LPG Cylinder Safety: Risks, Hazards, and Prevention Strategies.

Table of Contents

Figure 14: the effects of varying occupational LPG exposure on cardiovascular, pulmonary, hepatic, and oxidative stress biomarkers. (Science Direct). 15

Figure 15: Burst Test LPG Cylinders (Source: YouTube). 17

Figure 16: Safe practices of LPG cylinder storage. 23

Figure 17: Awareness Campaign by PSO PAKGAS. 25

1. Introduction

1.1 Overview of LPG (Liquefied Petroleum Gas)

Liquefied Petroleum Gas (LPG) is a highly versatile energy source composed primarily of propane and butane. It is widely used across the globe in domestic, industrial, and commercial applications due to its clean-burning characteristics, portability, and efficiency. In households, LPG serves as a key fuel for cooking and heating, while in industrial sectors, it is used for power generation, metal cutting, and drying processes. In commercial settings, LPG powers businesses such as hotels and restaurants, which rely on it for cooking and heating purposes.

One of the major advantages of LPG is its ease of storage and transport in pressurized cylinders, making it ideal for areas with limited infrastructure. Globally, LPG is recognized as a lower-carbon alternative to other fossil fuels, contributing to reductions in greenhouse gas emissions when used in place of traditional fuels like coal or wood. Given its multiple uses and environmental benefits, LPG is critical for energy diversification, especially in countries with constrained natural gas supplies.

1.2 Context in Pakistan

In Pakistan, the significance of liquefied petroleum gas (LPG) has surged due to the country's declining natural gas reserves and an escalating demand for energy. Historically, natural gas has satisfied over 50% of Pakistan's energy requirements; however, production has diminished while consumption continues to rise, leading to acute shortages, particularly during winter months when demand peaks. The depletion of major gas fields and sluggish progress in exploration and production activities have exacerbated this energy crisis, prompting a shift towards alternative energy sources like LPG (Dawn, 2023).

As of 2024, the domestic production of LPG in Pakistan is insufficient to meet the growing demand, necessitating significant imports to bridge the gap. Approximately 4 million households currently rely on LPG for cooking and heating, a figure that is expected to rise as the energy shortage intensifies. Pakistan imports nearly half of its LPG requirements, with total consumption hovering around 1.1 million tons annually (IndexBox, 2024). The Oil and Gas Regulatory Authority (OGRA) has implemented policies aimed at increasing LPG's share in the energy mix, particularly in rural and hilly regions where access to piped natural gas is limited. This strategic shift is crucial as projections indicate that natural gas reserves may only last a few more decades without substantial new discoveries (S&P Global, 2024).

Figure 1: Pakistan LPG consumption - data, chart (Source: TheGlobalEconomy)

The demand for LPG in Pakistan is projected to grow significantly, with estimates suggesting it could surge from current levels of about 4,500-5,000 tons per day to approximately 15,000 tons per day in the coming years (Dawn, 2023). This growth is attributed to household consumption patterns that favor LPG for cooking and heating during colder months. OGDCL (Oil and Gas Development Company Limited) is the leading company in Pakistan's LPG production, holding about 50% of the market share as of January 2024. By the end of December 2023, OGDCL had exploration rights over approximately 91,781 square kilometers, which is around 38% of the total area being explored in the country. In terms of its contribution to national production during the fiscal year 2023, OGDCL was responsible for about 46% of crude oil, 29% of natural gas, and 36% of LPG produced in Pakistan. For the first half of fiscal year 2024, these figures remained similar, with OGDCL contributing approximately 46% of crude oil, 28% of natural gas, and 37% of LPG production.

Figure 2: Producer wise LPG production by major players (PARCO)

Pakistan heavily relies on importing Liquefied Petroleum Gas (LPG). In the fiscal year 2023 (FY23), the country imported approximately 542,134 metric tons (MT) of LPG, a 30.8% increase from 414,530 MT in FY22. During the first seven months of FY24, LPG imports further grew by 6%, totaling 337,897 MT compared to 318,839 MT in the same period of FY23. Additionally, about 1.1 million MT of LPG was imported in FY23, a 22.9% rise from 0.9 million MT in FY22. Most of this LPG, around 71.8%, was sourced from Iran. On the other hand, liquified propane imports came from China, the UAE, and the UK, contributing 37.0%, 61.6%, and 1.4% of the import bill for propane in FY23, respectively.

Figure 3: Source: PES, PBS

Note: The provided data is based on the latest available figures and covers imports of Propane and LPG under HS Codes 2711.1200 and 2711.1910, respectively. The volume of LPG imports, measured in metric tons (MT), has been sourced from the Oil and Gas Regulatory Authority (OGRA).

In response to this rising demand, OGRA is actively working to regulate the LPG market and address issues related to substandard cylinders and illegal decanting practices that pose safety risks. Recent reports indicate a troubling increase in illegal units producing substandard cylinders, complicating efforts to ensure safety and compliance within the sector (Dawn, 2023).

Figure 4: historic price/kg trend of LPG (Olx)

The government’s focus on enhancing LPG infrastructure aims not only to stabilize supply but also to improve access across various demographics. The proposed Pakistan LPG Policy 2024 emphasizes boosting domestic production while ensuring efficient import mechanisms. This policy aims to enhance market competitiveness by deregulating pricing regimes and preventing monopolistic practices within the LPG sector (Pakistan Today, 2024). Additionally, there are plans underway to issue new licenses for LPG importation and set up refrigerated terminals at ports for larger vessels—measures intended to streamline logistics and reduce costs associated with imports.

