Post on 01-Apr-2018
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 1
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 2
ACKNOWLEDGEMENTS
National Plumbing Services Training Advisory Group
Plumbing Industry Commission Victoria
© Commonwealth of Australia 2015
Construction and Property Services Industry Skills Council PO Box 151 Belconnen ACT 2616 Tel: 02 6253 0002 www.cpsisc.com.au This work is copyright, but permission is given to trainers and teachers to make copies and contextualise the resources for use within their own training organisation or in a workplace where training is being conducted. This permission does not extend to making copies for use outside the immediate training environment for which they are made, or the making of copies for hire or resale to third parties.
This work was first published in 2004 with the assistance of funding provided by the Commonwealth Government through the Australian National Training Authority (ANTA). The 2015 publication has been updated to reflect changes to the national units of competency.
The views expressed in this work do not necessarily represent the views of the Commonwealth of Australia or CPSISC. In addition, the Commonwealth of Australia and CPSISC do not give warranty or accept any legal liability in relation to the content of this work.
The website addresses and other contact information provided in this publication were compiled in good faith and were correct at the time of printing. The updating of these resources was completed by:
National Plumbing and Services Training Advisory Group, with funding and support provided by the Construction and Property Services Industry Skills Council (CPSISC):
This guide was developed in consultation with representatives of the Plumbing Industry by NPSTAG and CPSISC to support the implementation of the CPC08 Construction, Plumbing and Services Training Package.
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 3
Contents to be altered to suit.
What is this resource about? ............................................................................................. 1
How do I use this resource? .............................................................................................. 1
Flexible Delivery .............................................................................................................. 1
What do I have to do? ....................................................................................................... 1
Unit Descriptor ................................................................................................................. 2
Element ............................................................................................................................. 2
Performance Criteria ......................................................................................................... 2
How will I be assessed? .................................................................................................... 4
Are there any pre-requisites? ............................................................................................ 4
What other resources will I need? .................................................................................... 4
Texts ................................................................................................................................. 4
Safety ................................................................................................................................ 5
Workplace environment and safety .................................................................................. 5
Introduction ...................................................................................................................... 6
Properties of LPG ............................................................................................................. 7
Ignition and combustion principles .................................................................................. 9
Gas combustion .............................................................................................................. 10
Complete combustion ..................................................................................................... 10
Incomplete combustion ................................................................................................... 10
Chilling a gas flame ........................................................................................................ 11
Safety .............................................................................................................................. 11
Electrical safety .............................................................................................................. 12
Regulations ..................................................................................................................... 12
Quality assurance ............................................................................................................ 13
Planning .......................................................................................................................... 14
Other considerations ....................................................................................................... 14
Personal protective equipment ........................................................................................ 15
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 4
Choosing the right tools .................................................................................................. 15
Determining LP gas system requirements ...................................................................... 16
Determine the gas load .................................................................................................... 17
Calculate the storage capacity ......................................................................................... 17
Calculate the regulator size and any connections ........................................................... 19
Conversions..................................................................................................................... 20
Pigtail connections .......................................................................................................... 20
AS/NZS5601 Details requirements for caravans and catering vehicles ......................... 21
Checking the location and set out ................................................................................... 21
Cylinder requirements ..................................................................................................... 21
Cylinder installation ........................................................................................................ 21
Location of a cylinder ..................................................................................................... 21
Cylinder in a compartment .............................................................................................. 23
Cylinder regulator ........................................................................................................... 24
Consumer piping ............................................................................................................. 25
Restriction on pipe joints ................................................................................................ 26
Restriction on hose assemblies used as consumer piping ............................................... 26
Consumer instruction labels and plates ........................................................................... 26
Appliance installation ..................................................................................................... 26
General ............................................................................................................................ 26
Prohibited appliances ...................................................................................................... 27
Required clearance between appliance and fuel filler cap vent or vent .......................... 27
Water Heaters.................................................................................................................. 29
Flued appliances.............................................................................................................. 30
Air supply to appliances .................................................................................................. 30
Worksheet ....................................................................................................................... 32
Practical application ........................................................................................................ 37
Assessment checklist ...................................................................................................... 38
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 1
What is this resource about?
Welcome to CPCPGS3046A – Install LPG systems in caravans, mobile homes, and mobile workplaces.
This resource will help you gain the skills and knowledge necessary to demonstrate competence in this
unit.
How do I use this resource?
This resource is divided into four main sections:
• A learning unit, which contains background information on CPCPGS3046A – Install LPG
systems in caravans, mobile homes, and mobile workplaces
• Worksheets, which prepare you for the practical application
• Practical application, which allows you to experience installing LP gas systems in caravans,
mobile homes, and mobile workplaces
• Assessment materials, which help you demonstrate competency.
To complete this unit of competence you will need to:
• read the information contained in the learning unit
• complete the worksheets as instructed
• have your answers checked by your trainer or supervisor
• work with your trainer or supervisor to practice installing LP gas systems in caravans, mobile
homes, and mobile workplaces
• read the assessment checklist together with the assessment sheets
• complete the assessment.
Learning Resources are not intended to be the only source of information nor are they intended to be an
exhaustive form of instruction.
Flexible Delivery
The Trainer or Supervisor may adapt and deliver this Learning Resource to suit people from diverse
backgrounds to meet equity principles and conform to Legislative policies.
What do I have to do?
To demonstrate competence in this unit you will be required to show the required level of skills and
knowledge for each of the elements involved in CPCPGS3046A – Install LPG systems in caravans,
mobile homes, and mobile workplaces:
• Plan work activities
• Determine LP gas system requirements
• Install system
• Test and commission system
• Clean up.
If you are unsure of the meaning of these elements you should read the performance criteria on the
following page.
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 2
CPCPGS3046A Install LPG systems in caravans, mobile homes, and mobile workplaces
Unit Descriptor This unit of competency specifies the outcomes required to
determine the requirements for installing and commissioning
liquefied petroleum gas (LPG) systems with an operating pressure
not exceeding 2.75kPa in caravans, mobile homes and mobile
workplaces
Element Performance Criteria Elements define the
essential outcomes of a
unit of competency.
Performance criteria describe the performance needed to
demonstrate achievement of the element. Where bold
italicised text is used, further information is detailed in the
required skills and knowledge section and the range
statement. Assessment of performance is to be consistent
with the evidence guide
1 Identify LPG system
requirements.
1.1 Plans, specifications and any special instructions are obtained.
1.2 Work health and safety (WHS) and environmental
requirements associated with installing and commissioning
LPG systems in caravans, mobile homes and mobile
workplaces are adhered to throughout the work.
