1

Calor LPG Fork Lift Truck

REFUELLING training COURSE
INTRODUCTION
EMERGENCY PROCEDURE
REFERENCES
UNIT 1 LIQUEFIED PETROLEUM GAS (LPG) PROPERTIES, CHARACTERISTICS AND HAZARDS
UNIT 2 LPG BULK TANK & CYLINDER STORAGE
UNIT 3 HOSES & HOSE COUPLINGS
UNIT 4 CYLINDER REFILLING
UNIT 5 FIRE EXTINGUISHERS

Calor LPG Fork Lift Truck Refuelling

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INTRODUCTION
These course notes are designed to facilitate an open learning training programme. The Fork Lift Truck operatives
should work their way through the booklet and use the self-assessment questions to reach a level of knowledge
and understanding about the properties, characteristics, storage and use of Liquefied Petroleum Gas (LPG). The
operative will demonstrate competence to refuel a Fork Lift Truck (FLT) cylinder in a safe and proper manner by:
1)
2)

Completing a practical assessment of re-filling a FLT cylinder using an instruction card, and
Completing a short summary of written questions.

Calor Gas has made every effort to ensure that the technical training course notes and guidelines contained
within this booklet are accurate. They are designed to be relevant for both Northern Ireland and the Republic of
Ireland. Please note that in some circumstances; legislation, laws and standard practice may vary depending on the
area in which the training takes place. Please refer to the relevant standards in your area. The content should be
used as guidance material and not as a replacement of current regulations or existing standards.

EMERGENCY PROCEDURES
Action in Case of LPG Fire

Raise the alarm. The Fire Brigade and Calor Gas should be notified immediately.

Fires should normally be controlled but not extinguished until any source of gas escape can be
cut off.

If it is safe to do so, close tank valves in circumstances where a leak in pipework has ignited.
Isolate all valves upstream and downstream to starve the fire of gas.

A small fire can be dealt with using a dry powder fire extinguisher. Do not use water to
extinguish LPG fires.

Vessels should be cooled with water to prevent a pressure build-up.

Action in case of Gas Leak

Raise the alarm. The Fire Brigade and Calor Gas should be notified immediately.

Evacuate all persons, except those necessary to deal with the emergency.

Whenever possible, and if it is safe to do so, turn off all isolation valves necessary to cut off or
reduce the source or sources of escaping gas.

Calor Contact:
During business hours phone
ROI: 1850 812 450
NI: 028 9045 8466

Outside business hours phone

ROI: 01 291 6229
NI: 0845 075 5588

TRAINING COURSE NOTES

3

REFERENCES
LIQUEFIED PETROLEUM GAS CODES OF PRACTICE
UKLPG CoP1 Pt1 Installation & maintenance of fixed bulk LPG storage at consumer premises.
UKLPG CoP3

Recommendations for prevention & control of fire involving LPG

UKLPG CoP7

Storage of full and empty LPG cylinders and cartridges

UKLPG CoP11

Recommendations for the safe handling of LPG used as an internal combustion

engine fuel for motor vehicles.

UKLPG CoP20

Automotive LPG refuelling facilities

REGULATIONS
Republic of Ireland: Safety, Health and Welfare at Work Act 2005
Northern Ireland: Health & Safety at Work (Order) NI 1978

IRISH AND EU STANDARDS

IS3213

Code of Practice for the Storage of LPG Cylinders and Cartridges

IS3216

Code of Practice for the Bulk Storage of Liquefied Petroleum Gas

IS291

The Use, Siting, Inspection And Maintenance Of Portable Fire Extinguishers

ISEN13760

Automotive LPG Filling System For Light and Heavy Duty Vehicles Nozzle,
Test Requirements and Dimensions

ISEN60079

Electrical apparatus for explosive gas atmospheres

ETCI ET 105

National Rules for Electrical Installations in Potentially Explosive Atmospheres

(including amendments No. 1 and No. 2)

BRITISH STANDARDS
BS4089

Specification for hoses & hose assemblies for LPG

BS 7671

Requirements for electrical installations

BSEN 1762

Rubber hoses and hose assemblies for LPG

BSEN 60079

Electrical apparatus for explosive gas atmospheres

Note: All specified documents are current editions.

Calor LPG Fork Lift Truck Refuelling

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Unit 1
Liquefied Petroleum Gas Properties, Characteristics
& Hazards
AIM:
To provide background information about Liquefied Petroleum Gas (LPG) Propane to ensure that the trainee has
sufficient knowledge and understanding of the properties and characteristics of propane.

OBJECTIVES:
At the end of this module you should be competent to:
1. State the properties and characteristics of Liquefied Petroleum Gas (LPG) Propane.
2. State how LPG Propane is stored under moderate pressure.
3. Describe what LPG Propane appears like in a liquid state.
4. Describe how the vaporisation of LPG Propane occurs.
5. State the boiling point of Propane liquid.
6. State the safe levels to which Propane bulk tanks and cylinders can be filled.
7. State why tanks and cylinders must not be overfilled.
8. State Propane liquid expansion rates when released to atmosphere.
9. State where gas vapour will collect if it escapes.
10. State the limits of flammability of Propane.
11. State the hazards associated with LPG.
12. State the PPE required to be worn when handling LPG Propane liquid.
13. Describe the treatment for burns caused by liquid gas.