Despite these efforts, challenges remain. Black market operations have emerged as a significant concern, with reports indicating that consumers are often forced to pay inflated prices due to shortages exacerbated by illegal sales practices. The average price of LPG has reportedly reached Rs300-400 per kg in some areas, significantly above the government-fixed price of Rs257 per kg (Express Tribune, 2024). Such price manipulation highlights the urgent need for regulatory oversight and improved supply chain management.

2. Common Practices and Trends in Pakistan

2.1 Decanting and Cross-Filling

In Pakistan, the illegal refilling of LPG cylinders, commonly referred to as decanting and cross-filling, has become a prevalent practice that poses significant safety risks. Decanting involves transferring LPG from one cylinder to another without adhering to established safety regulations, often occurring in unregulated environments such as roadside stalls or small shops. Cross-filling refers to the practice of filling a cylinder designed for a specific type of gas with another type, which further increases the associated dangers. Both practices are illegal and highly dangerous due to the absence of proper equipment and safety checks. The lack of trained personnel handling these operations often leads to negligence regarding essential safety protocols, heightening the risk of gas leaks, cylinder explosions, and fires (IndexBox, 2024; S&P Global, 2024).

Figure 5: Illegal Decanting of LPG Cylinders (Source: arynews)

The consequences of these unsafe practices are alarming. In recent years, there has been a notable increase in incidents related to LPG cylinder explosions. According to a report by the Punjab Emergency Service Department, there were 328 incidents of fire caused by LPG cylinder leakage and explosions in the province over the past two years, with Lahore reporting the highest number of incidents (Dawn, 2023). The absence of regulatory oversight allows unauthorized distributors to engage in unsafe practices that endanger public safety. The Oil and Gas Regulatory Authority (OGRA) has acknowledged these issues and has attempted to enforce regulations; however, enforcement remains weak in rural and peri-urban areas where LPG usage is growing rapidly.

2.2 Substandard Cylinders

Another alarming trend in Pakistan is the circulation of substandard or expired LPG cylinders. Many cylinders in circulation lack proper certification and do not meet safety standards, leading to frequent accidents. Substandard cylinders are often made from inferior materials that are prone to corrosion and structural failures. A report by OGRA indicates that a significant number of cylinders do not comply with safety regulations, resulting in numerous incidents linked to poor-quality cylinders (IndexBox, 2024; S&P Global, 2024). In 2023 alone, several cylinder explosions were reported, many attributed to these substandard products. The government's efforts to regulate the manufacturing and sale of LPG cylinders have been insufficient, particularly in areas where enforcement is lacking.

Figure 6: Illegal Gas cylinder shops with substandard cylinders (Source: Yugmarg)

The consequences of using substandard cylinders are dire. In May 2024, a catastrophic explosion claimed the lives of 26 people in Hyderabad, highlighting the urgent need for reform in the LPG sector (Business Recorder, 2024). Poor-quality nozzles and valves make these cylinders ticking time bombs, resulting in thousands of injuries and fatalities over the years. Despite OGRA's attempts to ban the sale and purchase of substandard cylinders throughout Pakistan, compliance remains an issue (The Print, 2024). The regulatory body has issued notices to numerous LPG marketing companies regarding unauthorized sales but has struggled with effective enforcement.

Figure 7: liquefied petroleum gas (LPG) cylinder explosion claimed the lives of 26 people in Hyderabad

2.3 Inadequate Cylinder Testing and Maintenance

The safety of liquefied petroleum gas (LPG) cylinders in Pakistan is critically compromised by inadequate testing and maintenance practices. A significant number of cylinders in circulation are not subjected to regular inspections, leading to unnoticed wear and tear that includes corrosion, faulty valves, and weakening of the cylinder walls. International safety standards mandate periodic testing to ensure the integrity and safety of LPG cylinders; however, this is frequently overlooked in Pakistan. The absence of a nationwide standard for cylinder testing means that many cylinders are reused beyond their intended lifespan, significantly increasing the risks of ruptures or gas leaks, especially when these cylinders are mishandled during transportation or storage (IndexBox, 2024; S&P Global, 2024).

Figure 8: Poor Handling practices and irregular maintenance of LPG Cylinders (Source: The ExpressTribune)

Regular inspections are essential for identifying potential hazards before they result in catastrophic failures. Testing procedures can include visual inspections for signs of damage, pressure tests to check for leaks, and assessments of valve functionality (Mehran Metal Containers, n.d.). However, due to the lack of enforcement and regulatory oversight by authorities like the Oil and Gas Regulatory Authority (OGRA), many cylinders remain unchecked. Reports indicate that a substantial portion of the LPG cylinders in use do not comply with safety regulations, leading to numerous accidents that could have been prevented through proper maintenance (Business Recorder, 2024).

Figure 9: LPG cylinders reconditioning and requalification (Source: Siraga IEM)

2.4 Unregulated Distribution Channels

The distribution network for LPG in Pakistan also suffers from serious deficiencies due to unregulated channels. Many unauthorized distributors operate outside the formal market, selling LPG at inflated prices while bypassing essential safety measures. These illegal vendors often store cylinders in unsafe conditions—such as residential areas or near open flames—creating potential hazards for nearby communities. Storage facilities for these illegal vendors typically lack adequate ventilation and safety features like fire extinguishers. In the event of a gas leak, the probability of fire or explosion is significantly heightened due to the proximity of these storage points to populated areas (IndexBox, 2024; S&P Global, 2024).

