12 Aug Fuel Handling – JSA

Fuel Handling Job Safety Analysis (JSA)

Job / Task

Receiving, storing, transporting, dispensing, transferring, and handling gasoline, diesel fuel, and other approved fuels used for vehicles, mobile equipment, generators, tools, and temporary fuel systems.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with fuel handling and establishes controls to prevent fires, explosions, spills, static discharge, vapor exposure, skin or eye contact, environmental releases, vehicle movement, and injuries during fueling and fuel transfer.

Personnel Qualifications

Fuel handling shall be performed only by employees who are trained and authorized for the equipment, fuel, and task involved. Employees shall understand fuel hazards, container and transfer requirements, ignition-source control, spill prevention, bonding and grounding where required, emergency procedures, and required PPE.

Employees shall:

• Identify the fuel and review applicable labels and Safety Data Sheet (SDS) information.
• Inspect fuel containers, tanks, hoses, nozzles, pumps, valves, fittings, and transfer equipment before use.
• Use only approved containers and equipment intended for the fuel being handled.
• Control smoking, open flames, hot work, and other ignition sources.
• Shut down engines before fueling unless a specific approved procedure permits otherwise.
• Prevent overfilling and continuously monitor manual fuel transfers.
• Use bonding and grounding where required to control static electricity.
• Maintain spill-control materials and know applicable emergency procedures.
• Report leaks, spills, damaged equipment, and unsafe conditions immediately.
• Stop work when fuel identity, equipment condition, ignition control, containment, or other required safeguards are inadequate.

Required PPE

PPE shall be selected based on the fuel, transfer method, quantity, and work environment and may include:

• Safety glasses with side protection.
• Chemical splash goggles where splash exposure is reasonably anticipated.
• Face shield worn over eye protection where significant splash hazards exist.
• Fuel-resistant gloves selected for the product handled.
• Protective clothing appropriate to foreseeable splash or contact exposure.
• Safety footwear appropriate for the work environment and slip hazards.
• High-visibility apparel where fueling occurs near traffic or mobile equipment.
• Hard hat where construction or overhead hazards exist.
• Additional PPE specified by the SDS or hazard assessment.

JSA – Job Steps, Hazards, and Controls

Step 1 – Evaluate the Fueling or Transfer Task

Potential Hazards

• Fire or explosion.
• Fuel exposure.
• Vehicle movement.
• Environmental release.

Required Controls

• Identify the fuel, quantity, source, receiving equipment or container, and transfer method.
• Review the work area for ignition sources, traffic, drainage, ventilation, and spill hazards.
• Determine required PPE, containment, fire protection, and bonding or grounding controls.
• Verify the receiving tank or container has adequate capacity.
• Establish a safe work area before beginning.

Step 2 – Verify Fuel Identification

Potential Hazards

• Wrong fuel.
• Equipment damage.
• Incompatible mixing.

Required Controls

• Confirm the fuel type from labels, markings, SDS information, or other reliable identification.
• Verify the receiving equipment requires the same fuel.
• Do not transfer unidentified or contaminated fuel.
• Keep fuel containers properly labeled.
• Resolve discrepancies before beginning the transfer.

Step 3 – Inspect Fuel Containers and Tanks

Potential Hazards

• Leakage.
• Container failure.
• Fuel release.

Required Controls

• Inspect portable containers, drums, tanks, and fuel cells for leaks, corrosion, cracks, bulging, damaged closures, or other deterioration.
• Use only approved containers suitable for the fuel and service.
• Verify caps, vents, valves, and closures are serviceable.
• Do not use leaking or damaged containers.
• Secure portable containers against tipping or movement.

Step 4 – Inspect Fueling Equipment

Potential Hazards

• Hose rupture.
• Leaking fittings.
• Unexpected discharge.

Required Controls

• Inspect hoses, pumps, nozzles, fittings, valves, seals, and electrical components before use.
• Check hoses for cracking, abrasion, bulging, cuts, or deterioration.
• Verify components are compatible with the fuel and rated for the intended service.
• Do not use makeshift repairs or damaged equipment.
• Remove leaking or malfunctioning equipment from service.

Step 5 – Control Ignition Sources

Potential Hazards

• Fire.
• Explosion.

Required Controls

• Prohibit smoking, open flames, and unauthorized ignition sources in the fueling area.
• Control hot work and spark-producing activities according to applicable procedures.
• Keep fuel away from hot surfaces and equipment exhaust.
• Use suitable electrical equipment where required by the location.
• Stop fueling if an uncontrolled ignition source enters the area.

Step 6 – Position Vehicles or Equipment

Potential Hazards

• Vehicle movement.
• Struck-by injury.
• Collision.

Required Controls

• Park on a stable surface where practical.
• Place the transmission in park or neutral as appropriate and set the parking brake.
• Use wheel chocks where required by the conditions or procedure.
• Shut down the engine before fueling unless specifically permitted by an approved procedure.
• Prevent unauthorized movement during fueling.

