General Safety & Emergency Response

Training

When Safety Dies, Accidents Born

General Safety & Emergency Response

Time of the session: 30 Minutes
Language: Punurglish (Punjabi+Urdu+
English)
Method: Interactive Discussion/ Industrial
Cases

Objectives of the Training

Know/ Revise Properties of LPG
Understand LPG as Hazardous Material
Understand LPG Filling & Storage Plant,
Transportation and cylinder handling in
preview of Safety.
Basic understanding of Emergency
Procedures in the event of an LPG
Incident
To repeat what is already known to you

Arial view of the BORAL Gas site after the fire.

Note: LPG terminal (centre), fire damage to warehouses (centre left),
Tank No:1 in Sheas Creek (right),
and the destroyed Bottle Filling Shed (bottom right).

The Site
The LPG Terminal was built in 1969 and
contained a number of 100 Tonne elevated LPG
tanks. In the weeks prior to the explosion,
BORAL Gas was in the process of installing
new safety systems that would enable
isolation of the tanks from the distribution
manifolds and associated pipes. This was
only two weeks from completion when the
explosion happened. Had these tanks been
isolated then the explosion would have been
avoided.

The Boral Gas Incident

9:56 pm, 1990, Sydney
100 Tonne LPG storage tank ruptured and released about
47 Tonnes of LPG
Technically this was a BLEVE (Boiling Liquid Expanding
Vapour Explosion) the biggest to ever occur in the
Southern Hemisphere.
The fireball ascended several hundred meters into the air,
and the explosion was heard throughout Sydney
As a result of the explosion, many thousands of people
were evacuated from the city and airport was closed.
The emergency responders who attended the scene were
exposed to a terrifying and life-threatening situation. Their
bravery, training and good judgment undoubtedly saved
lives.

Sequence of events
On the 1st of April, there was 346 Tonnes of LPG at the
depot. Some time that Sunday evening, after all staff
had left the BORAL Gas St Peters site, a small leak

of propane started somewhere on a manifold

below Tank No: 1. The escaping vapour formed a
cloud at ground level, which eventually came into
contact with an ignition source some time
around 7:00pm.

Sequence of events
Between 7:00pm and 8:50 pm, the LPG manifold
fire grew to over half a Gigawatt in size.
The fire spread enhanced via failures of the
hydrostatic relief valves located on the Liquid
Manifold, and consequent melting of metal
pipes.
Because the isolation valves were open back to
the LPG tank, these pipes were able to feed the
growing fire without interruption.

Sequence of events
By about 8:50 the radiant heat and direct flame
contact from the manifold fire had heated the
100 Tonne tanks sufficiently to raise their internal
pressures to dangerous levels.
The Pressure Relief Valve (PRV) on Tank 1 had
started to cycle on and off so as to relieve this
pressure. The propane vapour that was released
ignited and formed jet
flames 40 m high.

Sequence of events
At 8:55 pm the Fire Brigade received an emergency call. The Fire
Brigade arrived at 9:12 pm and observed Tank No: 1 had an intense fire
involving its pressure relief valve and the large fire at the manifold.
At approximately 9:19 pm the PRV on Tank No: 2 operated. One minute
later members of the Fire Brigade heard a high-pitched sound and
withdrew some distance from the fire.
At 9:39 pm Tank 3 ruptured at the top of its hemispherical end forming a
300mm x 75mm slit. The ignited vapour produced a fan shaped flame
80m high. The Tank emptied over a period of about 6 mins.
Between 9:39 and 9:56, the PRV on Tank No: 1 remained continuously
open. Tank No: 2 also ruptured in a similar way to Tank 3. The thermal
radiation was so intense that tyres caught fire on many LPG Road
Tankers parked nearby, and the PRVs on their tanks started to operate.
At 9:56 pm Tank No: 1 ruptured. A Boiling Liquid Expanding Vapour
Explosion (BLEVE) occurred, as the heated end of the tank tore away.
The resulting fireball was some 200 m in diameter, ascended 1
kilometre into the air and lasted for 14 seconds.

Sequence of events
The main part of the Tank rocketed 500ft
into nearby Sheas Creek. The Tank
impacted and destroyed a LPG Road
Tanker parked beside the Tank and a
500kVA electrical sub station.
The fireball, and discharged propane,
ignited fires in warehouses adjacent to the
depot

Sequence of events
At about 10:05 pm, a major fire also
developed in an LPG Bottle Filling Shed
with numerous domestic sized cylinders of
LPG bursting and shooting spectacularly
into the sky.
The fire continued until 1 am the following
morning when the Fire Brigades
considered the fire under control.

Tank No 1 resting in Sheas Creek, about

500ft from the depot

Contributing Factors
1. The site was vacant on the Sunday afternoon, so the there
was no staff on site who could have intervened or raised
alarm at an early stage of the fire.
2. The pipes and manifolds were open to the LPG Tanks so that
any leak could potentially drain hundreds of tonnes of LPG.
3. The fire and leak alarms that were installed were not
connected to the Fire Brigades.
4. The signs for the controls of the drencher system where not
able to be read, so that the Fire Brigades could not switch on
water sprays which could have cooled the tanks.
5. The orientation of the hydrostatic relief valves on the liquid
propane manifold projected vapour in the direction of pipes
also containing propane, and so caused progressive failures
to pipes and escalation of the fire.

