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Liquefied Petroleum Gas LPG Risk Assessment

Liquefied Petroleum Gas LPG Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
  • • Fully Editable MS Word & PDF Formats Included
  • • Pre-filled Content – Ready to Deploy Immediately
  • • Customisable – Easily Add Your Logo & Site Details
  • • Includes 2 Years of Free Compliance Updates

Liquefied Petroleum Gas LPG Risk Assessment

Product Overview

Identify and control organisational risks associated with Liquefied Petroleum Gas (LPG) storage, handling and use through a structured, management-level WHS Risk Management framework. This Risk Assessment supports compliance with the WHS Act, strengthens Due Diligence for Officers, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance, Compliance and WHS Duties: Assessment of PCBU, Officer and worker obligations, allocation of WHS responsibilities, and oversight arrangements specific to LPG operations.
  • LPG Procurement, Supply Chain and Cylinder Management: Management of supplier selection, delivery logistics, chain-of-responsibility issues, cylinder ownership, traceability and lifecycle controls.
  • Design, Engineering and Fixed Installation Management: Assessment of LPG system design, pipework and pressure equipment, hazardous area classification, and engineering verification processes.
  • Storage, Segregation and Site Layout Management: Management of cylinder storage locations, separation distances, traffic interfaces, ventilation, ignition source controls and security arrangements.
  • Documentation, Information and Safety Data Sheet Management: Protocols for maintaining current SDS, technical manuals, permits, drawings, and LPG-specific operating procedures accessible to relevant personnel.
  • Training, Competency and Supervision Systems: Assessment of role-based LPG training needs, competency verification, licensing requirements and supervision levels for workers and supervisors.
  • Maintenance, Inspection and Testing Regimes: Management of inspection schedules, leak testing, integrity checks, defect reporting, and engagement of competent persons for LPG equipment servicing.
  • Emergency Preparedness, Response and Incident Management: Planning for gas leaks, fires, explosions and loss-of-containment events, including emergency equipment, drills, communication protocols and post-incident review.
  • Contractor, Visitor and Third-Party Interface Management: Controls for contractor induction, permits to work, hot work near LPG, and coordination with suppliers, transport providers and neighbouring businesses.
  • Monitoring, Auditing and Continuous Improvement: Systems for inspections, performance indicators, consultation, corrective actions and periodic review of LPG risk controls and management plans.

Who is this for?

