March 22, 2013 RE: PROPANE SYSTEM & REGULATOR TESTING/INSPECTION PROCEDURE Regulators: Symptom: Pressure Drop Cause: External leaks detected at pigtail hose MPT fitting connection(s) to regulator body inlet. Remedy: Use thread seal compound (RED) that will permit removal and replacing pigtail hoses. Change torque wrenches to ensure correct setting through 100% assembly process. Upon final assembly - thread seal to cure for 24 hours before pressure testing. o Testing prematurely with wet thread seal may likely mask potential leaks. Enhance quality assure processes. Status: Implemented Cause: External leaks detected at 1/2 in. MPT fitting connection to regulator body outlet. Remedy: Use thread seal/lock compound (GREEN) that will NOT permit removal and replacing the 1/2 MPT X ½ MFL fitting. Change torque wrenches to ensure correct setting through 100% assembly process. Upon final assembly - thread seal to cure for 24 hours before pressure testing. o Testing prematurely with wet thread seal may likely mask potential leaks. Enhance quality assure processes. Status: Implemented Cause: External leaks detected at regulator body at joint between pressure adjusting screw housing & regulator body. Remedy: Remove, replace & return as indicated by test results. Status: Continue testing @ RV mfg. facility & dealer service shops. Remove, replace & return as indicated by test results.
Cause: Pressure drop (fluctuation) internal of regulator. o Rapid pressure drop in excess of 2 in. W.C. (0.5 kpa) o Pressure drop @ or less than 2 in. W.C. (0.5 kpa) Primarily observed by RV dealer technicians during Pre-delivery inspection (PDI) prepping for retail delivery Remedy: Rapid pressure drop in excess of 2 in. W.C. (0.5 kpa) Remove, replace & return as indicated by test results. Pressure drop @ or less than 2 in. W.C. (0.5 kpa) o Change regulator Status: Continue testing @ RV mfg. facility & dealer service shops. Remove, replace & return as indicated by test results. For pressure drop @ or less than 2 in. W.C. (0.5 kpa) as of prior to, including and beyond March 22, 2013 Remove, replace & return as indicated by test results UNTIL TECHNICAL DATA AND SUBSTANTIATION IS PROVIDED BY CAVAGNA. Symptom: Lock-up Pressure too high Cause: Lock-up Pressure exceeds 14-in. W.C. (3.5 kpa). During Dealer PDI. Remedy: Ensure proper regulator operating pressure adjustment procedure is followed. Remove, replace & return as indicated by adjustment and test results. Status: Remove, replace & return as indicated by adjustment & test results. Request detailed step-by-step procedural instruction guide sheet.
PROPANE SYSTEM TEST General Guidelines for Testing at RV Manufacturing Plant & Dealers: Before conducting pressure drop testing of a propane system, it is important that the ambient air, the system piping, (including hose), and the pressure source gas (air or propane) is nearly as equal as possible. Starting with unequal temperatures will interfere with the test. o Colder piping will often reflect a drop in pressure. o Pressure will be observed to rise as the temperature increases. In addition, be careful to avoid sudden temperature changes. o For example, in cold climate areas on a winter day when testing near an overhead door the test pressure may likely be affected by a blast of cold air whether from a door immediately in front of the RV being tested or from adjacent door(s) that would be opened even for a brief time. o Therefore, it is recommended testing the propane system be conducted while the RV is outside and the pressure source gas (air or propane) has been outside as well to ensure the temperatures are relatively the same OR o RV s be moved to inside of the service shop at least over night to permit warming up before testing. PIPING SYSTEM & PROCESS APPLIANCE CONNECTIONS DURING RV MANUFACTURING Reference STP0004; To verify the propane supply system integrity as leak-free at the factory as is the manufacturing test process AFTER ALL APPLIANCES ARE CONNECTED. Disconnect the main supply hose @ the regulator outlet. Ensure the piping system and test pressure source is the same a practical. Connect external air pressure test apparatus W/manometer gauge to the main supply hose. Pressurize the supply system W/O the regulator to 10 14 in. W.C. Ensure the pressure in the entire system is equalized. Turn off the pressure inlet source. Apply bubble leak test solution to all appliance connection fittings. Allow pressure to stand 3 minutes minimum. PASS/FAIL o PASS No bubbles indicated at connections NO drop in pressure is indicated on the test pressure gauge or manometer. o FAIL Bubbles indicated appearing at connections ANY drop in pressure indicated on the test pressure gauge or manometer. Locate source of leak and repair and retest until the system is demonstrated to be leak-free according to PASS criteria.