Unit 1

TRAINING COURSE NOTES

5

WHAT IS LIQUEFIED PETROLEUM GAS (LPG)?

Liquefied Petroleum Gas (LPG) is a term used for Hydrocarbon gases that exist as vapour under ambient
conditions of temperature and pressure, but which can be liquefied by the application of moderate pressure or
refrigeration.
The composition of LPG is hydrogen and carbon which is referred to as hydrocarbons. The chemical formula of
Commercial Propane is: C3H8
Liquefied Petroleum Gas is a very versatile, portable and manageable fuel and a naturally occurring by-product of
the oil extraction process. The two most common LPG gases are known as Propane and Butane. Calor Propane is
used to power fork lift trucks.

HOW IS LPG STORED?

Calor LPG is easily stored and delivered in cylinders and specially constructed bulk tanks.

Propane 7 Bar (100psi)

It is stored as a liquid under moderate pressure. Varying temperatures will alter the pressure inside a vessel. As a
liquid, LPG expands when its temperature rises.
At a standard ambient temperature of 15C and an atmospheric pressure of 1013.25 mbar (STP), the pressure
inside a vessel storing Propane is 6.9 bar (similar to the pressure found in a lorry tyre.)
If the temperature was to rise to around 30C 40C then the pressure in the vessel storing Propane would rise to
approximately between 9 bar and 15 bar.

WHAT DOES LPG LOOK LIKE?

LPG in its liquid state is colourless and odourless and as a vapour, it cannot be seen.

IS LPG DETECTABLE IF PRESENT IN THE AIR?

In its natural form LPG is not readily detectable in air. However for safety reasons a stenching agent called Ethyl
Mercaptan is added during production to aid detection by smell at very low levels.

Unit 1

Calor LPG Fork Lift Truck Refuelling

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CAN AN ESCAPE OF LPG BE DETECTED OTHER THAN BY SMELL?

YES when the liquid evaporates, it has a cooling effect on the surrounding air and will cause any water vapour
present in the air to freeze.
This effect may show at a point of a leak in a pipe, hose or fitting.. Sometimes frosting can be seen at the point
of escape and part of the gas cloud is usually visible. Leaks can also be seen as a shimmering effect due to the
refractory differences between gas and air.

HOW IS THE GAS VAPOUR PRODUCED?

When heated, liquid LPG boils in a similar way to water in a kettle. LPG boils at very low temperatures. The
boiling point is the temperature at which LPG boils and changes from its liquid state to vapour. For propane at
atmospheric pressure, the boiling point is approximately -42C.

SHOULD THE LPG BULK TANK OR CYLINDER BE FILLED COMPLETELY?

NO an LPG storage vessel can never be filled completely as LPG liquid has a high rate of expansion. In order
to allow for expansion, LPG vessels are only filled to between 80% and 87% of their design capacity. This space
allows for expansion and contraction of the stored liquid due to changes in ambient temperature.

Bulk tanks are filled to 80% 87%

of design capacity

HOW DO YOU KNOW WHEN A FLT CYLINDER HAS BEEN FILLED

CORRECTLY?
A 29-litre FLT cylinder will be filled to the fixed liquid level indicator. Once the liquid gas blows from the liquid
level indicator the filler will stop filling. The content gauge will confirm the fill.
It would be dangerous to over fill an FLT cylinder (or any LPG storage vessel) as this would mean that there is
insufficient space for the liquid to expand. If the cylinder or storage vessel was to become hydraulically full it
could result in a severe leakage of gas with disastrous consequences.
If it is necessary to reduce the fill of gas in a FLT cylinder, DO NOT move the vehicle. Start the engine and burn off
the LPG.

Unit 1

TRAINING COURSE NOTES

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IF WE SPILL LIQUID GAS WHAT WILL OCCUR?

The liquid will expand over 200 times when vaporised.
A very small quantity of liquid LPG escaping to atmosphere will produce vast amounts of flammable gas. One
volume of Propane liquid will produce 274 volumes of gas vapour.

1 VOLUME
OF LIQUID
274 VOLUMES
PROPANE
VAPOUR

IF THERE IS A GAS ESCAPE WHERE DOES IT GO TO?

LPG vapour is heavier than air. Any gas escape will find its way to the lowest level. Gas vapour collecting in drains
or vehicle inspection pits could possibly build up to an explosive or flammable mixture that will be extremely
difficult to disperse.
Specific Gravity

Air = 1.0

Propane = 1.5

Propane is one and half times heavier than air.

Unit 1

Calor LPG Fork Lift Truck Refuelling

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IS LPG FLAMMABLE AND AT WHAT IGNITION TEMPERATURE WILL IT

IGNITE?
LPG is extremely flammable and will readily ignite. When LPG is mixed with air, a highly flammable mixture can be
produced. The flammability range is between 2% to 11% by volume of gas in air.