2.5 Safety Risks Associated with Unregulated Practices

The culmination of unsafe practices—including decanting, the use of substandard cylinders, poor maintenance, and unregulated distribution—results in severe safety hazards such as cylinder explosions, fires, and injuries. As demand for LPG rises during winter months—when natural gas shortages are prevalent—the risk of accidents involving improperly stored or filled cylinders increases dramatically. In 2023 alone, numerous incidents were reported linking cylinder explosions to inadequate testing and maintenance practices (Dawn, 2023).

To mitigate these risks effectively, stronger enforcement of safety regulations by government agencies like OGRA is essential. This includes implementing rigorous inspection protocols and introducing stricter penalties for violators. Public awareness campaigns should also educate consumers about the dangers associated with using substandard cylinders or purchasing LPG from unauthorized vendors. Additionally, introducing cylinder exchange programs can help replace old or damaged cylinders with certified safe ones, thereby reducing the risk of accidents caused by faulty equipment (S&P Global, 2024; Business Recorder, 2024).

3. Hazards Related to LPG

3.1 Cylinder Explosions

LPG cylinder explosions represent a significant risk in Pakistan, driven by various factors including the use of substandard cylinders, improper refilling practices (decanting), and over-pressurization. The safety of LPG cylinders is heavily influenced by their quality.

1. Over-pressurization: LPG cylinders are designed to handle specific pressure levels, and overfilling can increase pressure beyond safe limits. Domestic and commercial cylinders typically operate at a pressure of 5-15 bar (depending on the temperature and the LPG type), but if the cylinder is overfilled or exposed to high temperatures, pressure can rise to dangerous levels, potentially causing explosions. Under extreme heat conditions (like fire), LPG expands, leading to rapid pressure increases that substandard cylinders cannot withstand.

2. Poor-quality Materials: Cylinders made with inferior materials or substandard manufacturing processes are more likely to fail. Certified cylinders are usually made of high-strength steel and designed according to standards that ensure their ability to withstand internal pressure and environmental conditions. These cylinders undergo rigorous testing for burst pressure (typically around 3 to 5 times the working pressure) and are equipped with safety valves to release excess pressure if needed.

3. Faulty or Missing Valves: A critical safety feature in LPG cylinders is the pressure relief valve (PRV), which automatically releases gas if internal pressure exceeds safe limits. Substandard or poorly maintained cylinders often lack proper valves or have malfunctioning ones, leading to uncontrolled pressure build-up. Certified valves are typically made of corrosion-resistant materials like brass, which can endure high pressure and temperature changes. When this valve fails or is absent, the cylinder can rupture when exposed to excessive heat or pressure. A report indicated that in 2023 alone, there were 328 incidents of fire caused by LPG cylinder leakage and explosions in Punjab, with Lahore recording the highest number of incidents (Dawn, 2023).

4. Improper Decanting and Handling: Decanting, or the illegal practice of transferring gas from one cylinder to another, often skips safety protocols. This can result in overfilling, gas leaks, or contamination. Decanting increases the risk of explosion because cylinders may be filled beyond safe levels, leading to stress on the material or valve malfunction. The Punjab Emergency Service Department reported that 17 citizens died in incidents related to LPG cylinder explosions over the past two years, with many others suffering severe burns and injuries (Dawn, 2023).

Figure 10: Hyderabad LPG cylinder blast costing lives of 23 people (Source: Geo.tv)

3.1.1 Pressure and Temperature Effects:

Explosion Pressure: Cylinders can typically withstand internal pressures up to around 30 bar, but in cases of extreme pressure due to overfilling or high temperatures, they can rupture. Substandard cylinders may fail at lower pressures.
Temperature Sensitivity: LPG is highly sensitive to temperature changes. At temperatures of 40°C (104°F), pressure inside the cylinder rises significantly. Cylinders left in direct sunlight or exposed to open flames are at high risk. For both domestic and commercial cylinders, temperature extremes (above 50°C) can lead to an explosive failure, especially if the cylinder is not equipped with a functioning pressure relief valve.

Figure 11: Two injured in cylinder blast in Quetta (The Baluchistan Express, 2021)

3.1.2 Domestic vs. Commercial Cylinders:

Domestic Cylinders: These are smaller (typically 11.8 to 15 kg capacity) and used in homes. They are more prone to improper storage and handling (e.g., placing them near heat sources), which can increase the risk of leaks or explosions.
Commercial Cylinders: Larger cylinders (45.4 kg or more) used in industrial or commercial settings are built to handle higher pressures, but improper use, storage, or lack of safety inspections can cause failures. Commercial cylinders may also face additional risks from environmental exposure (e.g., outdoor storage).

3.2 LPG Leaks

Undetected LPG leaks pose a significant safety concern, as LPG is highly flammable and can lead to catastrophic fires or explosions if not handled correctly. Being heavier than air, LPG tends to accumulate in low-lying areas, making it challenging to detect without specialized equipment. In enclosed or poorly ventilated spaces, leaked LPG vapors can reach explosive concentrations. A small spark or open flame can ignite the gas, resulting in devastating fires or explosions (Dawn, 2023; Weekly Safety, n.d.).

