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Department of Energy

Oil Industry Management Bureau

CODE OF SAFETY PRACTICE IN LPG REFILLING PLANT

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TABLE OF CONTENTS Page

FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . iii

ACKNOWLEDGEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 DEFINITION OF TERMS. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1

3 TANK TRUCK AND LORRY PROCEDURE. . . . . . . . . . . . .. 4

3.1 Vehicle Safety Entry Check – Tank Truck Operation. . . . . . . . 5


3.2 Vehicle Safety Entry Check – Lorry Operation. . . . . . .. . . . 7

4 CYLINDER REFILLING PROCEDURE . . . . . . . . . . . . . . . .. . 8

4.1 Counting Check of Empty Cylinders. . . . . . . . . . . . . . . . . . . 9


4.2 Segregation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Unloading of Brand New &Requalified-Repair Cylinders from
Supplier/Vendor . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.4 Cylinder Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5 LPG CYLINDER HOUSEKEEPING . . . . . . . . . . . . . . . . . . . . 12

5.1 LPG Cylinder Storage Housekeeping. . . . . . . . . . . . . . . . . 13


5.2 Stacking. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.3 Locations/Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5 General Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . 15
5.6 Maintenance Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.7 Frequency of Periodic Examination. . . . . . . . . . . . . . . . . . . 16
5.8 Periodic Examination of LPG Storage Tanks and Pipework . . 17
5.9 Periodic Examination of Other Equipment . . . . . . . . . . . . . . . 20
5.10 Routine Inspection of LPG Storage Tanks, Pipework
and Other Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.11 Periodic Examination of LPG Bulk Trucks . . . . . . . . . . . . . 22
5.12 Other Equipment . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.13 Records . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 FIRE DRILLS AND FIRE MARSHALL . . . . . . . . . . . . . .. . . . 25


6.1 Fire Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Procedures Before and During Fire Drill. . . . . . . . . . . . . . . 26
6.3 Fire Tetrahedron Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.4 Basic Fire Safety. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5 Fire Extinguisher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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7 PERSONNEL TRAINING REQUIREMENTS . . . . . . . . . . . . .31
7.1 Liquefied Petroleum Gas (LPG) Product Knowledge. . . . . . .....32
7.2 Basic Fire Fighting Seminar (BFFS) . . . . . . . . . . . . . . . . . . . .32
7.3 First Aide Training Seminar (FATS) . . . . . . . . . . . . . . . . . . . .32
7.4 Basic Occupational Safety and Health Seminar (BOSH) . . . . 33

ANNEXES

Annex 1: Personnel Protective Equipment (PPE) . . . . . . . . . . . . . . 35


Annex 2: Training Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Annex 3: Manual Handling and Lifting Safety . . . . . . . . . . . . . . . 37
Annex 4: Occupational Safety and Health Standards (OSHS)
Minimum Requirements ........................ 40
Annex 5: Composition of Special Working Group (SWG) . . . . . . .46
Annex 6: Signing Ceremony . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

TABLES AND FIGURES

Table 1: Frequency of Periodic Examination . . . . . . . . . . . . . . . . . . 16


Figure 1: The Fire Tetrahedron Theory . .. . . . . . . . . . . . . . . . . . . .27
Figure 2: Operating your fire extinguisher . . . . . . . . . . . . . . . . . . . . . 30

BIBLIOGRAPHY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

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FOREWORD

This Code of Safety Practices in Liquefied Petroleum Gas (LPG) Refilling


Plant was prepared by the Oil Industry Management Bureau (OIMB) of the
Department of Energy in collaboration with downstream oil industry stakeholders
and other concerned government agencies such as Bureau of Philippine Standards /
Department of Trade and Industry (BPS/DTI), Bureau of Working Condition
(BWC) , Occupational Safety and Health Center / Department of Labor and
Employment (OSHC/DOLE), Bureau of Fire Protection/ Department of Interior and
Local Government (BFP/DILG), Metals Industry Research and Development
Center / Department of Science and Technology (MIRDC/DOST), and Safety
Organization of the Philippines (SOPI) specifically to serve as safety guide and
manual for all downstream oil industry players or companies on good practice
procedures with reference to health, environment, and safety.

In the development of this Code, the following standards were considered:

 Philippine National Standards (PNS/DOE FS 2 : 2006) LPG Refilling Plant-


General Requirements
 National Fire Protection Association 58 (NFPA) – Liquefied Petroleum Gas
Code
 Occupational Safety and Health Standards
 Fire Code of the Philippines, RA 9514
 Philippine Liquefied Petroleum Gas Association (PLPGA) Safety Code

The Oil Industry Standards and Monitoring Division (OISMD) of the Oil
Industry Management Bureau organized and led the creation of Special Working
Group that worked specifically on the deliberation of this Code.

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ACKNOWLEDGEMENT

The development of this Code of Safety Practice in LPG Refilling Plant


was spearheaded by the Oil Industry Standards and Monitoring Division (OISMD)
and Retail Market Monitoring and Special Concerns Division (RMMSCD) under
the Oil Industry Management Bureau of the Department of Energy (OIMB/DOE).
Likewise, this Code would not have been possible without the help and support of
several individuals/representatives who in one way or another
contributed/participated actively and unselfishly shared their valuable assistance and
technical expertise in the deliberation of the various topics:

Concerned Government Agencies:


 Department of Trade and Industry – Bureau of Philippine Standards
 Department of Labor and Employment – Bureau of Working Conditions/
Occupational Safety and Health Center
 Department of Interior and Local Government – Bureau of Fire Protection

Downstream Oil Industry LPG company organization


 Liquefied Petroleum Gas Industry Association (LPGIA) – (1) Tank Truck
and Lorry Procedure, (2) Cylinder Refilling Procedure
 Philippine Liquefied Petroleum Gas Association (PLPGA) – (3) LPG
Cylinders Housekeeping and Preventive Maintenance
 Liquefied Petroleum Gas Refillers Association (LPGRA) – (4) Fire Drills
and Fire Marshall
 Liquefied Petroleum Gas Marketers Association (LPGMA) – (5) Personnel
Training Requirements

Safety Practitioners/Organization
 Safety Organization of the Philippines, Inc. (SOPI) – Manual Handling and
Lifting Safety

We would also like to extend our heartfelt thanks to our DOE officialsfor
the support and encouragement we acquired while this Code was in progress.

Above all, to our dear Almighty God for giving us the strength, wisdom,
guidance and enormous blessings throughout the deliberation of this Code.

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1 SCOPE

This Code covers the typical activities associated in the normal operations of an
LPG Refilling Plant. The Company Authorized Personnel (Responsible Officer/s)
including its personnel should be able to demonstrate their competence on how to
achieve an appropriate understanding of safety, health and environmental risk as
well as appropriate mitigation measures. This Code also identifies minimum
training requirements for all personnel involve and working within the LPG
refilling plant premises.

NOTE 1: This Code does not cover operations of garage Auto LPG Plant.

2 DEFINITION OF TERMS

For the purpose of this Code, the following terms should mean or be understood as
follows:

Aboveground Storage Tank - a tank or pressure vessel where all parts of which are
exposed above grade

Approved - acceptable to the authority having jurisdiction

Authority Having Jurisdiction (AHJ) - an organization, office, or individual


responsible for enforcing the requirements of a code or standard, or for approving
equipment, materials, an installation, or a procedure.