Sample Propane System Test Kit. to pressurize the piping system after li t d b i Main supply hose. Disconnected from l t Test hose kit with gauge connected to RV propane main supply hose without the Service shop air hose through test apparatus regulator supplies 10 14-
System Test Procedures ITEM: PROPANE SYSTEM (AFTER APPLIANCES) DOCUMENT NO: STP 0004 PAGE 1 OF 2 DEPARTMENT: ALL LINES REVISION: ISSUED BY: CODES & STANDARDS & QUALITY REVISION DATE: Propane System After ALL Appliances Connected Pressure Drop 3 MINUTES Test Equipment: PRESSURE GAUGE, INCREMENTS NO GREATER THAN 1.0-INCH WATER COLUMN - TESTER SHUT-OFF VALVE TO BE BETWEEN THE AIR SOURCE AND THE PRESSURE GAUGE Propane System After Appliances PROCEDURE: 1. AFTER ALL APPLIANCES ARE INSTALLED AND CONNECTED, ATTACH THE HOSE FROM THE TESTER TO THE SYSTEM SUPPLY FITTING. 2. OPEN THE VALVE ON THE TESTER UNTIL THE PRESSURE IS NO LESS THAN 10 NO MORE THE 14 INCHES OF WATER COLUMN. THIS WILL BE THE NUMBERS AROUND THE CENTER OF THE GAUGE DIAL. 3. CLOSE THE TESTER VALVE. NOTE THE PRESSURE READING ON THE GAUGE [IT WILL VARY FROM UNIT TO UNIT]. 4. OBSERVE TESTER GAUGE TO SEE IF THE PRESSURE HOLDS OR DROPS. 3 MINUTES MINIMUM. 5. USE SOAP WATER SOLUTION AT ALL APPLIANCE CONNECTIONS DO NOT USE PRODUCTS THAT CONTAIN AMMONIA OR CHLORINE. WATCH FOR BUBBLES AT THE CONNECTIONS. 6. IF NO BUBBLES PRESENT AT THE CONNECTIONS AND THERE IS NO DROP IN PRESSURE ON THE GAUGE TEST IS OK. AND MAY BE DISCONNECTED. 7. A LEAK IS INDICATED IF BUBBLES SHOW AT THE CONNECTIONS OR THE PRESSURE ON THE GAUGE DROPS. LOCATE SOURCE OF LEAK AND RE-TEST UNTIL PRESSURE HOLDS AND NO BUBBLES SHOW AT THE CONNECTION(S). PASS/FAIL CRITERIA: PASS: TEST AT 10 14 INCHES WATER COLUMN (6 8 OUNCES) PRESSURE HOLDS AND NO BUBBLES VISIBLE AT CONNECTIONS. FAIL: ANY DROP IN PRESSURE OR BUBBLES PRESENT AT THE CONNECTIONS. DEFECTIVE SYSTEM COMPONENTS. DEFECTIVE SYSTEM COMPONENTS MUST BE REPLACED. DEFECTIVE SYSTEM COMPONENTS INCLUDING KINKED COPPER TUBING SHALL NOT BE REPAIRED. DEFECTIVE TEST EQUIPMENT. UNIT PAST STATION NOT SIGNED ON THE HARD COPY. CHECK YOUR TEST EQUIPMENT DAILY. REPORT ANY DEFECT TO YOUR GROUP LEADER IMMEDIATELY. AFTER THE TEST IS COMPLETED DATE AND SIGN FIRST AND LAST NAME SO IT CAN BE READ AT THE PROPER SECTION ON THE HARD COPY ECN: Rev. Description of Reason: Date: Issued By: Jayco, Inc. Codes & Standards
System Test Procedures ITEM: PROPANE SYSTEM (AFTER APPLIANCES) DOCUMENT NO: STP 0004 PAGE 2 OF 2 DEPARTMENT: ALL LINES REVISION: ISSUED BY: CODES & STANDARDS & QUALITY REVISION DATE: Gas Line Test AFTER APPLIANCES ARE CONNECTED HOLD AT 10-14 INCHES OF WATER COLUMN OR (6-8 OZ.) FOR 3 MINUTES (SOAP APPLIANCE CONNECTIONS) CRITICAL CONTROL ^ 14 inches of water column Pointer must be between these 10 inches of water column ECN: Rev. Description of Reason: Date: Issued By: Jayco, Inc. Codes & Standards