Figure 12: Physical and chemical properties of the LPG (Tukiman er al, 2018)

In an ideal scenario, LPG cylinders should be equipped with leak detection systems and undergo regular inspections for damage to prevent leaks. However, many domestic users in Pakistan are unaware of the necessity for these inspections. The illegal practice of decanting further exacerbates the risk of gas leaks, as it often bypasses established safety protocols (S&P Global, 2024).

3.3 Fire Hazards

The flammable nature of LPG vapors significantly increases fire hazards in situations involving poor ventilation or improper storage. When LPG leaks into an enclosed area, it can form an explosive mixture with air. Even a minor spark—caused by static electricity, a cigarette, or a light switch—can ignite this accumulated gas, leading to fires or explosions (Weekly Safety, n.d.; Energy Update, 2024).

Improper storage practices also contribute to fire hazards associated with LPG. Cylinders should ideally be stored in well-ventilated areas away from direct sunlight, heat sources, and flammable materials. However, unregulated distributors and illegal decanting operations frequently store cylinders in unsafe locations—such as residential areas or near open flames—thereby increasing the risk of fire (Dawn, 2023).

Figure 13: LPG Gas Business Signage Warning Safety

The lack of adherence to safety protocols can have dire consequences. In recent incidents reported in Lahore and other cities, poorly stored cylinders have led to significant property damage and loss of life. For example, a tragic incident in May 2024 resulted in multiple injuries and fatalities due to an explosion linked to a gas leak that went undetected (Dawn, 2023).

3.4 Health Risks

In addition to the physical dangers of explosions and fire, exposure to liquefied petroleum gas (LPG) can lead to significant health hazards. Inhalation of LPG vapors poses serious risks, particularly in poorly ventilated areas where the gas can accumulate. LPG is heavier than air, which means it tends to settle in low-lying areas, displacing oxygen and increasing the risk of suffocation. Prolonged exposure to low levels of LPG can lead to respiratory issues, dizziness, nausea, and headaches. In severe cases, exposure to high concentrations of LPG can result in asphyxiation due to the displacement of oxygen (NCBI, 2021; Chemscape, n.d.).

LPG contains mercaptan, a sulfur-containing compound added to give the gas its distinctive smell, making leaks detectable. However, the presence of mercaptan does not mitigate the health risks associated with prolonged exposure. Studies have shown that acute inhalation of LPG can lead to respiratory symptoms such as wheezing, coughing, and chest tightness. Long-term exposure may result in central nervous system damage and other serious health complications (NCBI, 2021; WHO EMRO, 2013).

Figure 14: The effects of varying occupational LPG exposure on cardiovascular, pulmonary, hepatic, and oxidative stress biomarkers. (Science Direct)

In enclosed environments where LPG is used for cooking or heating without adequate ventilation, the risk of suffocation becomes particularly concerning. The accumulation of LPG vapors in these spaces can reach explosive concentrations, creating a hazardous environment for occupants (Chemscape, n.d.; Elgas, n.d.).

3.5 Summary of Health Effects

Health Effect	Description
Respiratory Issues	Symptoms include cough, wheeze, chest tightness, and nasal irritation due to inhalation.
Dizziness and Nausea	Prolonged exposure can lead to dizziness, nausea, and headaches.
Asphyxiation Risk	Displacement of oxygen in confined spaces increases the risk of suffocation.
Central Nervous System Damage	Long-term exposure may cause CNS damage leading to fatigue and cognitive impairments.

4. Chemical Composition and Cylinder Manufacturing Standards

Liquefied petroleum gas (LPG) is primarily composed of propane (C₃H₈) and butane (C₄H₁₀), both of which are hydrocarbons. These gases can be easily liquefied under pressure, allowing for convenient storage in metal cylinders. The chemical properties of LPG make it a highly efficient fuel; however, they also necessitate stringent safety standards for its storage and handling to prevent accidents (Mehran Metal Containers, n.d.).

4.1 Cylinder Manufacturing Standards

Certified LPG cylinders are manufactured to withstand the high pressures required to store LPG in its liquid form. Typically made from steel or aluminum, these cylinders are designed to comply with international safety standards such as ISO 4706 and BS EN 1442. These standards specify the required thickness of the cylinder walls, the types of welding allowed, and the inclusion of essential safety devices like pressure relief valves and rupture discs. Pressure relief valves are critical components, as they release excess pressure to prevent explosions caused by over-pressurization (IndexBox, 2024; S&P Global, 2024).

The manufacturing process involves several key steps:

1. Material Selection: High-quality steel sheets are selected for their strength and resistance to corrosion. This ensures durability and longevity under high-pressure conditions (Supplier Cylinder, 2023).

2. Cylinder Formation: The steel sheets are cut into specific sizes and subjected to deep drawing processes to create the cylindrical shape. This stage requires careful control of pressure to avoid defects (Minsheng, n.d.).

3. Welding: Various welding techniques are employed to ensure secure connections between cylinder components. Each weld undergoes rigorous inspection to confirm its integrity (Mehran Metal Containers, n.d.).

4. Testing: Before being approved for use, each cylinder must undergo a series of tests:

· Hydrostatic Testing: This test checks the cylinder's ability to withstand internal pressure without leaking or rupturing.

· Leak Testing: Conducted after hydraulic testing, this ensures that no gas escapes from the cylinder.

· Periodic Re-testing: Cylinders must be re-tested every ten years to confirm their continued safety (Supplier Cylinder, 2023).