BFP – Bureau of Fire Protection. The Bureau of RA 9514 Fire Code of the
Philippines 2008 and its IRR

Buried or Underground Storage Tank - a tank or pressure vessel all parts of which
(except the manhole) are completely buried below the surrounding or general grade
of facility

Class B Fires - fires involving flammable liquids and gases

Class C Fires – fires involving energized electrical equipment

Code - a standard that is an extensive compilation of provisions covering broad


subject matter or that is suitable for adoption into law independently of other codes
and standards

Company Authorized Personnel (Responsible Officer/s) - a person that because of


his/her nature of works at the refilling plant, or his/her training and/or level of
competency is tasked to oversee and ensure compliance of a particular activity to a
given set of rules or procedures. As used in this document, a Company Authorized

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Personnel must be knowledgeable of among other, the Code of Safety Practices for
the particular activity he/she is assigned to oversee

Cylinders - a portable container designed and constructed/manufactured in


accordance with the Philippine National Standards for Liquefied Petroleum Gas
(LPG) Steel Cylinders – Specification PNS 03-1: 2000. The capacity permitted
under this specification is from 1.0 L to 150 L water capacity

DOE - The Department of Energy

Fire - the active principle of burning, characterized by the heat and light of
combustion

Fire Drill - a practice drill for the orderly and safe evacuation of occupants in the
buildings

Fire Protection - for the purposes of this code shall be defined in the broad sense to
include fire prevention, fire detection, and fire suppression

Hearing Protection – a hearing device designed to prevent noise - induce hearing


loss

Hot Works – any job using open flames, sources of heat or one that could ignite
materials in the work area

Installations - tanks, vessels, pumps, compressors, accessories, piping and all other
associated equipment required for the receipt, transfer, storage and shipment of
LPG

LPG - a gas liquefied by compression consisting of hydrocarbon predominantly


propane (C3H8), butane (C4H10) or their mixture; liquefied petroleum gas in either
the liquid or vapour state. The more specific terms liquid LP-Gas or vapor LP-Gas
are normally used for clarity

Machine – is a tool containing one or more parts that use energy to perform an
intended action

Personal Protective Equipment (PPE) - a device designed to be worn by LPG


Refilling Plant personnel for protection against safe and health hazards. It acts as a
protection barrier between the body of a person working at the LPG Refilling Plant,
and the potential hazards, hereby reducing the risk of bodily injury.

PNS - The Philippine National Standards

Product Loading - Withdrawal of LPG products in cylinders

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Product Unloading - the refilling plant is receiving LPG product deliveries via
lorry/ies

Protective clothing – a body protection to keep the body free from corrosive, oily,
dirty and dusty materials

Refilling Plant - shall refer to any installation that is used for refilling LPG into
cylinders and has LPG bulk storage and refilling facilities thereof

Risk - the possibility that harm (death, injury or illness) might occur when exposed
to a hazard

Shall - indicates provision that is mandatory

Should - a provision that is highly recommended but not mandatory

Tank Truck - any vehicle carrying or towing a cargo tank used for transporting
flammable fluids.

Ventilation - the process of supplying or removing air by natural or mechanical


means to or from any space

Water Capacity - total volume of tank or pressure vessel in water, expressed in


litters, gallons, m3 or ft3

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TANK TRUCK AND LORRYPROCEDURE

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3 TANK TRUCK AND LORRY PROCEDURE

3.1 Vehicle Safety Entry Check (Minimum Requirements) – Tank Truck


Operation

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the following tasks as follows:

3.1.1 Notify and direct the driver to properly position the vehicle to designated
area in such a way that in the event of an emergency, the vehicle could
easily exit without any additional manoeuvres.

3.1.2 The driver shall switch-off the engine, place shifting lever to neutral
position, apply park brake (hand brake/foot brake) and wood chocks to the
front & rear tire.

3.1.3 Ensure that the vehicle registration and driver’s license are not expired.

3.1.4 Check if the vehicle has a current BFP Conveyance Clearance.

3.1.5 Observe if the vehicle start easily and with no backfiring/stalling. If it


fails, Company Authorized Personnel to report to his supervisor or plant
management for proper and immediate action.

3.1.6 All vehicles shall conform to the following specifications prescribed under
DC 2013-09-0022 “Directing All LPG Industry Participants To Observe
Minimum Safety Standards In the Transportation and Distribution of LPG
In Cylinders”:

a. Body

i. The main body of the vehicle shall be a metal cage


ii. The use of closed vehicle in transporting filled or used empty
cylinders is strictly prohibited; e.g. closed cargo vehicle, closed
van or with enclosed cargo space which restricts the dissipation of
gases from within.
iii. The cargo space of the vehicle must be isolated from the driver’s
compartment, engine and its exhaust system, and must have
substantially flat floors.
iv. The vehicle shall be equipped with suitable racks and belts to hold
the cylinders securely in a position that shall minimize the
possibility of movement, tipping and physical damage.

b. Electrical System

i. All signal, brake and emergency/hazard lights must be working.


ii. The front and back horns must be working.
iii. Light bulbs and electrical wirings must not be exposed.

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iv. A rubberized battery terminal cover shall be used.
v. The windshield wipers must be working.
vi. The cigarette lighter must be removed from its receptacle.

c. Tires

i. The tire ply should be intact, with no visible separation, wide tear,
holes or bulges. No recapped tires shall be used.
ii. Wheel chocks must be used.
iii. Thread measurement shall have a minimum of 2mm for all tires.
iv. All tires shall have complete wheel nuts.

d. Brake system

i. There must be no visible leaks or excessive pedal movement.


ii. The air pressure gauge (when applicable) shall be operating.
iii. The park brake (hand brake/foot brake) should always be
operational.

e. Required Permanent Signages

i. Signages located at the side of the cargo compartment shall


conform to the dimensions prescribed in Annex 1 of DC 2013-09-
0022 “Directing All LPG Industry Participants to Observe
Minimum Safety Standards in the Transportation and Distribution
of LPG in Cylinders”.
ii. The signage located at the back of the cargo compartment shall
conform to the dimensions prescribed in Annex 2 DC 2013-09-
0022 “Directing All LPG Industry Participants to Observe
Minimum Safety Standards in the Transportation and Distribution
of LPG in Cylinders”.
iii. Signages indicating the tank vehicle operators/haulers/contractor’s
company name shall be located at the door on both sides of the
cab compartment.
iv. Subject to the rules and regulation of the Land Transportation
Office, the signage “LPG Delivery”, as mirror image, shall be
provided at the front of the vehicle.

f. Others

i. Pursuant to the DOE/PNS FS 2:2006 “LPG Refilling Plant-


General Requirements” and its future amendments, the engine of
vehicles entering the loading area of refilling plants shall be of the
compression ignition (diesel) type.
ii. The vehicle must carry BPS-certified fire extinguishers, with at
least 2 x 10 pounds capacity, dry chemical or CO2 with a B:C
rating placed accessibly near the driver and attendant.
iii. Seat belts shall be functional for both driver and attendants.

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iv. The vehicle must be provided with early warning devices.
v. There should be no engines/radiator leaks.
vi. Cracked windshields side and rear view mirrors shall not be
allowed. Ball mirrors are in good working condition.

3.2 VEHICLE SAFETY ENTRY CHECK (MINIMUM


REQUIREMENTS) – LORRY OPERATION

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the following tasks as follows:

3.2.1 Notify and direct the driver to properly position the vehicle to designated
area in such a way that in the event of an emergency, the vehicle could
easily exit without any additional manoeuvres.

3.2.2 The driver shall switch-off the engine, place shifting lever to neutral
position, apply park brake (hand brake/foot brake) and wood chocks to the
front & rear tire.

3.2.3 Ensure that the vehicleregistration and driver’s license are not expired.

3.2.4 Check if the vehicle has a current BFP Conveyance Clearance.

3.2.5 Observe if the vehicle starts easily and no backfiring/stalling. If it fails,


Company Authorized Personnel to report to his supervisor or plant
management for proper and immediate action.

3.2.6 Ensure that tires and wheels are in good condition. If the tread is less than
2mm depth, the Distributor should be advised to change with new tires and
allow to withdraw as last load.

3.2.7 Ensure that the front tires are original including the spare tire. Recap tires
are only allowed as rear tires, without damage or bulge.

3.2.8 Ensure that all wheel studs and nuts are completely present.

3.2.9 Ensure that the vehicle is in good condition, no leakage from fuel
tank/lines, no leakage on engine and transmission oil and exhaust system.
3.2.10 Check if 3pts. Inertia seatbelts working, windshield, and ball mirrors in
good working condition.

3.2.11 Ensure that the vehicle has2 x 10 pounds capacity, dry chemicalwith B:C
rating placed accessibly near the driver and attendant.

3.2.12 Ensure that the vehicle electrical system is in good condition (i.e. battery
terminals covered with non-conductive material, battery isolating switch
working, lighting system (headlights, brake lights, signal lights, etc. and
horn working).

