BAGUIO GAS CORPORATION

LPG REFILLING PLANT PROCEDURE

I. OBJECTIVE:

To provide a clear overview, procedure and process flow on the daily activities in producing LPG quality products

in a safe way.

II. SCOPE:
This procedure describes the guidelines in proper implementation of rules and regulation in LPG refilling
plant pursuant to the Republic Act (RA) No. 11592, otherwise known as LPG industry Regulation Act and its
Implementing Rules and Regulations (IRR).

III. ROLES AND RESPONSIBILITIES

1. BULK DISTRIBUTOR
 Ensure adequate and stable supply of LPG in bulk
 Submit to the DOE a regular certification or report on the contracts or agreement it has entered
with bulk consumers, refillers, and auto-LPG dispensing stations with a reasonable period from the
execution thereof; and
 Ensure the periodic testing and requalification of LPG Pressure Vessels and periodic calibration of its
measuring devices by the concerned government agency or duly recognized testing facility.
 Comply with the issuance of BIR-registered sales invoice of official receipt to costumers/clients upon
conclusion of sales.
 Comply with the display of DOE LTO, Business permit and all other relevant permits and clearances
required by law or regulation in the business premises.

2. HAULER
 Submit to the DOE a regular list or report of all authorized motor vehicles used for transport of LPG
in bulk, filled and unfilled Pressure Vessels
 Submit a regular certification or report to the DOE on the contracts or agreements it has entered
with LPG industry participants within a reasonable period from the execution thereof
 Transport and deliver LPG in bulk and filled or unfilled LPG Pressure Vessels using only authorized
motor vehicles which comply with the safety standards, requirements, and guidelines pursuant to
section 8 of RA No. 11592, otherwise known as LPG Industry Regulation Act.
 Comply with the issuance of BIR-registered sales invoice of official receipt to costumers/clients upon
conclusion of sales.
 Comply with the display of DOE LTO, Business permit and all other relevant permits and clearances
required by law or regulation in the business premises.

3. REFILLER
 Fill LPG cylinders under its own Trademark or Trade Name or its duly authorized Trademark or Trade
Name in accordance with a notarized contract or agreement.
 Fill LPG cylinders accurately as to the required net content of the LPG cylinder.
 Test the weight and conduct a leak test of every cylinder before it leaves the refilling plant
 Refill only LPG cylinders that comply with the PNS and bear the necessary safety and quality marks
from DTI.
 Refuse to refill the following
 1. LPG Cartridges
2. Cylinders not designed or intended for refilling of LPG due to noncompliance with the PNS or
uncertified or not allowed by DTI and do not bear the necessary safety and quality marks,
whichever is applicable.
 Periodically check compliance of dealers with the following:
1. Content requirements of LPG sold
2. Proper calibration and sealing of measuring devices.
 Refuse entry of transport motor vehicle if not compliant with DOE DC 2013-09-0022 entitled
“Directing all LPG Industry participants to observe minimum safety standards in the transportation
and distribution of LPG in cylinders” and its future amendments.
 Comply with the issuance of BIR-registered sales invoice of official receipt to costumers/clients
upon conclusion of sales.
 Comply with the display of DOE LTO, Business permit and all other relevant permits and clearances
required by law or regulation in the business premises.

4. MECHANICAL MAINTENANCE ENGINEER

 Supervise Mechanics, Heavy Equipment Operators, Drivers and Technicians.
 Provides technical support for plant operations.
 In charge of the maintenance of the company’s
a. Fleet of vehicles
b. Heavy equipment
c. Mechanical facilities
 Prepare designs, schedule and supervise installation of client gas lines.
 Provides guidance and scheduling in the maintenance of client gas lines
 In charge of the repair and maintenance of LPG cylinders
 Responsible for the safe off site operation of deployed company equipment and vehicles

5. PLANT ENGINEER
 Supervision of storage facility operator, filling scale operator, scale man, helpers, refillers.
 Dispatcher
 In charge of the refilling plant operations and safety.
 Responsible for product quality assurance by weight and cylinder status.
 Schedule and supervise maintenance activities (preventive maintenance, inspection, testing and
maintenance of plant equipment and facilities).
 Check and monitor production
 Schedule LPG bulk withdrawal.

6. INSTALLER
 In charge of the installation of gas pipelines of the costumers.
 Provide a regular inspection on the installed gas pipelines to insure that there are no LPG leaks and
the pipes are still in good conditions.
a. DRIVERS & HELPERS
 Responsible for the delivery of LPG tanks in a safe and proper way to the costumers.