Figure 15: Burst Test LPG Cylinders (Source: YouTube)

Unfortunately, in Pakistan, many cylinders in circulation do not meet these stringent standards. The widespread use of substandard or expired cylinders remains a significant issue, leading to an increase in accidents. Some cylinders may be counterfeit or refurbished, often bypassing the testing process entirely, which further escalates the risks associated with their use (Dawn, 2023; S&P Global, 2024).

Summary Table: Key Manufacturing Standards for LPG Cylinders

Standard	Description
ISO 4706	Specifies requirements for refillable LPG cylinders.
BS EN 1442	Details safety requirements including wall thickness and welding standards.
Pressure Relief Valves	Essential for preventing explosions due to over-pressurization.
Hydrostatic Testing	Validates the cylinder's ability to withstand internal pressure.

5. LPG Cylinder Safety Measures

5.1 Quality Standards for Cylinders

The safety of liquefied petroleum gas (LPG) cylinders is highly dependent on the manufacturing standards and regulations imposed by authorities like the Oil and Gas Regulatory Authority (OGRA) in Pakistan. These standards ensure that cylinders are produced, tested, and maintained to withstand high pressures, thereby ensuring public safety. OGRA has established several guidelines for the certification, design, and testing of LPG cylinders. In Pakistan, the standards for LPG cylinder manufacturing and testing are aligned with international norms such as ISO 22991 and BS EN 1442, ensuring that cylinders are built to withstand extreme conditions (IndexBox, 2024; Mehran Metal Containers, n.d.).

1. Cylinder Design

LPG cylinders are typically made of steel or aluminum and are designed to contain LPG in a liquid state at high pressure. They must meet minimum wall thickness requirements to ensure they can handle pressures up to 17.5 bar (250 psi), depending on the gas composition and environmental factors. Each cylinder is equipped with pressure-relief valves that allow controlled gas release to prevent rupture from over-pressurization (S&P Global, 2024).

2. Certification

Certified LPG cylinders must undergo hydrostatic pressure testing to ensure they can withstand twice their normal working pressure. Additionally, each cylinder is subjected to radiographic examination to check for manufacturing defects such as welding issues, which could weaken the structure (Mehran Metal Containers, n.d.). This rigorous testing process is essential for maintaining safety standards and preventing accidents.

3. Periodic Inspections

Every LPG cylinder must be periodically inspected, usually every ten years, to ensure its continued safety. In Pakistan, many substandard cylinders remain in circulation, contributing to frequent accidents. Regulatory bodies mandate periodic testing to identify weaknesses such as corrosion, valve malfunctions, or cracks (Dawn, 2023; S&P Global, 2024). Regular inspections help ensure that any potential hazards are addressed before they result in catastrophic failures.

5.2 Handling and Storage Best Practices

The proper handling and storage of LPG cylinders are critical in mitigating risks such as leaks, explosions, and fires. According to international safety guidelines and OGRA’s protocols, the following practices are essential for safe LPG handling and storage:

1. Storage Location:

LPG cylinders should always be stored in well-ventilated areas, as LPG is heavier than air and can accumulate in low-lying areas, creating an explosive hazard if ignited. Storage rooms should have ventilation openings at both high and low levels to allow any leaked gas to disperse safely.

2. Avoiding Heat and Sparks:

LPG cylinders must be kept away from sources of heat, sparks, or open flames, as LPG is highly flammable. Cylinders should be stored at a safe distance from electrical appliances, kitchen equipment, or direct sunlight. OGRA’s guidelines recommend a minimum clearance of 3 meters from any heat source.

3. Handling During Transportation:

During transportation, LPG cylinders should be secured in an upright position to avoid damage to valves and minimize the risk of leaks. Vehicles transporting LPG cylinders must be equipped with fire extinguishers and leak-detection systems.

4. Leak Detection:

When handling LPG cylinders, it is essential to regularly check for leaks using a soap solution. A leaking cylinder can be identified if bubbles form when the solution is applied around the valve or connections. Leaks must be dealt with immediately by turning off the cylinder valve and moving the cylinder to an outdoor space.

5.3 Proper Maintenance of Cylinders

Routine inspection and maintenance of LPG cylinders are vital for ensuring their longevity and preventing hazardous incidents. Proper maintenance includes regular visual checks, leak tests, and valve replacements. The following are key aspects of LPG cylinder maintenance:

Valve Integrity:

The cylinder valve is a critical component, as it regulates the release of gas. Damaged or corroded valves can lead to uncontrolled gas leaks, posing a significant safety risk. Valves should be regularly inspected for signs of wear, rust, or physical damage. If necessary, valve replacement should be carried out by certified professionals (Pune Gas, n.d.; Mehran Metal Containers, n.d.).

Corrosion Prevention:

LPG cylinders, especially steel ones, are susceptible to corrosion over time, particularly if exposed to moisture. Cylinders must be stored in dry areas, and periodic repainting of cylinders is recommended to prevent rust. Cylinders showing signs of advanced corrosion should be decommissioned to avoid structural failures (S&P Global, 2024; Energy Update, 2024).

Periodic Testing:

In line with international safety standards, LPG cylinders should be periodically tested every 10 years. This includes hydrostatic testing, where the cylinder is filled with water and subjected to high pressure to check for leaks or ruptures. Additionally, ultrasonic testing can be used to detect thinning of the cylinder walls due to wear or corrosion (Budget Gas, n.d.; Mehran Metal Containers, n.d.).

