how to reset safety valve on propane tank factory

Check that the hose attachment is properly connected to the propane tank, and double-check that the screw-on valve is tightened. Some propane tanks have safety features that won’t allow gas to escape from the canister unless the hose connection is tightly secured with the gas release mechanism.

Take a look at your connector. If it’s less than an inch long, it won’t be long enough to depress the check valve inside the valve. In this case, you’ll need a new connector that’s over an inch long.

If your valve is turned all the way on, the tank may not release propane. This is a safety feature. Start over, turning the valve only once, then igniting the grill.

If none of these actions work, it’s possible that you have a faulty regulator, which stops the flow of propane. In this case, it’s best to get a new hose with a regulator, and try again.

Gauges, regulators, valves … welcome to your propane tank! If you’ve only used propane to power a gas grill in the past, the larger tanks may be intimidating. It can seem like a whole new world at first, especially if you’re used to powering your home using other fuel sources like natural gas, whose components may not be as visible. And while your propane supplier often handles a lot of the periodic propane tank maintenance and refilling, it’s a great idea to know the basics — especially if you own your own tank. No worries — we’ll make it easy for you. So you can feel confident and secure managing the day-to-day operations of living with propane.

Here’s a quick glossary ofpropane tank parts along with their functions — plus a few tips for making sure your propane tank stays in good working order.

PropaneFill Valve: When your propane is delivered, this is the valve that the technician attaches to the fuel hose. The hose from the truck connects to this valve. The hose end coupling screws into the valve with a gasket to create a reliable seal that prevents gas from escaping.

Service (Shut Off) Valve: Essentially the master switch to the propane supply, the service valve is the point at which propane gas enters the piping system to supply all the appliances that connect to it.

Float Gauge Assembly:The float gauge shows the volume of propane in the tank. Sometimes called a dial gauge, the float gauge is made of several parts: a mechanical float that lives inside the tank (much like the float you’d see if you lift the lid off your toilet’s water tank) connected to a reader on the outside of the tank that displays the liquid level (this may be a numeric gauge or a visual one color coding for safe, under-, and over-fill levels). It doesn’t show the exact amount of liquid in the tank, but it is reliable for everyday monitoring of your tank’s propane level.

To check the approximate propane level in your tank, look at the float gauge. It will be a round (or roundish) device on the tank (see image above) with a needle over a range of numbers or graphic indicators. The numbers will range from 5 to 95—indicating a percentage of volume, not the number of gallons remaining. If you see a level below 30, it means that your tank is getting low and needs to be refilled.

If you’re an AmeriGas customer, you may also have a remote tank monitor that automatically transmits the tank’s percentage to us every day. You can check your tank’s current status—without looking at your tank—by logging into your AmeriGas account.Learn more about our online services.

Relief Valve: This is the safety relief mechanism designed to vent propane in the event that pressure builds — for example, if the heat rises very suddenly to an extreme temperature (as might happen in a forest fire or other emergency situation). A spring inside the valve is designed to release if the pressure inside the tank builds to a certain level, at which point the valve will open slightly and start to hiss. If pressure rises excessively, the valve will open completely. The relief valve allows pressure to be released quickly and safely. All propane tanks are required by law to have a relief valve. You may also hear it called a pop-off valve or a pressure-venting valve.

FixedLiquid Level Gauge: Also known simply as a fixed liquid level gauge or the bleeder valve, this is the only tank component that gives a precise measure of how much liquid propane is in the tank. It’s used only by certified propane service providers when filling the tank — and even then, it’s used only to monitor, not to refill (propane goes into the tank through the fill valve).

Vapor Return Valve: Also known as the vapor equalizing connection or vapor equalization valve, this feature is required on all ASME propane tanks. They are usually deployed in the event that the liquid in the container becomes very overheated and must be evacuated from the container.

Liquid Withdrawal Valve: Used by technicians to withdraw liquid propane from the tank so it can be moved or disposed of. Note: Never attempt to remove liquid propane from a tank on your own. This should only be done by a professional using specialized equipment.

PropaneRegulator:Though they come in many shapes and sizes, the function of all propane regulators is the same — they maintain a safe and effective level of pressure on propane within the tank. This helps keep the flow steady and usable. These components make a persistent humming noise when operating — don’t worry, it’s normal.

You’re aware of what your tank should look like when it’s “all systems go” — as well as some important warning signs that will tell you it’s time to contact a professional. Armed with these basic terms and tips, you’re set up for propane success.

