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DPNS 1961:2010

Liquefied Petroleum Gas Regulators for domestic use - Specification

DPNS FOR COMMENTS

DRAFT PHILIPPINE NATIONAL STANDARD DPNS 1961:2010 Foreword The Philippine National Standard, Liquefied Petroleum Gas Regulators for domestic use – Specification, was prepared by the Technical Committee on Gas Cylinders (BPS/TC 6) and approved by the Bureau of Product Standards. This standard aims to establish a national guide for the manufacture of LPG regulators for domestic use and to serve as a basis for fair competition among manufacturers, distributors, purchasers and users.

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DRAFT PHILIPPINE NATIONAL STANDARD DPNS 1961:2010 Liquefied Petroleum Gas Regulators for domestic use - Specification 1 Scope 1.1 This Philippine National Standard specifies requirements for materials, construction, performance and testing of liquefied petroleum gas pressure regulator for domestic use with a maximum capacity of 2 kg/hr. 1.2 This standard does not cover regulators for outdoor use (equipped with relief device), commercial and industrial with high pressure multi-stage application. 2 References The titles of the standard publication referred to in this standard are listed in the inside back cover. 3 Definitions For the purpose of this standard, the following definitions shall apply. 3.1 regulator a device that reduces vapor pressure of a cylinder at a constant outlet pressure for the system 3.2 domestic regulator a single stage low pressure device that reduces the gas pressure at the outlet to less than 3.5 kPa using single unit connection 3.3 high pressure regulator a device that reduces the gas pressure at the outlet to above 7 kPa 3.4 lock-up pressure the outlet pressure of the regulator at no flow condition 3.5 delivery pressure the outlet pressure of the regulator at flow condition 4 Materials 4.1 General All component parts shall be manufactured from, or be treated with, materials that are not adversely affected by mechanical, chemical or thermal influences that may be encountered in normal use.

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4.1.1 The body construction shall be sealed or force fitted type. 4.1.2 The body shall be able to withstand pressure of 1.72 MPa. 4.1.3 The recommended service life of the regulator should be 5 years from the date of manufacture. 4.2 Metal components Metal components shall be made from the materials listed in Table 1 or other materials that ensure the standards of performance, durability and safety of regulators and devices are not less than those attainable by the use of any of the materials listed in Table 1.

Table 1 – Material specification Material Specification Brass (cast) Brass for hot pressings Brass bars for screwing and turning Brass sheet Aluminum castings Grey cast iron Zinc alloy die castings

PNS 1442 PNS 1449 PNS 1450 PNS 1447 PNS 1444 ISO 185 PNS 629

4.3 Brass parts Brass parts shall not be susceptible to stress corrosion cracking. The susceptibility to stress corrosion cracking shall be determined by the method given in PNS 1448. 4.4 Zinc alloys Zinc alloys and die casting shall only be used if they comply with PNS 629, and if the parts will not be exposed to a temperature higher than 80 °C. For gas-carrying parts and parts which could affect the safe operation of the regulator only class 2 alloy is permitted. 4.5 Solder Solder which has a melting point below 450 °C after application shall not be used for gas-carrying parts except for additional sealing. 4.6 Rubber type material for diaphragms, valve pads and seals 4.6.1 Rubber materials for diaphragms, valve pads and seals shall be LPG - resistant and are made of synthetic rubber. 4.6.2 Material which may be exposed to ozone concentrations above normal and/or sunlight in use or storage shall comply with the ozone resistance requirements of PNS 1340.

