When it comes to LPG-fueled industrial equipment in Australia, such as forklifts, sweepers, tow tractors and elevated work platforms. Annual safety LPG inspections are not optional.
They are a strict requirement under Australian Standard AS 4983:2003, Gas fuel systems for industrial vehicles.
These inspections ensure that LPG systems remain structurally sound, leak-free and compliant with national safety regulations. Failure to properly inspect and maintain LPG components can lead to equipment damage, operational hazards and major safety risks.
This article breaks down the technical requirements of LPG inspections in Australia and highlights why adherence to the Standards is essential for every operator and business.
Annual LPG Installation Re-Examination — AS 4983:2003 Requirement
AS 4983:2003 mandates that every LPG installation must be re-examined at least once every 12 months to ensure it has not deteriorated to an unsafe condition. This annual inspection covers structural, mechanical and functional components of the fuel system.
Below is an overview of what these inspections must include.
1. Leak Detection and System Integrity
A complete LPG system leakage check must be carried out to ensure all joints, fittings and fuel lines maintain proper containment.
2. Cylinder Life and Compliance – AS 2337 Series
Inspectors must verify cylinder age and retest dates. If a cylinder will exceed its approved life before the next annual check, it must be sent for re inspection in accordance with:
- AS 2337.2 – LP Gas cylinder re-inspection
- AS 2337.1 and AS 2337.3 – CNG cylinder inspection and testing
3. Structural Damage to LP Gas Containers
LPG cylinders must be inspected for dents, bulging, cuts and fire damage. A cylinder must be referred to a certified test station if any of the following are found:
- Dents deeper than 10% of the dent diameter, or over 6.5 mm if located on a weld
- Sharp impressions or creases over 75 mm long or deeper than 25% of the wall thickness
- Cuts or gouges penetrating the surface
- Bulging where circumference varies more than 1%
- Any fire damage
These conditions indicate compromised cylinder strength and a risk of failure under pressure.
4. Corrosion Assessment
Corrosion inspection focuses on areas prone to moisture accumulation, including:
- Drip lines
- Water traps
- Areas under clamping bands
- Cylinders must be referred for testing if corrosion meets or exceeds:
- 50% loss of original wall thickness, or remaining thickness under 1.1 mm
- Corrosion over 75 mm long, or reducing thickness below 75% of original
- Adjacent pits less than 85 mm apart are considered general corrosion.
5. CNG Cylinder Damage and Corrosion
Under AS 2337.1 / AS 2337.3, CNG cylinders and their associated brackets, guards and heat shields must be checked for:
- Impact deformation
- Corrosion
- Fatigue
- Fire damage
Any loss of structural integrity requires immediate attention.
6. Cylinder Attachment and Mounting Hardware
Inspectors must verify:
- No rust, abrasion or impact damage
- All fasteners are tight and undamaged
- Correct orientation of LPG cylinders
- Proper tension on quick-release bands
- No evidence of cracking or metal fatigue
- Cylinders must remain securely mounted under all operating conditions.
7. Automatic Fill Limiter (AFL) Testing
Where an AFL is fitted, accuracy must be checked using either:
- A fixed liquid level gauge
- A refuelling dispenser meter
As per Clause 7.12 of AS 4983:2003. If no AFL is installed, retrofitting is strongly encouraged to prevent overfilling incidents.
8. Safety Fuel Shut-Off Systems
Depending on the LPG system type, inspectors must test:
- Fixed Container Automatic Shut-Off Devices
- Power is isolated and the engine is run until the line empties.
- Excess-Flow Valves
- Tested by activating the current-limiting device, removing a fuse or opening the wiring circuit.
Special safety precautions must be taken to avoid gas discharge hazards.
9. Fuel Control System Functionality
All automatic fuel shut-off devices and fuel changeover systems must be:
- Present
- Installed correctly
- Fully operational
Where a shut-off device is missing, retrofitting is recommended to meet modern safety expectations.
10. Manual Valve Operation
Every manual valve must be opened and closed to verify full movement and check for leaks at all gland and connection points.
11. Compartment and Sub-Compartment Inspection
Inspectors must confirm:
- Structural integrity
- Seal condition around joints and bulkheads
- Conduits are free from deterioration, kinks or punctures
Leak testing is performed in accordance with Clause 7.8.2 of AS 4983:2003.
12. Refuelling Connection Condition
This includes checking:
- Structural integrity
- Cleanliness
- Presence of dust cap and sealing washer
- Proper attachment of the connection housing
- No twisting or deformation of the remote fill line
13. Hydrostatic Relief Valve (LP Gas Only)
Inspect for signs of:
- Blockage
- Damage
- Tampering
A compromised relief valve can prevent pressure release, creating a significant safety hazard.
14. Protection Against Protrusion
LPG and CNG system components must not protrude beyond the equipment’s body unless properly protected.
Forklifts, tow tractors, EWPs: All components must remain within the equipment’s outer contour.
Other machines (e.g., sweepers): Any protruding parts must be shielded to prevent impact damage.
15. Compliance Plates and Markings
All required compliance plates, labels and markings must be:
- Present
- Legible
- Correctly fastened
- Missing or damaged plates compromise regulatory compliance.
Why These Inspections Matter
Compliance is more than a regulatory requirement. It is a critical component of safe industrial operations. LPG systems operate under pressure, are exposed to vibration and environmental conditions, and are integrated into mobile equipment that can be impacted or damaged during normal use.
A properly conducted annual inspection ensures:
- System safety
- Cylinder integrity
- Compliance with AS 4983:2003 and AS 2337 series
- Reduced risk of equipment failure or gas incidents
- Improved operational reliability
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