100%
Gas Vapour

Propane Gas
% to Air Mix

2% 11%
flammable
or explosive

Lower Explosive Limit

If the percentage of Propane in air reaches 2%, this is known as the Lower Explosive Limit (LEL) or Lower
Flammability Limit (LFL). Above this level, the mixture is flammable or explosive and requires only ignition to
combust.
Below this limit, the volume of propane is too weak in air to combust. In this case it should be noted that a
further rise in the concentration of propane can create a flammable mixture.
Upper Explosive Limit
If the percentage of propane in air reaches approximately 11%, this is known as the Upper Explosive Limit (UEL)
or Upper Flammability Limit (UFL). Up to and below this level, the mixture is flammable or explosive. Above
this level, the volume of propane in air is too strong to propagate a flame as the components of combustion (1
volume of propane to 5 volumes of oxygen) are not present. In this case, it should be noted that if the % volume
of propane in air was to disperse back to within the 2%-11% range; a flammable/explosive mixture would occur.
The ignition temperature for Propane is approximately 460C 580C

DOES LPG FLOW EASILY?

LPG has a low viscosity, in other words it flows with great ease. Propane as liquid or in a gaseous state will flow
with ease and will readily leak at any break within an installation.

LPG will also react adversely with oil based compounds that will result in the installation leaking gas. It is essential
to use special-jointing compounds that are suitable for use with LPG when making gas connections (e.g. Calortite
or PTFE tape)

Unit 1

TRAINING COURSE NOTES

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WHEN LPG IS BURNED, WHAT ARE THE PRODUCTS OF COMBUSTION?

When LPG has its full complement of oxygen and is completely burned, the combustion that takes place will
produce only Carbon Dioxide (CO2) and Water Vapour (H2O) which are harmless.
We already know that as a hydrocarbon gas, carbon atoms are present. It requires the correct amount of
combustion air to be present when the fuel is ignited to burn off the carbon.
One volume of Propane requires 24 volumes of air for complete combustion.



If the right amount of air is not present then the air will become vitiated. The CO2 increases and the O2 decreases,
there is then a real danger that the production of Carbon Monoxide (CO) will occur.
Once CO begins to form it rapidly reaches dangerous levels. CO is extremely TOXIC to humans and animals.

IS LPG TOXIC?
LPG is non-toxic but at very high concentrations in air LPG vapour is anaesthetic and subsequently an asphyxiate
by diluting or decreasing available oxygen. This would cause a person to become suffocated.

IS PERSONAL PROTECTIVE EQUIPMENT (P.P.E.) REQUIRED WHEN

HANDLING LPG?
LPG, particularly liquid, can cause severe frost burns to the skin, due to its rapid vaporisation and consequent
lowering of temperature.
Vaporisation of LPG can also cool equipment to the extent that it may be cold enough to cause cold burns.
It is essential to always wear protective clothing when the cooling of equipment is likely to occur or when
handling components where liquid LPG is present.
Gauntlet type gloves, goggles and cotton overalls MUST BE WORN when filling FLT cylinders or white refillable
cylinders.

WHAT SHOULD YOU DO IF SOMEONE IS BURNT BY LIQUID GAS?

IN SEVERE CASES SEEK MEDICAL ATTENTION IMMEDIATELY
Immerse affected area or apply copious amounts of tepid water to the
affected part of the body for at least 10 minutes. DO NOT APPLY DIRECT
HEAT OR HOT WATER.
Loosen any clothing that may restrict blood circulation to the affected areas.
Thaw out any frozen clothing and remove if possible. Do not damage skin
tissue.
Apply a large thick dressing to help retain the heat to the damaged area. The dressing must be loose fitting.
Do not give the injured person hot drinks or alcohol.
Seek medical advice as quickly as possible.

Unit 1

Calor LPG Fork Lift Truck Refuelling

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Self-assessment questions Unit 1

Q1. What do the letters LPG stand for?

________________________________________________________________________________

Q2. What type of gas is used as fuel gas for forklift trucks?

________________________________________________________________________________

Q3. Describe how LPG is stored?

________________________________________________________________________________

Q4. If the Standard Temperature is 15C and the Atmospheric Pressure is 1013.25mb what is

the pressure within a vessel containing propane gas?

________________________________________________________________________________

Q5. If the temperature were 20C would the pressure within a vessel be higher or lower?

________________________________________________________________________________

Q6. How will you know if a gas leak is present in air?

________________________________________________________________________________

Q7. Describe what you would see if a quantity of liquid gas were to escape to atmosphere?

________________________________________________________________________________

Q8. At what percentage level will propane gas be flammable or explosive?

________________________________________________________________________________

Q9. Should liquid gas escape to atmosphere how many times will it expand as a gas vapour?

________________________________________________________________________________

Q10. If liquid propane gas or vapour escapes to atmosphere will it rise or fall?

________________________________________________________________________________

Q11. When there is a gas escape what precautions must you take to prevent a fire or explosion?

________________________________________________________________________________

Q12. Is LPG toxic?

________________________________________________________________________________

Q13. Is it possible to receive burns from liquid propane gas? If so what is the minimum personal

protective clothing that you should wear?