1.3 Quality assurance requirements for company operations are
identified and adhered to.
1.4 Gas load and design requirements are determined from plans,
specifications, and job drawing or workplace instructions.
1.5 System capacity is calculated to ensure adequacy for the
required load and compliance with relevant Australian
standards and installation requirements.
1.6 Appropriate regulator and piping are identified in terms of
size, connection sizes and capacity, according to relevant
Australian standards and installation requirements.
1.7 Location of cylinders, appliances and piping set out is
identified according to job requirements and in compliance
with relevant Australian standards and installation
requirements.
1.8 Quantity of piping, components and fittings is estimated in
compliance with relevant Australian standards and
installation requirements.
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2 Prepare for
installation.
2.1 Materials, equipment, appliances and cylinders are ordered
and checked for compliance with docket and order form, and
for acceptable condition.
2.2 Appropriate tools and equipment for installing and
commissioning LPG systems in caravans, mobile homes and
mobile workplaces, including personal protective equipment,
are identified and selected.
2.3 Work is planned in conjunction with others involved in or
affected by the work.
2.4 Work area and materials are prepared to support efficient
installation of the system.
2.5 Sustainability principles and concepts are observed when
preparing for and undertaking work process.
3 Install LPG system,
including flue and
ventilation.
3.1 Cylinders, regulators, associated pipework, appliances and
fixings are installed in compliance with manufacturer
requirements, relevant Australian standards and installation
requirements.
3.2 Ventilation requirements are determined and installed
according to relevant Australian standards.
4 Test and
commission LPG
system.
4.1 Appropriate test equipment is selected.
4.2 System is tested according to relevant Australian standards
and manufacturer requirements.
4.3 System is commissioned according to relevant Australian
standards and manufacturer requirements.
4.4 Test data is recorded in format required by regulatory and
installation requirements.
4.5 Compliance plates and signage are located and fitted
according to statutory and regulatory authorities’
requirements, relevant Australian standards and installation
requirements.
5 Clean up. 5.1 Work area is cleared and materials disposed of, reused or
recycled according to legislation, regulations, codes of
practice and job specification.
5.2 Tools and equipment are cleaned, checked, maintained and
stored according to manufacturer recommendations and
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
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workplace procedures.
5.3 Information is accessed and documentation completed
according to statutory requirements.
Required knowledge
• electrical safety and requisite precautions
• how to access relevant information, including codes and technical standards
• job safety analysis (JSA) and safe work method statements (SWMS)
• process for determining material requirements
• procedures for installing and commissioning gas systems in caravans, mobile homes and mobile
workplaces
• properties of gas, gas safety, combustion principles, gas pressures, and cylinder installation and
ventilation requirements
• relevant statutory requirements related to installing LPG systems
• SI system of measurements
• workplace and equipment safety requirements
An up to date version of the ‘Unit Descriptor’ may be located on the Australian Government web site
training.gov.au
http://training.gov.au/Search/Training?searchTitleOrCode=&nrtSearchSubmit=Search&includeSupers
ededData=true&includeSupersededData=false&homePage=true&javaScriptEnabled=true&typeAllTra
iningComponents=true
How will I be assessed?
Your trainer or supervisor will decide with you how you will be assessed. Your assessment activity may
include completion of the student worksheet and practical task selected by your trainer or supervisor.
Your assessment should allow you to demonstrate all the skills and knowledge required to install LP
gas systems in caravans, mobile homes, and mobile workplaces.
This unit may be assessed in conjunction with other units of competence. Your trainer or supervisor
will tell you if you are to be assessed this way.
Are there any pre-requisites?
Prior to commencing CPCPGS3046A – Install LPG systems in caravans, mobile homes, and mobile
workplaces you must have successfully completed the following pre-requisite:
• CPCPCM2043A – Carry out WHS requirements
What other resources will I need?
To assist you the following resources have been suggested and should be available to you to do this
competency:
Texts
• AS/NZS 5601 part 1 and 2 Gas Installations (relevant version)
• AS/NZS1596 – 2000 Storage and handling of LP gas
• State or Territory regulations may override this learning guide.
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Safety
Workplace health and safety (WHS) requirements need to be observed in accordance with legislation.
You need to know the WHS laws governing your job. Revision of CPCPCM2043A – Carry out WHS
requirements, before commencing this unit is advisable.
In any work situation you can reduce the risk of injury to yourself and others by using appropriate
personal protective equipment (PPE). The types of PPE that you may require:
• overalls – used for the protection of the installer when working in different conditions
• boots – it is recommended that soft soled footwear is worn while working on roofs, as deep
grooved footwear pick up small stones and debris that might damage or scratch the roof sheets
• safety glasses or goggles to protect the eyes from injury when cutting the sheets with a power
saw
• ear plugs or muffs to protect the installer’s hearing from excessive noise
• dust masks or respirators to protect the user from breathing in dust or fine particles when
cutting the sheets with a power saw
• gloves, for the protection of the installer’s hands when working with different types of pipes,
tools and equipment.
Workplace environment and safety
Handling of materials Manual lifting and handling techniques must always be followed
according to WHS requirements. You should move materials into
position by hand where possible. Excessive manual handling should be
avoided and cranes and other mechanical lifting devices should be
employed when necessary.
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Introduction
The aim of this unit is to teach you to design, install and test LPG in caravans, mobile homes, and
mobile workplaces.
States or Territories gas Authorities apply different certification schemes when the installation is
completed. It is therefore of the utmost importance that you have made the installation in a safe,
tradesman–like manner to ensure the safety of the consumer. The principles learnt here may be applied
to new or existing vehicles and marine craft. They are also relevant for any appliance replacement or
servicing that may be carried out in existing caravans.
A definition of a caravan is found in (relevant version) (AS/NZS 5601):
‘a structure that is or was designed or adapted to move from one place to another, whether it is towed,
transported or self-propelled, and which is intended for human habitation or use as a workplace. This
includes camper vans, mobile homes, on-site vans, and commercial food vans. It does not include
fabricated transportable homes or demountable classrooms, etc’.
A typical basic installation in a caravan, mobile homes, and mobile workplace would be a cooker and
refrigerator which are supplied by one 9 kg gas cylinder. Occasionally a room heater and/or hot water
service may also be installed.
The installation you will be doing is for a caravan, mobile homes, or mobile workplace so these training
notes will be written about these types of installation.
