By Viking Heating
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In this post, we’ll explore the regulations surrounding the use of LPG systems on leisure craft and narrowboats in the UK. These standards, such as BS EN ISO 10239:2017 and PD 54823:2016, are crucial for ensuring the safe and efficient installation, operation, and maintenance of LPG systems. Whether you’re navigating a small canal boat or a larger houseboat on the Thames, understanding these guidelines is essential for safe boating.
Tightness Testing of LPG Systems
Proper tightness testing is crucial to ensure the safety and functionality of LPG systems on boats. This testing helps to confirm that the system is free from leaks, which could lead to dangerous situations.
New Installations:
For new LPG installations or when new pipework is added to an existing system, the system must initially be tested using air as the test medium. This air test should be conducted at a pressure three times the normal working pressure of the system. For propane systems, this means a test pressure of 111 mbar. The use of air instead of LPG for this initial testing phase is a safety measure to avoid the risks associated with handling flammable gases during testing. This process is akin to the strength testing procedures used in commercial installations, ensuring that the system can withstand pressures greater than it will typically encounter during normal operation.
Ongoing Maintenance:
Regular maintenance and checks are essential to maintaining the safety of the LPG system. Tightness testing should be conducted in the following circumstances:
- Whenever work has been performed that may impact the integrity of the gas system.
- If there is any suspicion of a gas escape or leak.
- Prior to re-establishing an existing gas supply after it has been interrupted.
Bubble Testers and Pressure Gauges:
For vessels manufactured after August 2008, it is mandatory to include a simple means of conducting tightness testing in the LPG system. This could be through the installation of a pressure gauge or a bubble tester. Bubble testers are particularly useful because they provide a visual indication of gas leaks in the system by showing bubbles in a liquid-filled chamber if there is a leak. For vessels built before August 2008, the installation of such devices is not mandatory but is recommended for enhanced safety. Owners of these older vessels can decide whether to retrofit these devices.
Role of Gas Safe Register Inspectors:
Gas Safe Register inspectors play a crucial role in ensuring that LPG systems comply with relevant standards. They carry out tightness tests using pressure gauges, adhering to the procedures outlined in the standards. This ensures that any potential issues are identified and addressed promptly, maintaining the safety and integrity of the system.
Storage of LPG Cylinders
The safe storage of LPG cylinders is another critical aspect of LPG system safety. Whether full or empty, cylinders must be stored securely to prevent accidents, especially in the dynamic environment of a boat.
Cylinder Lockers and Housing:
LPG cylinders, along with pressure regulation devices and associated safety equipment, must be stored in designated cylinder lockers or housings. These storage areas must be designed to secure the cylinders against movement, which can occur due to the boat’s motion. Proper securing prevents damage to the cylinders and the associated equipment, which could lead to leaks or other hazardous situations.
Ventilation Requirements:
Given that LPG is heavier than air, any escaping gas tends to settle at low points. Therefore, cylinder lockers must be designed to allow any escaping gas to vent safely outside the craft at a low level. This prevents the accumulation of gas inside the boat, which could lead to explosive atmospheres. Proper ventilation is a critical safety feature to manage any unintentional gas releases.
Avoiding Ignition Sources:
To further mitigate the risk of explosions, it is essential to ensure that no potential sources of ignition are present within the cylinder storage compartments. This includes avoiding the installation of electrical devices unless they are certified as having ignition protection in accordance with ISO 8846. Ignition-protected devices are specially designed to prevent sparks or other sources of ignition in potentially explosive atmospheres.
Regulators and Over-Pressure Shut-Off (OPSO) Devices
Regulators and OPSO devices are vital components of LPG systems, ensuring that the gas is delivered at the correct pressure and preventing unsafe pressure levels.
Selection of Regulators:
The regulator installed in the cylinder locker must be suitable for marine applications and capable of delivering the appropriate pressure for the appliances connected to the system. Regulators must be compatible with the specific conditions they will encounter, including potential exposure to saltwater if the vessel is used in marine environments.
Over-Pressure Protection:
An OPSO device must be installed in the system. The OPSO protects against uncontrolled increases in pressure on the low-pressure side of the system, which could damage appliances or cause leaks. It is essential that these devices are marine-grade and capable of functioning correctly under the conditions they will face, including potential exposure to freshwater or saltwater.
Verification of Suitability:
Not all regulators and OPSO devices are suitable for marine use, especially in saltwater environments. The engineer installing or maintaining the system must verify the suitability of these components, ensuring they are appropriate for the conditions they will face. This includes checking that the materials and construction are resistant to corrosion and other environmental factors.
Pipework Materials and Jointing Methods
The materials used for pipework in LPG systems must be robust and suitable for the marine environment. The selection of appropriate materials and jointing methods is crucial to prevent leaks and ensure durability.
Materials for Rigid Pipework:
Only solid drawn copper or drawn stainless steel should be used for rigid pipework supply lines in LPG systems on boats. These materials are chosen for their durability, corrosion resistance, and ability to withstand the pressures involved in LPG systems.
Jointing Methods:
The joints in the pipework must be metallic in construction. Acceptable methods include brazing, hard-soldering, and the use of compression fittings or cutting ring-type fittings. Manufacturer-specified fittings, such as pliable corrugated stainless-steel tube fittings, may also be used if they are designed for LPG systems and approved for marine use.
Hoses and Hose Lines
Flexible hoses are necessary in certain parts of the LPG system, particularly where movement of components is expected. However, their use must be carefully controlled to ensure safety.
Specifications for Hoses:
Hoses used in LPG systems must be specifically designed for LPG and capable of withstanding the marine environment’s stresses and exposures. This includes resistance to UV light, saltwater, and physical wear and tear.
Installation and Routing:
Hoses should be kept as short as possible and must not pass through engine compartments, where they could be exposed to high temperatures or mechanical damage. They must be a continuous length and free from joints from within the cylinder compartment to the appliance, except where a flexible hose is required to connect a movable appliance, such as a gimballed stove.
End Fittings:
Hoses must have permanently attached end fittings to ensure a secure connection. They should not be subjected to tension or kinking under normal use, as this can lead to leaks or damage.
Shut-off Valves
Shut-off valves are a critical safety feature, allowing the user to quickly isolate the gas supply in an emergency.
Main Shut-off Valve:
Every LPG system must include a manually operated main shut-off valve located on the high-pressure side of the system. This valve may be part of the cylinder valve or integrated into the pressure regulation device.
Dual-Cylinder Systems:
For systems with dual cylinders, a manual or automatic changeover device must be installed, along with non-return valves. These ensure continuous supply even if one cylinder runs out while preventing back flow into an empty cylinder.
Appliance Shut-off Valves:
A shut-off valve must be installed in the low-pressure supply line to each appliance. If there is only one appliance, the cylinder valve may serve this purpose, provided it is easily accessible. Alternatively, a remotely operable solenoid valve can be used. This valve should automatically close in the event of a loss of electrical power, preventing uncontrolled gas flow.
Appliances for Marine Use
Appliances used in marine environments must be specifically designed and approved for such use. This includes consideration of the materials, construction, and safety features.
Selection and Installation:
Only appliances specified for marine use should be installed on boats. They must be in good working condition, even if second-hand, and fit for the intended purpose. The manufacturer’s instructions must be followed carefully, ensuring that the appliances are securely fixed to prevent undue stress on connected pipework.
Safety Features:
All installed appliances must be equipped with a flame supervision device, which automatically shuts off the gas supply if the flame goes out. This is a critical safety feature to prevent gas leaks. Additionally, appliances must be clearly labeled with the type of gas they are designed to operate on, ensuring that the correct fuel is used.
Ducts and Flues for Combustion Products
Proper ventilation and exhaust systems are essential to safely manage the combustion products generated by LPG appliances.
Installation Requirements:
Ducts and flues must be installed according to the manufacturer’s instructions, ensuring the complete discharge of combustion products outside the vessel. Care must be taken to avoid areas like canopies where gases could accumulate.
Flue Termination:
Flue systems must not have any dampers and should terminate at least 500mm away from refueling points, fuel tank vents, or other potential ignition sources. They must also be at least 300mm away from openings like windows, doors, or ventilation grills. The flue terminal should be robust and equipped with a guard to prevent accidental blockage or damage.
Owner’s Manual and Safety Documentation
Manufacturers must provide an owner’s manual for each leisure craft or boat, including detailed instructions for using the LPG system, safety advice, and maintenance requirements.
Contents of the Owner’s Manual:
The manual should cover:
- Operating instructions for the LPG system and appliances.
- Safety precautions and emergency procedures.
- Regular maintenance tasks and schedules.
- Instructions for carrying out safety checks.
This documentation is essential for ensuring that boat owners and operators understand how to safely use and maintain their LPG systems.
Boat Safety Scheme and Regulatory Compliance
The Boat Safety Scheme (BSS) plays a significant role in regulating the safety of LPG systems on leisure craft in the UK, particularly for vessels not covered by the Gas Safety (Installation & Use Regulations) 1998 (GSIUR).
Scope of the Boat Safety Scheme:
The BSS covers leisure craft and boats used for personal purposes. However, boats used for commercial purposes, such as hire, timeshare, shared ownership, or as floating businesses, fall under the GSIUR. This regulation requires that any work on the LPG system be carried out by a Gas Safe registered engineer who is competent in LPG systems for boats.
Gas Tightness Testing Under BSS:
For boats not covered by GSIUR, BSS examiners can check gas tightness using a bubble leak detector, if available, or by observing a test conducted by a Gas Safe engineer qualified in LPG systems for boats. However, any work involving the installation or replacement of appliances must be performed by a Gas Safe registered engineer.
Competency Requirements:
Engineers working on LPG systems in boats must have specific qualifications and be registered with the Gas Safe Register. This ensures that they have the necessary expertise to safely and correctly install and maintain these systems.
Conclusion
The safe installation, maintenance, and operation of LPG systems on leisure craft and narrowboats in the UK are governed by detailed standards and regulations. These include specifications for materials, installation methods, safety devices, and testing procedures. Compliance with these standards is essential for the safety of boat occupants and the protection of the environment. By following the guidelines set out in BS EN ISO 10239:2017 and PD 54823:2016, and ensuring that all work is carried out by competent professionals, boat owners can enjoy their time on the water with peace of mind, knowing that their LPG systems are safe and reliable. Check out the guidelines here!
Want to know more about LPG gas, then have a read of our blog “Future of LPG boilers in the UK”