________________________________________________________________________________

Unit 1

TRAINING COURSE NOTES

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Unit 2
Bulk Tank & Cylinder Storage
AIM:
This unit deals with the storage and siting of a Bulk LPG Tank and storage of Fork Lift Truck cylinders at
commercial premises, whether as stock or in use. It aims to provide the trainee with the minimum guidelines
on large, medium or small cylinder storage areas, which should enable them to carry out safety checks on
commercial premises. It also aims to empower the operative to promote safety and provide solutions to any
recognisable, potentially hazardous situation, and in the event of any incidents, provide information to assist the
Fire Service, Police or other authorities to deal with the situation.

OBJECTIVES:
At the end of this module you should be competent to state:
1. The regulations regarding the safe siting of LPG Bulk Tanks & LPG cylinders.
2. The safety features of individual Bulk Tanks.
3. Separation distances from Bulk Storage vessels and dispenser pumps to other fuel sources.
4. The minimum safety distances cylinders should be stored from exits, drains or cellars.
5. The types and size of LPG FLT cylinders.
6. The safety features of individual cylinders and their respective valves.

WHO OWNS THE LPG BULK STORAGE VESSEL?

The LPG storage vessel is the property of Calor Gas. Any fault or damage occurring to the storage vessel or
components should be reported to Calor Gas immediately.

During business hours phone
Outside business hours phone
ROI: 1850 812 450
ROI: 01 291 6229
NI:
028 9045 8466
NI:
0845 075 5588

Unit 2

Calor LPG Fork Lift Truck Refuelling

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WHAT ARE THE REQUIREMENTS FOR SITING THE STORAGE VESSEL?

For safety reasons minimum separation distances are required between the storage vessel and potential hazards.
Your Calor Energy Advisor will propose a safe area for siting the vessel complying with the relevant regulations,
before any storage vessel is delivered to your site.
However it is important that you are also aware of the need to maintain separation distances from other fuel
sources. The following diagrams and chart can be used for quick reference.
Storage areas shall be a safe distance from boundaries, buildings and fixed sources of ignition.
Storage of bulk tanks should be secure to prevent tampering by unauthorised persons.
Signage should be on display around the storage area to prohibit smoking and the use of naked flames.

Separation distances for Above Ground Bulk Tank Siting

LPG Capacity
(tonnes)

Distance from buildings, boundaries, property

lines or fixed source of ignition

Minimum Distance
between vessels (m)

Without fire wall (m)

With fire wall (m)

0,05 to 0,25

2,5

0,3

(0,3*)

Up to 1,1

1,5

Up to 4

7,5

Up to 60

15

7,5

1,5

Up to 150

22,5

11

1/4 of sum of the diameter

of 2 adjacent vessels

>150

30

15

1/4 of sum of the diameter

of 2 adjacent vessels

* This is increased to 1m in NI.

Additional notes:
(A) Overhead cables with a voltage of less than 1.0KV should be sited at least 1.5m from a plane drawn from the edge
of the vessel. This distance shall be increased to 10m for cables rated above 1.0KV.
(B) The separation distances are measured from the edge of the vessel.
(C) Adequate crash protection is required to prevent damage to any part of the installation.

Unit 2

TRAINING COURSE NOTES

13

SEPARATION DISTANCES FOR BULK TANKS

of up to and including 2000LTR capacity
Notes
(1) The vehicle must be at least 3m from
any manhole during filling.
(2) The pump assembly must be at
least 4.5m from buildings, boundary,
property or fixed source of ignition.
(3) The vehicle must be at least 4m from
buildings, boundary or fixed source of
ignition during filling.
(4) With a firewall in place, the distance
from the tank to buildings, boundary
etc. may be reduced from 3m to 1.5m.
Firewalls should be sited between 1m
and 1.5m from the nearest point of the
tank.

SEPARATION DISTANCES FOR BULK TANKS

of greater than 2000LTR capacity*
Notes
(1) The vehicle must be at least 3m from
any manhole during filling.
(2) The pump assembly must be at
least 4.5m from buildings, boundary,
property or fixed source of ignition.
(3) The vehicle must be at least 4m from
buildings, boundary, property or fixed
source of ignition during filling.
(4) With a firewall in place, the distance
from the tank to buildings, boundary
etc. may be reduced from 7.5m to 4m.
Firewalls should be sited between 1m
and 1.5m from the nearest point of the
tank.
* A Calor energy advisor will advise on the
requirements for individual circumstances
where the bulk tank capacity exceeds 9000LTR.

Unit 2

Calor LPG Fork Lift Truck Refuelling

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WHAT ARE THE MINIMUM REQUIREMENTS FOR CYLINDER STORAGE?

LPG cylinders must be stored in the upright position in a well-ventilated area, preferably in the open air.
The storage area surface should be load bearing.
Storage of cylinders should be secure to prevent tampering by unauthorised persons.
Appropriate signage should be on display around the storage area to prohibit smoking and the use of naked
flames.

LPG cylinder storage areas must be at least 2 metres (NI) / 3 metres (ROI) from openings to cellars, drains or
basements.
The whole of the storage area must be maintained at ALL times and be free from weeds, long grass and noncombustible materials.
Storage areas shall be a safe distance from boundaries, buildings and fixed sources of ignition.
Stored cylinders should not impede or endanger a means of escape.
Electrical equipment within 2 metres of storage must be flameproof to the required standard.
Suitable fire extinguishers (dry powder) should always be available in the storage area.