Before you can plan and install LP gas cylinders in caravans, mobile homes, and mobile workplaces,
there are a number of issues that you must know about. These include:
• the properties of LP gas
• ignition and combustion principles
• pressure and flow rates
• gas safety
• electrical safety.
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
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Note
There are two main types of LP gas: Propane and Butane. Because
of our climatic conditions, we use Propane for fuel gas.
Automotive LP gas is a mixture of Butane and Propane and is not
suitable for use with gas appliances.
Butane is also found in disposable gas canisters which can be
recognised by the rubber valve in the top of the canister. A needle
valve similar to the one used for inflating footballs, etc with a pump
is inserted through the rubber valve to obtain gas.
All references to LP gas from this point on refer to Propane.
Properties of LPG
• LP gas is colourless and heavier than air. It will flow downwards and collect on the ground
unless there is ventilation or air movement.
• A strong pungent odorant (Ethyl mercaptan) is added to assist in the detection of even minor
leaks.
• LP gas is non-toxic, but if inhaled in sufficient volume, asphyxiation may occur.
• If a given volume containing between 2-9.6% of LP gas in an air-mix is ignited, it will flash
and, if in a confined space, it will explode.
• LP gas is stored under pressure to maintain its liquid state. When the pressure is released, it
vaporises and in the process expands to 270 times its liquid volume. 1 litre = 0.270 m3 of gas
vapour.
• The travel of flame in LPG vapours in open air is about five metres/second
• Ambient temperature increases the vapour pressure of LPG inside containers and also causes
the LPG liquid to increase in volume. LPG cylinders and tanks are so designed that they
should never be filled with liquid to more than 83% of their total capacity.
• LP gas will cause deterioration of natural rubber. Therefore only approved jointing
compounds, lubricants and synthetic hoses must be used.
• The ignition temperature of Propane is between 493-5490 C.
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
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The average properties of Commercial LP gas (propane) at 150C
Formula C3H8
Specific Gravity of liquid (water = 1) 0.51
Specific Gravity of gas (Air = 1) 1.53
Boiling Point of liquid (vaporisation) at atmospheric pressure 0C – 420C
Kilograms per litre liquid 0.508
Litres per kilogram liquid 1.97
Cubic metres gas per kilogram liquid (101.325 kPa) 0.528
Cubic metres gas per litre liquid (101.325 kPa) 0.268
Flammability Limits (% gas in air)
Lower 2.4
Upper 9.6
Latent heat of vaporisation at Boiling Point (m3/kg) 0.536
Air required for combustion (volume/volume)
Stoichiometric 23.8
With 40% excess air 33.3
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
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Heating Values (megaJoules)
mJ/m3 (gas at 150C, 101.32b kPa) 96
mJ/litre (gas at 150C, 101.325 kPa) 0.0955
mJ/litre (liquid at 150C) 25.6
mJ/kg 50.01
Vapour Pressure (kiloPascals)
ºC kPa absolute kPa gauge
-15 295 195
0 480 380
20 850 750
40 1395 1295
55 1915 1815
Ignition and combustion principles
Combustion is a rapid chemical reaction between a fuel and oxygen, which gives off heat. Usually the
oxygen comes from the air, which is about 21% oxygen and 78% nitrogen.
Most fuels contain carbon and hydrogen and when combined with elements like oxygen, heat is given
off. In gas, carbon and hydrogen usually don’t appear as pure elements. Instead they are combined into
chemical compounds called hydrocarbons.
When hydrocarbons are burned, the heat of combustion breaks them down and they begin to react with
the oxygen, forming a new group of compounds called aldehydes. These in turn break down and react
with the rest of the oxygen producing carbon dioxide and water vapour.
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Nitrogen, being an inert gas, passes through the combustion reaction unchanged.
The heated gases, carbon dioxide, nitrogen and water vapour are called the products of combustion or
flue gases.
Once the gas or air mix is heated to the required temperature for ignition – between 4930 C and 5490 C
for propane – the resultant chemical reaction is generally sufficient to maintain further combustion.
Combustion or burning of gas (or any other fuel) can only occur when three factors are united. They are
the fuel, oxygen and ignition. Combining them together forms a combustion triangle.
The combustion triangle
Should one of the factors be omitted, combustion cannot take place.
Gas combustion
Gas combustion is generally described as:
• complete
• incomplete.
Complete combustion
Complete combustion is the total breakdown of the fuel into carbon dioxide, nitrogen and water vapour.
This is discussed in the previous section.
Complete combustion occurs when the correct volume of oxygen (obtained from the surrounding air) is
supplied for each volume of gas to be burnt.
The ratio is 24 parts air to 1 part gas (propane). We call this the ideal fuel/air ratio or stoichiometric
ratio.
Complete combustion ensures:
• maximum appliance efficiency
• safe products of combustion produced and released into the atmosphere.
The air to gas ratio to a burner is maintained by ensuring sufficient:
• primary air is available to the mixing tube of the burner, to mix with the gas prior to ignition
• secondary air is supplied to the burner head to maintain efficient combustion.
Incomplete combustion
When incomplete combustion occurs, other by products are produced, including the poisonous gas
carbon monoxide. There are two main causes of incomplete combustion:
• lack of oxygen
• chilling a gas flame.
Lack of oxygen is caused by:
• insufficient primary air
− being inspirated into the burners mixing tube by the gas stream
Note
Stoichiometric ratio means chemical
equation of combustion.
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
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• insufficient secondary air
− being supplied to the combustion area
• blocked or poorly designed flue
− helps prevent removal of products of combustion from the appliance.
Chilling a gas flame
Impingement of any solid object into the inner cone of the gas flame will cool some of the fuel below
its ignition temperature, thus preventing complete combustion from taking place.
All of the above contribute to the following main products of incomplete combustion.
• Carbon monoxide (CO).
• Water vapour (H2O).
• Deposit of soot (C)
• Loss of heat energy (mJ)
As a gas installer, you can ensure that incomplete combustion is avoided by checking the following.
• Appliance is assembled and installed correctly.
• Correct ventilation requirements are installed.
• Correct pressure regulator is installed for type of installation.
• All appliances have been adjusted to correct operating pressure.
• All burners have been checked and adjusted for correct aeration.
• Correct flue sizing and components have been used where applicable.
Because caravans, mobile homes, and mobile workplaces are essentially ‘confined spaces’, you must
take the utmost care when installing gas equipment to ensure that you have, completed all the correct
installation procedures, and so prevent an accident from occurring.
You should also clearly instruct the consumer to have regular maintenance carried out on their
appliances.
Safety
An extremely important aspect of working with LP gas systems is your own personal safety, as well as
the safety of your fellow workers.