Safety Note: We do not recommend attempting any propane system adjustments, repairs, or maintenance on your own. Only certified propane professionals are equipped with the gear and knowledge to properly assess and address propane systems safely.Please contact us for more information and service.

If you cook using a gas grill fueled by propane, you may have noticed a change in how the valve on the propane tank looks. Also, if you bought a gas grill in the last couple of years, the tank that came with the grill and the connection on the grill probably look different from what you are accustomed to seeing.

A safety note for you: Propane tanks of any design must be transported and stored in an upright position so the pressure relief device will function properly. Laying the tank on its side in the trunk of your car is a potentially very dangerous situation.

What happens if you have an older grill and have to replace the tank and get one with the Acme valve? Use it. They are compatible, as the left-hand-thread fitting on your older grill will screw into the internal threads on the Acme valve.

Also, there is another type of valve not widely available yet. This one is a quick disconnect, somewhat like a fitting that attaches an air hose to a pneumatic tool. This fitting will be covered later in this article.

All new cylinders from 4 pounds up to 40 pounds propane capacity must have the OPD valve. All cylinders from 4 pounds up to 40 pounds will have to have an OPD valve by April 1, 2002, or it will be illegal to fill them. It will not be illegal to use or transport them, only to fill them.

Now that you know how to make the connection between the grill and the tank, you need to know what the difference is in getting your tank refilled. If you take it to a place that fills your tank, you will notice no difference in filling the tank. The same piece of equipment that fills tanks with the POL valve will also fill through the Acme valves or OPD valves because of those internal threads. But there is a difference you need to recognize after you get your tank filled. As you get ready to travel with your newly-filled tank, instead of screwing a plug into the internal threads, you may press the optional dust cap over the external threads. The Acme valves and OPD valves have some built-in safeguards that prevent the escape of gas when the tank is not attached to the grill, even if the valve is open. This is the reason for the valve body being slightly larger. However, if you screw a plug into the valve, you defeat these safeguards. So be sure to leave the plug out of the Acme valves and OPD valves!

There are some other safeguards in the valve and connector combination that stop the gas flow if the tank is involved in a fire, even if the tank is still attached to the grill and even if the valve is wide open. Another safeguard limits the flow of gas from the tank should the hose break or leak.

The safety devices require you to open the valve on the tank before you open the burner valve. Otherwise, all you will get is enough gas to run a pilot light. If your grill will not light, try this:

You need to be attentive if you go to a cylinder exchange cabinet to turn in your empty tank for a filled one. If you have the old-style connector on your grill, you can use both of the widely-available screw-on valves. However, if you have a new grill with the connector that needs the new external threads, be sure to get a tank with the new Acme valve. Some of the exchange cabinets offer many tank styles. Get the one you need. Remember, the Acme valve will work on both styles of grill connectors discussed so far.

You may still see some non-OPD-equipped cylinders after April 1, 2002. This is legal. As mentioned earlier, you may use and transport non-OPD cylinders after this date. But you cannot have them filled.

As mentioned earlier, there is also a quick-disconnect valve and fitting combination available. (Some Weber gas grills use this fitting.) To make the connection with this combination, you simply pull back slightly on the collar ring on the valve and press the fitting firmly into the hole in the valve until it "clicks" into place. It will remain in place until you slide back the collar on the end of the valve. This valve and connector combination also has the safeguards mentioned earlier for the Acme valve. Your refueling choices are more restricted with this combination. These are rarely stocked in exchange cabinets. When you bought the tank with the quick-disconnect valve, you probably received a special fitting to be used to fill the tank. The fitting has the internal POL threads that allows the refiller to attach his equipment to your tank. Your refiller may or may not have this fitting. Be sure you have the fitting with you when you go to the refiller and when you leave with your full tank.

Propane tanks make grilling easy and convenient. In most cases, grilling is a pleasant way to spend a summer evening or weekend outdoors with family and friends. There have been few problems with propane tanks in these situations, but the potential for problems exists, as it does with any source of energy. To reduce the possibility of these problems, follow these steps:

If the tank becomes corroded or looses its collar ring (the carrying handle) or its foot ring (the support ring on the bottom), replace the tank immediately.

If you have questions about propane containers or propane use, contact your propane dealer or Richard Fredenburg, LP-Gas Engineer with the Standards Division, North Carolina Department of Agriculture and Consumer Services. Our address is 1050 Mail Service Center, Raleigh, NC 27699-1050. Our telephone number is (919) 733-3313.