IN WHAT AREAS SHOULD CYLINDERS NOT BE STORED?

LPG cylinders should not be stored:
In areas where combustible materials are stored.
Below ground level in basements or in cellars.
In close proximity to an LPG bulk tank.

WHAT SHOULD I DO IF A CYLINDER IS FOUND TO BE LEAKING?

If a leak is detected at a cylinder do not continue to use the cylinder.
Remove the cylinder to an open-air ignition free area.
Contact your gas supplier immediately any faults with cylinders must be reported to your Calor supplier.

Unit 2

TRAINING COURSE NOTES

15

BULK TANK STORAGE LIQUID OFF TAKE VESSEL CONNECTIONS AND

VALVES

HAND
PUMP

Tank Controls
- A) Filling Valve Connection
- B) Plastic Tank Hood
- C) Tanker Fill Connection
- D) Tank Service Valve (Normally
coloured red)
- E) Liquid Off-Take
- F) Liquid Off-Take Ball Valve
- G) Pressure Relief Valve
- H) Contents Indicator Float Gauge

On a hand-operated pump, as shown above the liquid off take connection is located at the top of the Storage
Vessel.

ELECTRIC
PUMP

Tank Controls
- A) Filling Valve Connection
- B) Plastic Tank Hood
- C) Tanker Fill Connection
- D) Tank Service Valve (Normally
coloured red)
- E) not used
- F) Liquid Off-Take Connection &
Ball Valve
- G) Pressure Relief Valve
- H) Contents Indicator Float Gauge

On an electric operated pump, as shown above, the liquid off take connection is located at the bottom of the
storage vessel.
Note: The electric pump must not be located under the storage vessel but fitted to one side of the storage
vessel area.

Unit 2

Calor LPG Fork Lift Truck Refuelling

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AUTOMOTIVE TANK AND CYLINDER IDENTITY

29 litre cylinder red with a black shroud around the cylinder fittings as shown below

3. Pressure Relief Valve

4. Contents float gauge

2. Fixed liquid level

5. Filler Valve

1. Liquid off take service

6. Locating hole

1. A service valve connection, which connects the vessel via a flexible hose to the vaporiser. This valve should be
turned off before filling commences.
2. A knurled brass screw connected to a tube within the cylinder. This screw is slackened off when filling
commences. The liquid blows off when the cylinder is filled to the correct level.
3. An internal pressure relief valve fitted to protect the cylinder from excess pressure. There is a black protective
cover fitted to prevent any ingress of water or dirt collecting on the valve.
4. A float gauge which determines the amount of liquid gas in the vessel as , , or full.
5. A threaded valve protected by a white plastic cap. Connects the filler hose via a filler nozzle.
6. This hole is found in the collar of the shroud. When the cylinder is correctly mounted either on the vehicle or
a filling cradle the hole will be directly centre facing the ground.
The FLT cylinder is mounted at the rear of the vehicle and fixed in position by straps.

Nozzle
Valve

check locating hole

Unit 2

TRAINING COURSE NOTES

17

Self-assessment questions
Q1. What is the distance that a vehicle must be when filling with LPG from the storage vessel?

________________________________________________________________________________

Q2. What distance should cylinders stored be from the storage vessel?

________________________________________________________________________________

Q3. There is a component fitted on a cylinder and a storage vessel that protects them from over

pressure. What is the component known as?

________________________________________________________________________________

Q4. List the valves and components of a 29 litre cylinder

______________________________________

______________________________________

______________________________________

______________________________________

______________________________________

Q5. Electrical equipment must be of a particular type what is it?

________________________________________________________________________________

Q6. Name the component that will indicate the cylinder has not been overfilled and what can occur as a

result of overfilling?

________________________________________________________________________________

Unit 2

Calor LPG Fork Lift Truck Refuelling

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Unit 3
Hoses & Hose Couplings
AIM:
The aim of this unit is to provide the trainee with the necessary information to identify breakaway couplings, fill
hoses, fill adapters and fill couplings of a Fork Lift Truck Dispenser installation. It also aims to recognise hazards
from a Drive Away and to ensure the safe uses of fill hoses and couplings.

OBJECTIVES:
At the end of this module you should be competent to:
Check hoses used meet the current regulation standard and the maximum length of hose permitted
State the reasons for daily inspection of hoses and the signs of wear and tear
State the reason for a breakaway or pull away coupling being installed
State the action to be taken in an emergency following a drive away
List the authorities that must be informed in the event of a drive-away or substantial leak
State the safety inspection procedures for the installation
Identify the fill couplings and how to use them

WHAT ARE THE REQUIREMENTS FOR HOSES, FILL CONNECTIONS AND

BREAKAWAY COUPLINGS?
It is important that the filling hose should be inspected prior to use on every occasion, as damaged hoses can
result in serious accidents.
Hoses must be designed to the regulation standard. (BS EN 1762 or BS 4089)
The Test Date must be stamped on the end fittings.
A hose should be replaced after 5 years whether showing signs of wear or not.