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CYLINDER REFILLING PROCEDURE

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4 CYLINDER REFILLING PROCEDURE

The company authorized personnel shall ensure compliance to the Tank Truck
Entry Procedure before allowing the LPG cylinders to be directed into the LPG
refilling platform area.

4.1 Counting Check of Empty Cylinders

4.1.1 Notify and direct the driver to properly position the vehicle to designated
area for empty cylinders counting.

4.1.2 Ensure that the driver shall switch-off the engine, place shifting lever to
neutral position, apply park brake (hand brake/foot brake) and wood
chocks at the front & rear tire.

4.1.3 Counting should be done in the presence of the distributor authorized


representative.

4.1.4 Ensure that counting should be done at eye level and at the elevated
counting platform.

4.1.5 Authorized personnel to counter check Distributor order list against actual
counting.

4.1.6 Note: If there would be discrepancy, they must re-count it again.

4.1.7 If everything is in order, notify driver to proceed to LPG refilling platform


unloading area.

4.2 Segregation

Company authorized representative to ensure that segregation of cylinders shall


be group in accordance to categories of findings; for repair, repaint,
requalification, scrap/ non-conforming, good and others. Ensure that all non-
conforming cylinders shall be labelled and removed from the filling platform
after identification to ensure that it will not be refilled.

Note 1: The following are the Non-conforming cylinders:

a. Damaged by fire f. With deformed/damaged foot rings


b. Badly dented g. With body leak
c. Deeply scoured h. With no permanent shrouds
d. Corroded (visual inspection) i. Fake and tampered
e. With deformed shrouds

Note 2: If due for requalification, the cylinders shall not be refilled.


Note 3: Cylinders shall not be refilled beyond 85% water capacity.

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4.3 Unloading of Brand New &Requalified-Repair Cylinders from
supplier/vendor.

4.3.1 Direct the driver to properly position the vehicle to designated area for
unloading of empty cylinders.

4.3.2 Ensure that driver shall switch-off the engine, place shifting lever to
neutral position, apply park brake (hand brake/foot brake) and wood
chocks to the front & rear tire.

4.3.3 Conduct random inspection for the Brand new, requalified, repair and
repainted cylinders before filling.

4.4 Cylinder Filling

4.4.1 Preparation for filling plant activities


The company authorized personnel shall ensure compliance to the
following preparation of filling plant activities:

a. Ensure that all filling machines are in good condition.

b. Ensure all filling machines are properly calibrated before to


commence filling operation and record the result of calibration to
logbook.

c. Ensure that Test Weight is also calibrated by authorized agency with


certificate (record on file) and sticker on it.

d. Ensure all service valves are opened for LPG liquid service line and
By-Pass differential valve return line.

e. Check and ensure that transfer pump-motor is in good running


condition, including electrical system and switches.

4.4.2 Filling of Empty LPG Cylinders

Company authorized personnel shall strictly adhere to the following procedure


for filling empty LPG cylinders:

a. Ensure proper placement of empty cylinders to the filling machine


platform.

b. Ensure that filling head of different sizes are properly mounted to


prevent gas release while filling.

c. Ensure proper encoding of cylinder tare weight per size per cylinders
in the filling machine’s keypad and it is advisable that filling of
cylinders shall be by batch per sizes.

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d. If the machine displays an error prompt, ensure to remove cylinder for
retaring, this means that there is an error on the tare weight encoding
or T.W. marked on the cylinder.

e. Ensure to observe flowing of LPG to the cylinder by hearing a hissing


sound. If they notice that the product is not flowing into the cylinder,
press the “Stop” button and remove the cylinder. If product is still
observed not flowing into the cylinder, report malfunctions to the
Supervisor or Plant manager.

f. Ensure that 100% of all filled cylinders shall be transferred to the


digital weighing scale and validate correct weight.

g. Ensure removal of cylinder with discrepancy below and excess target


of correct weight for topping and decanting respectively.

h. Ensure that all cylinders with correct weight will undergo leak testing
using the leak testing tool and soapsuds solution.

i. Ensure that all cylinders with leak findings shall be removed and
corrected. If the leak is in the main cylinder valve, the cylinder shall
be decanted and replace the cylinder valve.

j. Ensure to conduct segregation of cylinders in accordance to type of


leaks and schedule for decanting and repair as required.

k. Filled cylinders in good condition (i.e. correct weight, no leak, etc.)


should be provided with seal and cap. (this will vary per company)

l. Ensure proper handling, loading of filled good cylinders and properly


piled to Distributor packed vehicle, according to their order receipt.

m. Ensure that loading of good filled cylinders for 11kg will be limited to
3 layers/stacking.

n. Ensure that loaded 3 layers filled cylinders are applied with belt
restraint for stability and belt assembly is in good condition.

o. Instruct Distributor driver to proceed to the designated final counting


area.

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LPG CYLINDERS HOUSEKEEPING AND
PREVENTIVE MAINTENANCE

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5 LPG CYLINDERS HOUSEKEEPING AND PREVENTIVE
MAINTENANCE

5.1 LPG Cylinders Storage Housekeeping

The Company Authorized Personnel (Responsible Officer/s) shall strictly adhere


to the following tasks for LPG Cylinder Storage:

There should be storage areas for Good Cylinders. Filled and Empty cylinders
should be segregated in separate areas inside theRefillingPlant. The areas should
be properly labeled as “Filled Cylinders Area” and “Empty Cylinders Area”.

Note 1: If the area inside the Refilling Plant will allow, a separate area for new
cylinders labelled “New Cylinders” maybe added.

Note 2: Empty cylinders are conforming cylinders ready for refilling.

5.1.1 There should also be a storage area for “Used Cylinders”. Cylinders
waiting for inspection, for re-qualification, for repair and for scrappage
should have their respective areas labeled accordingly as “For Inspection
Area”, “For Re-Qualification”, “For Repair” (or this could be a
combined area “For Re-qualification and Repair”) and “For
Scrapping”.

5.1.2 Only qualified cylinders for refilling shall be placed in the filling platform.

5.1.3 Storage areas of Filled or Empty Cylinders should be at least 3.0M away
from the nearest source of ignition. Or if it can be avoided, there should be
no source of ignition near the cylinder storageareas.Note3: See PNS/DOE
FS 2:2006 Chapter 5 Section 5.8.

5.1.4 Stored cylinders shall be located to minimize exposure to physical damage


or tampering.

5.1.5 Stored cylinders (either filled or empty) should always be in upright


position.

5.1.6 Spark ignition engine should not be allowed near the cylinders storage
areas for either filled or empty.

5.1.7 It is an added advantage and safe practice that plant personnel directly
involve in segregation and separation of cylinders for different storage
areas should have sufficient knowledge and training about re-qualification,
repair and scrappage of cylinders. Note4: See also Part 2: Cylinder
Refilling Procedure, Section B- Segregation.

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5.1.8 It is a good practice that cylinders already sorted out and destined for re-
qualification, repair and scrappage should be marked on its body by an
“un-erasable” markings.

5.1.9 Plant personneldirectly doing segregation and sorting must have a basic
knowledge about Code of Safety Practice LPG Refilling Plant Part 2 –
Cylinder Refilling Procedure

5.2 Stacking

The Company Authorized Personnel (Responsible Officer/s) shall ensurethat the


procedures for Cylinder Stacking are followed strictly as itemized below:

5.2.1 Refilling plant with forklift or lifting/ hoisting or palletized equipment may
stack Filled and Empty Cylinders three (3) levels high. (Note 5: See also
PNS/DOE FS 2:2006- Section 5.8.2.12 letter d)

5.2.2 Manual stacking of filled and empty Cylinders should only be two (2)
levels high.

5.2.3 Ensure that the foot ring of the upper cylinder perfectly fits its collar or
collar assembly of the bottom cylinder.

5.2.4 Avoid stacking deformed foot ring and/or deformed collar or collar
assembly since this could lead to toppling or collapse of cylinder pile or
stack.

5.3 Locations/Storage Area

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the following tasks:

5.3.1 Cylinder storage areas should be located outside of buildings unless they
are specifically allowed to be located inside the building.

5.3.2 Cylinders should be installed only on aboveground and shall be set upon a
firm foundation or otherwise be firmly secured. The cylinder shall not be
in contact with the soil.

