in the closingcap to vent liquid before the cap is completely unscrewed.If a significant amount of the liquid continues to vent frombeneath the cap after 30 seconds, do not remove the cap.Should only vapor be leaking from under the cap, the con-nection to the withdrawal valve can usually be made.There is the possibility of liquid spray while opening thewithdrawal valve with an angle valve-special adapter. Forthis reason, protective clothing should be worn and extremecare taken throughout the entire process.Service ValvesShow the customer this valve and tell him to shut it off ifgas is escaping into the house or any other abnormal situ-ation takes place. Check the stem seal and shut off seatsperiodically for leakage and replace it is necessary (emptythe tank first).

42

sesaG-PLseiticapaCecifirOsaG-PL21elbaT)leveLaeStaRH/UTB(

ROECIFIROEZISLLIRD

ENAPORP ENATUBROECIFIROEZISLLIRD

ENAPORP ENATUB

800.0 915 985 15 135,63 414,14

900.0 656 447 05 248,93 861,54

10.0 218 129 94 163,34 751,94

110.0 189 211,1 84 389,64 362,35

210.0 961,1 623,1 74 880,05 387,65

08 084,1 876,1 64 692,35 024,06

97 807,1 639,1 54 146,45 449,16

87 080,2 853,2 44 922,06 082,86

77 926,2 089,2 34 963,46 379,27

67 942,3 486,3 24 590,17 995,08

57 185,3 950,4 14 429,47 049,48

47 911,4 966,4 04 920,87 954,88

37 876,4 303,5 93 315,08 512,19

27 180,5 067,5 83 127,38 219,49

17 594,5 032,6 73 068,78 506,99

07 573,6 722,7 63 702,29 235,401

96 439,6 068,7 53 213,89 454,111

86 318,7 858,8 43 571,001 665,311

76 023,8 334,9 33 797,301 276,711

66 848,8 130,01 23 583,901 700,421

56 559,9 682,11 13 340,711 986,231

46 535,01 349,11 03 911,431 640,251

36 521,11 216,21 92 663,051 664,071

26 537,11 403,31 82 103,061 827,181

16 763,21 020,41 72 085,861 411,191

06 800,31 747,41 62 716,571 290,991

95 066,31 648,51 52 916,181 698,502

85 333,41 942,61 42 828,781 539,212

75 620,51 530,71 32 697,291 765,812

65 275,71 129,91 22 053,002 131,722

55 939,12 278,42 12 525,502 799,232

45 036,42 229,72 02 996,012 368,832

35 967,82 516,23 91 549,322 088,352

25 508,23 091,73 81 664,332 376,462

BTU Per Cubic Foot = Propane—2,516 Butane—3,280Specific Gravity = Propane—1.52 Butane—2.01Pressure at Orifice, Inches Water column = Propane—11 Butane—11Orifice Coefficent = Propane—0.9 Butane—0.9

43

LINE

SIZ

ING

CH

AR

TMPGniwolFenaporPdiuqiLroFtrahCgniziSeniL31elbaT.epipnori/leets08/04eludehcSnodesaB.F°06taenaporP.porderusserpgisp1nodesaB

epiP).tF(

"2/1 "4/3 "1 "4/1-1 "2/1-1 "2 "2/1-2 "3 "4

04 08 04 08 04 08 04 08 04 08 04 08 04 08 04 08 04 08

01 1.7 0.5 0.51 3.11 3.82 2.22 85 6.74 78 37 961 341 962 922 574 014 769 648

51 8.5 1.4 2.21 2.9 0.32 1.81 5.74 8.83 17 95 731 611 912 781 783 433 987 096

02 0.5 5.3 5.01 0.8 9.91 6.51 0.14 5.33 26 15 911 001 981 161 533 982 286 795

03 1.4 9.2 5.8 5.6 2.61 7.21 4.33 3.72 1.05 6.14 79 28 451 131 382 532 655 684

04 5.3 5.2 4.7 6.5 0.41 0.11 8.82 5.32 3.34 9.53 48 17 331 411 632 302 184 124

05 1.3 2.2 6.6 0.5 5.21 8.9 7.52 0.12 6.63 1.23 57 36 911 101 112 281 924 673

06 8.2 0.2 0.6 5.4 3.11 9.8 4.32 1.91 2.53 2.92 86 75 901 29 291 661 193 343

07 6.2 8.1 5.5 2.4 5.01 2.8 6.12 7.71 5.23 0.72 36 35 001 58 771 351 263 713

08 4.2 7.1 2.5 9.3 8.9 7.7 2.02 5.61 4.03 2.52 95 6.94 49 08 661 341 833 692

09 3.2 6.1 8.4 7.3 2.9 2.7 0.91 5.51 6.82 7.32 55 7.64 88 57 651 531 913 972

001 2.2 5.1 6.4 5.3 7.8 8.6 0.81 7.41 1.72 5.22 25 2.44 48 17 841 821 203 462

051 8.1 2.1 7.3 8.2 1.7 5.5 6.41 9.11 0.22 2.81 5.24 9.53 86 85 021 401 642 512

002 5.1 1.1 2.3 4.2 1.6 8.4 6.21 3.01 9.81 7.51 7.63 0.13 95 9.94 401 98 212 581

003 2.1 9.0 6.2 9.1 9.4 8.3 2.01 3.8 3.51 7.21 7.92 1.52 5.74 4.04 48 37 271 151

004 0.1 7.0 2.2 7.1 2.4 3.3 8.8 1.7 2.31 9.01 6.52 6.12 9.04 8.43 37 66 941 031

44

CONVERSION FACTORS

Multiply By To Obtain

LENGTH & AREA

Millimeters 0.0394 InchesMeters 3.2808 FeetSq. Centimeters 0.155 Sq. InchesSq. Meters 10.764 Sq. Feet

