DOSO Template
DOSO Template
Date: 22/06/2021
Contents
List of Appendices
Appendix 1 – Safety Data Sheet (SDS) for LPG in English and Bahasa Malaysia
Page 2 of 22
Demonstration of Safe Operation Document
(Storage of Liquefied Petroleum Gas in Cylinder)
A. Identification of Major Accidents Hazards
1.1 LPG composition and The compositions of Liquefied Petroleum Gas are
physical criteria propane C3, butane C4, isobutene and 1,3-butadiene.
It is in liquid form when stored under pressure at
ambient temperature.
It is colourless and odourless. A distinctive and foul
smelling odorant, Ethyl Mercaptan is added for detection
purpose.
The Safety Data Sheet (SDS) for LPG is attached in
Appendix 1.
2.3 Layout plan The layout plan of the store showing details of the storage
location of cylinders and other hazardous substance,
together with the emergency equipment is found in
Appendix 2.
1.3 Lorry / forklift Access to the store restricted to If found to be not following
accident with other authorised vehicles and traffic flow, the workers to
vehicles personnel. stop vehicle.
One-way traffic flow system If found to be moving more
within the store. than 10 km/hr, the workers
Speed limit in the store imposed to advise driver to slow
at 10 km/hr. down.
Forklift drivers must attend and Report incident to the
pass the forklift safety manager.
competency course. Practise Emergency
Regular toolbox meeting to response if cylinders have
increase safety awareness. been damaged and
Unsafe Act / Condition Reporting leaking.
is done by distributors and Practise Medical response
remedial actions taken are if injury takes place.
recorded to ensure closing the
loops.
1.4 Cylinder falling off Cylinders on metal pallets are If found to be not secured,
from metal pallet during required to be secured with forklift driver need to first
handling locking bar. replace the locking bar
Forklift speed limit in the store before lifting the metal
imposed at 10 km/hr. pallet.
Forklift drivers must attend and Report incident to the
pass the forklift safety manager.
competency course. Practise Emergency
Forklift required to have seat belt response if cylinders have
and overhead protection been damaged and
installed. leaking.
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Regular toolbox meeting to Practise Medical response
increase safety awareness. if injury takes place.
Unsafe Act / Condition Reporting
is done by distributors and
remedial actions taken are
recorded to ensure closing the
loops.
1.5 Cylinder falling off Cylinders on lorry are required to If found to be not stable,
from lorry during be secured / strapped. workers need to first
handling (Loose) Regular toolbox meeting to rearrange the loose
increase safety awareness. cylinders before unloading.
Unsafe Act / Condition Reporting Report incident to the
is done by distributors and manager.
remedial actions taken are Practise Emergency
recorded to ensure closing the response if cylinders have
loops. been damaged and
leaking.
Practise Medical response
if injury takes place.
1.6 Internal pathway Store design follow MS 830 If found to be not following
system not appropriate standards. traffic flow, the workers to
One-way traffic flow system stop vehicle.
within the store. If found to be moving more
Speed limit in the store imposed than 10 km/hr, the workers
at 10 km/hr. to advise driver to slow
Cylinders stacked within the down.
storage boundary. Report incident to the
manager.
Practise Emergency
response if cylinders have
been damaged and
leaking.
Practise Medical response
if injury takes place.
1.7 Unsafe lorry Delivery vehicles are required to Unsafe lorries (e.g. bald
condition meet stringent NGCE standards. tyres, no seat belts) not
Vehicles are sent to Puspakom allowed to enter the store.
for inspection every six months. Report incident to the
Condition of vehicles inspected manager.
at gate checks. Practise Emergency
Regular toolbox meeting to response if cylinders have
increase safety awareness. been damaged and
Unsafe Act / Condition Reporting leaking.
is done by distributors and Practise Medical response
remedial actions taken are if injury takes place.
recorded to ensure closing the
loops.
2.1 Hole in cylinder All cylinders go through stringent Report incident to the
checks in the filling plant. manager.
All cylinders are subjected to Stop all activities.
requalification after the first 12 Do not operate electrical
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years and then thereafter every 7 switches.
years at the filling plant. Ensure there is no naked
flames, no smoking and no
starting of engines.
Stand by with fire
extinguishers at upwind
position.
Plug the leak using conical
wooden plug.
If leak cannot be stopped,
remove cylinder to well
ventilated open area, if safe
to do so.
Practise Medical response
if injury takes place.
2.2 Gas leak through All cylinders are thoroughly Report incident to the
cylinder valve checked for leaks at the filling manager.
plant and any leaks detected are For leaking compact valve,
immediately made safe. plug with blue safety cap.
Sealing caps, safety caps and For leaking POL valve, plug
labels are attached to all opening with brass POL
cylinders. plug.
Workers are required to conduct For leaking liquid
daily inspection of cylinders. withdrawal valve, plug with
CGA 555 brass plug.
Practise Medical response
if injury takes place.
3. Human Factor
3.2 Lack of job Workers are provided with If found to be ill, other
concentration, physical refresher trainings. workers to advise him to
or ill Rotation of duties among rest and seek medical
workers carried out. treatment.