Note
There are two grades of LP gas stored at service stations. One is for
automotive use only and could be a Propane/Butane mix, which is
dispensed through a driveway pump into the vehicle fuel container.
The other is Propane, which is decanted into portable cylinders for
barbeques and caravans.
These grades are not interchangeable and a dangerous situation could
develop if the auto gas is used for domestic or leisure appliances.
Products of incomplete combustion such as carbon monoxide may
cause serious or even fatal injuries.
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Liquefied Petroleum Gas (LPG) is flammable and when it burns it releases a considerable amount of
heat. This property, in conjunction with its portability, makes LPG an ideal fuel for domestic,
commercial, industrial and recreational use. However, LPG introduces fire hazards over and above
those of similar fuels and special care must be taken to keep it safe.
Efforts to prevent LPG fires are directed mainly at preventing gas escaping from the specially designed
storage cylinders. Where sound engineering, careful processes and vigilance is maintained, the hazards
of LPG can be controlled, making it safe for general use.
LPG is unique among the hydrocarbons because of the combination of volatility, vapour density and
flammability. When released to the atmosphere, LPG vaporises readily. The gas is heavier than air and
will drop to the lowest point and spread as readily as water. It will displace the warmer, lighter air
above it. It can move against a light wind.
LPG will run downhill and along depressions. It will diffuse into the air to form a flammable mixture. It
can travel a long way to reach an ignition point, and then flash back to the source of the leak. One case
record reports a flashback of 600 metres.
Keep this in mind should you ever have to cut in or extend an existing pipe. It must always be
disconnected at both ends and be purged with an inert gas. Refer to (relevant version) AS/NZS5601.
A second characteristic of LP gas which makes it hazardous is that it is stored as a liquid under
pressure. Loss of containment, eg a broken line or a damaged cylinder, will emit liquid under
pressure, not liquid under gravity, as with petrol, or gas under pressure, as with methane.
Therefore the amount of LP gas released from a break in a pipe will be much more than for either the
lighter or heavier hydrocarbons. Further, it can be emitted as a boiling liquid comprising both spray and
gas.
The old saying ‘don’t use a naked flame’ to test for leaks is very true, especially when you consider the
low flammability limits and other properties listed earlier. Don’t forget that you are working in a
confined space, so smaller quantities apply!
Always use soapy water or an electronic detector to locate leaks.
Other safety issues to consider are:
• cylinder location and housing
• pipe protection
• appliance location and ventilation
• appliance clearance to combustible materials
• clearance between appliance air intake/ flue outlet and the fuel filler cap.
Electrical safety
The appliances that you will be installing may or may not have electrical connections. Remember that
unless these connections plug in, they must be made by a qualified electrician.
AS/NZS5601 (relevant version), states that no electrical equipment other than a non-sparking shut-off
device may be contained in a cylinder compartment.
If you are using electric power tools during the installation, be aware that extension leads can get
snagged on metal chassis and bulkhead parts and could make the whole structure live if they become
partially or fully severed. To avoid danger use a safety switch or board with power tools.
Regulations
When installing gas cylinders you must observe the regulatory as well as any State or Territory WHS
requirements. You will require a copy of Australian Standards (relevant version) AS/NZS5601 and
AS/NZS1596 which govern the installation and operation of LP gas cylinders.
You will also require a copy of your state’s gas regulations.
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Note
You should carefully read part 2 of (relevant version)
AS/NZS5601which refers to LP Gas installations.
While many of the sub clauses in each are similar, there are some differences.
The main topics covered are:
• cylinder installation
• cylinder regulator
• consumer piping
• appliance installation
• air supply to appliances
• consumer instruction plates.
Quality assurance
Most companies these days have a policy for assuring quality to the customer. This policy is designed
to control the processes used within the company, record keeping, the quality of materials used and the
way the work is done.
You need to be aware of your company’s particular quality assurance requirements. A number of
quality assurance issues are dealt with in the next section ‘planning the job’.
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Planning
Before you begin the designing, installation and testing of LP gas systems in caravans, mobile homes,
and mobile workplaces you need to gather together information from a number of sources. The table
below shows some of the information sources you will use and the type of information each source can
provide you with:
Source of information The information you can get
Authorities Regulatory requirements, Local requirements,
Approval for ‘special’ installations. Vaporisation
rates of cylinders. Pipe sizing formulas.
Plans or specification Location, design and capacity of the system
Design drawing Gas load or design requirements
Regulatory requirements Work notices
Manufacturers’ specifications mJ rating of appliance, installation details such as
position of inlet pipe, dimensions, fixing details.
Site Inspection Better perspective of structure in relation to pipe
work and appliance installation. Meet other
tradesmen on site to discuss how job will proceed.
Manufacturers’ operating
instructions
Operating, commissioning and maintenance
procedures.
Gas Installation Code
AS/NZS5601 (relevant version)
Installation & testing recommendations.
Your State’s Gas Regulations Specific details regarding installation completion
notices, etc in your state.
You should always read the job specification in conjunction with the plan. There is often more detail in
the specification that you may need to know about eg specific make or size of valves or other
components, who is fitting in the appliance to the cupboards or structure, etc.
Some State Regulations call for a specific completion notice to be given to the owner. You will need to
check with your trainer or supervisor to see if this is case in your home state.
Your regulator may require a compliance plate to be attached to the caravan or marine vessel. Check
with your instructor.
Other considerations
You need to consider how the task you are about to do affects others. You should plan the task with the
others involved or affected by the work. Your company may have procedures regarding this and what
will need to be taken into account.
Some aspects of the job that you need to consider are listed below.
• Fitting your pipework to the chassis of the caravan. Brake lines and electrical cables also get
fixed to the chassis. Check out to see if they will be in the way.
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• Manual shut off valves must be accessible and adjacent to the appliance. Is the location you
wish to install it going to be in the way of another piece of equipment?
• There is a lot of movement with both caravans, mobile homes, and mobile workplaces.
Therefore the appliances have to be fastened to the structure. Otherwise they tend to fall over.
You will have to liaise with the tradesmen to ensure that they are fitting suitable materials for
the appliance to be fastened to.
• Buses are often used for mobile homes and usually have low level steps recessed into the
floor. This is where your low level ventilation has to be fitted, unless a vent can be fitted to the
bottom of the door. What is under the floor behind the steps? How will you prevent road dust
entering the vehicle?