Industrial Relations Commission

Judgement
Chief Inspector Richard Clarke on behalf of
a large investigation team brought two
matters before the Court under sections
15 and 16 of the Occupational Heath and
safety Act 1983. Justice Bauer found
BORAL Gas guilty of the two offences. It
was fined a total of $35,000 and order to
pay costs (which were considerable).

The Story Conclusion

The investigation of this event was a major effort
by many WorkCover and TestSafe (then LOSC)
staff. The capacity to undertake such highly
demanding, lengthy and arduous investigations
is a great strength of the organization and needs
to be maintained.
It is most fortunate that no one was injured or
killed as a result of this fire and explosion.
However, history shows that these kinds of
events will occur from time to time when safety
systems either fail or are non-existent.

The Boral Gas Incident Video

Product(C3H8 + C4H10)
Like natural gas, its combustible having
higher unit mass and hence heating value.
Heavier the air and lighter than water
It catches fire
Can cause anesthesia and cold burns
Its not toxic, its hazardous, hazard can be
minimized

LPG is lighter than water

LPG LIQUID

WATER

LPG is heavier than Air

AIR
OR
P
A
V
LPG

LIQUID TO VAPOUR EXPANSION

RATE

Is LPG Toxic

Hazards of LP gas
Flammable
Asphyxiant

1a

Hazards - Asphyxia
Most gases are heavier than air, some are lighter e.g. Helium,
but LP Gas is much heavier than air
Heavier gases displace the air and therefore oxygen thus
restricting breathing
Humans need approximately 18% oxygen to breathe (Normal is
approx 21%)
Some gases dilute or replace the oxygen normally in the
atmosphere. These are called asphyxiant gases
In enclosed spaces the effects of the gas replacing oxygen in
the air creates added danger

Hazards of LP gas
Can freeze tissue on contact
Exposure limits
Butane - 800 ppm
Propane - 1000 ppm

1b

Can LPG Burn Skin

LPG Bottles

Valve

Shroud

Main shell

Foot

Gas/Liquid level

PRV

Correct storage

Upright

Spaced

Cage

Compound

Safe Handling
Cylinders must not be thrown or subject to impact
Cylinders must be stored upright so as to protect the valves
and allow PRV to operate correctly
Never try to catch a falling cylinder
Valves must never be used as a lifting point
Do not use tools to operate cylinder valves
Always replace safety caps / plugs when the cylinder is
empty or not in use
Do not store cylinders in the horizontal position

Drive Safely

Drive Safely

The cab of a tanker truck caught fire

Driver of LPG tanker truck was dozing

LPG Lorry Hit a Shop

Bangkok LPG Tank Accident

Dozing made this

18 tones of LPG

The driver lost control while negotiating a sharp turn

An attempt to siphon off LPG to another tanker was not
successful as the intensity of the leak increased and only
a small quantity could be diverted. The leak was then
covered with wet sandbags.

In the impact of the accident the rotor gauge of

the tanker got ruptured and LPG began to leak

What saved/ killed them

Off all these accidents, reporting and
controlling panic saved them from big
disasters
They immediately reported the staff about
the emergency and electricity supply to
city or area was made of and other
requisite measures were taken

Pre-Filling: Have a round

Before filling operation check in the whereabouts for

Naked flames
Electrical equipment and live wires
Cigarettes smoke
Grinding/Welding operation
Buildings Exhaust, or air moving equipments

Dont fill gas if you find anything from above, report it and ask for
necessary arrangements.

No Smoking/ No Naked Flame

Switch Off The Mobile Phone During Filling

Electrical Appliances

Grinder

An angle grinder is believed to have sparked one of the most

destructive bushfires in Perth's history.

Burning Cigarette

Case Study WMIL

Electric short circuiting at 3 from bulk bowser
(mains were then made off). Electric welding
plant was 5 from bulk tanker.
Grinder flames at 6 ft from bulk tank (Supply
halted for some time)
Power house exhaust fan at 10 ft from bowser
Combustible dried leaves just outside fence
Know what is around you. Our people didnt know about the Power House before

WMIL Electric Welding Plant

WMIL

Electric Grinder flames

Dont be exposed to leakage

Keep you nose away from Fixed Level gauge
Fixed Level gauge leakage may be dangerous

MOV00007.3gp

LPG Hazards
Hazards of escaping un-burnt LPG
Fire
Explosion
Asphyxiation

Hazards of partially burnt gas

Asphyxiation
CO Poisoning

Driving Fitness
Physical
Mental
Remember:

You should never be sleepy

You shouldn't be ill

You shouldn't be fatigued

You had proper rest

Reporting on Vehicle Condition

Report anything that is unusual in bowser,
tank or vehicle
Report anything that needs repair,
maintenance or replacement
Take record with you

Emergency Response

# 080000050
Fire brigade Response Time?
Your response time?

Electric Cables
It is measured as the longitudinal distance
from the cables to the tank)
25ft min from Electric cables/ line/ transformers
Tanks should not be sited directly under/besides power cables
Similarly the bulk site should be 25ft (min) away from a drain, to
avoid vapor travel over it

Transfer Operation - Distance from

IC engines

ER MEASURES FOR LPG TANKER DRIVER

Move vehicle to open ground if possible.

Stop the vehicle engine.
Extinguish ignition sources / no smoking.
Turn electrical master switch off if without risk.
Shut off leak if minor and without risk.
Warn public / other vehicle drivers to keep away and
upwind from possible danger area.
Extinguish non LPG fires using vehicle extinguishers if
safe to do so.
Do not tackle a major fire.

ER MEASURES FOR EMERGENCY SERVICES

Keep public and other vehicles away from possible
danger area, and upwind.
Do not permit naked flames / ignition sources / smoking
near unignited leakage.
Keep vehicle tank cool with water spray if exposed to
fire.
Disperse unignited leakage with fine water spray using
monitors if available.
Do not extinguish leaking gas flames unless absolutely
necessary or unless the source of the leak can then be
isolated.
Consult an expert on whether to extinguish an LPG fire
using dry powder or foam.
DO NOT USE WATER JET ON A POOL FIRE
Extinguish all other fires.
If LPG may have entered drains inform police

In Emergency
Leakage

Squadron off the area 50

Close Valves, disconnect Supply, Emergency Shut-off valves
Keep people and flame away from gas
Ventilate as maximum as possible, let the gas disperse
Inform the emergency response helpline

Fire on or near the tank

Inform at the emergency number and PPG officials

Cool the tank
Isolate the tank - Get the tank out of the exposed area
Use the appropriate fire extinguishers to control fire near bulk tanks

Bulk Tank

SUGGESTED EXCLUSION ZONES IN CASE OF

UNIGNITED LPG LEAKS
Small vapour leak
characterized by a
smell of gas

30m

Large vapour leak

characterized by
loud hissing of gas

100m

Liquid Leak
Characterized by a
roar of Gas

200m

Exposed to leaked LPG or Asphyxia

INSTRUCTIONS FOR THE FIRST AID PROVIDER

Remove contaminated clothing as soon as possible
unless adhering to skin.
COLD BURNS - Flush affected areas with tepid water.
Seek medical treatment with symptoms apparently from
inhalation or contact with skin or eyes

IGNITED LPG LEAKS

Cut-off or reduce the supply of fuel if possible
If safe to do so, deflect or move any flame from
impinging on vulnerable plant
Before attempting to extinguish the flame, assess if the
LPG will cause an explosion risk

LPG VESSELS THREATENED BY FIRE

Keep exposed surfaces of the vessels cool with water
(monitors/fixed spray system)
Move the vessels where this is an option and it is safe to
do
Tackle fire and establish water curtain between it and
vulnerable plant

TACKLING THE INCIDENT

Carefully assess before any approach

Wear the right equipment
Ensure safe route of access and egress is available
Approach any fire or escaping LPG from upwind
Avoid coming in contact with LPG- it can cause severe
cold burns and saturate clothing which may be ignited
Any vessel involved in a fire may suddenly rupture.
Change in the size of fire, or noise from the PRV may be
an indication. There may be no Warning
If in doubt do not approach

UNIGNITED LPG LEAKS

1.
2.
3.
4.
5.
6.

Leaks may be identified by smell, noise or frost at the

source.
Suspected leaks may also be detected by soapy water
or gas detector
NEVER SEARCH FOR LEAKS WITH A NAKED
FLAME
Isolate the tank, in case of a mobile storage move to
safe area if possible
Ventilate the area
For Large Leaks, assist dispersal of LPG and protect
vulnerable plant areas with water sprays

Fire Extinguishers

Dont through Water On LPG Fire

Just in Case
Cool the tank

Cool the tank

PPEs
Emergency worker should have proper PPEs
Natural Fiber clothing should be used under the fire
retardant wear
Gloves and Eye protection should be worn to provide
protection against cold burns
Suitable respiratory protective equipment shall be used
Protective antistatic foot wear should be worn that has
no exposed metal surfaces

Wear PPEs and have with you

Safety Helmet
Hand Gloves
Goggles
Mask

TLA-571 Primary tanker Axle Break

Case
Axle broke and tyres got lost
Lessons:
Be vigilant
Try to critically view your lorry
Maintenance and its records
Dont hide and dont pass the buck, it is
killing

TTD-768 Bulk Lorry Case

Leakage at pump discharge flange
What could have happened
How to prevent
Maintenance

Summary

Know your surroundings

Carefully handle
No dozing/ no sleepiness
Uproot the cause of hazard
Report-inform office/police
Dont panic
Switch off the electric supplies
Cool the tank
Wear the PPEs

Q&A Session
1. What would you do if LP gas leaks?
2. What would you do if someone get
unconscious/ asphyxiated?
3. What would you do if there is a fire near the
bulk tank?
4. What would you do if there is fire on your bulk
bowser?
5. How would you differentiate the empty bowser
and a filled one?

Thank you