HOSE
WITH PROCOL

CONNECTOR

Unit 3

TRAINING COURSE NOTES

19

WHAT CHECKS MUST BE CARRIED OUT BEFORE REFUELLING STARTS?

Hoses need to be inspected daily and prior to use on every occasion.
Every time a vehicle is refuelled the FILLER checks the following visually:
Always check the condition of the hoses: no cuts, stretch marks, slippage or bulges.
Signs of wear are usually detectable by visual inspection.
Any suspect assemblies must not be used.
Arrangements should be made to inspect, and where necessary replace, faulty components.
If any damage is detected, do not use the hose and contact Calor.

BRaid showing

slippage

flattened
or stretched
blistering
or bulging
cuts

Dispenser Valve
DISPENSER GUN
(MANUAL)
Filler Valve

Filler Nozzle

Filler Valve Dust Cap

HOW DOES THE DISPENSER GUN OPERATE?

The ON position is when the lever is squeezed downward and the retaining latch is pulled back thereby locking
the lever in the depressed position.
To return the valve to the OFF position press the lever down further, which in turn will release the retaining latch.
Release your grip of the lever a small amount of gas will vent to atmosphere.

Unit 3

Calor LPG Fork Lift Truck Refuelling

20

WHY IS A BREAKAWAY COUPLING FITTED TO THE FILLING HOSE?

A Breakaway/Pull-away coupling is installed to minimise damage and any LPG release in the event of a vehicle
driving off whilst still connected to the dispenser.
When there is a breakaway coupling no more than two lengths of hose will be fitted.
The dispensing push button device is a fail-safe type (Dead mans device). The flow of LPG stops when button is
released.
Fig 1: REGO

Fig 2: ELAFLEX

WHAT DO I DO IF A VEHICLE DRIVES OFF STILL CONNECTED TO THE

DISPENSER?
If a re-usable pull away coupling is fitted then the release of LPG will normally be minimal.
IN THE EVENT OF A SUBSTANTIAL SPILLAGE, THE FOLLOWING PROCEDURES WILL APPLY:
Isolate the emergency switch at the dispenser. Turn off.
Turn off the LPG supply valves.
Remove or extinguish any source of ignition.
Do not start up vehicle engines which may be in the vicinity.
Summon the Fire Brigade.
Keep all personnel and members of the public away from the general area in which vapour may be spreading.
Alert neighbours, if appropriate, and advise of possible dangers, especially if there are cellars or basements in
which vapour could collect.
Contact Calor.
For minor gas leaks or hose breakaway, immediately report to your supervisor or manager, so they can contact
Calor. Also, the information above may be supplemented by your companys own safety procedures in line
with the current regulations.

CAN THE FILLER OPERATOR RE-CONNECT THE BREAKAWAY COUPLING?

NO the complete hose assembly will need to be inspected carefully and re-connected by a competent person
in accordance with manufacturers instructions.
If the hose and fittings show any signs of damage then they MUST NOT be put back into service.

Unit 3

TRAINING COURSE NOTES

21

Self-assessment questions
Q1. What Standard must hoses be designed to conform to?

________________________________________________________________________________

Q2. What is the recommended action to take when a hose has been in use for 5 years or more?

________________________________________________________________________________

Q3. List below how often you would be required to carry out inspection of the hose and what

damage you are looking for?

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

Q4. State why a breakaway coupling is fitted to a FLT dispenser hose?

________________________________________________________________________________

Q5. In an emergency, which involves a drive-away, what actions would you take?

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

Unit 3

Calor LPG Fork Lift Truck Refuelling

22

Unit 4
Cylinder Refilling
AIM:
It is essential that all operators are trained to fill liquid off-take refillable cylinders. The aim of this unit is to
provide the trainee with the necessary information to carry out the refuelling of the FLT cylinder using a hand
pump or electric pump FLT installation.

OBJECTIVES:
At the end of this module you should be competent to:
State the safety precautions put in place to protect the operative.
List the appropriate PPE clothing used.
State the safety inspection procedures before refuelling a cylinder.
Identify the different fill adapters and fill couplings.
Carry out safe refuelling of a vehicle fuel tank to recognised procedures.

SAFETY AT RE-FUELLING LOCATION

No smoking or naked flames.
No source of ignition should be permitted in the vicinity. Warning signs to this effect must be displayed.
Suitable fire extinguishers (dry powder 9kg) should be sited adjacent to the installation.
Ensure vehicle parking minimum distances.
Protect vessels & equipment from damage caused by impact.
PPE protective gloves and safety goggles must be available.

SAFETY OPERATING CONDITIONS PRESSURE SYSTEMS REGULATIONS

1. Ensure the cylinder is in test date. For Calor cylinder check the marking inside the cylinder shroud or on
coloured ring under service valve- (V Indicates Visual Test Date - H indicates Hydraulic Test Date). If beyond
test date year they MUST NOT be filled.
2. Ensure the cylinder to be filled is identified as an LPG cylinder for FLT use. A Calor Gas Cylinder can be
identified by either the appropriate embossing or labelling.
3. Ensure the cylinder has been designed and manufactured to a recognised specification and subsequent to
1989, BS 5045:Pt2.
4. Ensure that cylinders supplied with a bulk installation are fit for filling. Users should ensure that damage or
maltreatment does not take place.
5. Ensure the cylinder has been designed for filling in this manner.
6. Damaged cylinders must be set aside and not used. Contact Calor Customer Support to source a replacement.