5.3.3 Cylinders shall be located in an area where it will be protected from


damage from vehicles operating inside theRefillingPlant.

5.4 Handling

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the following tasks:

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5.4.1 11 kg and 22 kgcylinders when conveyed manually to their respective
storage areas (either empty or filled) should be lifted through collar handle
or collar ring, handled safely and should not be rolled on its side.

5.4.2 50 kgcylinders when conveyed manually to its storage areas should be


rolled through its foot ring slightly inclined.

5.4.3 The use of forklift and palletized equipment to transfer cylinders from one
area to another is always recommended.

5.4.4 The personnel involved in the transfer of cylinders should have an


appropriate PPEs i.e. hand gloves, long sleeve jackets, "maong pants",
safety shoes, eye goggles as a minimum.

5.5 General Preventive Maintenance

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the maintenance of the following tasks:

5.5.1 LPG Bulk storage tanks, equipment, pipework and associated systems
should be kept in good working order by a combination of Routine
Inspection, Periodic Examination and Regular Maintenance.

5.5.2 The maintenance program should emphasize elements of the system that
affect the integrity of the storage tanks and equipment and the ability to
react in an emergency.

5.5.3 Only trained and experienced personnel should be allowed to carry out all
maintenance work on a LPG refilling plant.

5.5.4 A detailed report should be issued after an examination and kept on record
(Item No. 9 - Records)

5.6 Maintenance Program

The Company Authorized Personnel (Responsible Officer/s) shall ensure that


maintenance program is strictly complied with:

Each LPG refilling plant should have a maintenance program, which covers the
storage tanks and pipework, protective equipment and instrumentation relevant to
the scale and complexity of the installation. Dependent upon the equipment on
site, the maintenance program should include:

5.6.1 Frequency of periodic tank and fittings inspection.

5.6.2 Inspection of tank supports, foundations and anchoring arrangements.

15
5.6.3 Integrity and corrosion inspections of aboveground and underground LPG
storage tankandpipeworks.

5.7 Frequency of Periodic Examination

The Company Authorized Personnel (Responsible Officer/s) shall be in-chargein


ensuring that the frequency of periodic examination is thoroughlyfollowed to wit:

The scope and period of examination and testing of the LPG systemis provided in
Table 1. Table 1 assumes routine inspections are carried out in accordance to
(Item No. 6 - Routine Inspection of LPG Storage Tanks, Pipework and other
Equipment). The periodic examination may be done earlier than provided for in
Table 1 if there are evidences or suspicions of serious defects.

Table 1: Frequency of Periodic Examination

EQUIPMENT INTERVAL

Aboveground storage tanks 5 yrs.

Underground storage tanks 5 yrs.

Pipeworks
Aboveground Pipeworks
10 yrs.
Underground Pipeworks
5 yrs.

Flexible Hoses
Gantry/Road Tanker/Jetty 6 months
Cylinder Filling 1 yr.

LPG Bulk Truck 5 yrs.

16
5.8 Periodic Examination of LPG Storage Tanks and Pipework

The Company Authorized Personnel (Responsible Officer/s) shall ensurethat the


following Periodic Examination of Tanks and Pipeworkarestrictlyobserved:

5.8.1 Aboveground tanks

Periodic examination of above ground tanks should include:

a. Visual examination of external surfaces and all welds for signs of


defects such as damage, corrosion, cracking, erosion, deformation,
leakage etc.

b. A check of wall thickness by internal visual examination or a wall


thickness survey (e.g. by the use of an ultrasonic thickness gauge).

c. Hydrostatic testing of tank using non-corrosive water to 1.2 times its


maximum working pressure every 5 years. In lieu of hydrostatic test,
radiographic, ultrasonic thickness gauging, magnetic particle, liquid
penetrant and or other equivalent non-destructive test shall be
performed on the tank. However, every 10 th year, hydrostatic testing
shall be mandatory as determined by the Agency Having Jurisdiction
(AHJ).

d. Replacement of pressure relief valves with recertified or new units at a


pressure not less than the tank maximum working pressure but not
above the tank design pressure. Capacity of the pressure relief valve
should meet design requirements. Pressure relief valves must not be
used beyond 10 years unless recertified by the manufacturer or its
accredited contractor.

e. Inspection of shut off valves, including remotely operated types and


other tank fittings for effective operation, signs of corrosion or
damageor due for replacement. Shut off valves and other tank fittings
should be replaced when they reached 20 years of service regardless of
condition.

5.8.2 Mounded or underground tanks

Periodic examination of mounded/underground tanks should include:

a. A visual check of exposed surfaces for signs of corrosion, damage,


leakage, etc.

17
b. Replacement of pressure relief valves with recertified or new units set
at a pressure not less than the tank maximum working pressure but not
above the tank design pressure. Capacity of the pressure relief valve
should meet design requirements. Pressure relief valves must not be
used beyond 10 years unless recertified by the manufacturer or its
accredited contractor.

c. Where cathodic protection is provided, the operation of sacrificial


anodes or impressed current systems should be checked if still
operating within designed specifications and replaced as necessary.
Records should be maintained to allow comparisons of the readings
obtained so as to allow investigation of any anomalous readings (see
alsoVehicleMaintenance under Item No. 7- Periodic Examination of
LPG Bulk Trucks).

d. Where cathodic protection is not provided, an internal visual


examination should be conducted and either a wall thickness check or
a hydrostatic test. Where internal examination is not reasonably
practicable the external surfaces of the tank should be exposed for
examination as directed by the trained and experienced person.

e. Inspection of shut off valves, including remotely operated types and


other tank fittings for effective operation, sign of corrosion or damage,
or due for replacement. Shut off valves and other tank fittings should
be replaced when they reached 20 years of service regardless of
condition.

5.8.3 Aboveground pipework

Periodic examination of aboveground pipework should include:

a. Checking for corrosion and damage particularly on sections where the


pipe passes through supports.

b. Checking for satisfactory condition of pipe supports.

c. Leak testing of pipework under operating pressure and checking end to


end electrical continuity for terminal and depot pipework with the
exception of cathodically protected sections.

d. Replacement of hydrostatic valves every 10 years with new units set at


a pressure not less than the maximum working pressure but not more
than the design pressure of the equipment they are protecting.

18
5.8.4 Underground pipework

Periodic examination for liquid and vapor pipework should include:

a. Check for leakage by appropriate means such as leak testing under


operating pressure, gas detection etc. at a frequency dictated by the
risks associated with its location, pressure of operation and
aggressiveness of their environment. Pipework may be subjected to
same pressure test done during installation when practicable. No
further testing is necessary if the system is constantly monitored e.g.
by gas detection system.

b. Pipework should be excavated for visual inspection and leak tested


under operating pressure when it incorporates buried screwed or
flanged joints orwhere there is any doubt of the effectiveness of the
corrosion protection system.

5.8.5 Flexible hoses

a. Each hose should be subjected to formal external visual inspections by


a trained and experienced person at the following intervals. Results of
these formal inspections should be recorded.

Road Tanker/gantry/jetty hoses - 6 months


Cylinder filling hoses - 12 months

b. A hose should be inspected for defects such as leakage, cuts, soft


spots, kinks, twists, flattening or blistering. Hoses with defects should
be rejected for LPG service.

c. In addition, jetty hoses should also be tested hydrostatically to its


maximum design pressure at least once a year.

d. Hose end couplings should be checked using appropriate gauges i.e.


GO/NO GO thread gauges for ACME couplings.

e. Where fitted, anti-abrasion outer covers must be inspected and


reported if they are damaged, incorrectly or inadequately fixed in
position. Corrective action must be taken immediately ensuring that
fixing is in accordance with the supplier’s instruction.

f. Hoses should be checked at least every year for electrical continuity.

19
5.9 Periodic examination of other equipment

The Company Authorized Personnel (Responsible Officer/s) shall ensure that the
periodic examination of the other equipment as listed below are strictly followed:

5.9.1 Product transfer system

a. Pumps, compressors and other associated equipment should be


checked in accordance to the manufacturer’s instructions or other
procedures prepared by a trained person. Seals and lubrication should
be given particular attention.

b. Differential bypass valve must be checked if they are still functioning


properly at the set pressure. Differential bypass valve 20 years or more
should be replaced.