This Risk Assessment is designed for Business Owners, Officers, Safety Managers and Operations Leaders responsible for planning, approving and overseeing LPG-related activities and infrastructure across their organisation.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, Compliance and WHS Duties
  • • Lack of clear allocation of WHS duties for LPG storage and use under WHS Act 2011 and WHS Regulation
  • • Inadequate understanding by officers and managers of due diligence obligations relating to LPG as a hazardous chemical and dangerous good
  • • Absence of an overarching LPG management plan and hazardous chemicals plan aligned with applicable Australian Standards (e.g. AS/NZS 1596 for LPG storage and handling)
  • • Failure to consult, cooperate and coordinate with other duty holders (suppliers, contractors, landlords) regarding LPG hazards and controls
  • • Inadequate review of legal changes, standards and industry guidance related to LPG, resulting in outdated systems
2. LPG Procurement, Supply Chain and Cylinder Management
  • • Procurement of non-compliant LPG cylinders, hoses, valves or regulators that do not meet Australian Standards or supplier specifications
  • • Inadequate supplier vetting leading to unreliable filling practices, incorrect gas mix or contamination
  • • Poor control over cylinder ownership, leasing, test dates and traceability, increasing the risk of using out-of-test or damaged cylinders
  • • Lack of systems for managing delivery schedules, manual handling risks and secure transfer of LPG at the workplace
  • • Insufficient documentation and specifications for LPG installations, leading to incompatible fittings or over-pressurisation risk
3. Design, Engineering and Fixed Installation Management
  • • Poorly designed LPG storage and piping systems that do not meet separation distances, ventilation requirements or ignition source controls
  • • Lack of formal design review and risk assessment for new or modified LPG installations
  • • Insufficient pressure regulation, over-pressure protection and emergency shut-off arrangements
  • • Inadequate ventilation and gas detection in enclosed or semi-enclosed spaces where LPG is used or stored
  • • Failure to manage change when plant layout, building use or adjacent work activities change, affecting LPG risk profiles
4. Storage, Segregation and Site Layout Management
  • • Improper storage of LPG cylinders (e.g. indoors without adequate ventilation, near ignition sources, in thoroughfares or egress routes)
  • • Inadequate segregation of LPG from incompatible substances, heat sources and public access areas
  • • Lack of up-to-date site plans showing LPG storage areas, isolation points and emergency access routes
  • • Overstocking of LPG in limited spaces without consideration of maximum safe quantities and fire load
  • • Poor controls on temporary or short-term storage for projects, events or maintenance activities
5. Documentation, Information and Safety Data Sheet Management
  • • Outdated, inaccessible or incomplete safety data sheets (SDS) for LPG
  • • Lack of clear written procedures and work instructions for LPG-related tasks, leading to inconsistent practices
  • • Poor labelling and signage on cylinders, pipework and storage areas, resulting in misidentification during routine work or emergencies
  • • Insufficient documentation of plant registration, compliance certificates, inspection records and test reports
  • • Workers and contractors not being provided with relevant LPG hazard information before commencing work
6. Training, Competency and Supervision Systems
  • • Workers using or managing LPG without adequate training in hazards, controls and emergency response
  • • No formal competency assessment for high-risk LPG-related roles (e.g. maintenance personnel, supervisors, contractors performing hot work near LPG)
  • • Inadequate supervision of new or inexperienced workers dealing with LPG systems
  • • Failure to provide refresher training, resulting in skill fade and normalisation of unsafe shortcuts
  • • Contractor personnel assuming their own company training is sufficient without verification by the PCBU
7. Maintenance, Inspection and Testing Regimes
  • • Lack of a planned maintenance system for LPG plant, resulting in deteriorated hoses, valves, regulators and fittings
  • • Failure to monitor cylinder test dates and integrity, leading to use of out-of-test or damaged cylinders
  • • Inadequate periodic inspection of storage areas, pipework, supports and protective barriers
  • • Maintenance and repairs being carried out by unqualified or unsupervised personnel using inappropriate parts
  • • No verification that gas detection systems, alarms and emergency shut-off devices are functional
8. Emergency Preparedness, Response and Incident Management
  • • Inadequate emergency planning for LPG leaks, fires, explosions or cylinder failures
  • • Workers and contractors not knowing how to isolate LPG systems safely in an emergency
  • • Poorly coordinated response between in-house personnel, emergency services and neighbouring businesses or tenants
  • • Emergency equipment (fire extinguishers, spill control, shutdown devices) not suited to LPG risks or not readily accessible
  • • Insufficient incident reporting and investigation for LPG-related near misses and events, resulting in repeat incidents
9. Contractor, Visitor and Third-Party Interface Management
  • • Contractors performing work near LPG systems without understanding site-specific hazards and controls
  • • Hot work, excavation or building modifications impacting LPG lines or storage areas due to poor coordination
  • • Visitors and third parties (delivery drivers, customers, tenants) entering LPG risk zones without controls
  • • Multiple PCBUs on site failing to coordinate LPG emergency arrangements and isolation procedures
  • • Insufficient control over temporary works (scaffolding, fencing, events) that obstruct access to LPG equipment or emergency isolation points
10. Monitoring, Auditing and Continuous Improvement
  • • No systematic monitoring of LPG risk controls, leading to gradual degradation of standards over time
  • • Failure to analyse trends in LPG-related incidents, near misses, inspection findings and maintenance data
  • • Audit programs not covering LPG-specific requirements, resulting in gaps in compliance and risk control
  • • Lack of worker consultation and feedback mechanisms on the effectiveness of LPG controls
  • • Management not receiving timely information on LPG risk performance, affecting decision-making and resource allocation

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – Managing risks of hazardous chemicals in the workplace Code of Practice: Guidance on identification, assessment and control of hazardous chemical risks including LPG.
  • Safe Work Australia – Labelling of workplace hazardous chemicals Code of Practice: Requirements for correct LPG cylinder and container labelling.
  • Safe Work Australia – Preparation of safety data sheets for hazardous chemicals Code of Practice: Guidance on SDS content and availability for LPG products.
  • AS/NZS 1596:2014: The storage and handling of LP Gas — Technical requirements for design, installation, storage and handling of LPG systems.
  • AS/NZS 5601 (Series): Gas installations — Requirements for design, installation and commissioning of gas installations using LPG.
  • AS 4332:2004: The storage and handling of gases in cylinders — General requirements relevant to LPG cylinder management.
  • AS 1851:2012: Routine service of fire protection systems and equipment — Maintenance of fire protection measures associated with LPG hazards.
  • AS/NZS ISO 45001:2018: Occupational health and safety management systems — Requirements with guidance for use.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

$79.5

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