In the manufacturing industry, we’re taught to look at the big picture when it comes to troubleshooting. If a pressure relief valve experiences failure, is releasing pressure before a system reaches maximum pressure, or is constantly leaking or chattering, it’s always best to assume that there’s something wrong with the system.

When maintained properly, a pressure relief valve can stay in service for up to 30 years, and if you’ve been having your valves tested regularly, it’s likely that there’s something else in your system that’s to blame. That said, pressure relief valves can and do fail, and it’s important to be able to recognize the signs in order to quickly solve the problem, and keep your facility safe. Here are 3 signs of pressure relief valve failure to watch out for when you’re troubleshooting your facility’s system:

If your system isn’t reaching pressure, this could be a sign of pressure relief valve failure. In some cases, this could be fixable. If the valve was calibrated to the wrong set pressure, it could simply be releasing early. This happens occasionally when changes are made to your facility’s plant design, and technicians forget to recalibrate pressure relief valves for the system’s new normal operating pressure. Your valve technicians can go in and adjust the valve’s set pressure to address this issue.

If that doesn’t solve the problem, and all other aspects of your system seem to be functioning properly, then it’s possible that your pressure relief valve needs to be changed. After years of service, the valve could have become damaged or eroded by dirt and debris in the environment, blocking the valve from fully closing. This often causes chattering, where the valve isn’t fully open, but is opening and closing rapidly, preventing it from properly doing its job.

When your system cannot reach pressure, you’ll likely experience production slowdown, if not total downtime. It’s good to know that checking your pressure relief valves can help you determine the problem.

Pressure relief valves and safety relief valves are what keep your facility safe. In the event that your system builds up above the maximum pressure for safe functionality, safety relief valves open up to let off additional pressure, keeping your facility, your employees, and your equipment safe.

If your system is above pressure and your pressure relief valves have not released, this is likely a functional pressure relief valve failure. Again, you’ll need to make sure that the valves are set to the correct set pressure, and you’ll want to take a look at the big picture of your system to understand why it’s functioning overpressure in the first place. Outside of those two concerns, if your pressure relief valves haven’t released, it’s likely that they’ve failed.

Contaminants, like dirt, lint, rust, sludge, or even the misalignment of the valve can cause the pressure relief valve to stick. At this point, you might see that your system is above pressure, or you’ll notice other pressure relief valves in the system releasing to make up for this valve’s malfunction.

While the other two signs are pretty obvious, this last sign is more noticeable when you’re directly inspecting your pressure relief valves. Leaking valves are a problem, and can contribute to slower, less efficient production, but they can be more difficult to notice as their effect on the entire system can be much smaller. This is part of the reason that preventative valve testing and maintenance is so important.

If your pressure relief valve has no pressure, it’s likely that the balance hole has become plugged, the spring is broken, or the valve simply has a loose fit. In the case of a loose fit or broken spring, replacement is a must. The valve isn’t able to function properly within your system, which means it’s not protecting your facility, your employees, or your equipment in the event that there is a larger problem.

Pressure valve leakage is a little more complicated to troubleshoot, as there are a variety of potential causes. It could be the valve itself, it could be that misalignment is causing a failure to reseat after a correct opening, or it could be that there is greater pressure in your system than the valve’s set pressure. A quality inline safety relief valve testing system can help you here. Systems like AccuTEST offer a leak check capability that allows you to test specifically for pressure leaks.

The greatest takeaway from this article should be that a malfunctioning pressure relief valve is most often a symptom of a greater problem, rather than a problem itself. As we mentioned earlier, pressure relief valves that are properly maintained can last for up to 30 years. In most cases, it’s important to look at the “why” behind pressure relief valve failure, rather than just replacing the valve in question.

This article from the Journal of Emerging Technology and Advanced Engineering provides a helpful flowchart outlining the troubleshooting procedure to take in the event that you experience any sort of pressure relief valve failure.

If your facility is having trouble diagnosing a pressure relief valve failure, inline testing can help. Instead of removing the valve and either replacing it or sending it out for testing, use inline testing equipment like the AccuTEST system to quickly and efficiently test your pressure relief valve and safety valve’s functionality. You’ll get accurate, real-time results helping your facility get back on track quickly, and safely. For more information about AccuTEST, give us a call at 616-394-1401 or request a live demo today!