Personal protective equipment
During the planning stage you will need to select and use various PPE to protect yourself including:
• dust mask or respiratory equipment. When working on fibreglass. Also required when
tradespersons other than yourself are cutting or drilling near you
• earmuffs or plugs. When yourself or others are using grinders
• safety glasses or goggles for any drilling, cutting or grinding operations
• knee pads or a kneeling pad when working underneath the caravan – beats kneeling on a
screw!
• a 240v electrical safety switch connected to any power tools
• welding shield appropriate for any mig, tig or arc welding operations such as pipe support
bracket fabrication
• protective clothing for above welding operations
• steel toe cap safety boots or shoes.
Choosing the right tools
To complete the planning stage you will need to identify a range of hand and power tools and
equipment that you might use. These may include:
• flaring tool for making joints in copper tube – generally 10 mm
• copper tube benders or spring
• copper tube cutters
• expanding tool for forming sockets in copper tube
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• branch forming tool if fittings are to be formed in the pipe itself (not common practice for this
type of installation)
• oxy/acetylene or oxy/LPG set for brazing joints
• 100 mm angle grinder for cutting through steel step risers for vent openings
• range of drill bits suitable for timber and metal, sized to pipe grommet diameter
• small diameter hole saws in lieu of above for grommet holes and drain hole in cylinder
compartment
• large diameter hole saw for flue pipes that go through roof
• open end adjustable spanners to suit hex fittings – two of each size to ‘hold against yourself’
when tightening nut onto fitting
• pop rivet pliers
• cordless drill
• Phillips head and or hex head bits to suit above
• 240v drill with chuck large enough for hole saw shanks
• suitable length extension lead
• safety cut out switch for 240 v power – can save your life in the event of severing an electric
lead or if pools of water are present
• tin snips – left and right hand for cutting through cladding on vans for vent and flue openings
• calking gun for sealing around vents, flashings, etc
• 15 kPa digital manometer for leak testing ‘rough in’ pipe work
• manometer for checking and adjusting regulator for operating and lock up pressures
• suitable testing tee to attach manometer to pipe work for leak test
• thermometer for checking or adjusting oven thermostat and hot water temperature
• various types of welding plant as required
• hand trolley or dolly for moving appliances and gas cylinders.
Determining LP gas system requirements
Before you can design, plan and install an LP gas system in a caravan, mobile homes, and mobile
workplaces you must be able to understand and state the requirements of the system. You will need to
be able to consider the following:
• gas load
• storage capacity
• regulator size and connections
• pipe size
• vehicle type
• appliance type and installation requirements
• materials, cylinders and components
• tools and equipment.
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Determine the gas load
The gas load requirements need to be determined from the design drawing or any other sources. For
example, you can determine gas load requirements by adding together the mJ/hr rating of each
appliance to be installed.
The total is called the gas load.
The rating of each appliance can be found in:
• job specification – appliance specs should be included
• design drawings
• manufacturers’ installation instructions
• appliance data plate.
Once you have determined the total load, you can use this figure to calculate storage capacity, regulator
capacity and pipe sizes.
Calculate the storage capacity
The term ‘caravan’ found in (relevant version) AS/NZS5601 can mean any type of vehicle from a
camper trailer to a large passenger bus converted to a mobile home or a handy van with a pie warmer to
a mobile kitchen with two pizza ovens!
However, the storage capacity of the LP gas cylinders for the installation you will be doing at
Registered Training Organisation (RTO) may be calculated using the following rule of thumb:
In a small to medium sized van it is normal to fit one 9 kg cylinder. If a hot water service (HWS) is
installed, two 9 kg cylinders may be fitted.
Example 1
How long will one 9kg cylinder of LP gas last if the appliances use 50 mJ/hr?
1 kg of propane liquid will produce approximately 50 mJ.
9 x 50 = 450 mJ
Appliances use 50 mJ/hr
450 mJ
50 mj = 9 hours
If, for example, the appliances are used for say half an hour per day, the cylinder will last for 18 days.
For 15 minutes per day usage, the cylinder will last 36 days approximately.
Because individual needs will be different, it is almost impossible to calculate exactly what people’s
requirements will be.
• Do they only stay in caravan parks or do they pull off the road and camp overnight?
• Are they ‘going bush’ for six weeks or longer?
• Do they cook a roast leg of lamb when they head off for the weekend?
There are a myriad questions like these and no real answers, but as said earlier, the rule of thumb
generally works out fine.
The storage capacity selected must be adequate for the load details given in the design instruction.
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Example 2
Let’s consider a 32 seat passenger bus that is being converted to a mobile home.
The owners intend to drive it to a camping ground and stay for a week whenever they have holidays.
The owner proposes installing an upright cooker (35 mJ/hr), a refrigerator
(12 mJ/24hr), and a 14 litre storage hws (5 mJ/hr).
How much gas storage does he need?
Assume that only two hotplate burners are used on most days. Each burner is rated at 5.4 mJ/hr each
when full on. Total use for a day is one hour so 5.4 x 2 = 10.8 mJ used. (In reality the figure will be less
than this because when the contents of the pot or frying pan are hot, the burner is turned to simmer, but
we calculate using the full rate).
Once the fridge is turned on and gets cold it uses 12 mJ/day. Generally the refrigerator should be cold
to start with as it is normal to run it off the vehicle’s 12 volts electrical supply to maintain a low
temperature when travelling.
Usually the HWS is only used for washing dishes. Let’s assume that once it’s heated up (takes about 35
minutes), it will cycle say three times during the day for about 10 minutes. Let’s say 6 mJ/day.
Now total all the figures:
10.8 (for the cooker)
12.0 (for the refrigerator)
6.0 (for the HWS)
28.8 mJ/day
You would probably round this up to 30 mJ/day.
We know we have 450 mJ / 9 kg cylinder, so 450 divided by 30 = 15 day’s use (approx).
The only factor we haven’t looked at is – Can a 9 kg cylinder vaporize/supply this amount of gas?
You learned about this in CPCPGS3059A – Install LPG storage of aggregate storage capacity up to 500
litres.
Look at the table below which shows the vaporization rate of a cylinder in terms of the temperature of
the liquid and the percentage of the ‘wetted’ surface of the cylinder.
‘Wetted surface’ means that part of a cylinder in contact with the liquid gas inside.
I’ve used 30% full (wetted surface area) at – 70 C. as this gives a good rate at all but the coldest
temperatures.
Cylinder Diameter Height mJ Litres
4.5 kg 0.31 0.19 13.42 0.52
9 kg 0.31 0.33 23.32 0.91
15 kg 0.31 0.62 43.82 1.71
Reading across the row for a 9 kg cylinder we see that 23.32 mJ is the hourly vapor rate from one
cylinder.