REGULTOR After the piping system and the appliance connections have been successfully proven leakfree, by test, the regulator fittings and connections shall be tested. Connect the main piping system supply hose to the regulator outlet fitting o 2-wrenches correctly sized to the fitting and hose connector flare nut must be used. Slip-joint jaw type tools (adjustable pliers (channel-locks)) shall not be used. Connect the green Type 1 Acme Nut connector to the cylinder service valve outlet of the propane cylinder to be used for charging the piping system. o Ensure the green Acme nut is completely connected to the cylinder outlet. If the green Acme nut is not properly tightened and seated there will be little or no gas flow. Slowly turn on the tank valve. Apply bubble leak test solution to all regulator fittings, connection and joints. Apply bubble solution Apply bubble solution PASS/FAIL o PASS No bubbles indicated at regulator fittings, connections and joints. o FAIL Bubbles indicated appearing at any at regulator fittings, connection and joints. DO NOT attempt to tighten or remove any regulator fitting, connection and joint including pigtail hose connections to the regulator body. Remove and replace the entire regulator kit assembly with all fittings and pigtail hoses in place. Retest until the system is demonstrated to be leak-free according to PASS criteria. Complete a material rejection slip with a DETAILED description of the observed defect and place at the rejection area for proper return to the supplier.
PIPING SYSTEM & APPLIANCE CONNECTIONS DURING RV DEALER PDI PROCESS Reference STP0004(a); To verify the propane supply system integrity with the same process used by dealership technicians during PDI.. Connect the main supply hose @ the regulator outlet. Connect a cylinder of propane to the ACME TYPE I nut. Connect a manometer gauge or water manometer to a range top burner spud (downstream of the range appliance regulator). Ensure all appliance valves and pilot lights are turned off. Pressurize the supply system through the regulator to 10 14 in. W.C. Turn on the range burner with the gauge or manometer connected. SLOWLY turn on and ignite the other range top burner(s), refrigerator and furnace to equalize system pressure and to ensure no air pockets in the piping system. Return open burners of all appliances to off. Turn off the propane pressure inlet source Slowly open a second burner on the range top to reduce the pressure to 8-in W.C. (2.0 kpa). Turn off the second burner AS SOON AS THE PRESSURE ON THE GAUGE OR MANOMETER IS @ 8-in W.C. (2.0 kpa). Monitor the system test pressure for at least three (3) minutes or for the duration prescribed for individual dealer test procedure policy. If no leak(s) are detected disconnect the test gauge/manometer and reconnect the range burner assembly to the appliance spud. PASS/FAIL PASS No bubbles indicated at connections NO drop in pressure is indicated on the test pressure gauge or manometer. FAIL Bubbles indicated appearing at connections ANY drop in pressure indicated on the test pressure gauge or manometer. Locate source of leak and repair and retest until the system is demonstrated to be leak-free according to PASS criteria.