Performance of workers are Practise Medical response
monitored. if injury takes place (e.g.
Regular toolbox meetings to cylinder falling down and hit
increase safety awareness. worker).
Close supervision and regular Report incident to the
Unsafe Act / Condition Reporting manager.
by supervisor or manager. Re-assign to other duties.
Use of PPE (safety shoes & hand
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gloves).
4. Natural Factor
4.1 Flood danger Store design follow MS 830 Shut down all electrical
standards. power.
Proper drainage in place. Report incident to the
Storage area is raised. manager.
Practise Medical response
if injury takes place.
5. Control System
6. Source of Fire
6.1 Cigarette butt Workers and visitors not allowed If found, workers/visitors
to smoke inside premise. need to put off the cigarette
Signage board on “no smoking” immediately.
at entrance and inside work area. Report incident to the
Access to the store restricted to manager.
authorised vehicles and Practise Emergency
personnel. response if fire occurs.
6.2 Fire from neighbour Store built with minimum safety Report incident to the
(factory, house, etc) distance and standards manager.
according to MS 830. Practise Emergency
Dialogues with neighbours on fire response if fire occurs.
prevention and fire-fighting Apply water to cylinders to
procedures. cool them.
Carry out joint fire drills with Remove cylinders to a safe
neighbours. area if possible.
Remove all important
documents from office and
safe keep in a safer
location.
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6.4 “Buried” live cables Survey and record the exact Report incident to the
due to high voltage location of cables, type of cables manager.
cable dug and cause and protection. Practise Emergency
spark response.
Practise Medical response
if injury takes place.
6.5 Thunder danger Identify area for type of electrical Report incident to the
protection. manager.
Regular inspection and Practise Emergency
maintenance by approved response.
electrical contractor. If fire, extinguish fire using
fire extinguishers or hose
reel.
If fire occurs in the store and resulted in the catastrophic failure of the cylinder, an explosion from
the BLEVE (Boiling Liquid Expanding Vapour Explosion) phenomena will happen. The effect from
this phenomenon can be measured by the blast overpressure and thermal radiation.
The consequence distances of the blast overpressure are as appended in the table below.
Blast
Overpressure 12 kg 14 kg 50 kg Effects
(bar)
0.02068 69.00 m 72.63 m 111.00 m Safe distance (non-major destruction
except for ceiling and broken glass
window, but no flying object)
Based on the table, the consequence distance of the blast overpressure at 0.2086 bar is 14.55m
and 22.23m for 14 kg and 50 kg cylinders respectively, whereas the level of damage received from
the consequences is little damage on heavy machines (3000 lbs) in industrial building, distortion of
steel building and pulling away from the foundation.
The consequence distances of the radiation intensity are as appended in the table below.
Radiation
Intensity 12 kg 14 kg 50 kg Effects
(kW/m2)
4 39.32 m 41.37 m 62.49 m Sufficient to cause pain to personnel if
unable to reach cover within 20s, however
blistering of the skin (second degree burn)
is likely, 0% lethality
Based on the table, the consequence distance from cylinder position radiation of 37.5 kW/m 2 is
13.11m and 19.56m for 14 kg and 50 kg cylinders respectively, whereas the level of damage
received from the consequences is sufficient to cause damage to process equipment.
1.2 HSSE policies The following Company HSSE polices have been established,
communicated to all workers and are displayed in the office:
HSSE Policy
No Smoking Policy
Alcohol and Substance Abuse Policy
1.3 Workers qualification All workers must have basic reading and writing skills with
clean safety and security records.
All workers must be medically fit.
All workers are provided with relevant trainings, including
Product Knowledge, Safe Handling of Cylinders and
Emergency Response (ER).
Forklift drivers are required to undergo Forklift Safety
competency course.
Drivers must possess valid driving licence.
1.4 Key personnel The manager is responsible for the overall operations and
emergency control of the store.
In his absence, the supervisor will assume full responsibilities.
1.5 HSSE toolbox The HSSE toolbox meeting is held regularly with involvement of
meeting management and workers.
1.6 Incident reporting All work related incidents, including near misses are required
to be reported to NGCE focal person and as per statutory
requirements.
Incidents are investigated and recorded in the “Incident
Investigation Form’ (see Appendix 4).
These incidents are investigated to:
o Identify weaknesses in the system
o Provide learning opportunities
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o Prevent recurrence
o Demonstrate visible commitment to improve
2.1 Method for detecting Regular walkabout in the store by the manager and supervisor
the presence of gas to check for leakages.
Workers have also been trained to detect leaks from cylinders.
Leaks can be detected by the presence of a distinctive ‘LPG
smell’.
Small leaks will show up as bubbles if detergent mixed with
water is applied to suspected leak area.
Large leaks will also be obvious through hissing or frosting
around leaks.
3.1 Detection of faulty All cylinders are checked at filling plants before being sent out.
cylinders Workers are required to check the condition of cylinders upon
being delivered by haulier lorries.
Regular walkabout in the store by the manager and supervisor
to check for rust spots, dents and damages on the cylinders
3.2 Safety maintenance The following maintenance is carried out on a regular basis by the
of store and other manager or supervisor:
safety control Fire extinguishers – inspected monthly with valid bomba
equipment certification
Hoses/sprinklers/hydrants – tested monthly
Water tanks/pumps – tested monthly
Forklift – follow manufacturer maintenance recommendation
First aid kit – inspected monthly and replenished accordingly
3.3 Checks on vehicles Gate checks are applied to ensure the following:
entering store Only authorised vehicles are allowed entry
Lighters and cigarettes are surrendered
Drivers wear safety gloves and shoes
Vehicles are equipped with safety belts, fire extinguishers and
have good tyres
Drivers reminded to drive within the speed limit and according
to directional signs
3.4 Inspection on Regular walkabout in the store by the manager and supervisor to
housekeeping check for the following:
Store clean without litter
No overgrown grass or plants within or encroaching from
outside
Drainage clean and flow of water unobstructed
Proper storage area for damaged metal pallets
Proper disposal area for waste material
Non business related items not kept in store
Dedicated area for fuels and lubricants
3.5 Record keeping The maintenance records kept are described in item 3.2.
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maintenance Records are kept by the supervisor and reviewed by the
manager.
4.1 Safety procedures Before entering the store, visitors shall be subjected to the
for visitors following checks/procedures:
To register name on log book before entry
To wear safety shoes before entering the store
To read and understand the prohibited item list
To park vehicle outside the store
To observe all safety instructions in the store
5.1 Auditing system The following audits are conducted to improve safety
performance:
Audit Area Frequency
Unsafe Act / Condition Daily/weekly/monthly
NGCE HSSE Yearly
1.0 Types of training, Relevant HSSE training is provided to the workers as described in
briefing and safety the HSSE Training Matrix contained in Appendix 5.
information given to
the workers, visitors Visitors are briefed on evacuation procedures.
and public
Notice board and the following safety signs are prominently
displayed in the store:
LP Gas Store
No Smoking
No Naked Light
Highly Flammable
Emergency Procedure
Emergency Contact Number
2.0 Names of workers The name of workers and training courses provided is listed in
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that have undergone Appendix 6.
safety training
3.0 List of safety List of safety equipment used during training includes the
equipment following:
Fire extinguishers
Hoses / sprinklers / hydrants
Water tanks / pumps
2. Workers
Store Address (direct line) 017-3881119 AT STORE GAS
Store Manager 018-7777183 280KM
Supervisor 017-5129053 AT STORE GAS
Security Guard/Representative 018-9006096 AT STORE GAS
3. NGC Energy
Customer Service Hotline 1 800 88 5808 -
Operations Executive - -
Retail Sales Agent - -
Account Manager - -
HSSE Manager 019 335 8126 -
Chief Executive Officer 019 336 8993 -
4. Neighbours
PCT (KERPAN) TRADING SDN
012-3088775 60 METER
BHD
S TWO COATING ENTERPRISE 010-3939350 20 METER
[……….] [……….] [……….]
[……….] [……….] [……….]
[……….] [……….] [……….]
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Provide decision on tier-3 response
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3.1 General Emergency Response Procedures
1 Leak gas without fire Raise the alarm and stop all activities
Do not operate electrical switches
Ensure no naked lights, No smoking, No starting of engines
Immediately evacuate from the affected area to the nearby
vicinity which is free of leak gas
If it is a minor leak:
Stand by with fire extinguishers at upwind position
Stop the leak by plugging / capping, if it is safe to do so
If it is a major leak:
Evacuate the premises
Apply water to the cylinder and adjacent cylinders to cool them
Stop the leak by plugging, if it is safe to do so
2 Leak gas with fire Raise the alarm and stop all activities
Do not operate electrical switches
Ensure that no naked lights, No smoking, No starting of
engines
Immediately evacuate the premises. All personnel must be
kept upwind of any gs leak
Apply water to the cylinder and adjacent cylinders to cool them
and disperse LPG
Stand by the fire extinguisher at upwind position
Stop the leak by plugging, if it is safe to do so
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Append
ix 1:
Safety
Data
Sheet
(SDS)
for LPG
in
English
and
Bahasa
Malaysi
a
Append
ix 2:
Layout
[Append layout plan containing the following:
• Location and quantity of filled cylinder empty cylinder, gate, office and potential source
of fire (motor, main switch, pump, etc)
• Location and quantity of other hazardous substance according to Regulation category
• Plan
whether it is toxic substance, explosive and oxidizing substance
Accessibility location or emergency equipment at site such as fire extinguisher, siren,
water hose, fire wall, water sprinkler, gas detector, etc]
Append
ix 3:
Organis
[Append organisation structure of the company]
ation
Structur
e
Append
ix 4:
Incident
Investig
ation
Form
Append
ix 5:
HSSE
Trainin
g Matrix
Append
ix 6:
List of
Worker
s and
Trainin
g
Course
s
Provide
d
Append
ix 7:
Emerge
ncy
Respon
se
Team