7. MAINTENANCE TEAM
 Provides automotive services for all vehicles used for operations.
 Repair of foot rings and collar of damage LPG cylinders.

8. REFILLERS
  Responsible for filling empty cylinders.
 Helping the drivers and the helpers in unloading and loading of LPG cylinders.

9. SCALE MAN
 Responsible in checking the weight of the filled cylinder coming from the analog weighing scale
whether it is over or underweight.

10. GATE KEEPER

 Count the incoming and outgoing LPG cylinders and check if the number of cylinders are the same
on the gate pass issued and the requisition form.
 Record the odometer and fuel level of the vehicles.

IV. DEFINITION OF TERMS

1. ACTIVITY – refers to storing, refilling, transportation, distribution, and marketing of LPG for residential,
commercial, industrial or automotive use.

2. LPG SEAL – refers to the protective cover otherwise known as security seal placed on the gas outlet of an
LPG cylinder of the type that it needs breaking or destroying before LPG can flow out of the cylinder.

3. REFILLERS – refers to a service provider authorized by the trademark owner to refill LPG cylinders on the
latter’s behalf, or any trademark owner which refills LPG into its own LPG cylinders.

4. REFILLING PLANT – refers to a facility with LPG bulk storage tanks and refilling equipment, used for refilling
LPG cylinders

5. REQUALIFICATION – refers to the process by which an LPG Pressure Vessel is inspected, tested, and re-
evaluated in accordance with the prescribed PNS and other accepted codes and standards with the adopted
by the DTI as PNS to determine its viability for continued use, distribution. Repair, or scrappage, whichever
may be applicable.

6. REPAIR – refers to the removal and replacement of parts of LPG cylinder, or the performance of any other
corrective and restorative measures, in accordance with the prescribed method under the PNS and other
accepted codes and standards as adopted by the DTI as PNS, with the end goal of restoring the viability and
fitness of LPG cylinders for public use.

7. SCRAPPAGE – refers to the destruction of defective LPG cylinders declared by the requalifier or repairer to
be unfit for use.

8. TARE WEIGHT – refers to the net weight of an LPG cylinder excluding its content as engraved or stamped in
the collar and painted in the body or permanently marked in the body thereof. It shall be expressed in
kilograms or grams in accordance with the applicable PNS.

9. Back yard Welding – refers to LPG cylinders that are uncertified and illegally manufactured, for example, 22
kilograms net content converted into 11 kilograms

V. NOTES
 1. Steps of unloading/LPG bulk withdrawal
1.1. Check first the plastic seal if tampered.
1.2. The initial reading of the roto gage, pressure and temperature is recorded.
1.3. Start unloading when the necessary conditions are met.
1.4. Sample of LPG using a hydrometer is extracted to measure the actual temperature and density of
the sample.
1.5. After unloading, the final reading of the roto gage, pressure and temperature is recorded.
1.6. Proceed to vapor recovery until the pressure of the bullet reaches 40 psi or .28 kg/cm 2.

2. Unloading returned empty cylinders for refilling.

2.1. Physical count of the cylinders before unloading.
2.2. Inspect the cylinders if they are qualified for refilling.
2.3. If qualified and tare weights are visible, it will go directly in the line for refilling.

3. Checking of tare weight

3.1. Check if the tare weights of the cylinder are visible.
3.2. If the tare weights are not visible, they will be weighed first and tare weight will be marked on the
cylinder before it will be lined up for refilling.
3.3. Make sure that the LPG cylinder is fully emptied before weighing it for its tare weight.

4. Refilling of LPG cylinders

4.1. The empty cylinders in the truck will be unloaded and arranged beside the weighing scale.
4.2. Before starting the pump, make sure that the hydraulic pumping pressure is set to 200 psi and see
to it that the valves for refilling are open.
4.3. Put the cylinder on the weighing scale and connect the filling head, read the tare weight and verify
fill quantity before filling it to preset quantity.
4.4. After refilling the cylinders, the weight content and leaks will be checked before putting a seal.

5. Checking of weight of filled LPG cylinder

5.1. The scale man will check the weight of the content of the cylinder using a digital weighing scale if
the desired weight is attained.
5.2. If it is underweight, the LPG tank will be returned to the refillers for additional while if it is
overweight, the content will be reduced using an empty cylinder.