ITEM: System Test Procedures PROPANE SYSTEM (AFTER APPLIANCES) AT RANGE SPUD DOCUMENT NO: DEPARTMENT: ALL LINES REVISION: ISSUED BY: CODES & STANDARDS & QUALITY REVISION DATE: STP 0004(A) PAGE 1 OF 2 Propane System After ALL Appliances Connected Pressure Drop 3 MINUTES Test Equipment: PRESSURE GAUGE, INCREMENTS NO GREATER THAN 1.0-INCH WATER COLUMN TESTER SHUT-OFF VALVE TO BE BETWEEN THE AIR SOURCE AND THE PRESSURE GAUGE Propane System After Appliances PROCEDURE: 8. AFTER ALL APPLIANCES ARE INSTALLED AND CONNECTED, REMOVE A RANGE/COOKTOP BURNER ATTACH THE TESTER TO A RANGE SPUD OPEN THE BURNER VALVE THAT IS CONNECTED TO THE TESTER LEAVE OPEN FOR THE DURATION OF THE TEST. 9. PRESSURIZE THE ENTIRE SYSTEM UNTIL THE PRESSURE IS NO LESS THAN 10 NO MORE THE 14 INCHES OF WATER COLUMN (6-8 OZ./SQ. IN). BE SURE THE PRESSURE IS EQUALIZED THROUGHOUT THE ENTIRE SYSTEM. SHUT OFF THE PRESSURE SOURCE TO THE SYSTEM. NOTE THE PRESSURE READING ON THE GAUGE [IT WILL VARY FROM UNIT TO UNIT DEPENDING ON SYSTEM SIZE, TEMPERATURE AND HUMIDITY]. 10. WHILE CAREFULLY MONITORING THE TEST GAUGE ON THE BURNER SPUD OPEN ANOTHER RANGE BURNER TO REDUCE THE SYSTEM TEST PRESSURE TO 8 INCHES WATER COLUMN (5OZ/SQ. IN) THIS PREVENTS THE RANGE/COOKTOP REGULATOR FROM LOCKING UP AND BECOMING A FACTOR IN THE TEST. 11. OBSERVE TESTER GAUGE TO SEE IF THE PRESSURE HOLDS OR DROPS. 3 MINUTES MINIMUM. 12. USE SOAP WATER SOLUTION AT ALL APPLIANCE CONNECTIONS DO NOT USE PRODUCTS THAT CONTAIN AMMONIA OR CHLORINE. WATCH FOR BUBBLES AT THE CONNECTIONS. 13. IF NO BUBBLES PRESENT AT THE CONNECTIONS AND THERE IS NO DROP IN PRESSURE ON THE GAUGE TEST IS OK. AND MAY BE DISCONNECTED. 14. A LEAK IS INDICATED IF BUBBLES SHOW AT THE CONNECTIONS OR THE PRESSURE ON THE GAUGE DROPS. LOCATE SOURCE OF LEAK AND RE-TEST UNTIL PRESSURE HOLDS AND NO BUBBLES SHOW AT THE CONNECTION(S). PASS/FAIL CRITERIA: PASS: TEST AT 8 INCHES WATER COLUMN (5 OUNCES SQ./IN) PRESSURE HOLDS AND NO BUBBLES VISIBLE AT CONNECTIONS. FAIL: ANY DROP IN PRESSURE OR BUBBLES PRESENT AT THE CONNECTIONS. DEFECTIVE SYSTEM COMPONENTS. DEFECTIVE SYSTEM COMPONENTS MUST BE REPLACED. DEFECTIVE SYSTEM COMPONENTS INCLUDING KINKED COPPER TUBING SHALL NOT BE REPAIRED. DEFECTIVE TEST EQUIPMENT. UNIT PAST STATION NOT SIGNED ON THE HARD COPY. CHECK YOUR TEST EQUIPMENT DAILY. REPORT ANY DEFECT TO YOUR GROUP LEADER IMMEDIATELY. ECN: Rev. Description of Reason: Date: Issued By: Jayco, Inc. Codes & Standards
System Test Procedures ITEM: PROPANE SYSTEM (AFTER APPLIANCES) AT RANGE SPUD DOCUMENT NO: DEPARTMENT: ALL LINES REVISION: ISSUED BY: CODES & STANDARDS & QUALITY REVISION DATE: STP 0004(A) PAGE 2 OF 2 Gas Line Test AFTER APPLIANCES ARE CONNECTED HOLD AT RANGE SPUD 8 INCHES OF WATER COLUMN OR (5 OZ.) FOR 3 MINUTES SOAP APPLIANCE C ONNECTIONS) CRITICAL CONTROL ^ Remove burner from Connect hose of tester to spud. Open this burner control valve leave open for duration of test. Set initial pressure @ 10-14 inches water column OR 6. - 8. Oz. (2.5 3.5 kpa) Allow pressure to equalize. Reduce Pressure to 8 inches water column Or 5 oz. (2.0 kpa) ECN: Rev. Description of Reason: Date: Issued By: Jayco, Inc. Codes & Standards