These safety measures are critical in ensuring that LPG remains a safe and effective fuel source. Neglecting these practices, particularly in regions where LPG use is widespread, can lead to catastrophic accidents. The implementation of strict adherence to standards and the elimination of substandard practices can significantly reduce risks.

6. Safe Distribution Practices

The safe distribution of LPG plays a critical role in minimizing risks associated with handling, storage, and transportation. Given the flammable and pressurized nature of LPG, proper practices and protocols must be in place throughout the supply chain. This section outlines the key aspects of safe distribution, with an emphasis on the role of licensed distributors, transportation safety, and cylinder recalls and replacements.

6.1 Role of Licensed Distributors

Purchasing LPG from licensed distributors is essential to ensure the quality and safety of the cylinders being supplied. Licensed distributors follow strict regulatory guidelines set by bodies like OGRA in Pakistan, ensuring that the LPG is stored, handled, and distributed in compliance with safety standards. Illegal or unregistered distributors often bypass these safety regulations, resulting in the sale of substandard or expired cylinders, which significantly increases the risk of accidents such as leaks or explosions (OGRA, 2024).

Licensed distributors are required to:

1. Source LPG from Authorized Suppliers

Licensed distributors are required to source LPG from authorized suppliers. This ensures that the gas is of the correct composition and pressure level, thereby reducing the risk of incidents caused by improper gas mixtures. Ensuring quality at this level is crucial for maintaining safety throughout the supply chain (LPG Production & Distribution Policy, 2016).

1. Ensure Proper Cylinder Maintenance

All cylinders provided to consumers must be checked for leaks, structural integrity, and valve functionality. Distributors are responsible for ensuring that cylinders meet the safety standards established by national and international regulatory bodies, such as ISO 22991 for LPG cylinders. Regular maintenance checks help identify potential hazards before they lead to catastrophic failures (S&P Global, 2024; Weekly Safety, 2024).

2. Provide Training to Handlers

Distributors often employ staff for refilling and delivering LPG cylinders, making it crucial that these individuals are properly trained in handling LPG. Training programs should focus on best practices for refilling and transportation to reduce the risk of accidents during these processes (Weekly Safety, 2024). Properly trained personnel can significantly mitigate risks associated with improper handling.

6.2 Transportation Safety

The transportation of LPG is another critical phase where potential hazards must be addressed. Whether in road tankers or via cylinder distribution vehicles, strict safety protocols are necessary to mitigate the inherent risks of transporting a pressurized and flammable substance.

1. Vehicle Standards: Road tankers used for LPG transportation must be built to meet the specifications laid out in BS EN 1442 and ISO 22991 standards. These vehicles are designed to safely transport large quantities of LPG under high pressure, featuring reinforced tanks and pressure-relief valves to prevent over-pressurization. In Pakistan, these tankers must also undergo regular inspections and maintenance to ensure they remain fit for transporting flammable gases (OGRA, 2024).

2. Securing Cylinders During Transport: For smaller quantities, LPG cylinders should be secured in upright positions in vehicles to avoid damage to valves or the cylinders themselves. Unsecured cylinders pose a significant danger, as they can shift during transport, increasing the risk of leaks or explosions. The use of cylinder cages and protective barriers in transport vehicles is advised to minimize these risks.

Figure 16: Safe practices of LPG cylinder storage

3. Regulatory Compliance: Drivers of LPG transportation vehicles must be trained in hazardous material handling, and vehicles must be equipped with fire extinguishers, first-aid kits, and leak-detection systems. Compliance with these regulations ensures that transporters can quickly respond to emergencies, reducing the impact of any potential accidents.

4. Avoiding Non-standard Tankers: A significant risk in LPG transportation arises from the use of non-standard tankers or vehicles, which often lack the necessary safety features such as pressure-relief valves, emergency shutoff systems, and protective barriers. Non-standard tankers may also transport LPG at unsafe pressure levels, creating conditions ripe for disaster. In 2020, a series of incidents in Pakistan involving unregistered transporters highlighted the need for stricter enforcement of transportation regulations (Khan, 2023).

6.3 Cylinder Recalls and Replacement Programs

LPG cylinders, especially those that have been in circulation for extended periods or have suffered damage, must be recalled and replaced to avoid accidents. Cylinder recalls and replacement programs serve as important safety measures, ensuring that old or unsafe cylinders are removed from circulation.

1. Identification of Unsafe Cylinders: Substandard cylinders—either due to expired certifications, corrosion, or valve failures—should be immediately recalled by the distributor. This involves routine inspections and safety checks at refill stations and distributors to identify defective cylinders.

2. Government-led Recall Programs: The government, through regulatory bodies such as OGRA, has periodically implemented recall programs aimed at removing unsafe LPG cylinders from the market. These programs rely on licensed distributors to recall old or damaged cylinders and replace them with certified ones that meet international safety standards. The recall system in Pakistan is not always well-enforced, but improvements in regulatory oversight have been made in recent years (OGRA, 2024).

3. Cylinder Replacement Procedures: Consumers should be educated about the importance of exchanging old or damaged cylinders for new ones. Licensed distributors offer replacement programs that allow consumers to trade in expired or unsafe cylinders for those that have been inspected and certified as safe. These programs reduce the number of unsafe cylinders in circulation, thereby reducing the risk of accidents.