The new propane tanks have a flow control valve to stop excessive gas flow. Sometimes when changing tanks I have to open the valve and then close it. Then wait a minute for the valve to reset. Then open the valve again. Maybe do that a couple of times. The open or empty gas line with no pressure allows the flow control valve to cap off the flow. Once the line gets pressurized there is no big rush of gas flow to set off the flow restrict-or. I had one of my 3 bottles at home have a big issue with it so I traded it in instead of refilling that bottle. A modern 2 bottle regulator has these flow control check valves in the gas port too. They plug the line when you disconnect a bottle. I had one of those ports get corroded and not flow gas too. Remove the hose and check the port on the regulator for corrosion. When you replace the hose make sure you check for leaks and not just hook up the hose.

It’s summertime, folks, and that means it’s the grilling season. Sure, we all love grilling year round but there’s nothing quite like a summer barbecue. Before you fire up that grill I allow me to engage you in a quick discussion about our ‘propane bottles.’

Grilling cylinders are technically known as 20 lb. DOT cylinders because they are built to DOT specifications. DOT specifications include rules that deal with metal thickness, pressure capabilities, and longevity of the tank. These cylinders can only legally contain 20 lbs. of propane. Propane weighs 4.24 lbs. per gallon. That means there is approximately 4.7 gallons of propane in your grilling cylinder when it’s full.

Grilling cylinders can be refilled or exchanged at a cylinder exchange cage. Refilling stations must refill the cylinder by weight. That’s why when you get your grilling cylinder refilled, the attendant will place it on a set of scales before they start the pump. Sometimes the attendant even uses a screwdriver and opens a small hole in the valve. You’ll hear a hissing noise as the bottle fills. When the grilling cylinder reaches 80% capacity, a white mist will shoot out of the small hole indicating that the cylinder is full. ‘Full’ in the propane industry, when regarding tanks and cylinders, is actually 80% of the water capacity of the tank or cylinder being filled. Propane is very susceptible to temperature changes and will expand or contract greatly with changes in the outside temperatures. To compensate for this possible dangerous expansion, we never completely fill up a tank or cylinder. We always stop at the 80% level.

Grilling cylinders are equipped with all kinds of safety features. One such feature is the OPD valve. The OPD valve ensures that your grilling cylinder isn’t over filled. All cylinders that hold less than 100 lbs. of propane are required by law to have this type of valve installed. OPD stands for Overfill Protection Device and that is exactly what it is designed to do. As the cylinder is being filled and the liquid level rises, it also raises a small float attached to the bottom of the valve. As this float rises to approximately 809% of the volume of the tank, the valve will shut and stop propane from being allowed into the cylinder. Despite the OPD being required by law to be on your grilling cylinder, the law also says it must still be filled by weight. The OPD is a safety backup.

Your grilling cylinder is rated to be used for a period of 12 years from the date of manufacture. On the cylinder collar you will ding the date of manufacture in a month-year format, stamped into the metal. Each time that your cylinder is filled it must be visually inspected and looking at the date of manufacture is usually one of the first items that the refilling agent will look for. A cylinder may be re-qualified by doing a visual inspection by a properly trained agent and will require a new date followed by the letter E stamped into the collar. This will allow the cylinder to be filled for another 5 years. Some companies do this re-qualification for their customers but most do not.

Many customers find that the cylinder exchange cages are the way that they prefer to get a full cylinder of propane for their grill. The customer brings an empty cylinder to the cage location, leaves the empty, and gets a full cylinder. The price for exchange is generally higher than having your cylinder refilled yourself but the exchange cage locations are generally open when a cylinder filing station may be closed. When using the exchange cages, the customer is assured that the cylinder has benen inspected and filled by a professional. Another drawback of the exchange process is that some companies will, by policy, not put a full 20 lbs. of propane in the exchange cylinder. Be sure to check the cage before purchasing to ensure that you are getting a full 20 lb. cylinder.

Another safety measure installed in grilling cylinders is an excess flow valve. The excess flow will engage and stop the full flow of propane through the valve if it sense that the gas line may have been broken or installed incorrectly. Over the years, I have seen customers open the valve swiftly, allowing gas to fill unpressurized gas hose so quickly that the excess flow ‘thinks’ that there is a problem and will shut the gas. It will release a small amount of gas to pressurize the hose on the downstream side of the valve in order to reset itself. For an unknowing customer, this small amount of gas being released is just enough to light a very small flame in their grill. This usually lends to the assumption that there’s something wrong with the grill. If this happens to you, simply turn off the burners on the grill and turn the cylinders valve to the off position and the excess flow will reset itself. You may even hear a small click when the reset occurs. After being reset, open the valve slowly (very slowly). Once the hose is pressurized, full gas flow will occur.