RECREATIONAL VEHICLE PROPANE SYSTEM TEST REQUIREMENTS NFPA 1192 Standard on Recreational Vehicles 2011 Edition Chapter 5 Fuel Systems and Equipment 5.3.20 Testing Low-Pressure Piping Systems for Propane Leakage After Appliances Are Connected. 5.3.20.1 After appliances are connected to the piping system, the entire piping system shall be proven by test to be leak-free by maintaining an air pressure of not less than 8 in. water column (1.99 kpa) or more than 14 in. water column (3.5 kpa). 5.3.20.2 Before the test is begun, the temperature of both air and piping shall be approximately the same, and a uniform temperature shall be maintained throughout the test period. 5.3.20.3 Leaks, if observed, shall be located and corrected. 5.3.20.4 Products containing ammonia or chorine shall not be used for locating leaks. 5.3.20.5 Defective material shall be replaced. 5.3.20.6 A pressure drop test shall be permitted to be conducted by any of the following methods: (1) Air pressure as follows: (a) The entire system shall be pressurized to not less than 8 in. water column (1.99 kpa) or more than 14 in. water column (3.5 kpa),the appliance shutoff valves shall be closed, and the system shall be isolated from all sources of pressure. (b) When the test gauge is installed downstream of an appliance regulator, before the test is begun, one valve shall be opened and the pressure lowered to 8 in. + 0.5 in. water column (1.99 kpa + 0.125 kpa) so that he regulator is in an open condition. (c) The pressure in the system shall be measured over a period of 3 minutes with a monometer or with a pressure sensing device designed and calibrated to read, record, or indicate a pressure loss due to leakage during the test period. (d) During the 3-minute period, a drop in pressure shall not occur. (2) Bubble-type leak detector as follows: (a) A bubble-type leak detector shall be installed between the source of air pressure and the piping system. (b) The bubble detector shall not indicate any airflow for a period of 1 minute. (3) As an alternative to the pressure drop test, the appliance and regulator connections shall be tested for leakage in accordance with 5.3.20.1 using either soapy water or a bubble solution.
NOTE: The following requirement is for RV s that are installed with propane cylinders that are remote from each other and are inter-connected from one cylinder to a single stage regulator @ 30 psi (207 kpa) through iron piping or a high-pressure hose rated @ 350 psi (2410 kpa) to the system distribution 2-stage regulator connected to the other cylinder. 5.3.22 Leak Testing the Regulated High-Pressure Piping Systems. 5.3.22.1 After the piping system regulators, related fittings, and connections are installed in the RV, the entire regulated high-pressure piping system shall be proven by test to be leak-free by of not less than 15 psi (103 kpa) nor more than 30 psi (207 kpa) from the high-pressure regulator side of the system, and all connections shall be tested with either soapy water or a bubble solution. 5.3.22.2 Before the test is begun, the temperature of both air and piping shall be approximately the same, and a uniform temperature shall be maintained throughout the test period. 5.3.22.3 Leaks, if observed, shall be located and corrected. 5.3.22.4 Products containing ammonia or chorine shall not be used for locating leaks. 5.3.22.5 Defective material shall be replaced.