5.9.2 Electrostatic protection


Grounding and bonding connections as applicable should be inspected visually at
least once a year and the electrical resistance should be checked to ensure it is not
more than 5 ohms.

5.9.3 Electrical equipment

Ancillary electrical equipment such as cables and connections, particularly


explosion proof connections, switches etc. should be inspected to ensure they are
in satisfactory condition in accordance with manufacturers/installers instructions
for at least once a year.

5.9.4 Firefighting and emergency system

Firewater, gas detection, over-fill prevention and alarm systems and other safety
critical equipment should be checked for correct operation in accordance with the
manufacturer’s instructions or at least once a year. If standby power generation is
part of the firefighting/emergency response system, it should be tested under load
at least once a year.

Fire extinguishers should be inspected and maintained at regular intervals


according to the manufacturer’s instructions or at least once a year.

5.10 Routine Inspection of LPG Storage Tanks, Pipework and other


Equipment

The Company Authorized Personnel (Responsible Officer/s) shall ensure that the
Routine Inspection of Tanks, Pipework and other Equipment are strictly
implemented:

20
5.10.1 General

Routine inspection of LPG storage tanks and other equipment in a LPG refilling
plant should be carried out at least annually but in many sites this may be done
conveniently as part of the routine filling operation. Routine inspection should be
done in accordance to a written procedure with appropriate remedial action plans
for defects observed.

5.10.2 Scope

Routine inspection should include:

a. Full visual inspection for corrosion, damage and leakage for tanks,
equipment and pipework. Particular emphasis on undersides of pipe
and areas in contact with supports.

b. Inspection of storage site for any flammable material stored around the
tank and if ventilation is adequate.

c. Checking the concrete pads and piers to ensure they are in satisfactory
condition and that there are no signs of differential settlement.

d. Checking the pressure relief valves to ensure it is free from corrosion


and drain holes are not blocked to prevent water from retaining in the
pressure relief valve.

e. Visual inspection of flexible hoses each time it is used or, in the case
of hoses in daily use e.g. cylinder filling every day prior to start up.

f. Thread gauging with the use of Go/No-Go gauges of all depot and
terminal ACME couplings annually and replacement if worn.

g. Recording the cathodic protection voltage for protected underground


tanks and/or pipework to confirm it is within specifications at least
once a year.

h. Checking that insulating flanges and couplings as applicable are not


bridged and that they are providing isolation of cathodically protected
parts of the system from above ground parts.

i. Checking that the earthing rod is securely connected to the tank and
earthing/bonding connections are in good condition.

j. Checking the filling scales to ensure it is within the set filling


tolerance.

21
5.11 Periodic Examination of LPG Bulk Trucks

The Company Authorized Personnel (Responsible Officer/s) shallensurethat


Periodic Examinations of LPG Bulk Trucks are strictly applied as follows:

5.11.1 Vehicle Maintenance

General vehicle maintenance must be carried out based on the recommendation


of the original equipment manufacturer (OEM). This schedule is distinct from the
schedules for LPG-specific equipment such as the tank, piping, hoses, meters,
etc. Other factors such as local legislation, the local operating environment,
historical records, best estimates of maintenance costs, including downtime costs,
etc., must also be considered. See also Part 1 of Code of Safety Practices for an
LPG Refilling Plant(Tank Truck and Lorry Entry Procedure).

5.11.2 LPG BulkTrucks and Pipework

a. The LPGBulkTrucks and pressure containing pipework must be


requalified every five years.

b. The tank must be purged and gas freed to allow visual internal and
external examinations to check for obvious defects, e.g. dents,
corrosion, etc. Thereafter, the tank must be subjected to a hydrostatic
test at the pressure appropriate to the tank design code, followed by
visual internal and external inspection.

c. Non-destructive testing and visual inspection should be performed


upon the recommendation of a trained and experienced person.

d. All attachment welds on the tank wall internally or externally should


be subject to non-destructive testing, e.g. magnetic particle or dye
penetrant crack detection tests on nozzle welds and structure
attachment fillet welds.

e. All other welds on tank mountings must be subjected to thorough


visual inspection for cracks and/or corrosion. Provided that such tests
do not reveal the need for repair work (see below), valves, fittings and
pipework must be reassembled and a pneumatic leak test must be
performed to ensure pressure containment of the complete system.

f. Pressure relief valves (PRV) must be replaced at the time of the above
tests with equivalent new, or properly recertified valves. Pressure
relief valves must not be used beyond 10 years unless recertified by
the manufacturer or its accredited contractor.

22
g. Internal shut off valves (ISV) must be tested for full functionality and
it must be confirmed that they are fully leak-tight when closed. ISV
more than 20 years from date of manufacture should be replaced
regardless of condition.

5.12 Other Equipment

5.12.1 LPG Hose

Hoses shall be subjected to a formal external visual inspection by a trained


person following the requirements indicated in (Flexible Hoses underItem No. 4-
Periodic Examination of Tanks and Pipework).

5.13 Records

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the safekeeping of records and shall be made available at all times containing
the following:

Detailed records should be maintained of all inspections, tests, and repairs or


replacement of tanks, equipment or fittings.

5.13.1 Inspection Reports


Where inspections reveal defects or significant deterioration, this should be
recorded and the inspection methods used plus any remedial action taken should
be detailed. A trained and experienced person should also assess the effects of
such deterioration; defect or repair and either endorse or revise the safe working
limits of the tank or equipment. Specifically, the following should be recorded:

a. Minimum safe operating temperature

b. Minimum safe operating pressure

c. Maximum safe operating pressure

d. Maximum permissible loading on supports

e. Date of next inspection

5.13.2 Repair Standards

The standard of any modifications or repair work should be at least equivalent to


the original design and manufacturing standard. If installation integrity may be
affected by such work, it should be supervised and certified by a trained and
experienced person, who should endorse or revise the safe operating limits.

23
Hot work must only be carried out under a Permit to Work system or after a
proper risk assessment has been conducted. Welding on the tank shell or
elsewhere on the pressure system must be only carried out by suitably qualified
welders to written procedures approved by the inspection authority.

Weld repairs to the tank shell and pressure system must only be carried out after
the tank and pressure system have been satisfactorily purged and cleaned to
eliminate any LPG and a “Gas Free” certificate has been issued. Regular gas
testing must be carried out at least every two hours whilst the work is in progress
to ensure the tank and pressure system continue to be gas free.

24
FIRE DRILLS AND FIRE MARSHALL

25
6 FIRE DRILLS AND FIRE MARSHALL

6.1 Fire Drill

6.1.1 A fire drill should be conducted at least 2 times a year to provide


experience for workers in case of emergency.

6.1.2 There shall be detailed emergency escape plan placed in specific locations
around the refilling plant. The plant shall indicate in the plan and designate
an "assembly area" so that everybody will know where to proceed in case
of emergency or "mock" emergency.

6.1.3 The plant shall have an alarm system (siren or gong) to indicate the
following:

a. Actual emergency or occurrence of leak and/or fire with personnel


evacuation

b. Fire drill only with simulated evacuation

c. Cessation of an emergency condition

d. Completion of fire drill and return to normal working status.

6.1.4 There should also be hand held fire extinguishers in specific locations
around the plant to help stop early fires.

6.1.5 Fires caused by LPG are considered Class B fires.

6.1.6 Class B fires are flammable liquid fires.

6.1.7 Fire extinguishers should be labelled dry powder fire extinguisher; it is


most suitable against Class B and C fires.

6.2 Procedures Before and During Fire Drill

The Company Authorized Personnel (Responsible Officer/s) shall be responsible


for the following tasks as follows:

6.2.1 Contact local fire station to inform them of incoming drill as not to raise
any false alarm.

6.2.2 Inform all workers that a mock fire drill will be conducted on that day.

6.2.3 Treat mock fire drill as if there was a real fire incident.

26
6.2.4 Sound the alarm or gong for the start of fire drill, so everybody inside the
plant will know.

6.2.5 Don’t panic.

6.2.6 Stop working or anything you are doing.

6.2.7 Proceed to the nearest emergency exit or open space or designated


assembly area.