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4.7 Valve pads and diaphragms 4.7.1 General – No sample shall be taken into use after test. 4.7.2 Material requirements – The material shall be such that, when the assembled regulator device is subjected to the test described in 4.7.3 the diaphragm will not pull out or burst at a pressure lower than 300 KPa. After this test the regulator or device shall comply with the soundness requirements of this standard. 4.7.3 Method of test Apply pressure (air or nitrogen gas is suitable) through the outlet connection to the underside of the diaphragm mounted in a regulator in the fully assembled condition (i.e. as it would be supplied by the manufacturer to a buyer). Block the inlet, if required. Apply pressure at a rate of 70 kPa per second up to the level specified and upon reaching the required test pressure, hold this pressure for not less than 60 seconds. 4.7.4 Swelling – The valve pad fitted in its housing shall show no evidence of being forced out of position due to swelling or other cause, when immersed for 70 hr at 40 + 5 °C in LPG. 5 Assembly and workmanship 5.1 All parts of a regulator shall be free from sharp edges, corners and any defects or design features, which might cause damage, injury or incorrect operation. The parts shall be clean internally and externally. 5.2 Holes used in the assembly of the device, e.g. for fixing screws, shall be at least 1 mm from gas ways. Holes communicating with gas ways and used for manufacturing purposes shall be closed mechanically with a metallic seal so as to ensure a way that any unauthorized interference can be detected. 6 Screw threads 6.1 Sealing threads Where a pressure tight joint is made on the thread, the thread shall comply with either (a) BS 21 or (b) other threads such as N.P.T. (specified in ANSI/ASME B1.20.1 - 1983) 6.2 Fastening threads Threads required for fastening or assembly shall comply with BS 1580, ISO 228-1, ISO 68-1 or any other appropriate standard. Self-tapping screws that cut a thread and produce swarf shall not be used for connecting gas-carrying parts or parts that may be removed in servicing. Where self-tapping screws are used for such

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purposes, only those that form a thread shall be use and they shall permit replacement by machine screws complying with the appropriate International Standard. The application of such self-tapping screws shall be limited to malleable materials, and to prevent cracking of the material they shall be positioned such that the centers are no closer to an edge than one major diameter of the thread. 7 Connections 7.1 General 7.1.1 Any screwed inlet unions designed for direct connection to gas cylinder valves shall comply with BS 341. 7.1.2 Threaded connections shall comply with clause 6. 7.1.3 Integral hose connectors shall be designed to accept flexible hose and tubing. 7.1.4 Liquefied petroleum gas nozzles shall be as shown in Figure 8 and Table 4. 7.1.5 Factory fitted hose nozzles not intended to be interchangeable shall comply with 7.1.3. 7.1.6 Interchangeable hose nozzles or other non- integral fittings shall be removed prior to any tests. 7.2 Torque and bending moment 7.2.1 Requirements – The regulator or device shall be of sufficient mechanical strength to resist the stresses and conditions of normal use. A regulator or device that withstands the connection torque and bending moment tests described in 7.2.2 without showing any sign of cracking or any significant permanent distortion and which remains functional and subsequently complies with the soundness requirements of this standard shall be deemed to have sufficient mechanical strength. No sample shall be taken into use after any tests described in 7.2.2 7.2.2 Methods of test 7.2.2.1 Screwed inlet connection torque test method – With the body of the regulator or device rigidly clamped, apply the appropriate test torque given in Table 2 to the inlet connector for 10 seconds in each rotational direction.

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Table 2 – Torque and bending moment requirements for screwed connections

Rated capacity (kg/h) Torque (N-m) Bending moment (N-m) up to 1 above 1 to 2

N-m 30 35

N-m 30 35

7.2.2.2 Screwed inlet connection bending moment test method – Fit a pipe 300 ± 25 mm in length terminated with a screwed inlet union to the inlet connection of the regulator or device. Apply the force required to give the appropriate test bending moment given in table 2 to the pipe. Apply the force for 10 seconds in each of four directions, perpendicular to each other and to the axis of the pipe (see Figure 1). 7.2.2.3 Threaded connection torque test method – Fit a suitably threaded pipe 300 ± 25 mm in length to the connections of the regulator or device. With the body of the regulator or device rigidly clamped apply the appropriate test torque given in table 3 to the pipe for 10 seconds.

Table 3 – Torque and bending moment requirements for threaded connections

Nominal pipe thread size (inch)

Metric threads o.d. (mm)

DN (mm)

Torque (N-m)

Bending moment (N-m)

1/8 1/4 3/8

10 12 16

6 8 10

15 20 35

25 35 70

7.2.2.4 Threaded connection bending moment test method – Following the torque test of 7.2.2.3, applying the force required to give the appropriate test bending moment given in Table 3 to the pipe. Apply the force for 10 seconds in each of four directions, perpendicular to each other and to the axis of the pipe (see Figure 1).

