Refuelling, Recharging and Hazardous Conditions
This domain tests energy-source hazards: diesel, LPG, lead-acid batteries and the environments where forklifts operate. The exam expects control of ignition, ventilation, PPE and spill response.
Core rules
- General refuelling: engine off, no smoking or open flame, designated area, spill kit available, PPE as required, and no mobile phone use if site rules prohibit it. Clean up spills immediately.
- LPG: change cylinders only in a ventilated area, check seals and connections, close the valve when parked, and leak-test with soap solution, never a flame. Store cylinders upright and secured.
- Battery charging: lead-acid charging produces hydrogen. Charge in a ventilated, designated area with no ignition sources. Wear acid-resistant gloves and eye protection; know the eyewash and spill kit location. Switch the charger off before disconnecting to reduce arcing.
- Flammable atmospheres: use explosion-protected trucks rated for the zone. Diesel or LPG trucks in confined spaces can produce carbon monoxide.
- Hazardous conditions: wet or oily floors, dock edges, high winds, poor lighting and steep ramps require reduced speed or a stop-work decision.
Worked example
An operator plans to charge a battery in a closed storeroom next to a smoking area. Reasoning: charging releases hydrogen, and a closed room allows accumulation; the smoking area adds an ignition source. The task must move to a ventilated charging bay with no ignition sources. The operator needs acid PPE, eyewash access and a spill kit before connecting the charger.
Traps
- Using a flame to check for an LPG leak.
- Charging a battery in an aisle or unventilated room.
- Using water on a live electrical or battery fire.
- Refuelling with the engine running.
- Ignoring carbon monoxide risk from LPG or diesel trucks indoors.