Hazard identification and preventive measures for LPG loading and unloading vehicles

The initial speed when loading and unloading the vehicle should not be too high, in order to prevent rapid vaporization, a sharp drop in temperature, and cooling. Freezing can damage or crack pipelines, valves, and flanges. It causes leaks~~Vehicles used for loading and unloading must enter the site, and they need to be equipped with flame arresters. Make sure the connection interface is in good condition temporarily during loading and unloading, and use a combustible gas detector to monitor the atmospheric environment at all times. Safety measures are in place: fire extinguishers, steam.

Job Hazard Analysis (JHA) Form
Task: Vehicle loading and unloading
Area/Process: Tank farm operations
Department: Loading and unloading workshop
(Note: R = Risk level = Likelihood L × Severity S)

| Sequence | Work step | Hazards or potential incidents | Main consequences | Existing safety controls | Likelihood L | Severity S | Risk level R | Recommended improvements/control measures |
|----------|------------|--------------------------------|------------------|------------------------|-------------|------------|---------------|------------------------------------------|
| 1 | Vehicle flame arrestor sparks causing fire/explosion, injuries, equipment damage | | | Wear flame-resistant helmets before entering the plant area | 1 | 5 | 5 | Wear flame-resistant helmets before entering the plant area |
| 2 | Static electricity from grounding wires causing fire/explosion, injuries, equipment damage | | | Connect two grounding wires to the vehicle body before loading | 1 | 5 | 5 | Connect two grounding wires to the vehicle body before loading |
| 3 | Static electricity from steel wire hoses causing fire/explosion, injuries, equipment damage | | | Use solvent-resistant anti-static hoses | 1 | 5 | 5 | Use solvent-resistant anti-static hoses |
| 4 | Injuries and equipment damage due to static electricity resulting from improper use of personal protective equipment | | | Provide personal protective equipment for loading personnel | 2 | 5 | 10 | Provide personal protective equipment for loading personnel |
| 5 | Air contamination from asbestos cloth, affecting employee health | | | Implement proper labor protection measures | 2 | 4 | 8 | Implement proper labor protection measures |
| 6 | Motor damage and equipment failure due to incorrect pump startup/shutdown procedures | | | Follow safe operating procedures | 3 | 6 | 18 | Follow safe operating procedures |