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Dimension is in millimeters

≥ 300

L

Regulator or device

Left Right

Down

Up

Bending moment = F x L

Figure 1. Bending moment test: schematic 7.2.2.5 Integral hose connections bending moment test method – Rigidly clamp the body of the regulator or device and apply the force required to give the test bending moment of 10 N⋅m to the connector. Apply the force for 10 seconds in each of four directions perpendicular to each other and to the axis of the outlet connector (see Figure 1). For the purpose of carrying out the test it is permissible to extend the effective length of the outlet connector by the use of a length of close fitting steel tube fitted over the useful length of the connector. 7.3 Quick Connect Action 7.3.1 External soundness (see 15.1) shall be maintained during complete operation of the system including connection and disconnection of the regulator to the cylinder valve. It is permissible for there to be a minimum momentary escape of gas during connection. 7.3.2 If the regulator is capable of pointing in different directions when attached to the cylinder valve, soundness of the connection shall be assured in all positions even during rotation. 7.3.3 The inlet of the regulator shall contain a manual means of opening and closing the flow of gas. 7.3.4 The direction of operation of rotary controls shall be clearly indicated on the regulator.

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7.3.5 With the regulator connected, 10 000 operations of opening and closing the gas supply shall be effected after which the regulator shall comply with 7.3.1 and 7.3.2. 7.3.6 The regulator shall be connected and disconnected 5 000 times to a cylinder valve which it is designed to fit, after which it shall comply with 7.3.1, 7.3.2, 7.3.7, and 7.3.8 when connected to a new valve. 7.3.7 The regulator attached to the cylinder valve shall be able to resist a force of 400 N applied in the opposite direction to the direction of coupling without disconnecting and shall still comply with 7.3.1 and 7.3.2 during the test. 7.3.8 The regulator attached to the cylinder valve shall comply with 7.3.1 and 7.3.2 when a bending moment of 50 N⋅m is applied to the inlet connection in the least favorable direction for 10 seconds. 7.3.9 Means shall be provided to ensure that the regulator will itself meet the soundness requirements of this standard when it is in the “gas off” position. 7.3.10 It shall not be possible to connect or disconnect the regulator from the cylinder valve with the gas supply in the ‘on’ position. 7.3.11 Where turning off the gas and disconnecting the regulator is combined in a single control, a single continuous movement of the control shall be prevented by a mechanism which shall be separately operated before the regulator can be disconnected. 7.3.12 The open and closed positions of gas flow shall be clearly marked and detectable by feel. 7.3.13 The gas supply valve shall be readily accessible and easily operable when in use. 8 Vents 8.1 General Breather holes and vents shall be protected against blockage or shall be properly located so that they do not easily become blocked. They shall be so arranged that the diaphragm cannot be damaged by a sharp device inserted through the breather hole or vent. 8.2 Screens Protection against insects shall be provided where applicable, e.g. by a vent screen.

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9 Valves 9.1 Valve pad fixing A valve pad shall be so retained that it cannot work out of position under service conditions. Compliance shall be checked by examination of the valve pad after carrying out the tests described 4.7.4, 10.1.6 and 10.1.7. 10 Performance 10.1 General 10.1.1 Gases used for testing – The performance tests shall be carried out using the appropriate gas for which the regulator or device is designed, i.e. LPG or, if this is not practicable, such alternative gases as air or nitrogen, etc. may be used provided that the regulator or device has been previously exposed for 70 hr to the gas for which the regulator is designed. 10.1.2 Test temperature – Unless otherwise specified, setting and performance tests shall be carried out at 20 ± 5 °C. 10.1.3 Chatter – A regulator or device shall not chatter or vibrate while being tested. If chattering occurs when using air or nitrogen, etc., the test shall be repeated using the gas for which the regulator or device is designed. The test shall be up to a maximum of: (a) Single stage LPG regulators: 300 kPa 10.1.4 Orientation – The tests shall be carried out with the regulator or device in its recommended orientation. The regulator shall comply with 10.1.8 in all orientations. 10.1.5 Rated capacity – The rated capacity shall be obtained with both: (a) the maximum designed bore size or outlet nozzle (see clause 7); (b) the maximum designed bore of inlet connection (see clause 7). 10.1.6 Drop test – A complete regulator or device shall be dropped from a height of 1 m in any position on to a hard surface (e.g. concrete). After the test the regulator shall remain functional and comply with the following at 20 °C only. Lock-up: 10.1.8 Outlet pressure measurement: clause 16. Soundness: 15.1

