22 Mar Equipment Refueling – Safe Refueling Practices

Equipment Refueling – Safe Refueling Practices

Equipment refueling involves flammable or combustible fuels that can create serious fire, explosion, exposure, and environmental hazards. Whether refueling heavy equipment, generators, trucks, or portable equipment, employees must follow established procedures and control all potential ignition sources.

Before Refueling

Before beginning refueling operations:

• Park equipment in an approved or suitable refueling area whenever possible.
• Shut off the engine unless the equipment is specifically designed and approved for refueling while operating.
• Set the parking brake and secure the equipment against unintended movement.
• Chock wheels when necessary.
• Allow hot equipment to cool when required.
• Identify and eliminate nearby ignition sources.
• Verify that the correct fuel is being used.
• Inspect fuel hoses, nozzles, containers, and dispensing equipment for leaks or damage.
• Make sure appropriate spill-control materials and fire protection are readily available.

Never begin refueling if conditions could allow fuel vapors to contact an ignition source.

Control Ignition Sources

Gasoline vapors are particularly hazardous because they can ignite rapidly and travel to an ignition source.

During equipment refueling:

• No smoking or vaping is permitted in the refueling area.
• Keep open flames, sparks, hot work, and other ignition sources away.
• Do not refuel near welding, cutting, grinding, or other spark-producing operations.
• Do not use damaged electrical equipment near fuel-transfer operations.
• Shut down portable equipment before adding fuel.
• Never use an open flame to provide lighting or inspect a fuel tank.

Observe all posted NO SMOKING and FLAMMABLE warnings.

Safe Fuel Transfer

Remain attentive throughout the entire refueling process.

• Never leave a fuel nozzle unattended while dispensing fuel.
• Maintain control of the nozzle.
• Do not overfill the tank.
• Allow adequate space for fuel expansion.
• Keep the nozzle in contact with the tank or fill opening when required to control static electricity.
• Follow bonding and grounding requirements applicable to the fuel-transfer system.
• Do not use makeshift funnels, hoses, or containers.
• Keep fuel caps and dispensing equipment clean and properly secured.
• Replace the fuel cap after refueling is complete.

Never use gasoline or other fuels for cleaning tools, equipment, parts, clothing, or your hands.

Portable Fuel Containers

Fuel must be transported and stored in containers approved for the intended use.

• Clearly identify containers by their contents.
• Keep containers tightly closed when not in use.
• Protect containers from physical damage.
• Keep them away from heat and ignition sources.
• Do not use open buckets, beverage containers, or other unapproved containers for fuel.
• Store fuel only in designated areas and quantities permitted by company procedures and applicable regulations.

Never place gasoline or other fuel into an unlabeled container.

Spill Prevention and Response

Fuel spills can create fire, slip, health, and environmental hazards.

To prevent spills:

• Inspect equipment before dispensing.
• Position hoses and nozzles carefully.
• Avoid overfilling.
• Use drip pans or secondary containment where appropriate.
• Stay with the equipment throughout refueling.

If a spill occurs, stop dispensing immediately and control ignition sources. Keep employees and equipment away from the affected area and follow the company’s spill-response procedures.

Report spills as required. Do not wash fuel into storm drains, waterways, soil, or other unauthorized areas.

Fire Protection

Appropriate fire-extinguishing equipment must be readily accessible in or near designated refueling areas as required by applicable regulations and site procedures.

Employees should:

• Know where the nearest appropriate extinguisher is located.
• Keep access to fire extinguishers unobstructed.
• Know the site’s emergency procedures.
• Never attempt to fight a fire unless trained, authorized, and conditions allow it to be done safely.

If fuel ignites or conditions become unsafe, stop work, warn others, evacuate the area, and initiate the site’s emergency procedures.

Personal Protective Equipment

Wear PPE appropriate for the fuel and refueling operation. Depending on the task, this may include:

• Safety glasses or goggles.
• Fuel-resistant gloves.
• Protective footwear.
• Appropriate work clothing.

Review the Safety Data Sheet (SDS) for the fuel and follow applicable PPE, handling, and first-aid requirements.

Immediately remove clothing that becomes significantly contaminated with fuel and follow established decontamination procedures.

Refueling Portable Equipment

Small engines such as saws, pumps, compactors, and other gasoline-powered equipment require the same attention as larger equipment.

Before refueling:

• Shut the engine off.
• Allow hot surfaces to cool sufficiently.
• Move away from ignition sources.
• Place the equipment on a stable surface.
• Refuel carefully without overfilling.
• Wipe up spilled fuel and allow vapors to dissipate before restarting.

Never refuel a hot gasoline-powered tool immediately after shutting it down if spilled fuel could contact hot engine components.

Remember

Safe equipment refueling requires controlling fuel, vapors, ignition sources, static electricity, and spills. Shut equipment down, eliminate ignition sources, use approved dispensing equipment and containers, prevent overfilling, and clean up or report spills immediately.

Fuel the equipment—not the fire. Take the time to refuel safely every time.