4. Awareness Campaigns: Public awareness campaigns highlighting the dangers of using old or uncertified cylinders can support these recall and replacement efforts. For example, campaigns that inform consumers about the risks of explosions due to over-pressurization or valve failure encourage the adoption of safer practices.

Figure 17: Awareness Campaign by PSO PAKGAS

7. Risk Management in LPG Supply Chain

Effective risk management is essential in the LPG supply chain due to the hazardous nature of the gas and its increasing demand in Pakistan, especially during the winter months. This section will discuss key areas such as storage infrastructure, supply chain bottlenecks, and the critical role of training and education for safe handling and emergency preparedness.

7.1 Storage Infrastructure

One of the most pressing concerns in Pakistan’s LPG supply chain is the inadequate storage infrastructure. The country’s LPG storage capacities are limited, especially in up-country regions where demand surges during winter. This has created a reliance on on-demand imports to meet consumption, which increases risks associated with supply disruptions and unsafe storage practices.

1. Current Storage Capacity: Pakistan's storage capacity remains far below international benchmarks. The country lacks sufficient dedicated LPG storage terminals and facilities, leading to a reliance on temporary and often substandard storage solutions. According to OGRA’s 2024 report, the lack of proper storage facilities increases the risk of leaks, over-pressurization, and fire hazards due to improper containment systems.

2. Need for Investment in Storage: Investment in modern, purpose-built storage facilities that meet international standards such as ISO 11625 for the safe storage of LPG is critical. Safe storage infrastructure should include pressure-controlled vessels and automated safety systems to monitor temperature and pressure fluctuations. Additionally, ensuring that LPG storage terminals are located away from densely populated areas can significantly reduce risks associated with accidents (OGRA, 2024).

3. Geographical Disparity: While urban areas may have more secure storage solutions, rural and northern regions often resort to using outdated and unsafe infrastructure. As Pakistan’s demand for LPG rises by 8-10% each year (Nisar, 2024), the need for proper storage infrastructure becomes even more critical.

7.2 Supply Chain Bottlenecks

LPG distribution faces numerous bottlenecks in Pakistan, particularly regarding the inadequate and unsafe transportation systems.

1. Unsafe Road Tankers: One of the major concerns in the LPG supply chain is the use of unsafe and non-standard road tankers for transporting gas. Many of these vehicles do not meet the required safety standards for pressurized gases, such as the BS EN 1442 or ISO 22991 standards, which specify the construction and operation of LPG containers and vehicles. The use of these non-compliant tankers has led to several accidents in recent years, further emphasizing the need for stricter regulatory enforcement (Khan, 2023).

2. Inadequate Transportation Capacity: With the growing demand for LPG, transportation capacities have not scaled accordingly. This often leads to overloading, where cylinders are stacked improperly or tankers are filled beyond their capacity. These practices increase the likelihood of accidents, leaks, or explosions during transit.

3. Bureaucratic Delays and Supply Disruptions: Import and distribution processes are often subject to bureaucratic inefficiencies, leading to supply disruptions. These delays not only hamper the timely delivery of LPG but also increase the risk of improper storage and handling at interim facilities. In 2023, several regions faced shortages due to delays at port terminals and issues with distribution networks (Pakistan Government, 2023).

7.3 Training and Education for Handling LPG

The safe handling of LPG is not only the responsibility of distributors and regulators but also of retailers and consumers. Training and education play a vital role in reducing the risks associated with LPG use, storage, and transportation.

1. Distributor and Retailer Training: Licensed distributors and retailers must undergo regular training to stay up-to-date on safety protocols and handling procedures. Regulatory authorities like OGRA often provide these training programs, covering aspects such as:

Safe storage and transportation of LPG cylinders.
Procedures for detecting and handling leaks.
Emergency response protocols, including the use of fire extinguishers and gas detectors.

2. Consumer Education: Public awareness campaigns are necessary to educate consumers about the proper use and storage of LPG. For instance, consumers should be made aware of the importance of regularly checking cylinder valves, not using expired or damaged cylinders, and ensuring adequate ventilation in areas where LPG is stored or used. These campaigns can be delivered through local community centers, media, and government programs.

3. Emergency Response Preparedness: Both distributors and consumers must be trained in emergency response procedures in case of leaks, fires, or cylinder explosions. Regular drills and the availability of safety equipment (such as gas detectors and fire extinguishers) at distribution centers and retail points can help mitigate risks. Local governments can also partner with fire departments to train communities on how to respond to LPG-related incidents (Weekly Safety, 2024).

8. Prevention Strategies and Recommendations

Ensuring the safety and sustainability of LPG use in Pakistan requires a multi-faceted approach that involves public education, stricter enforcement of regulations, and the adoption of modern technologies. This section will cover several recommended prevention strategies, including public awareness campaigns, regulatory enforcement, technology adoption, and the need for regular cylinder testing.

8.1 Enforcement of Regulations

While Pakistan has regulatory frameworks in place to manage LPG safety, more robust enforcement of these regulations is needed. The Oil and Gas Regulatory Authority (OGRA), alongside other agencies, must intensify its oversight of cylinder manufacturing, distribution, and usage.

1. Tightening Oversight of Cylinder Manufacturing: Stricter regulations on the production of LPG cylinders should be enforced to ensure they meet international safety standards such as ISO 22991 and BS EN 1442. These standards govern the material quality, valve specifications, and overall construction of LPG cylinders to withstand high pressure (OGRA, 2024). Manufacturers should face heavy penalties for failing to comply with safety guidelines.