One last thing to be aware of when handling your grilling cylinder is a hissing sound coming from the back side of the valve. This is the pressure relief valve. It is designed to relive excess pressure that may build up inside of the cylinder. If you discover the valve is hissing or leaking, move the cylinder away from people and buildings in a cool place and away from any source of ignition. Call the person that filled the cylinder and follow their directions.

There are more than 600,000 propane-fueled forklifts operating today in manufacturing plants, warehouses, and distribution centers across the United States, and it’s not hard to understand why. Propane-fueled forklifts maintain consistent, 100 percent power throughout operation and offer ground speed advantages greater than other energy sources. What’s more, the December 2010 passage of the Tax Relief, Unemployment Insurance Reauthorization, and Job Creation Act of 2010 included a propane fuel tax credit of 50 cents per gallon through Dec. 31, 20111.

With many experienced forklift operators nearing retirement, it’s important manufacturing plant ownership and management adequately prepare the next generation. That’s especially true regarding refueling propane-fueled forklifts.

While exchanging an empty propane cylinder for a full replacement isn’t difficult, as the steps outlined in this article illustrate, those steps should never be considered a substitute for forklift manufacturer operator safety training courses and applicable standards. The latter includes, but is not limited to, Occupational Health and Safety Administration (OSHA) Standard 1910.178 and American National Standards Institute/Industrial Truck Standards Development Foundation (ANSI/ITSDF) Standard B56.1-20092.

The good news for less-experienced forklift operators is that there are no procedural differences to remember between these classes when conducting a propane cylinder exchange.

According to both the Propane Education & Research Council PERC4 and the Railroad Commission of Texas, that exchange should always be conducted by appropriately trained personnel using proper safety procedures5. Personnel that have not been appropriately trained should never attempt to exchange a propane cylinder, and must defer to co-workers with appropriate training.

Appropriately trained personnel should use personal protective equipment (PPE) when exchanging propane cylinders: proper gloves, since contact with liquid propane can cause frostbite, and eye protection, like safety glasses. Forklift manufacturers6 also recommend reviewing the forklift operator’s manual for any manufacture or model-specific information or tips before handling or changing propane cylinders.

PERC and the Railroad Commission of Texas recommend the following procedure to remove an empty cylinder from a forklift7:Park the forklift in a designated safe area, turn off the engine, and engage the parking brake.

Inspecting a full propane cylinder after its removal from the facility’s cage, typically installed by a propane provider, will help ensure good working use. Forklift manufacturers8 typically recommend the following steps:Look for rusting, dents, or gouges on the cylinder.

Sight: Frost can sometimes be seen in the area of a leak. Also, if an operator suspects a leak but can’t locate it, a soap-and-water mixture can be applied, which produces bubbles at the leak point.

PERC and the Railroad Commission of Texas recommend the following replacement cylinder installation procedure9:Using proper lifting techniques, lift and place the cylinder on the forklift. Ensure the forklift’s locating pin is properly inserted through the locating pin hole on the cylinder’s collar.

Verify the propane hose is not chafed or cut, and the gasket/O-ring is properly installed in the male quick-connect fitting, and then connect and tighten the male and female quick-connect fittings.

Keep in mind that if a forklift’s locating pin is broken, the cylinder can be mounted in any position. This could falsely indicate an empty cylinder, among other problems, so the forklift should be removed from service immediately.

With manufacturing plant ownership and management identifying the next generation of forklift operators, it’s crucial that appropriate training and safety are addressed as part of that process. Since propane-fueled forklifts are heavily used in manufacturing plants, that’s especially true with regard to propane cylinder exchange.

The steps listed above are a basic outline of the cylinder exchange process; further training is necessary to acquire the knowledge to safely exchange a forklift propane cylinder. Reviewing a manufacturer’s current forklift operator safety training courses and materials, along with standards like OSHA 1910.178 and ANSI/ITSDF B56.1-2009, will help ensure appropriate training and safety measures are in place.

The Propane Education & Research Council was authorized by the U.S. Congress with the passage of Public Law 104-284, the Propane Education and Research Act (PERA), signed into law on October 11, 1996. The mission of the Propane Education & Research Council is to promote the safe, efficient use of odorized propane gas as a preferred energy source through research and development, training, and safety initiatives.

6 -- Propane-fueled forklift refueling safety information contributed by Toyota Material Handling U.S.A. was reviewed for this portion of this article. For more information, visit http://www.toyotaforklift.com/.

8 -- Propane-fueled forklift refueling safety information contributed by Toyota Material Handling U.S.A. was reviewed for this portion of this article. For more information, visit http://www.toyotaforklift.com/.