6.2.8 Don’t run, just walk fast.

6.2.9 Walk along the RIGHT side of any staircase in going down. Leave the
other side open for the fire fighters. Always hold on to the provided hand
rails. Do not rush and be on guard on tripping and protruding parts of
stairs, slippery areas and on low ceiling along the stairs.

6.2.10 Don’t talk while walking.

6.2.11 Give way to elderly, physically challenged or expectant mothers.

6.2.12 Proceed to the safe assembly point.

6.2.13 Do not attempt to re-enter any building currently on fire.

6.2.14 Maximum time allotted for evacuation should be 2 minutes to 3 minutes.

6.3 Fire Tetrahedron Theory

Figure 1: The Fire Tetrahedron Theory

6.3.1 Heat

a. Produced by exothermic reaction (a chemical reaction will always


produce more energy. More energy equates to more heat.)

27
b. An exothermic reaction chemical or physical reaction that releases
heat.

6.3.2 Fuel

a. Any substance that can undergo combustion. It may come in three


states of matter; solid, liquid and gas.

b. LPG is unique as it has two forms when it is in storage, liquid and


vapor form.

6.3.3 Oxidizing Agent

a. Oxygen is the most common oxidizing agent. Oxygen does not


actually burn, it only support combustion.

b. Fire can be present without oxygen, as long as there is still an


oxidizing agent present e.g. nitrates, peroxides, iodine, chlorine and
etc.

6.3.4 Chemical chain reaction

a. Is the fourth and new element that must be present before a fire can
occur.

b. An uninhibited chemical reaction between the three elements; fuel, an


oxidizing agent and heat.

6.4 Basic Fire Safety

6.4.1 Any source of ignition, open flame or any substance that can start fires
should be kept at least 15 m (50 ft) from any storage unit of LPG.

6.4.2 There shall be basic firefighting equipment like fire extinguishers,


sprinkler systems and hose box installed around the refilling plant.

6.4.3 There shall be a water sprinkler fire protection system on the bulk storage
tanks, refilling hall, product receiving facility and pump and compressor
area.

6.4.4 Refilling plant shall have sufficient water source (in the form of water
reservoir, water pond or water storage tanks) to meet a fire scenario of
"firefighting" internal for at least (1) hour without outside or external help.

6.4.5 In any case of small fire, workers can use designated fire extinguisher to
prevent the spread of fire.

28
6.4.6 Any electrical wire should be regularly checked for any issues, cut or loose
wires sticking out.

6.4.7 In case of a small fire break, assigned and trained personnel should be the
only people to use fire extinguishers to prevent spread and enlargement of
fire.

6.4.8 Interference is the process of applying extinguishing agents to the fire to


inhibit the chemical reaction at molecular level.

6.4.9 Only fight a fire if the following are present:

a. The fire is small and contained

b. You are safe from toxic smoke

c. You have a means of escape

d. Your instincts tell you it's OK

6.4.10 Any worker in the compound should be trained in basic fire safety in case
of emergency.

6.4.11 There must be one worker assigned to call the respective government
agency or fire station in any case of emergency.

6.5 Fire Extinguisher

The P-A-S-S technique for fire extinguisher use:

P - Pull the pin. It is there to prevent accidental discharge.

A - Aim low at the base of the fire. This is where the fuel source is.

S - Squeeze the lever above the handle. Release to stop the flow. (Some
extinguishers have a button instead of a lever)

S - Sweep from side to side. Move toward the fire, aiming low at its base. Sweep
until all flames are extinguished. Watch for re-igniting. Repeat as necessary.
Have site inspected by fire department.

Place any fire extinguisher that has been used on its side on the floor. It will be
collected and recharged after the fire scene is secure.

29
Figure 2: Operating your fire extinguisher

REMEMBER

√ Learn Pull-Aim-Squeeze-Sweep (PASS) to help you remember how to use fire


extinguishers and what to do with them after use.

30
PERSONNEL TRAINING REQUIREMENTS

31
7 PERSONNEL TRAINING REQUIREMENTS

7.1 Liquefied Petroleum Gas (LPG) Product Knowledge

a. Target Participants: All Refilling Plant Employees

b. Program Highlights:

i. What is LPG?
ii. Composition of LPG
iii. Uses of LPG
iv. Parts of LPG Cylinders
v. Proper Refilling Procedure
vi. Proper Handling of LPG Cylinders
vii. Household Safety Tips
viii. Safety procedures in Handling
ix. LPG leak at Home

c. Training Period: as determined by the company

7.2 Basic Fire Fighting Seminar (BFFS)

In accordance to with REPUBLIC ACT NO. 9514, otherwise known as the “Fire
Code of the Philippines of 2008”; this training is conducted in coordination and/or
supervision of the BFP or Fire Safety Practitioners.

a. Target Participants: Plant Manager, Plant Supervisor and Selected


Personnel;

b. Program Highlights:

c. Training Period: two (2) Days or as determined by BFP

7.3 First Aide Training Seminar (FATS)

In coordination with Philippine Red Cross, there are 2 Basic Programs that can be
merged on this module: Occupational First Aid and BLS CPR/AED and
Emergency First Aid

a. Target Participants: Plant Manager, Plant Supervisor and Selected


Personnel;

b. Program Highlights:

Both programs are recommended for workplace offering first aid, CPR
with AED and responding to occupational hazards. The Emergency

32
First Aid modules shall focus on day to day emergencies that a person
may encounter.

c. Training Period: three (3) Days or as determined by the training entity

7.4 Basic Occupational Safety and Health Seminar (BOSH)

This is aligned with Article 126 of the Labor Code of the Philippines.

a. Target Participants: Plant Manager, Plant Supervisor, Refillers,


Drivers & Helpers;

b. Program Highlights:

Seminar Outline:

Module 1:

 Introduction to OSH in the Philippines


 Global and Local OSH Situation
 Work Accident/Incident theories
 Unsafe Acts & Unsafe Condition
 Hazard Identification, Risk Assessment and Control
 Housekeeping
 Personal Protective Equipment

Module 2:

 Basic Industrial Hygiene


 Materials Handling and Storage
 Fire Safety
 Machine Safety
 Electrical Safety
 Lock-out Tag-out (LOTO)
 Environment Control Measure

Module 3:

 Occupational Safety and Health Legislation


 Control Measures of Occupational Health Hazards
 Occupational Health
 Employees Compensation Commission
 Job Hazard Analysis
 Accident and Incident Investigation

33
Module 4:

 Emergency Preparedness and Management


 Safety and Health Inspection
 Basic Adult Learning
 Communication in Safety
 Human Elements in Safety
 OSH Programming
 Principle of Health and Safety Management
 Re-entry Planning

Examination and awarding:

 Post Test
 Awarding of Certificates

c. Training Period: Four (4) Days or as determined by the training entity

34
ANNEX 1
Personal Protective Equipment (PPE)

Protective Safety Hard Safety Appropriate Hearing Respirator Face Apron Full Body
Activity Clothing Spectacles Hat Shoes Gloves Protection Shield Harness
Truck Entry Point
A. Vehicle Safety Entry Check
   
B. Lorry Loading Operation
    
C. Lorry Unloading Operation
    
Cylinder Refilling Point / Platform
A. Entry Check
   
B. Counting Check of Empty Cylinders
   
(> 85dB @ 8
C. Segregation
    hours continuous
exposure)

D. Cylinder Filling
    
(> 85dB @ 8
hours continuous   
exposure)
E. Final Counting Check
   
Cylinder Housekeeping /Storage Area
A. Storing
   
B. Stocking
   
CylinderRepainting Area
      
35
ANNEX 2
TRAINING REQUIREMENTS
Frequency
Responsible
Training Target Nature of Training of
Government
Requirements Participants Training Provider Training/No.
Agency
of Hrs.
A. Liquified All personnel Mandatory DOLE In-house Part of
Petroleum (safety orientation/profe employment
Gas (LPG) program) ssional requirement
Product organization
Knowledge

B. Basic Fire Plant manager, Mandatory BFP Certificate of Yearly


Fighting plant supervisor competency
Seminar and selected issued to the
(BFFS) personnel(establish training provider
ed fire brigade) to conduct
firefighting
seminar by
regional BFP (40
hrs)
Two (2) days