VOLUME & MASS

Cubic Meters 35.315 Cubic FeetLiters 0.0353 Cubic FeetGallons 0.1337 Cubic FeetCubic cm. 0.061 Cubic InchesLiters 2.114 Pints (US)Liters 0.2642 Gallons (US)Kilograms 2.2046 PoundsTonnes 1.1024 Tons (US)

PRESSURE & FLOW RATE

Millibars 0.4018 Inches w.c.Ounces/sq. in. 1.733 Inches w.c.Inches w.c. 0.0361 Pounds/sq. in.Bars 14.50 Pounds/sq. in.Kilopascals 0.1450 Pounds/sq. in.Kilograms/sq. cm. 14.222 Pounds/sq. in.Pounds/sq. in. 0.068 AtmospheresLiters/hr. 0.0353 Cubic Feet/hr.Cubic Meters/hr. 4.403 Gallons/min.

MISCELLANEOUS

Kilojoules 0.9478 BTUCalories, kg 3.968 BTUWatts 3.414 BTU/HRBTU 0.00001 ThermsMegajoules 0.00948 Therms

45

Multiply By To Obtain

LENGTH & AREA

Inches 25.4 MillimetersFeet 0.3048 MetersSq. Inches 6.4516 Sq. CentimetersSq. Feet 0.0929 Sq. Meters

VOLUME & MASS

Cubic Feet 0.0283 Cubic MetersCubic Feet 28.316 LitersCubic Feet 7.481 GallonsCubic Inches 16.387 Cubic cm.Pints (US) 0.473 LitersGallons (US) 3.785 LitersPounds 0.4535 KilogramsTons (US) 0.9071 Tonnes

PRESSURE & FLOW RATE

Inches w.c. 2.488 MillibarsInches w.c. 0.577 Ounces/sq. in.Pounds/sq. in. 27.71 Inches w.c.Pounds/sq. in. 0.0689 BarsPounds/sq. in. 6894.7 KilopascalsPounds/sq. in. 0.0703 Kilograms/sq. cm.Atmospheres 14.696 Pounds/sq. in.Cubic Feet/hr. 28.316 Liters/hr.Gallons/min. 0.2271 Cubic Meters/hr.

MISCELLANEOUS

BTU 1.055 KilojoulesBTU 0.252 Calories, kgBTU/HR 0.293 WattsTherms 100,000 BTUTherms 105.5 Megajoules

CONVERSION FACTORS

46

FLOW EQUIVALENTS ANDTEMPERATURE CONVERSION

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YLPITLUM:YB

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—foyticapacwolf

:enaporP:enatuB:riA

36.055.077.0

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—foyticapac

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51.138.124.1

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—fo

:enaporP:enatuB:saGlarutaN

18.017.092.1

dnaENAPORPevahuoyfIwolftnelaviuqewonkottnaw

—foyticapac

:enatuB:saGlarutaN:riA

78.095.132.1

noisrevnoCerutarepmeT51elbaT

F° C° F° C° F° C°

04- 04- 03 1.1- 09 2.23

03- 4.43- 23 0 001 8.73

02- 9.82- 04 4.4 011 3.34

01- 3.32- 05 0.01 021 9.84

0 8.71- 06 6.51 031 4.45

01 2.21- 07 1.12 041 0.06

02 7.6- 08 7.62 051 6.56

FISHER LITERATURE

LP-12: Regulator Selection And Pipe Sizing Chart.Handy reference guide for selecting Fisher regu-lators with convenient method of sizing pipe on thereverse side.

LP-15: Give A Regulator The Attention It Deserves.Explains how domestic self-operated regulatorswork; gives installation and maintenance tips.

LP-18: How Drip Lips Can Prevent Regulator Freezeups.Shows how drip lip style vents can reduce thepossibility of vent blockage due to freezing rain.

LP-19: How To Keep Your Internal Valves Working.A discussion about the operation, installation andmaintenance of Fisher’s C-Series Internal Valves.

LP-24: Plain Facts About Freezing Regulators.Describes how a regulator can freeze internallyand gives tips to prevent this situation.

LP-26: Safety Practices For Domestic Tank Fittings.Offers inspection and maintenance programs toreduce tank fitting problems.

LP-29: Complying With NFPA Transfer Area Rulings.An overview of the NFPA requirements with ex-amples of acceptable equipment.

LP-31: LP-Gas Equipment Buyer Guide.Serves as a general reference of availableequipment.

LP-32: Inspecting LP-Gas Regulators: What To Look For.Discusses service life, reducing vent blockage,corrosion, inspection, etc.

Tech Talk: Two-Stage Regulation.Describes how two-staging gives more uniformregulation, reduces trouble calls.

Tech Talk: Trouble Shooting Truck Pumping Systems.Gives procedures on how to trouble shoot a bobtailor transport pumping system when it doesn’t work.

The contents of this publication are presented for informa-tional purposes only, while every effort has been made toensure their accuracy, they are not to be construed as war-ranties or guarantees, express or implied, regarding theproducts or services described herein or their use or appli-cability

For information contact:

Your Local Fisher DistributorOr call 1-800-558-5853 for the Distributor near you.

Printed in the USA

Rev. 3/98

D450116T012

ISO 9001