This is for continuous use. As our situation is intermittent, ie not all appliances are being used at the one
time, there shouldn’t be any problems encountered.
Note
If we had a greater hourly load, (say 85 mJ/hr), then two cylinders
would need to be manifolded together to provide the required
vaporisation.
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Calculate the regulator size and any connections
There are different types of regulators for different gases and different purposes:
• single stage is the only one permitted in accordance with (relevant version) AS/NZS5601:
When you go to your local supplier to select a regulator, you’ll need to know the total load of the job.
You will also be confronted with the fact that there are different makes, types and prices, automatic
changeover, manual changeover and singles and most important of all, different flow rates.
Prest-O-Lite (USA) regulator Single regulator
Manual changeover regulator Automatic regulator
Note
AS/NZS5601 (relevant version), requires that an OPP (over pressure
protection) type of regulator be fitted. Read the clause to find out
why.
Many small regulators do not have any adjustment, the outlet pressure is fixed. If you install one of
these types and cannot get the desired pressure at the appliances, you have either selected the wrong
regulator (capacity size) or will have to use an adjustable type in its place.
Basic installations either use a single regulator or a manual changeover regulator if two cylinders are to
be fitted.
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Conversions
Depending on where the regulator was made – Asia, Europe or America, the information you require
may be in different units to those we use in our metric system. You will need to do some unit
conversions. The list below gives some examples.
Gas consumption rates
• 1 mJ = 948 BTU (British thermal units)
• 1 kW = 3.6 mJ
Working Pressures
• 1” WG = 0.250 kPa
Supply Pressures
• 1 PSI = 6.895 kPa
• 1 Bar = 100 kPa ∴1mB = 1 kPa
Volume Rate of flow
• 1 kg (liquid) = 1 litre = 0.27 m3 vapour = approx. 32 mJ/hr
Example
One popular regulator gives a flow rate of 4 kg/hr. How many mJ/hr is this?
Looking at the list above for volume flow rate, you will find that 1kg = approx. 32 mJ/hr.
Multiply 4 x 32 = 128 mJ/hr flow through the regulator.
Using the motor home example on the previous page where approx. 40 mJ/hr is used with everything
operating, then the regulator will be more than adequate.
Pigtail connections
The pigtail connection from the cylinder to the regulator can either be 6 mm copper or a flexible rubber
type with an integral excess flow valve incorporated in the POL fitting. (The abbreviation POL comes
from the trade name for Prest-O-Lite in USA).
Pigtails are available with different outlets:
• inverted flare
• m BSP
• c x MI union.
Rubber pigtail with m BSP thread
The inverted flare types are generally supplied with the regulator (manual or automatic changeover).
The ¼’ m BSP or ¼’ compression union types are used with single regulators (see diagram).
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There are various regulator manufacturers produce ‘capacity’ charts for their regulators, and you would
need to consult these charts for any installation, including the minor one you will be installing.
AS/NZS5601 (relevant version) Details requirements for caravans and catering vehicles
Checking the location and set out
The selected location of the LP gas cylinders and regulators must comply with (relevant version)
AS/NZS5601 – Gas installations and AS/NZS1596 and allow access for filling or exchanging
containers.
Cylinder requirements
AS/NZS5601 (relevant version) states that the cylinder must comply with AS2030.1 (which states that a
cylinder must not be filled unless it has a current stamp mark of a certified test station) and
AS/NZS1596.
When you read AS/NZS1596, it states that cylinders with the identification mark ‘4’ must not be used
for installation in caravans or similar mobile applications.
The following points apply to caravans, etc that have a cylinder system designed to remain connected to
the consumer piping system while the caravan is moving.
Cylinder installation
Clearances around the cylinder must comply with those specified in the appendices. Although the
figures depict a building, the clearances also apply to caravans.
A cylinder must not be installed inside a caravan unless it is in a cylinder compartment, as per (relevant
version) AS/NZS5601.
Location of a cylinder
On a caravan, cylinders may be located:
• mounted externally on the draw bar of the van
• in a similarly secured location on the caravan wall which would normally face the towing
vehicle. (May or may not be covered with a light weight cover, open at the bottom)
• in a fully open recess within the profile of the van, which is vapour proof to the inside of the
caravan.
• in a cylinder compartment within the profile of the caravan or on the draw bar.
The cylinders must be installed upright with the valve uppermost. This is to ensure the safety valve inlet
is always in the vapour space and clear of the liquid contents of the cylinder.
The cylinder or cylinder carrier must be rigidly secured and be capable of withstanding a steadily
applied load of four times the weight of the filled cylinder from any direction.
Mobile home Caravan
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Camper trailer Poptop campervan
Poptop caravan
Cylinder in special compartment
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Twin cylinder installation with threaded hook bolts used for securing
Cylinder clamp Cylinder cradle
Cylinder in a compartment
If the compartment is accessible from the inside of the van, then there is a restriction on the total
number and capacity of the cylinder(s). In this case cylinders must not exceed two (2) 15kg cylinders.
A durable label as per (relevant version) AS/NZS5601 must be attached in a prominent position
adjacent to the cylinder compartment, usually on the door.
The cylinder compartment size and the location of equipment must comply with the following as
appropriate.
• Only cylinders and their associated equipment are to be housed in the compartment.
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• Associated equipment includes:
− support bracket(s)
− regulator and pigtail(s)
− contents gauge (if required)
− consumer piping
− possibly an isolating valve
• The drain outlet must be in a position where the cylinders won’t obstruct it.
• Easy removal of the cylinder(s) and operation of the cylinder valves must be possible.
• The compartment must be constructed of material that is water and corrosion resistant.
• The filled cylinder(s) must be able to be secured.
• The compartment must be sealed to prevent gas vapour from entering the caravan.
• The access door or opening must be openable without the use of tools, ie screwdriver or
spanner. A keyed lock is acceptable.
• A minimum 25 mm diameter drain must be fitted to the base of the compartment and be
terminated at a point which faces away from the forward direction of travel (this to prevent
pressurising of the compartment, by air forcing up the drain pipe when travelling). It must also
be directed away from, and be:
− at least 1 m from any opening into the caravan, unless the opening is at least 150 mm
above the drain outlet
− at 1.5 m from any source of ignition unless the source of ignition is at least 500 mm
above the outlet.
• The compartment must not contain any electrical equipment other than a non-sparking shut off
device.
Cylinder regulator
A cylinder regulator must be rigidly fixed to the van or other rigid mounting, and be positioned with the
diaphragm vertical and the vent pointing vertically down and be protected.
