Chapter Two

Introduction

LPG cylinder filling plants vary considerably in size, complexity and layout. The type and size depends on such factors
as maximum potential throughput requirements, size and type of cylinder filled and the number/grades of products
handled. The land available and budget are of course two other important factors when deciding on the investment.

The detailed design of filling plants, and the associated cylinder filling equipment, should be undertaken by an
appropriate supplier based on the required performance specification. Some suppliers may have ISO 9001
accreditation, or be working towards it, which will provide assurance on quality and business systems operations.

The plant specification should comprehensively cover the throughput, safety and quality requirements over various
phases of development.

The specification would likely include:

- The basic operations undertaken in the filling plant and maintenance areas e.g. cylinder inspection, cylinder
filling, leak testing, checks to ensure no overfilling, cylinder evacuation and vapour recovery, re-valving,
cylinder requalification, maintenance and repair of cylinders, grit blasting, painting, etc.

- The products to be handled, including contaminated products encountered in the marketplace that needs to
be stored

- A listing of all the relevant standards and legislation the plant is to comply with including Health, Safety and
Environmental (HSE) requirements affecting personnel engaged in the operation of the plant and the
protection of people and property in offsite areas

- Licensing and other requirements for operating an LPG plant. This should include a full risk analysis to identify
any potential hazards. LPG cylinder filling plants should be in industrial zones well away from centres of
population

- The number of cylinder types/sizes and cylinder valve types involved

- The projected throughput per product, per cylinder size/type, per cylinder valve type, over the planning
period and peak daily/weekly/monthly demand

- The number of productive operating hours available over the planning period and peaks

- Details of all operations and limits/tolerances related to each operation, e.g. filling accuracy, size of
detectable leak, check weighing accuracy’s

- Manning levels and the degree of automation

- Method of transporting and handling cylinders

- Capacity of requalification, repair, maintenance and painting facilities

- Bulk LPG storage requirements

- Storage areas for full and empty cylinders