Safety Management System for the Loading and Unloading of Hazardous Chemicals 1. Purpose: To strengthen the safety supervision over the dispatching, procurement, and loading/unloading of hazardous chemicals in our company, to standardize the operational practices of those responsible for such tasks, and to ensure safe production at all stages related to hazardous chemicals. These regulations are formulated in accordance with the \"Work Safety Law\", the \"Regulations on the Safety Management of Hazardous Chemicals\" sowie other relevant laws, regulations, and standards, taking into account the actual conditions of our company. 2. Scope of application: It is applicable to the daily management of the shipping, purchasing, and loading/unloading processes of hazardous chemicals within the company. 3. Responsibilities 3.1 These provisions are formulated by the company’s Safety Committee, which is also responsible for their interpretation. 3.2 The Safety Committee is responsible for the comprehensive supervision and management of the dispatch, procurement, and loading/unloading of various hazardous chemicals. 3.3 The Procurement Department is responsible for reviewing the qualifications of suppliers at the time of purchase and shipment. 3.4 The gatekeeper is responsible for checking the safety condition of vehicles carrying hazardous chemicals entering the plant. 3.5 The warehouse is responsible for supervising and managing the loading and unloading of hazardous chemicals. 4. Provisions 4.1 Qualification verification system: 4.1.1 Qualifications of the purchasing entity (or supplying entity). Possess a license for the safe production of hazardous chemicals or a business license for such activities. 4.1.2 Qualifications of the transportation enterprise owning the transport vehicle. Possess a License for the Operation of Road Transport of Dangerous Goods. 4.1.3 Qualifications of transport vehicles. Possesses: (1) Motor vehicle driving license ； (2) Road Transport Permit consistent with the approved business scope ； (3) The transport vehicle and tank are consistent with the photos on the vehicle registration document ； (4) The rated load capacity specified in the Road Transport Permit is consistent with that indicated on the vehicle registration document ； (5) The maximum filling capacity of the registration certificate for mobile pressure vessels (pressure tank trucks) shall not exceed the load capacity specified in the vehicle registration document. 4.1.4 Qualifications of drivers and escorts. Must possess: (1) Driver’s license and “Qualification Certificate for Commercial Road Transport Drivers” ； (2) Courier’s “Road Transport of Dangerous Goods Operation Certificate”. 4.1.5 Safety warning signs and markings. Transport vehicles and tanks must be equipped with warning signs in accordance with relevant regulations, and marked with characters such as “Toxic”, “Explosive”, “Corrosive”, as well as road transport hazard labels. If any of the above documents is missing or the requirements are not met, delivery or receipt will not be granted. 4.2 Qualification registration system. The supply and marketing department shall maintain records of the relevant qualifications of purchasing and supplying entities, and file copies of such qualifications. 4.3 System for inspecting the safety condition of vehicles carrying hazardous chemicals entering the plant. When hazardous materials transport vehicles enter the company, the security guard is responsible for checking the safety condition of the vehicles, verifying whether they match the details specified in the delivery order, ensuring that the drivers and escorts have the appropriate identification documents, and checking that the vehicles are equipped with fire extinguishers and other necessary emergency equipment. 4.4 Safety education system for loading and unloading personnel 4.4.1 Personnel in our company who are responsible for the loading and unloading of hazardous chemicals must undergo three levels of safety training provided by the company; only those who pass the examinations and obtain a safety operation certificate may be allowed to take up their duties. 4.4.2 Personnel responsible for loading and unloading hazardous chemicals must be familiar with the safety procedures for such operations as well as various safety management systems, and be able to implement them conscientiously ； Be familiar with the hazardous factors present during the loading and unloading of hazardous chemicals, as well as potential leaks, fires, and explosions. Master the measures and methods for preventing and dealing with such incidents, so as to ensure proper response in the event of an accident and reduce its severity. 4.5 Operating procedures during loading and unloading. 4.5.1 In any of the following situations, loading and unloading operations of hazardous chemicals must be stopped immediately, and proper measures must be taken: 4.5.1.1 During thunderstorm weather ； A fire broke out near 4.5.1.2 ； 4.5.1.3 Leakage of hazardous chemicals ； 4.5.1.4 Loading and unloading are strictly prohibited from 18:00 daily to 08:00 the next day (in special cases, loading and unloading may only be carried out with the approval of the company’s deputy general manager in charge of safety). 4.5.2 Before loading and unloading, it is necessary to first check the vehicle’s transportation qualifications, the qualifications of the driver and escort, as well as the vehicle’s safety equipment. 4.5.3 Strengthen on-site personnel management. Staff must properly wear and use personal protective equipment in accordance with relevant regulations, and operate in compliance with standard procedures to ensure safety at the loading and unloading sites. 4.5.4 Storage equipment, electrical facilities, and the methods used for loading and unloading must comply with the requirements of relevant standards and specifications; reliable safety measures must be taken to ensure protection against fire, explosion, water damage, static electricity, excessive pressure, and dropping or dragging. 4.5.5 During the loading and unloading process, it is necessary for the driver or escort from the shipping/leasing party, along with our company’s operators, to be present. The loading and unloading operations shall be carried out by our company’s staff; outsiders are strictly prohibited from performing these tasks. The loading and unloading personnel must remain at their posts, adhere strictly to the operating procedures, and strictly control the number of vehicles entering the site (no more than two vehicles are allowed). Overloading, mixing different types of goods, or incorrect handling of goods is strictly prohibited, and the weight of the goods must not exceed the approved load capacity. 4.6 Safety approval system before vehicle departure from the factory. After the loading and unloading is completed, the personnel responsible for it must inspect and verify the amount of cargo loaded/unloaded, the condition of the securing measures, as well as the availability of safety protection equipment. Vessels that do not meet these requirements are strictly prohibited from leaving the loading/unloading site. 4.7 Shipping registration system. After the loading and unloading staff confirm that there are no issues with the vehicle, they carefully record the inspections and approvals carried out during the shipping and loading/unloading processes based on the actual situation, and establish work records. 5. Penalty Provisions 5.1 If the relevant departments fail to carry out their duties as required, 2–10 points will be deducted from the safety management score of those units, and the persons in charge of such units will be fined 50–100 yuan. 5.2 If personnel responsible for loading and unloading hazardous chemicals fail to follow the operating procedures, 2–10 points will be deducted from the safety management score of the relevant unit each time. 5.3 If a safety accident occurs due to failure to fulfill duties or non-compliance with operating procedures (without any casualties), 5–15 points will be deducted from the safety management score of the relevant unit each time, and the person in charge of that unit will be fined between 100 and 500 yuan. In cases where casualties occur, the relevant responsible persons will be handed over to the judicial authorities for handling. For non-conformities not covered in 5.4 and above, 2–10 points will be deducted from the safety management score of the relevant unit for each one. Appendix 1: Safety Operating Procedures for Methanol Loading and Unloading 1. After the vehicle is parked in the designated location, check whether the vehicle used for loading and unloading hazardous materials is equipped with a fire shield; apply the hand brake, turn off the engine, and secure the wheels with brackets (sleepers). Once the doors are locked, hand the vehicle keys to the loading/unloading personnel. These personnel must thoroughly inspect the vehicle’s grounding system, ensuring that it is connected to a conductive surface. Charging begins 15 minutes after the vehicle has been stationary. 2. Loading and unloading personnel must wear protective equipment, glasses, and rubber gloves. Slowly insert the flexible hose into the filling port of the tank truck; avoid any violent impacts. 3. The loading/unloading personnel check that the area between the storage tank and the final valve remains unobstructed, that the equipment is in good condition, and that there are no leaks of hazardous materials. After activating the automatic quantitative distribution system, check the shielded pump corresponding to that serial number and adjust the outlet valve to maintain the pressure at 0.3–0.5 Mpa. 4. During the unloading of hazardous materials, the volume of the product must not exceed 90% of the tank’s capacity. If the amount to be unloaded is insufficient such that the remaining capacity in the tank falls below 10% of its total capacity, unloading must be stopped immediately; overloading is strictly prohibited. 5. After the handling of hazardous materials is completed, the vehicle should be left to stand for 15 minutes before the static clamps are removed. Only after the personnel responsible for the handling have checked that the equipment is safe can the vehicle keys be given to the driver, who can then start the vehicle and leave.

The loading flexible hose should be equipped with an emergency cut-off device to prevent leakage accidents.