You cannot use a regulator with a POL connection and connect it directly to the cylinder. The reason
for this is that the connecting piece between the 1st and 2nd.stage sections of the regulator are considered
to be a weak point, and could crack or break with all the vibration and movements of the caravan.
The connection of the regulator can be made by:
• Copper pigtail
• Hose assembly
• Stainless steel
There is not much room in most compartments, so make sure you don’t position the regulator too high,
to prevent kinking of the hose or piping when fitting them.
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Consumer piping
The set out of the piping system needs to be in accordance with the design drawing or instruction and
comply with the (relevant version) AS/NZS5601 Gas installations and AS/NZS1596.
Consumer pipe and fittings must be free of defects and comply with (relevant version) AS/NZS5601.
This also applies to errors you might make during installation, eg:
• start to cut pipe with tube cutters in the wrong place and then move them to correct cut off
position, leaving a groove in the pipe
• not making the flare the correct length (too short, any strain on the pipe can pull the flare and
cause a leak, etc.)
Consumer piping (piping downstream of the regulator) must not be located where it is likely to be
damaged, unless adequate protection is provided. This could be a metal conduit or similar.
Clipping piping to the floor or side of the chassis as shown below is acceptable.
Typical locating position for pipe
Use a grommet or similar where piping penetrates partitions, floors or structural members. This is to
prevent abrasion of the pipe which could eventually lead to a gas leak.
Ensure that there is flexibility in the piping to prevent loosening of any component due to vibration and
movement of the structure or thermal expansion and contraction.
Pipe support is required for hose assemblies as well as metal piping. Only use suitable non-ferrous clips
that are compatible with the type of pipe used, and space the clips as per the Table in (relevant version)
AS/NZS5601. Note the part about changes of direction and tees in the table.
Where more than one appliance is to be installed:
• the main run of piping is to be installed outside the caravan
• each appliance must be connected separately to the main run (can’t tee off inside the van)
• the branch pipe must enter adjacent to the appliance (not behind it, as this makes it difficult to
connect and also to locate and repair leaks should they occur. It also places the manual shut
off valve in a location where it is accessible).
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Restriction on pipe joints
• Making pipe joints in inaccessible positions (once the wall or floor is in place) is not
permitted.
• No pipe joints are allowed where the piping passes through a sleeping accommodation area or
engine compartment.
Restriction on hose assemblies used as consumer piping
• If only one appliance is to be installed, then a hose assembly is acceptable, as long as it is in
one continuous length from the regulator outlet to the appliance inlet, and is supported in
accordance with (relevant version) AS/NZS5601.
• If a hose assembly is to be used to connect between the manual shut off valve on the rigid
consumer piping and the appliance –
− ensure the manufacturers specs allow it (many don’t!)
− it must be of adequate diameter for the appliance’s gas consumption.
− Hose assemblies shall be as short as practicable
Worksheet
Now go to the Worksheet and answer Questions 13 – 18.
Consumer instruction labels and plates
There are three for caravans:
• a warning label fixed near cooking appliances and gas lights
• an instruction plate to be displayed near cylinders
• an instruction plate to be displayed near an appliance (usually the cooker).
Appliance installation
The location of cylinders and appliances must comply with (relevant version) AS/NZS5601 Gas
installations and AS/NZS1596. The location should be in accordance with the design of the job, unless
this contravenes the regulatory requirements.
General
All appliances should:
• be GTRC approved
• be installed to (relevant version) AS/NZS5601 and the manufacturer’s installation instructions
• be in a position which is convenient for the consumer, but also protected from draughts or
damage
• be accessible for servicing
• have adequate provision of air for combustion
• make maximum use of natural light
• be suitably secured to minimise movement and prevent strain on the pipe connection
• be installed inside the caravan so that in the event of a fire at the appliance, the exit is not
restricted
• Gas appliances must have adequate separation from flammable materials such as curtains,
bedding and wall panelling.
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Prohibited appliances
• Water heaters other than room sealed type
• Space heaters
− Only room-sealed types of space heater are permitted. That is because the air for
combustion comes from outside the van and the products of combustion discharge
outside as well.
• Appliances designed to operate unregulated or at pressures exceeding 2.75 kPa (unless
specifically approved by the authority).
− Generally what is known as a high pressure LPG appliance. That is, one which
connects directly to a cylinder or via a hose coupling, such as camping stoves. Can be
either propane or butane fuelled.
Required clearance between appliance and fuel filler cap vent or vent
Except for caravans fuelled by diesel, the minimum clearance between a fuel filler cap or fuel tank vent
and an appliance flue or combustion air intake must be 1metre.
Poor design of some mobile units increases the risk of fire or explosion, especially if the fuel tank filler
and refrigerator vents are on the same side. Refer diagrams below.
Placing vent
This diagram below shows what happens when the fuel filler and ‘fridge vents are on the same side.
Petrol vapour sinks from the filler inlet and quickly enters ventilation openings. The refrigerator pilot
would ignite the explosive vapour/air mixture instantly.
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Petrol vapour
An accessible manual shut off valve must be provided on the inlet connection to an appliance.
Remember that the branch pipe must be adjacent to the appliance.
The appliance must also be secured. This is to minimise movement and vibration of the appliance as
well as minimise strain on the appliance connection. If the appliance has been designed for caravan or
marine installation, it will include special fixing brackets. If the appliance is an ordinary domestic type,
you will have to fabricate the bracket yourself.
The installation of a refrigerator must comply with the following.
• The refrigerator must be installed with the means to exhaust the combustion products to the
outside atmosphere (refrigerator manufacturers have special flue kits for this type of
installation. See figures below).
Refrigerator vent kits
• The refrigerator must be installed within a sealed recess as per requirements of (relevant
version) AS/NZS5601. Refer to diagrams below.
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Sealed recess details
Types of vents
Note
Additional ventilation is required for the refrigerator. This ventilation
is to assist in the proper functioning of the refrigerator and must not
be less than the following table.
Refrigerator storage capacity (L) Minimum free area of ventilation
(mm2)
Not exceeding 100 L 32500
Exceeding 100 L and not exceeding 200 L 45000
Exceeding 200 L 65000
Water Heaters
Water heaters other than room sealed type are not permitted to be installed. Instantaneous water
heaters other than room-sealed types are not permitted to be installed in a bedroom, bathroom, toilet or
combined sleeping or living room. Storage water heaters shall not exceed 40 mJ/hr if installed in a toilet
or bathroom.