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10.1.7 Endurance test 10.1.7.1 Requirement – A regulator shall withstand 50 000 cycles of complete opening and closing of the valve as described in 10.1.7.2 without mechanical failure or the development of leakage. At the completion of the test the lock-up pressure shall not exceed 110% of the discharge pressure. 10.1.7.2 Method of test – Supply the regulator inlet with air or nitrogen gas at 700 kPa for single stage LPG regulators and at a temperature of 20 ± 5 °C. Install quick-acting valves upstream and downstream of the regulator and the downstream valve exhausts to atmosphere. Connect the valves to a suitable time switch so that as one opens the other closes with a complete cycle time of approximately 5 seconds. Arrange the test so that the diaphragm is fully flexed and the valve is held on its seat for a minimum of 1 second. 10.1.8 Lock-up – The device shall lock-up when flow is reduced to zero from nominal flow conditions over a period of 2 seconds. Lock-up shall be achieved at not more than 60 seconds after cessation of flow. 11 Sealing After testing by the manufacturer, the body and cover of each regulator and device shall be sealed to discourage interference with the internal mechanism and pressure setting (when not intended to be adjustable) in such a way that unauthorized interference can be detected. 12 Marking and Labeling 12.1 Permanent marking A regulator or device shall be clearly and permanently marked with the following: (a) manufacturer’s name, mark or symbol and country of origin; (b) make and model; (c) the year and month of manufacture (d) the direction of flow if this is not permanently established by the design of

the connections; and (e) type of gas (LPG and/or propane) 12.2 Minimum Labeling Requirements A regulator or device shall be labeled with the following: (a) nominal outlet pressure or pressure range and flow rate; (b) the number of this standard, for locally manufactured regulators; (c) its correct and registered trade name or brand name; (d) its duly registered trademark; (e) its duly registered business name;

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(f) the address of the manufacturer, importer, repacker of the consumer product in the Philippines; and

(g) country of manufacture, if imported; and 12.3 Additional markings Additional marking or means of identification shall be permitted. 13 Packaging 13.1 Protection from damage A regulator or device shall be so packed as to minimize risk of damage in transit. 13.2 Protection from foreign matter A regulator or device shall be protected to prevent the entry of foreign matter. Where plastic bags are used the minimum thickness of plastics shall be 0.05 mm. 14 Instructions 14. 1 Instructions shall be provided in English and Filipino language for the user and the installer. They shall be clear and unambiguous with warnings clearly shown and grouped together. They shall be packed with the regulator or device and shall contain at least the following information, as applicable. (a) Name and address of manufacturer and country of origin (b) Make & model. (c) The outlet pressure or pressure range over which the regulator or device

complies with this standard. (d) The rated capacity: where outlet connectors with restricted bores are

supplied, the capabilities obtainable with each connector size. (e) A warning showing the type or types of gas for which the regulator is

designed. A warning that the regulator may only be connected to the type of valve designed to accommodate it. For clip-on regulators, the valve size and/or system.

(f) A warning that adequate ventilation should be provided. (g) Warning regarding unauthorized interference. (h) There are no repairable parts. The regulator is disposable. The maximum

life is five years after the date of manufacture, after which the regulator shall be disposed.

(i) An instruction to the consumer that the regulator shall not be disconnected from the gas cylinder whilst the appliance remains alight and that in the event of the appliance failing to extinguish when the gas valve is turned off it essential that the regulator is not disconnected from the cylinder.

(j) Instructions for any use-resettable device. (k) Instructions for fitting outlet connectors.

(l) Where outlet connectors for flexible hoses are employed, the required size and type of hose and detailed instructions for fitting including the correct use of hose clips.

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(m) Instructions for making the connections, including diagrams, paying particular attention to condition of any washer or seal where required.

