In recent years, we have seen many facilities begin to fill their own PIT LPG cylinders on-site rather than contract this service out. Typically, we find this “change” was poorly managed: no PPE Hazard Assessment, no (or very poor) training on the task, LPG improperly located, improper electrical classification around the LPG tank and the filling station, etc. This comes down to management not recognizing the risk associated with what is viewed as a very simple task, which they equate to a low-hazard/risk task.
Here is an incident that is not all that rare when a facility fills its own LPG cylinders associated with PIT operations…
A forklift operator at an industrial site was filling a liquid propane cylinder on the forklift and also heard a hissing sound. The operator then started the forklift, and a flash fire explosion occurred at the forklift and propane dispensing system.
Failure scenario(s)
An incorrect hydrostatic relief valve was installed in the propane dispensing system’s liquid piping. The relief valve’s set discharge pressure was 250 psi, which was below the minimum requirement of 375 psi.
The forklift operator had not received the training required to transfer propane.
While the forklift operator was filling the propane cylinder, propane leaked from the system and accumulated around the forklift. The operator started the forklift, creating an ignition source that ignited the propane vapor, creating a flash fire.
CLICK HERE for the full report