B.1 Fire drill Fire Brigade In-house BFP Fire drill Twice a year
certificate as (Three times
Mandatory witnessed by recommende
local BFP d by the
industry)
C. First Aid Selected personnel Mandatory DOLE Certified by the Every Three
Training Phil. Red Cross (3) years
Seminar
(FATS)

C.1 First aider As per DOLE Mandatory DOLE


training requirement:

For every 50
personnel = one
first aider

One first aider per


shift
D. Basic Selected personnel Mandatory DOLE OSHC One time
Occupational (Safety officer) accredited safety
Safety and training
Health Part Time Safety organization
Seminar Officer
(BOSH 40 hrs of training
as requirement
by DOLE
E. Plant Technical Mandatory DOE as part PLPGA and Every three
Operation Personnel of the SCC LPGIA three (3) (3) years
Training requirements days
for Refilling
Plant

36
ANNEX 3

MANUAL HANDLING & LIFTING SAFETY

RULES ON LIFTING:
If you need to lift something manually
 Reduce the amount of twisting, stooping and reaching
 Avoid lifting from floor level or above shoulder height, especially heavy
loads
 Adjust storage areas to minimize the need to carry out such movements
 Consider how you can minimize carrying distances
 Assess the weight to be carried and whether the worker can move the load
safely or needs any help – maybe the load can be broken down to smaller,
lighter components

BEFORE LIFTING:

 Remove obstructions from the route.


 For a long lift, plan to rest the load midway on a table or bench to change
grip.
 Keep the load close to the waist. The load should be kept close to the body
for as long as possible while lifting.
 Keep the heaviest side of the load next to the body.
 Adopt a stable position and make sure your feet are apart, with one leg
slightly forward to maintain balance

SAFE TECHNIQUES FOR LIFTING:

Think before lifting/handling. Plan the lift. Can handling aids be used? Where is
the load going to be placed? Will help be needed with the load? Remove
obstructions such as discarded wrapping materials. For a long lift, consider resting
the load midway on a table or bench to change grip.

Adopt a stable position. The feet should be apart with one leg slightly forward to
maintain balance (alongside the load, if it is on the ground). Be prepared to move
your feet during the lift to maintain your stability. Avoid tight clothing or unsuitable
footwear, which may make this difficult.

Get a good hold. Where possible, the load should be hugged as close as possible to
the body. This may be better than gripping it tightly with hands only.

37
Start in a good posture. At the start of the lift, slight bending of the back, hips and
knees is preferable to fully flexing the back (stooping) or fully flexing the hips and
knees (squatting).

Don’t flex the back any further while lifting. This can happen if the legs begin to
straighten before starting to raise the load.

Keep the load close to the


waist. Keep the load close to
the body for as long as possible
while lifting. Keep the heaviest
side of the load next to the
body. If a close approach to the
load is not possible, try to slide
it towards the body before
attempting to lift it.

Avoid twisting the back or


leaning sideways, especially
while the back is bent.
Shoulders should be kept level
and facing in the same
direction as the hips. Turning
by moving the feet is better
than twisting and lifting at the
same time.

38
Keep the head up when handling. Look ahead, not down at the load, once it has
been held securely.

Move smoothly. The load should not be jerked or


snatched as this can make it harder to keep control and
can increase the risk of injury.

Don’t lift or handle more than can be easily


managed. There is a difference between what people can
lift and what they can safely lift. If in doubt, seek advice
or get help.

Put down, and then adjust. If precise positioning of the


load is necessary, put it down first, and then slide it into the desired position.

39
ANNEX 4

OCCUPATIONAL SAFETY AND HEALTH STANDARDS (OSHS)


MINIMUM REQUIREMENTS
OSHS RULINGS OSHS SELECTED PROVISIONS
Rule 1020: Registration  “Each employer … shall register his
business with the Regional Labor Office or
authorized representative having
jurisdiction thereof to form part of a
databank of all covered establishments.”
[Rule 1021]
D. O. 16 – 01 Series of  “All safety officers must complete the
2001: Rule 1030 as Bureau – prescribed training course prior to
emended their appointment vas in their respective
places of employment.”
 “All full – time safety officers must meet
the requirement of duly – accredited Safety
Practitioners or Safety Consultants by the
Bureau.”
 “The employment of a full – time safety
officer may not be required if the employer
enters into a written contract with a
qualified consultant or consulting
organization whose duties and
responsibilities shall be the duties of a
safety practitioner … The employment of a
consultant, however, will not excuse the
employer from the required training of his
supervisors or technical personnel.” [Rule
1033(1 – 2, 5)]
Rule 1040: Health and  “In every workplace of employment, a
Safety Committee and health and safety committee shall be
Duties of The Safety organized … ” [Rule 1041]
Officer
 “The Health and Safety Committee is the
planning and policy making group in all
matters pertaining to safety and health. The
principal duties of the Health and Safety
Committee are:
- Plans and develops accident prevention
programs for the establishment.
- Directs the accident prevention efforts
of establishment in accordance with the
safety programs, safety performance

40
and government regulations in order to
prevent accidents from occurring in the
workplace.
- Conducts safety meetings at least once
a month.
- Reviews reports of inspection, accident
investigations and implementation of
program.
- Submits reports to the manager on its
meeting and activities.
- Provides necessary assistance to
government inspecting authorities in
the proper conduct of their activities
such as the enforcement of the
provisions of the OSHS.
- Initiates and supervises safety training
for employees.
- Develops and maintains a disaster
contingency plan and organizes such
emergency service units as may be
necessary to handle disaster situations
pursuant to the emergency
preparedness manual for establishments
of the Office of Civil Defense.” [Rule
1043.01]

 “The principal function of the Safety Man is


to act as the employer’s principal assistant
and consultant in the application of
programs to remove hazards from the
workplace and to correct unsafe work
practices”. For this purpose, the Safety Man
has the following duties:
- Serves as Secretary to the Health and
Safety Committee.
- Acts in an advisory capacity on all
matters pertaining to health and safety
for the guidance of the employer and
the workers.
- Conducts investigation of accidents as
member of the Health and Safety
Committee and submits his separate
report and analysis of accidents to the
employer.
- Coordinates all health and safety

41
training programs for the employees
and employer.
- Conducts health and safety inspections
as member of the committee.
- Maintains or helps in the maintenance
of an efficient accident record system
and coordinates actions taken by
supervisors to eliminate accident
causes.
- Provides assistance to government
agencies in the conduct of safety and
health inspection, accident
investigation or any other related
programs.
- For purposes of effectiveness in a
workplace where full-time safety man
is required, he shall report directly to
the employer.” [Rule 1047]
Rule 1050: Notification  “All work accidents or occupational illness
and Keeping of Records of in places of employment, resulting in
Accidents and / or disabling condition or dangerous
Occupational Illness occurrence … shall be reported by the
employer to the Regional Labor Office or
duly authorized representative … ” [Rule
1053.01]
Rule 1060: Premises of  “Good housekeeping shall be maintained at
Establishments all times through cleanliness of building,
yards, machines, equipment, regular waste
disposal, and orderly arrangement of
processes, operations, storage and filling of
materials.” [Rule 1060.01(4)]
Rule 1070: Occupational  “The employer shall exert efforts to
Health and maintain and control the working
Environmental Control environment in comfortable and healthy
conditions for the purpose of promoting and
maintaining the health of his workers.”
[Rule 1077.01(1)]
Rule 1080: Personal  “Every employer shall at his own expense
Protective Equipment furnish his workers with protective
equipment for the eyes, face, hands and
feet, protective shields and barriers … ”
[Rule 1801.01(1)]

 “All personal protective equipment shall be

42
of the approved design and construction
appropriate for the exposure and the work to
be performed.” [Rule 1801.02]

 “The employer shall be responsible for the


adequacy and proper maintenance of
personal protective equipment used in his
workplace.” [Rule 1801.03]

 “No person shall be subjected or exposed to


a hazardous environmental condition
without protection.” [Rule 1801.04]
Rule 1090: Hazardous  “Control by general ventilation to provide a
Materials continual flow of fresh air to keep the
concentration of contaminants within safe
limits.” [Rule 1093.02(4)]