(n) Instructions for connection, orientation, turning on and turning off the regulator including diagrams if required. Instructions for leak testing and the correct procedure in the event of a leak.

14.2 Instructions can be printed directly in the packaging provided that it contains the above information. If not, a separate paper for instructions shall be packed together inside the box. 15 Soundness 15.1 Requirement A regulator shall be considered to be leaktight if it does not exhibit any leak when tested as described in sub-clause 15.1.2. 15.1.2 Methods of test 15.1.2.1 Test the completed regulator at a pressure of 15 kPa applied through the outlet connection and held for a period of not less than 60 seconds. 15.1.2.2 Test those parts of LPG regulators using a manometer or Grade 1.5 Bourdon Gauge as specified in JIS B 7505 subjected to cylinder pressure at a pressure of 1.4 MPa applied through the inlet connection and held for a period of not less than 120 seconds with the outlet connection sealed. Example of equipment set-up for flow rate test is shown in Figure 2.

Outlet

Sample regulator

Manometer

Float type area-flowmeter or orifice flow meter

inlet

300 300

Unit: mm

Figure 2 - Example of Equipment for flow-rate test

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16. Outlet Pressure Measurement 16.1 With the upper limit value of 1.56 MPa and the lower limit value of 0.07 MPa of the supply pressure at the inlet and with the two points between them, 1 MPa and 0.5 MPa, the lock-up pressure and output pressures (mm H2O) corresponding to the flow rates of 0%, 5%, 100% and one point percentage in the middle of 5 and 100% of the marked capacity are measured and presented in the performance curves with the flow rate of the regulator on the abscissa and the outlet pressure (regulated pressure) on the ordinate (see Figure 3), and it is examined whether regulated pressures and maximum lock-up pressures are within the permissible limits of the regulated pressures at the flow rates not more than the marked capacity.

Figure 3 - Graphical representation of testing flow rate

Example: The case where the outlet pressures (regulated pressures) fall within the frame of chain-lines, and the shut-up pressures are not more than 350 mm H2O, (3.5 kPa).

1 MPa ----

. . . .

..

. .

.

Permissible limits of Regulated pressure Outlet pressure - Measuring point

1.56MPa . . .. . ..

.

..

Inlet pressure 350

330

280 -

230

0 5 % Flow rate

100%

Outlet pressure

0.5 MPa

0.07 MPa

17. Sampling 17.1 Performance Testing - At least two samples shall be selected at random from each lot of 100 regulators or a fraction thereof of each size. 17.2 Nozzle Dimensions - At least one sample shall be selected at random from each lot of 100 regulators or a fraction thereof of each size. 18. Retests 18.1 In case of failure in any of the tests specified, retests shall be made on two samples from the same lot, both of which shall pass. 18.2 If any of the samples failed, the whole lot shall be rejected.

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Figure 4. Typical diagrammatic sectional illustration of POL-type regulator

Diaphragm plate

Loading spring

Cover

Diaphragm

Connector

Outlet

Lever

Valve pad

Valve seat

Inlet connection

Cylinder valveactuating pin

Cam

Latch mechanism incorporated here

Interlock

Gas on/off switch with interlock

Air vent

Spring adjuster

Sealing cap

Figure 5. Typical diagrammatic sectional illustration of

a quick connect action regulator

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Figure 6. Typical illustration of A/S Bayonet regulator

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1 2 3 4 5 6 7 8 9 10 11 12 13

Figure 7. Typical illustration of snap on regulator.

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Dimensions in millimeters

R2

R1

L7

L7

L7

L8

D6

ANG

R2

D5

D4

D3

D2

D1

Figure 8 - Regulator outlet Nozzle dimensions

NOTE: 1. It is important that the hose nozzle profile has no sharp edges that could cut the hose while it is in use.

2. It is highly recommended that the LPG hose nozzle on the appliance inlet

shall be of the same configuration as in the figure above.

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Table 4. Dimensions of Regulator Outlet Nozzle.

D1

D2

D3

D4

D5

D6

∅8.2 Max

∅10.0-∅10.5

∅12.2-∅12.5

∅12.7-∅13.0

∅13.2-∅13.5

∅11.0-∅11.5

L7

L8

R1

R2

ANG

6.4-6.6

25.5-26.5

R1.0-R1.5

R0.3-R0.5

110-130

INFORMATIVE ANNEX CONVERSION TABLES

___________________________________________________________________ Time

60 sec = 1 min 3600 sec = 1hr 60 min = 1 hr 2 4 hr = 1 day ___________________________________________________________________

Pressure

14.7 psi = 1 atm 100 KPa = 1 bar 1 in H2O (15.6°C) = 0.0361 psi 1.01325 bar = 1 atm 14.504 psi = 1 bar 1 kg/cm2 = 14.23 psi 101 325 N/m2 = atm 760 mm Hg (0°C) = atm 1 N/m2 = Pa ___________________________________________________________________

Energy and Power

778.16 ft-lb = 1 BTU 550 ft-lb/sec = 1 hp 1.3558 Joules = 1 ft-lb 1.055 KJ = 1 BTU 2 544.4 BTU/hr = 1 hp 1 kcal = 3.98 BTU ___________________________________________________________________

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References The following standards through reference in this text form part of this National Standard. At the time of publication of this PNS, the editions indicated were valid. All standards are subject to revisions, and parties to agreements based on these standards are encouraged to investigate the possibility of applying the most recent editions of the standards indicated below. PNS 629:1991/ JIS H 5301:1990 - Zinc alloys die casting - Specifications PNS 1340:1995/ISO 1430-1:1980 - Rubber vulcanized - Resistance to

ozone cracking - Part 1: Static strain testPNS 1442:1996/ BS 1400:1985 - Copper alloy ingots and copper alloy

and high conductivity copper castings - Specifications

PNS 1444:1996/ BS 1490:1988 - Aluminum and aluminum alloy ingots and castings for general engineering purposes - Specifications

PNS 1447:1996/ BS 2870:1980 - Rolled copper and copper alloys sheet, strip and foil - Specifications

PNS 1448:1996/ BS 2871-2:1972 - Copper and copper alloys - Part 2: Tubes for general purposes - Specifications

PNS 1449:1996/ BS 2872:1989 - Copper and copper alloy forging stock and forging - Specifications

PNS 1450:1996/ BS 2874:1986 - Copper and copper alloy rods and sections (other than forging stock) – Specification

ISO 68-1:1998 - ISO general purpose screw threads – Basic profile - Part 1: metric screw threads

ISO 185:1988 - Grey cast iron - Classification ISO 228-1:1994 - Pipe threads where pressure-tight joints

are not made on the threads - Part 1: Designations, dimensions and tolerances

BS 21: 1985 - Specification for pipe threads for tubes and fittings where pressure tight joints are made on the threads (metric series)

BS 1580: 1962 - Specification for Unified screw threads ANSI/ASME B1.20.1: 1983 - Pipe Threads, General Purpose (inch)

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BUREAU OF PRODUCT STANDARDS Department of Trade and Industry

Technical Committee 6 - Gas Cylinders

Chairman 1 Ramon C. Cuison Red Clover Consultants, Inc.

Vice-Chairman 2 Antonio Pineda

ASEPHIL Members Association: 3 Zozimo L. Bugarin Liquefied Petroleum Gas Industry Association/Ferrotech Steel Manufacturers/Requalifiers: 4 Benjamin R. Guerrero

Caimol Marketing 5 John Glenn D. Macoy Pilipinas Shell Petroleum Corp. 6 Jeffrey Mejugue

Rogelio Bautista* FSC Metal Corporation

7 Roy C. Nadal

Glittertec Corporation

8 Anthony Jay R. Ricafort Constancio Arabejo* Petron Corporation

Government Agencies: 9 Robert R. Cardinales

Energy Industry Administration Bureau Department of Energy

10 Felino E. Cueto

Nona I. Pilariza* Industrial Technology Development Institute Department of Science and Technology

11 Nelson Se, Sr. Gerard Venezuela* Bureau of Fire Protection

12 Constante Viloria

Bureau of Working Conditions Department of Labor and Employment

Testing Institution: 13 Florante A. Catalan

Metals Industry Research and Development Center, DOST

Project Manager 14 Sheryll C. Micosa

Bureau of Product Standards

* Alternate