The diagrams below depict two types of balanced flue storage HWS. The first model is fitted through
the wall externally. The other is installed internally and only the balanced flue penetrates the wall.
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Balanced flue storage HWS
Flued appliances
Flues shall be installed in accordance with (relevant version) AS/NZS5601. Take note that there should
be a minimum clearance of 50 mm between the lowest opening of the cowl and the outer roof of the
caravan. Clearances to combustible surfaces must also be adhered to.
Air supply to appliances
When appliances other than room–sealed types are installed, two openings to provide permanent and
unrestricted ventilation must be fitted to the caravan.
• In the case of a pop-top leisure caravan, this requirement needs to be satisfied whether the top
is up or down.
• In the case of a camper trailer (one which folds to trailer height), the requirement need only be
satisfied when the trailer is fully erected.
The openings must be located at opposite sides or ends of the area except in the case of the popup type
van when the top is down. This is because the opening is in the canvas part of the popup.
Where the lower ventilation is fitted in the floor, it must conform to (relevant version) AS/NZS5601.
The free area must have a minimum free ventilation area calculated using the following formula, but in
no case shall the total area of the ventilation openings be less than that given in (relevant version)
AS/NZS5601.
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Name:………………………………………………………
Worksheet
CPCPGS3046A: - Install LPG systems in caravans, mobile homes, and mobile workplaces
The student should complete this worksheet before attempting the practical installation.
The worksheet may form part of the assessment and should be checked and signed off by your trainer
or supervisor.
1. State the flammability limits for LPG
Upper
Lower
2. How many mega Joules are there in one cubic metre of LPG?
3. Is natural rubber tubing suitable for conveying LPG? Explain why.
4. Name the three factors which must be present to obtain combustion.
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6. What is the ideal air/gas ratio for LPG?
7. List the main products of complete and incomplete combustion.
Complete Incomplete
8. What would be the effect of having insufficient air supply to a burner?
9. List three gas safety requirements to be considered when planning to install LPG in a caravan.
10. List four sources where you can get information from for your installation.
(a)
(b)
(c)
(d)
11. List the steps in determining the requirements for an LPG system in a caravan.
12. When installing the pipework to more than one appliance in a caravan, where must the tees be
located?
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13. Are individual isolating valves required for each appliance? Circle one
Yes
No
14. List the location and clause number of the following consumer labels:
Type Location Clause No.
Cylinders
Appliance
15. The diagram below is a cross section of a caravan chassis. Indicate where the pipe work
should be placed.
16. How is the pipework protected from airborne stones etc?
17. The diagram below represents the piping to appliances in a caravan.
From the information supplied, calculate the pipe sizes from the OPP regulator.
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Section Load Size
18. State the minimum requirements for horizontal and vertical clearance to combustible material
from cooktop burners on gas cookers.
19. Indicate if the following statements are true or false.
Caravans require a leak detection system True or
False
Recreational vehicles require a galvanized cylinder. True/False
Unflued space heaters can be installed in caravans. True/False
Abrasion protection of pipework is not required for handy vans. True/False
Refrigerators installed in an enclosed space require additional
ventilation.
True/False
Balanced flue hot water services can be fitted in mobile homes. True/False
23. What is the minimum diameter and maximum length of a cylinder compartment?
Minimum diameter
Maximum length
24. Refer to (relevant version) AS/NZS5601 Clause 6. A cylinder regulator must be___________
to ensure the maximum ______________________does not exceed 3 kPa with all connected
appliances ____________________
25. What restrictions apply to using a hose assembly as consumer piping?
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Trainer or Supervisor’s Signature:
Date of Completion:
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Name:………………………………………………………
Practical application
CPCPGS3046A: Install LPG systems in caravans, mobile homes, and mobile workplaces
Your trainer or supervisor will now work with you to demonstrate and explain installing LP gas
systems in caravans, mobile homes, and mobile workplaces.
The following points will be covered.
Plans or specifications and any special instructions are obtained
WHS requirements associated with the installation and commissioning of LP gas systems in
caravans, mobile homes, water craft and mobile work places, and the workplace environment,
are adhered to throughout the work
Quality assurance requirements for company operations are identified and adhered to
Gas load or design requirements are determined from plans, specifications or job drawing or
workplace instructions
Capacity of the system is calculated to ensure adequacy for the required load and compliance
with standards and workplace requirements
Appropriate regulator and piping is identified in terms of size, connection sizes and capacity in
accordance with standards and workplace requirements
The location of cylinders, appliances and piping set out is identified in accordance with job
requirements and in compliance with standards and workplace requirements
Quantity of piping, components and fittings are estimated in compliance with standards and
workplace requirements
The required materials, equipment, appliance(s) and cylinder(s) are ordered and checked for
compliance with docket or order form and for acceptable condition
Appropriate tools and equipment for the installation and commissioning of LP gas systems in
caravans, mobile homes, water craft and mobile work places, including personal protective
equipment, are identified and selected
Work is planned in conjunction with others involved in, or affected by, the work
Work area and materials are prepared to support the efficient installation of the system
Cylinder(s), regulator(s), associated pipework, appliance(s) and fixings are installed in
compliance with manufacturers’ requirements, standards and workplace requirements
Compliance plates are located and fitted in accordance with regulatory requirements, standards
and workplace requirements
Appropriate test equipment is selected
System is tested in accordance with standards and workplace requirements
System is adjusted to provide the required flow pressure in conformance with standards and
workplace requirements
Test data is recorded in the format required by regulatory requirements and workplace
requirements
Work area is cleared and materials disposed of or recycled in accordance with State or Territory
legislation and workplace procedures
Tools and equipment are cleaned, checked, maintained and stored in accordance with
manufacturers’ recommendations and workplace procedures
Documentation is completed in accordance with workplace requirements
CPCPGS3046A - INSTALL LPG SYSTEMS IN CARAVANS, MOBILE HOMES AND MOBILE WORKPLACES
© Commonwealth of Australia 2015 38
On completion of this practical application you will be assessed. To prepare for your assessment make
sure you read the Assessment Checklist, the Assessment Task and Questions.
Trainer or Supervisor’s Signature:………………………………………………..
Date of Completion;………………………………
Assessment checklist
CPCPGS3046A: - Install LPG systems in caravans, mobile homes, and mobile workplaces
Criteria Yes No
Have the worksheets been successfully completed?
Has the practical task been completed?
Are the job specification and local authorities’ or utilities’ requirements
available?
Trainer or Supervisor’s Signature:……………………………………………….
Date of Completion:…………………………….