6. Sealing of cylinders
6.1. Seal the LPG cylinders for safety, guaranteed that it is weighed correctly.

7. Inspection of cylinders
7.1. Check if the cylinders are not dilapidated and check the cylinder conditions with regards to rust,
dent, improper painting, leaking valve, corroded foot ring and bottom cap.
7.2. Asses the cylinders if they are within the limit to be refilled or repaired. Repainted or needs to be
washed before filling it
7.3. Attached below is a procedural inspection and requalification process, refer to Figure 1.

Procedural inspection and requalification of LPG cylinders

Figure 1.
Visual Inspection
Check the date of manufacture, latest date of requalification and/or condition of cylinders

Below 10 years from date of 10 years and 5 years and above

manufacture or below 5 years above from date from date of last
from date of last requalification of manufacture requalification

Check for physical and external defects Asses physical condition of cylinder

No defect and clean No defect but dirty NO APPARENT DEFECTS

DEFECTIVE

Rusty/scales/ Fire Leaks Dents/cuts/

cracked paints damage digs/gouges
Asses extent Inspect/asses and
of damage measure
Minimal or no Extensive Needs Within Beyond
apparent damage fire damage repairs repairable allowable
limits limits
De rust Reject, condemn
and clean and destroy Within serviceable
limits
Asses extent of Beyond corrosion
corrosion or damage limits

Within Needs repairs For Repairs

limits
Flare Flare

Decant Decant
Gas recovery Gas recovery

De valve De valve

Repair as required

Requalify Requalify

Reject condemn and destroy

Reject condemn
Stress relieve and destroy
De rust and Clean

Stamp or Stencil Date Stamp or stencil

Re valve Re valve

Wash and Repaint

Clean
Refill

PROCESS FLOW
ACTIVITY RESPONSIBITITY OF DETAILS

Start
 Lolito M. Fernandez
LPG bulk hauling & Jaime B. Seredio

LPG bulk withdrawal to empty Jessie Cunanan & Refer to Notes 1

stationary storage Plant Engineer

Empty cylinders returned for Refillers Refer to Notes 2

refilling plus new/repaired LPG Drivers &
cylinders fit for refilling Helpers

Fill line for inspection Refillers Refer to figure 1

& Notes 7

Is the cylinder defective

or is it due for
Refer to figure 1
requalification for the 5
year or 10 year test? YES

NO

Is it clean or YES To wash and Scrape the

needs repair? repaint area old paint and
let it dry
NO
Refillers &
Check the tare weight Refer to Notes 3
Helpers

Refilling of LPG cylinders Refillers Refer to Notes 4

Read tare weight and verify fill Refillers Refer to Notes 4

quantity, connect the filling
head and checked leaks

Checking of the weight Scale Man Refer to Notes 5

content, are the FAILS
BB
cylinders overfilled?

PASS
AA

ACTIVITY RESPONSIBILITY OF DETAILS

AA
 Leak detection of all cylinders, Evaluate cylinder All workers
are there any visible leaks from and inspect:
valve or cylinder
Repair or scrap

Scale Man & Refer to Notes 6

Sealing of cylinders
Refillers

Issuance of gate pass

Refer to Forms
Glen Chogsayan &
(Gate pass)
Ludovico Sabino

Is the refilling storage

emptied before 5 PM? CC
NO
YES

Proceed to LPG bulk withdrawal Jessie Cunanan & Refer to Notes 1

Plant Engineer

Continue LPG refilling from Refillers

Reserve stationary tank

ENDING INVENTORY Refer to Forms

Glen Chogsayan
(daily inventory)
END

BB

Adjust fill quantity by additional Refillers Refer to Notes 4

or reduction until it meets the
required weight

Checking of the weight content Scale Man Refer to Notes 5

AA

ACTIVITY RESPOSNSIBILTY OF DETAILS

CC
 Cut off, count all the filled
cylinder for the ending stock Glen Chogsayan Refer to Forms
in the daily production (daily inventory)

Jessie Cunanan
Continue the operation using Plant Engineer
the other storage

Ending Inventory Glen Chogsayan Refer to Forms

(daily inventory)

END

FORMS
Sample Daily Production
Requisition Form

Daily Inventory
Unloading Records

Gate Pass
REFERENCES

1. Philippine Liquefied Petroleum Gas Association “Basic Training manual for LP-Gas Service man”
2. Department of Energy, Department Circular No. DC 2022-11-0037 “Guidelines on the registration and issuance
of license to operate to qualified DOE-Regulated LPG industry participants and penalizing certain prohibited
acts”
3. World LPG Association