2. Regulating Illegal Decanting Practices: Many accidents related to LPG stem from the illegal practice of decanting. To address this, OGRA and local law enforcement need to increase their inspections of unlicensed retailers and implement stricter penalties for engaging in unsafe refilling practices.

3. Monitoring of Licensed Distributors: Only licensed distributors should be allowed to sell LPG cylinders to consumers. OGRA should regularly audit distributors to ensure compliance with safety standards, especially regarding the maintenance and testing of cylinders. This will ensure that only high-quality, certified cylinders are in circulation (Khan, 2023).

8.2 Encouraging Use of Technology

Integrating modern technologies into LPG systems is a proactive measure that can significantly improve safety and reduce accidents.

1. Pressure Sensors and Leak Detectors: Technologies such as smart pressure sensors and LPG leak detectors can be installed in homes and businesses to alert users in case of abnormal pressure levels or gas leaks. These devices, which are relatively inexpensive, provide an additional layer of safety and can prevent accidents caused by undetected leaks (Pakistan Government, 2023).

2. Automated Cylinder Valves: Automated shut-off valves, which close when a leak is detected, can further enhance safety. These devices are especially useful in homes where LPG usage is prevalent, reducing the risk of explosions due to gas accumulation.

3. IoT-Enabled Monitoring Systems: For large-scale commercial use, Internet of Things (IoT)-enabled monitoring systems allow for real-time tracking of LPG levels, pressure, and temperature, ensuring that any issues are immediately addressed (Weekly Safety, 2024).

8.3 Mandatory Periodic Cylinder Testing

Cylinder testing is critical to ensuring the safety of LPG containers. Regular inspections can identify issues such as valve wear, corrosion, and structural weaknesses that could lead to accidents.

1. Certified Inspection and Testing: It is recommended that OGRA mandate periodic testing of all LPG cylinders in circulation. This includes both home and industrial cylinders, which should be tested by certified professionals every three to five years, depending on usage conditions (OGRA, 2024).

2. Establishing Testing Facilities: OGRA and other regulatory bodies should establish certified testing facilities across Pakistan to ensure accessibility. The testing process should include a detailed inspection of the cylinder's integrity, valve function, and pressure capacity to meet safety standards.

3. Cylinder Replacement Programs: OGRA should implement a cylinder recall and replacement program for expired or substandard cylinders. Consumers should be encouraged to trade in old cylinders for new, certified ones through subsidized programs, reducing the number of unsafe cylinders in circulation.

9. Conclusion

9.1 Summary of Key Points

The use of Liquefied Petroleum Gas (LPG) in Pakistan, especially for household consumption, presents both opportunities and significant safety risks. With the increase in demand during the winter season, the country faces the challenge of managing an unregulated LPG market where unsafe practices, such as illegal decanting, cross-filling, and the distribution of substandard cylinders, are common. These practices drastically increase the risks of accidents, including cylinder explosions, fires, and health hazards from LPG leaks (OGRA, 2024). Despite the presence of regulatory frameworks, a lack of enforcement and public awareness has led to frequent incidents related to LPG misuse.

One of the key hazards associated with LPG is the use of substandard cylinders, which often fail to meet the international safety standards that govern their design and construction. These cylinders are not subjected to periodic testing, leading to structural weaknesses that pose significant risks to users (Pakistan Government, 2023). Moreover, improper transportation of LPG via unregulated and unsafe tankers further exacerbates these dangers, as road accidents involving such vehicles can have devastating consequences (Khan, 2023). This report has highlighted the need for stronger regulatory oversight, public education campaigns, and the adoption of advanced safety technologies like leak detectors and smart pressure sensors.

9.2 Call to Action

To mitigate the risks associated with LPG use, all stakeholders—government bodies, LPG distributors, manufacturers, and consumers—must take responsibility and work towards safer practices. The Oil and Gas Regulatory Authority (OGRA) should enhance its enforcement of safety standards in LPG cylinder manufacturing, transportation, and distribution. This includes ensuring that licensed distributors are the only authorized vendors and that the use of substandard cylinders is eradicated through rigorous testing and recall programs.

Public awareness campaigns are equally essential. The general population, especially in rural and urban households that rely heavily on LPG, must be educated about the dangers of illegal practices like decanting and cross-filling. Media campaigns, community outreach, and safety training programs can play a significant role in raising awareness and promoting safer handling, storage, and usage of LPG (Pakistan Government, 2023).

Furthermore, the adoption of modern technologies such as IoT-enabled monitoring systems, pressure sensors, and automated shut-off valves should be encouraged across both residential and commercial settings. These technologies provide early warning systems for leaks or abnormal pressure levels, helping prevent accidents before they occur (Weekly Safety, 2024).

References:

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LPG Cylinder Safety: Risks, Hazards, and Prevention Strategies.

Figure 10: Hyderabad LPG cylinder blast costing lives of 23 people (Source: Geo.tv)

Figure 11: Two injured in cylinder blast in Quetta (The Baluchistan Express, 2021)3.1.2 Domestic vs. Commercial Cylinders:

6. Safe Distribution Practices

7. Risk Management in LPG Supply Chain

8. Prevention Strategies and Recommendations

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Figure 11: Two injured in cylinder blast in Quetta (The Baluchistan Express, 2021)

3.1.2 Domestic vs. Commercial Cylinders: