Forklift Liquid Propane Safety And Storage

8 Tips For Changing A Forklift Liquid Propane (LP) Tank

Because liquid propane (LP) is a flammable and explosive gas, changing a forklift LP tank on a forklift offers risks. To keep ourselves and co-workers safe, we must act responsibly.

1. Wear Personal Protective Equipment (PPE). LP fuel is stored under high pressure and at a temperature of -44 degrees Fahrenheit. Direct contact with the fuel can cause frostbite, damaging your skin and eyes. To prevent injury, always wear wrap-around safety glasses and thick rubber gloves when handling LP tanks
2. Check for remaining fuel. Never assume that because the forklift engine died that fuel isn’t present. Ensure the line and fitting have no remaining fuel that can spray on your hands or face when you disconnect the coupler.
3. Disconnect. Unscrew the fitting off the tank. Remove the empty tank and store it properly.
4. Inspect. A leaking tank can result in an explosion. Inspect your fuel tank for frost build-up, dents, gouges, heavy rust and o-ring condition. Also check the lift truck hose and fitting for any visible damage.
5. Tank position. Put the tank on the locating pin. The locating pin on the forklift’s tank bracket serves four purposes: it positions the tank properly for the hose and fitting alignment to connect without twisting or stretching the hose; ensures the pressure relief valve won’t spray LP fuel; aligns the main valve pick-up tube inside the tank to get almost all the fuel out of the bottom; and allows the fuel gauge to read correctly.
6. Check the valve and o-ring. Make sure the valve on the new tank is turned off before attaching the hose coupler. If the coupler is connected to an open valve, it could disrupt the check valve and cause LP to spray. Additionally, check that the o-ring from the empty tank hasn't dislodged and blocked the check valve. If the check valve is obstructed, fuel won't flow, and the forklift won't start.
7. Connection and the valve. Fully screw the forklift fitting onto the tank fitting and hand-tighten it. Slowly open the valve, taking care not to over-tighten, so you can quickly shut it off in case of a leak, fire, or explosion. Once the valve is fully opened, the 10% surge valve inside the tank will automatically close if an LP hose or fitting fails, ensuring safety.
8. Look, listen, and smell. If you see visible white frost, hear rushing noises or smell a bad odor – you have a leak! Because it is heavier than air, LP vapor pools on the ground and will look for a source of ignition. Shut off the tank valve and ventilate the area.

Liquid Propane (LP) Gas Safety And Storage

A significant number of forklifts in the U.S. are powered by LP, or liquefied petroleum, which is a flammable mixture of hydrocarbon gases, mainly propane and butane. One gallon of LP gas is equivalent to 270 gallons of vapor, meaning an 8-gallon LP gas cylinder can hold approximately 2,400 gallons of vapor.

Its highly flammable nature makes LP gas vulnerable to creating fires and explosions. Along with the use of PPE, having proper ventilation is vital to release vapors are not captured, especially in areas with nearby ignition sources. 

Storage of LP gas is addressed by OSHA regulation 1910.178(f)(2): The storage and handling of liquefied petroleum gas fuel shall be in accordance with NFPA Storage and Handling of Liquefied Petroleum Gases (NFPA No. 58-2012), which is incorporated by reference as specified in Sec. 1910.6.

For specific instruction on storage of LP gas at your facility, contact your local fire marshal.

Checking Your Forklift For A Propane Leak

If you smell propane coming from your forklift, focus initially on ventilation. Open up doors and windows in the area and turn off the forklift’s liquid propane (LP) tank. In an open, well-ventilated area, LP vapor can safely dissipate. However, because LP vapor is heavier than air, it can collect on the ground like water, remaining undetected and posing a potential fire hazard if exposed to an ignition source.

Forklift Propane Leak Test

Ensure the area is well-ventilated before turning on the LP tank. Apply soapy water to the fittings and hoses using a small brush or a soaked paper towel. If there's a propane leak in the fuel system, bubbles will form at the leak's source, indicating the problem.

Running Out Of Forklift Fuel

Accidents can occur when a forklift runs out of fuel unexpectedly.

Picture an operator using a paper roll clamp attachment to lift a load. After raising the load to the proper height, the operator moves forward to place it on top of other rolls. Suddenly, the forklift engine shuts off due to running out of fuel. The operator is forced to exit the safety of the overhead guard, find a new liquid propane (LP) tank, and stand near a 4,000 lb roll of paper that is slowly lowering while the forklift is refueled, creating a dangerous situation.

Forklift Fuel Risks And Prevention

Whether it causes loss of function or a long hike to locate a LP tank, running out of forklift fuel puts operators and nearby pedestrians in danger. Also, some facilities have strict rules about changing LP tanks due to the risk of fire or explosion and effort must be made to tow the forklift to an approved fueling station.

Options to assist operators include installation of low fuel indicator lights, use of tanks with a fuel gauge or checking the weight of the tank.

ProLift is your partner for equipment maintenance and safety training. Keep your forklift operators aware of risks associated with liquid propane.