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PERSONAL SAFETY AND PERSONAL PROTECTIVE EQUIPMENT (PPE)

The FILLER must wear the following Personal Protective Equipment (PPE):
Goggles and neoprene gloves or gauntlets
Long sleeve cotton overalls or jacket
Safety shoes or boots
Note: Nylon overalls/jacket can produce static electricity, which could be a source of ignition.

WHAT IS THE ROUTINE PROCEDURE AT EACH REFUELLING TASK?

The cylinder will need to be correctly located into the mounting brackets on the FLT. Ensure the arrow on the
base of the cylinder points downwards to indicate that the cylinder is correctly positioned for filling. This will
align the internal pipes and gauges for correct operation.
DO ensure the FLT engine is turned OFF.
DO ensure the handbrake of the FLT is ON.
DO make sure any Mobile Phone or device is switched OFF.
DO ensure the fill coupling is not damaged.
DO ensure the cylinder valve neoprene seal is intact and free from dirt.
DO fill the vehicle tank to the fixed maximum liquid level gauge.
DO follow the procedures as shown on the re-fuelling instruction card.

DO NOT allow anyone to smoke or use a naked flame in the vicinity.

DO NOT overfill.
DO NOT drop the filling nozzle or drag the hose and filling nozzle along the ground this will result in damage
to the union and subsequent leakage.
WHEN MANUAL HANDLING THE FLT CYLINDER ALWAYS TREAT IT AS FULL

Unit 4

Calor LPG Fork Lift Truck Refuelling

24

LPG Fork Lift Truck Refuelling Procedure

1. Park Forklift truck 3 meters from storage vessel and switch OFF engine.
Engage hand brake.
Put on PPE gloves & goggles.

2. Close OFF cylinder service valve by turning valve fully clockwise.

3. The cylinder can be filled on the truck or removed. If the cylinder is removed for the filling procedure, it must
be in a horizontal position with the locating pin at the six oclock position.
Fixed Liquid
Level Valve
4. Check contents gauge and fixed liquid level valve
to ensure cylinder is not already full.

5. Remove cylinder filler valve dust cap. Check that the filler
valve neoprene-sealing ring is in place and is undamaged.

Contents Gauge

Neoprene-Sealing
Ring

6. Connect dispenser gun nozzle to cylinder filler valve. Tighten by turning

valve union fully clockwise. Open dispenser gun nozzle by depressing the
gun lever and locking into place by pulling latch back.

7. Slacken cylinder fixed liquid level valve by turning anti-clockwise, an audible hissing sound will be heard this
is gas vapour venting. (If white vapour cloud present, do not attempt to fill. Re-check contents gauge.)

Unit 4

TRAINING COURSE NOTES

25

Manual / Hand Pump

8. To commence filling crank pump handle back and forth.
Monitor contents as filling.
9. Stop cranking when white vapour cloud
appears at fixed liquid level valve.

Electric Pump
8. To commence filling switch on pump by pressing the push
button.
9. Release push button to stop pump when white vapour
cloud appears at fixed liquid level valve.

10. Close OFF fixed liquid level valve by turning valve fully clockwise.
Close OFF dispenser gun nozzle valve by depressing lever and releasing
the latch. White vapour trapped between the nozzle and the filler valve
is vented to atmosphere.

Do not attempt to break the connection if the gas continues to flow. Re-depress trigger and contact
Calor Gas.*

11. Disconnect filler gun nozzle from cylinder filler valve and stow safely. Replace dust cap. Ensure all valves on
the storage tank are closed at all times when the installation is not in use.
*NOTE: DO NOT disconnect dispenser gun from filler valve if gas vents continuously.
Cause: Filler valve seating is open because of ingress of dirt or grit or seal damaged.
Cure: Attempt to dislodge dirt by tapping valve firmly with a rubber or wooden mallet until gas stops.

IF FOR ANY REASON THE CYLINDER HAS BEEN OVERFILLED, IT IS ESSENTIAL THAT THE
FORKLIFT TRUCK ENGINE IS RUN TO REDUCE THE QUANTITY OF GAS IN THE CYLINDER
TO A SAFE LEVEL, BEFORE LEAVING THE REFUELLING SITE.

Unit 4

Calor LPG Fork Lift Truck Refuelling

26

Self-assessment questions
Q1. What PPE must be worn whilst refilling an FLT cylinder?

________________________________________________________________________________

Q2. What is the most important check carried out on a cylinder filler valve before connecting the

filling nozzle?

________________________________________________________________________________

Q3. When a cylinder is filled remotely from the FLT, how do you ensure that the valves are situated

correctly when mounting the cylinder onto the cradle?

________________________________________________________________________________

Q4. If you did not mount the cylinder correctly what might occur?

________________________________________________________________________________

Q5. On completion of the filling cycle what should you ensure is replaced?