Canadian Standards Association Z240 RVSeries-08 Z240.4.2-08 Installation requirements for propane appliance and equipment in recreational vehicles 11 Leak testing of piping, tubing, and hose systems 11.1 Test procedures 11.1.2 Step 2 After the appliances are connected, the piping system shall be shown to be leak free by using an initial air pressure between 2.5 and 3.5 kpa (0.36 and 0.5 psi) or 250 and 356 mm (10 and 14 in) of H2O (water) column. Before the test is begun, the temperature of the air and piping shall be approximately the same, and a uniform temperature shall be maintained throughout the test. Detected leaks shall be corrected. Defective materials shall be replaced. The test shall be conducted in accordance with one of the following methods: (a) The appliance shut-off valves shall be closed and the system shall be isolated from all pressure sources. With the test gauge installed downstream of the appliance regulator, open one valve and lower the pressure to 1.99 ± 0.5 kpa (0.29 ± 0.07 psi) or 200 ± 12 mm (8 ± 0.5 in) of H2O (water) column so that the appliance regulator is open. The pressure in the system shall be measured for 3 min with a manometer or pressure-sensing device designed to detect a pressure loss due to leakage. During the 3 min test a drop in pressure shall not occur. (b) A bubble-type leak detector shall be installed between the source of air pressure and the piping system. The detector shall not indicate airflow for 1 min. Alternatively; the appliance connections shall be tested for leakage with soapy water or bubble solution. 11.2 Locating of propane leaks The following requirements shall apply to the locating of propane leaks: (a) an approved liquid leak detector solution or device shall be used; (b) products containing ammonia or chlorine shall not be used; (c) matches, candles, flame, or other sources of ignition shall not be used; (d) artificial illumination shall be restricted to battery-operated hand flashlights of the safety type or certified explosion-proof equipment; and (e) electric switches in or adjacent to the area of leakage shall not be operated unless they are designed for hazardous locations.
CAN/CSA-B149.1-05, Natural gas and propane installation code 6.22 Testing of piping, tubing, hose, and fittings 6.22.1 The source of test pressure shall be isolated while the piping or tubing system is under test, and the system shall retain the test pressure for the minimum duration required in Table 6.3 without showing any drop in pressure. COMMENTARY NOTE NOT PART OF THE STANDARD 6.22.1and table 6.3 is for before appliances Canadian inspection authorities use 6.22.3 for dealers when testing RV propane systems with appliances connected. 6.22.3 After an appliance is connected, the system shall be tested in the following manner: (a) Before turning on the gas for the test, a check shall be made to ensure that any opening from which gas can escape is closed. (b) Immediately after allowing the gas into the piping or tubing system, a test shall be made to determine that no gas is escaping by carefully watching the test dial of the meter or by using a manometer. (c) Where a meter is not provided, the pressure shall be measured with either a pressure gauge or equivalent device calibrated to read in increments not greater than those specified in Clause 6.22.2(b), with the following exceptions: (i) for a system where the working pressure is 0.5 psig (3.5 kpa) or less, the pressure gauge or equivalent device shall be calibrated to read in increments of not greater than 1 in w.c. (250 Pa); and (ii) for a system where the working pressure exceeds 0.5 psig (3.5 kpa) but does not exceed 5 psig (35 kpa), the pressure gauge or equivalent device shall be calibrated to read in increments of not greater than 2 in w.c. of pressure (0.5 kpa). (d) The test described in Item (b) shall be of 10 min duration. (e) Each appliance connection, valve, valve train, and system component shall be checked while under normal operating pressure with either a liquid solution or a leakdetection device to locate any source of a leak. 6.22.4 An addition to an existing piping or tubing system shall be tested as an individual system in accordance with Clause 6.22, except that (a) where the addition is 20 ft (6 m) or less in length and the normal working pressure is less than 0.5 psig (3.5 kpa), the addition shall be leak tested in accordance with Clause 6.22.3(e); and (b) where the addition is accomplished using a welded tie-in, and the new system has been tested in compliance with Clause 6.22, the tie-in weld shall be tested in accordance with Clause 6.22.3(e).