LPG forklift truck fire risk

Health and Safety Executive - Safety notice

Issue

HSE is aware of a number of fires on, and around, liquefied petroleum gas (LPG) powered forklift trucks and other similar vehicles that have occurred during starting.

Outline of the problem

Build-up of deposits in fuel systems, in particular, the vaporiser units of LPG powered vehicles has led to a number of fires.

Trucks not starting due to sticking valves

Deposits in vaporiser units, flow regulators and shut off valves cause the truck to fail to start, particularly from cold. Build-up of deposits can lead to sticking valves and the mixture supplied to the engine being too rich to be ignited.

Repeated starting attempts can release unburned LPG

Repeated starting attempts can result in the release of unburned LPG, which in extreme cases can be ignited, setting fire to the vehicle and surrounding materials.

Action required

Operators

• review your safe system of work in relation to the use of all LPG powered lift trucks and similar vehicles
• provide information, instruction and training for all operators about the hazards raised in this alert
• park LPG vehicles in well ventilated areas free from flammable material, particularly when parking overnight or for longer periods

If a truck does not start within the normal few seconds

• do NOT continue to turn (crank) the engine over using the starter
• do NOT repeat the normal engine starting procedure
• do NOT spray volatile agents into the air intake in an attempt to aid starting
• get off the truck and close the shut off valve to isolate the gas bottle
• secure the truck to prevent further starting attempts
• ensure the area is well ventilated
• do NOT attempt to solve or repair the problem yourself, arrange for a competent maintenance engineer to do a check of the LPG system

Service and maintenance engineers

If you are presented with an LPG powered truck with a starting problem:

• do NOT follow the normal starting procedure
• isolate the LPG supply by closing the shut off valve
• ensure that the area is well ventilated
• disconnect the battery
• release LPG pressure trapped in the fuel supply system
• follow the manufacturer’s guidance for inspection of the LPG system

LPG is cold, take appropriate precautions when working with it. Once released LP gas is heavier than air and can pool in low lying areas, where it can be ignited by any source of ignition, including static electricity, electrical sparks and hot surfaces.

Guidance

• Approved Code of Practice and guidance Rider-operated lift trucks: Operator training and safe use  
• guidance About liquefied petroleum gas (LPG)

Relevant legal documents

Regulation 12 of the Provision and Use of Work Equipment Regulations 1998 (PUWER) requires that the risks to users from work equipment catching fire are adequately controlled.