________________________________________________________________________________

Q6. If you have over filled a cylinder how will you safely reduce the level of gas?

________________________________________________________________________________

Q7. What information must be readily available at the filling point?

________________________________________________________________________________

Unit 4

TRAINING COURSE NOTES

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Unit 5
Fire Extinguishers & Emergency Procedures
AIM:
The aim of this unit is to provide the trainee with information on the correct fire extinguisher for Electric or
Hand Pump installations. It also aims to enable them to follow procedures in the event of any emergency or an
uncontrolled release of LPG and to recognise the potential hazards involving such a release whether an escape of
gas only or if followed by a fire.

OBJECTIVES:
At the end of this module you should be competent to:
State the fire extinguisher to use in the event of a LPG fire
State the procedures for dealing with an uncontrolled release of LPG involving a fire
State the procedures for dealing with an uncontrolled release of LPG NOT involving a fire

WHAT CLASSES OF FIRES ARE THERE?

These are shown in the chart:

Cloth, wood
or paper

Flammable
liquids

Flammable
gases

Electrical
hazards

Water or
Hydrospray

Spray Foam

ABC Dry
Powder

CO2 Gas

Unit 5

Calor LPG Fork Lift Truck Refuelling

28

CLASS A FIRES
Freely burning fires fuelled by ordinary combustible materials cloth, wood, paper and dry grass.
Cooling by water or spray foam is best method of extinguishing this type of fire.

CLASS B FIRES
Fires fuelled by flammable liquids such as oils, spirits, petrol and LPG.
Tackling with Spray Foam, CO2 or Dry Powder is the effective way of extinguishing this type of fire.

CLASS C FIRES
Fires fuelled by flammable gases such as Propane, Butane and Methane.
Tackling with Dry Powder is the effective way of extinguishing this type of fire.

ELECTRICAL HAZARD FIRES

It is most important that the power supply is disconnected. The fire can be dealt with according to the
classification it falls into.
When the power supply cannot be isolated and there is a real risk of electric shock then only use non-conductive
extinguishing agents, such as Dry Powder, CO2 on this type of fire.
Ventilating systems, computer rooms, control rooms switch gear and conveyors are among the danger areas.

VEHICLE FIRES
Spray Foam and Dry Powder are the most effective way of dealing with this type of fire.

WHAT DO I DO IF THERE IS A FIRE CAUSED BY IGNITED LPG?

Call the Fire Brigade. Tell them there is an LPG Fire.
If it is safe to do so, bring the fire under control by turning OFF the isolating valves on the bulk tank and if safe
to do so, use a fire extinguisher.
Shut OFF any other valves within the system - if safe to do so.
Evacuate the public and non essential staff.

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IN THE EVENT OF A FIRE WHAT IS THE MOST SUITABLE FIRE

EXTINGUISHER TO USE?
Use a dry powder fire extinguisher and only attempt to extinguish the fire if it is safe to do so.
Ideal for first aid fire fighting as it will knock down a fire but as it has very little cooling effect, the fire could start
up again. It is essential to get any isolating valves turned OFF as quickly as possible.
DRY POWDER EXTINGUISHER:
Predominantly red in colour with an icon and identifying colour triangle.
Works by altering the thermal decomposition to produce non-flammable products by
cooling - chemical inhibition of combustion.
Safe on live electrical equipment although does not readily penetrate spaces inside
equipment.
METHOD OF USE:
The discharge nozzle should be directed at the base of the flames and with a rapid
sweeping motion the flame should be driven towards the far edge until the flames are
out.
If the extinguisher has a shut-off control, the air should then be allowed to clear. A
FIRE MAY RE-IGNITE. If the flames re-appear the procedure should be repeated.
WARNING:
Dry Powder has a limited cooling effect and care should be taken to ensure the fire does not re-ignite.
NOTE:
There are also Dry Powder Fire Extinguishers available for specialist use. One for fighting fires involving metals and
another for fighting fires involving petrol or diesel.

WHAT DO I DO IF THERE IS A SUBSTANTIAL SPILLAGE OR A LEAK OF LPG?

Action in the event of an emergency without a fire:
Call the Fire Brigade. Tell them there is a substantial leak of LPG.
Call the Police. They can assist in diverting traffic and crowd control.
Isolate the electrical supply to all dispensers by the MASTER SWITCH.
Remove sources of ignition.
Do not move vehicles.
Stop the flow of LPG if possible.
Evacuate members of the public and non-essential staff.
Keep everyone away from the area in which the gas vapour is spreading.
Alert neighbours to the danger especially if there are nearby cellars or basements.
Report incident to the Gas Supplier.

Unit 5

Calor LPG Fork Lift Truck Refuelling

30

Self-assessment questions
Q1. If it is safe to do what is the correct fire extinguisher to use to put out a fire fuelled by LPG?

________________________________________________________________________________

Q2. If a fire started what is the emergency procedure that you should take?

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

________________________________________________________________________________

Q3. A fire is extinguished using dry powder. Can this fire re-ignite and what may be the cause?

________________________________________________________________________________

Unit 5

CG701421/5.13/ISS.1

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NOTES

Calor LPG Fork Lift Truck Refuelling

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NOTES