 “All containers with hazardous substances


shall be properly labeled.” [Rule 1093.04]
Rule 1100: Gas and  “Authorization, before welding and cutting
Electric Welding and operations are allowed … shall be inspected
Cutting Operations by the safety man. He shall issue a written
permit or authorization for welding and
cutting, indicating therein the precautions to
be followed to avoid fire or accidents.”
[Rule 1100.01(5)]
Rule 1120: Hazardous  “No worker or group of workers shall enter
Work Processes a confined space unless a watcher is
available who is familiar with the job and in
contact with the men at regular intervals and
equally provided with breathing apparatus
for ready in case of emergency.”
 “Adequate means of ingress and egress
from any confined or enclosed space shall
be provided.”[Rule 1121.01(5, 9)]
Rule 1150: Materials  “Secure storage. Storage of materials shall
Handling and Storage not create a hazard. Bag containers, bundle,
etc., stored in tiers shall be stacked,
blocked, interlocked and limited in height
so that they are stable and secure against
sliding or collapse.”
 “Housekeeping. Storage areas shall be kept
free from accumulations of materials that
constitute hazards from tripping, fire,

43
explosion, or pest harborage. Vegetation
control shall be exercised when necessary.”
[Rule 1150.01(2 - 3)]
Rule 1170: Unfired  “Vessels containing or are used as
Pressure Vessels containers for liquefied petroleum gas
(LPG), chemicals, catalyst and other
corrosive gases shall be subjected to
internal and / or external inspection,
including hydrostatic tests ...” [Rule 1173]
Rule 1180: Internal  “The Regional Labor Office through its
Combustion Engine duly authorized representative shall conduct
inspection of internal combustion engine
accompanied by the representative of the
owner / or the supervising plant mechanical
engineer for operation and maintenance ...”
[Rule 1182]
Rule 1200: Machine  “All moving parts of prime movers,
Guarding transmission equipment and all dangerous
parts of driven machinery shall be
effectively guarded, unless so constructed
or located to prevent any person or object
from coming or brought into contact with
them”.[Rule 1202]
Rule 1230: Identification  “Specifying the contents of piping system
of Piping System shall be primarily on the basis of stenciled
or lettered legends. Use of color as a means
of specifying the type of material conveyed
in a piping system shall be in conformity
with the provisions of the OSHS.” [Rule
1230.02]
Rule 1940: Fire Protection  “All place of employment … shall be
and Control provided with portable fire extinguishers for
protection against incipient fires;” [Rule
1944.05(1a)]
 “Portable extinguishers shall be maintained
in fully charged and operable condition and
kept in their designated places at all times
when not in use;” [Rule 1944.05(1b)]
 “Every place of employment depending on
the magnitude of potential fires and the
availability of assistance from the public
fire department shall organize a fire brigade
to deal with fires and other related
emergencies.” [Rule 1948.02(1)]

44
 “Fire exit drills shall be conducted at least
twice a year to maintain an orderly
evacuation of buildings, unless the local fire
department requires a higher frequency of
fire drills.” [Rule 1948.03(1)]

 “Fire brigade as required by the local


department or the Fire Code shall be
organized.” [Rule 1948.03(7)]

45
ANNEX 5

COMPOSITION OF THE SPECIAL WORKING GROUP (SWG)

Concerned Government Agencies

Lorenzo S. de Guia
Bureau of Fire Protection
Department of Interior and Local Government

DivinaCamarao
Environmental Management Bureau-NCR
Department of Environment and Natural Resources

Gilbert Q. Marquez
Bureau of Working Conditions
Department of Labor and Employment

Bryan Paul Paraiso/Lawrence C. Blas


Occupational Safety & Health Center
Department of Labor and Employment

Downstream Oil Industry Association

Mercedita G. Pastrana
LPG Industry Association (LPGIA), Inc.

Ramon C. Cuison
Philippine LPG Association (PLPGA)

Ronie H. Badidles
LPG Marketers Association (LPGMA)

Bernardo M. Bolisay
LPG Refillers Association (LPGRA)

Safety Practitioners/Organization

Edwin D. Villanueva
Safety Organization of the Philippines Inc. (SOPI)

46
OIMB Technical Secretariat

1. OIC-Dir. Melita V. Obillo


Dir. Rino E. Abad

2. Asst. Dir. Rodela I. Romero

3. Chief Alvin David T. Lim (OISMD)


Chief Renante M. Sevilla (RMMSCD)

4. OISMD Technical Secretariat


 Zenaida G. Lazaro
 Arnold O. Dela Vega
 Eleanor R. Hainto
 Rona F. Macas
 Rhodora C. Pascual
 Marc Caesar D. Genio
 Paulo C. Torno
 Lorench A. Soledad

47
ANNEX 6

SIGNING CEREMONY

November 9, 2017- DOE-AVR. Completion and signing of the newly developed


Code of Safety Practice in Liquefied Petroleum Gas (LPG) Refilling Plant by
DOE-OIMB, industry stakeholders [Philippine Liquefied Petroleum Gas
Association (PLPGA), Liquefied Petroleum Gas Refillers Association (LPGRA),
Liquefied Petroleum Gas Industry Association (LPGIA) and Liquefied Petroleum
Gas Marketers Association (LPGMA)], and other concerned national government
agencies i.e. DILG-BFP (Bureau of Fire Protection), DOLE BWC & OSHC
(Bureau of Working Conditions and Occupational Safety and Health Center).

48
BIBLIOGRAPHY

Asian LP Gas Summit 2014: Building a Safer Cleaner Energy Future with LPG,
(2014). Retrieved from http://www.wazzuppilipinas.com/2014/03/asian-lp-gas-
summit-2014-building-safer.html

Flo Gas delivery trailer and lorry with mixed load of butane and propane
cylinders driving along motorway, (n.d.). Retrieved from
http://c8.alamy.com/comp/DWGX0W/flo-gas-delivery-trailer-and-lorry-with-
mixed-load-of-butane-and-propane-DWGX0W.jpg

LPG Refilling Tank Systems- Carousal, (n.d.). Retrieved from


http://lpgservicesnigeria.com/wp-
content/uploads/2015/03/imagesnewsk40DSCF8056.jpg

LPG - BAP Maintenance, (n.d.). Retrieved from


http://www.bapmaintenance.co.uk/wp-
content/uploads/2016/09/lpg_bapmaintenance.jpg

Fire Protection in Bonita Springs Florid, (n.d.). Retrieved from


http://www.bonitastorageinn.com/storage_and_moving/bonita_springs_pictures/b
onita_springs_fire_protection_for%20storage.jpg

Corporate Training Experts,(n.d.). Retrieved from


http://akeynotespeaker.com/wp-content/uploads/2012/11/Workshops-seminars-
corporate-training1.jpg

DSouza, A.P. (January 14, 2014). Indane LPG cylinder lorry drivers call off
strike. Retrieved from https://www.kannadigaworld.com/news/india/63149.html

Halliburton releases new LWD density service for oil & gas industry, (August 16,
2016). Retrieved from http://www.offshoreenergytoday.com/wp-
content/uploads/2016/08/Halliburton.jpg

Mexican pipeline images, (n.d.). Retrieved from


https://www.oilandgaspeople.com/news/images/newsimage-1-pipeline-and-
guage.jpg

Anhydrous Ammonia Bullet, (n.d.). Retrieved from


http://img3.tradeee.com/up/lpgfillingplant/86362.jpg

49
The Differences Between Butane and Propane, (n.d.). Retrieved from
https://butanesource.com/blog/102-the-differences-between-butane-and-propane
Technical information LPG carburetor adjustment, (n.d.).Retrieved from
http://www.safefiredirect.co.uk/ProductImages/3757-600-600/lpg-highly-
flammable-safety-sign.jpg

Fire Extinguishers in the Workplace, (n.d.).Retrieved from


http://www.guardiansecurity.com/wp-content/uploads/2017/03/pass.jpg

https://en.wikipedia.org/wiki/Liquefied_petroleum_gas

50
CODE OF SAFETY PRACTICE IN
LPG REFILLING PLANT