Step 7 – Establish Spill Controls

Potential Hazards

• Soil or water contamination.
• Slip hazard.
• Fire.

Required Controls

• Keep an appropriate spill kit readily available.
• Use drip pans, absorbent pads, berms, or other containment where warranted.
• Protect storm drains, waterways, and sensitive areas when required.
• Do not begin transfer when foreseeable spill consequences cannot be adequately controlled.
• Keep the fueling area free of unnecessary combustible materials.

Step 8 – Bond and Ground When Required

Potential Hazards

• Static discharge.
• Fire or explosion.

Required Controls

• Determine whether the fuel, containers, and transfer method require bonding or grounding.
• Bond conductive source and receiving containers where required.
• Establish required grounding before transfer.
• Maintain connections throughout the transfer.
• Do not proceed if required bonding or grounding cannot be verified.

Step 9 – Open the Fuel Tank or Container

Potential Hazards

• Vapor exposure.
• Splash.
• Pressure release.

Required Controls

• Open caps, bungs, or valves slowly.
• Position the face and body away from openings.
• Relieve pressure only by approved methods.
• Keep closures clean and protected from contamination.
• Stop if unusual pressure, heat, or other abnormal conditions are observed.

Step 10 – Insert and Secure the Fuel Nozzle or Hose

Potential Hazards

• Splash.
• Hose movement.
• Spill.

Required Controls

• Verify the correct fill opening before inserting the nozzle or hose.
• Position the nozzle securely to minimize movement and splash.
• Do not wedge or defeat nozzle safety features.
• Keep hoses arranged to prevent trips, vehicle damage, or excessive strain.
• Maintain control of manually operated nozzles.

Step 11 – Begin Fuel Transfer

Potential Hazards

• Unexpected flow.
• Leak.
• Static ignition.

Required Controls

• Start pumps or open valves slowly to establish controlled flow.
• Observe the hose, nozzle, fittings, pump, and receiving tank for leakage.
• Maintain required bonding or grounding.
• Keep the transfer within equipment flow and pressure limits.
• Stop immediately if leakage or abnormal operation occurs.

Step 12 – Monitor Fueling

Potential Hazards

• Overfill.
• Spill.
• Unattended release.

Required Controls

• Remain in attendance during manual fueling or transfer.
• Monitor fuel level and flow continuously.
• Do not rely solely on automatic shutoff devices when direct monitoring is required.
• Reduce flow as the receiving tank approaches the intended fill level.
• Keep access to emergency shutoff controls clear.

Step 13 – Prevent Overfilling

Potential Hazards

• Overflow.
• Fire.
• Environmental release.

Required Controls

• Know the receiving tank’s safe capacity.
• Allow appropriate expansion space.
• Do not top off beyond the safe fill level.
• Stop transfer immediately if fuel backs up, foams, or approaches overflow.
• Contain and report any release promptly.

Step 14 – Fuel Portable Equipment and Small Engines

Potential Hazards

• Fire from hot surfaces.
• Spill.
• Burns.

Required Controls

• Shut down equipment and allow hot components to cool before refueling.
• Move portable equipment to an appropriate fueling location when practical.
• Use approved safety cans or dispensing containers.
• Use funnels or controlled dispensing devices when needed to prevent spills.
• Wipe up minor drips before restarting equipment.

Step 15 – Handle Portable Fuel Containers

Potential Hazards

• Strains.
• Spill.
• Vapor release.

Required Controls

• Keep containers closed except during filling or dispensing.
• Do not fill portable containers while they are inside a vehicle passenger compartment or other location that creates an unsafe static or vapor condition.
• Place containers on a stable surface during filling.
• Use proper lifting techniques or mechanical assistance for heavy containers.
• Secure containers upright during transport.

Step 16 – Fuel Generators or Temporary Equipment

Potential Hazards

• Fire.
• Carbon monoxide.
• Hot-surface ignition.

Required Controls

• Shut down and cool the generator or engine before fueling.
• Keep fuel away from exhaust components and other hot surfaces.
• Operate combustion equipment where exhaust cannot accumulate in occupied areas.
• Store reserve fuel away from the operating equipment and ignition sources as required.
• Clean spills before restarting.

Step 17 – Transfer Fuel from Drums or Totes

Potential Hazards

• Spill.
• Static ignition.
• Container movement.

Required Controls

• Use approved pumps, hoses, and fittings compatible with the fuel.
• Secure drums, totes, or tanks against movement.
• Use bonding and grounding where required.
• Do not pressurize containers unless they are specifically designed and approved for that method.
• Maintain secondary containment where required.

Step 18 – Respond to a Hose or Equipment Leak

Potential Hazards

• Fuel spray.
• Fire.
• Environmental release.

Required Controls

• Stop the pump or close the source valve immediately when safe.
• Eliminate ignition sources and keep personnel away.
• Do not continue using leaking equipment.
• Contain the release within the limits of training and available equipment.
• Tag and remove defective components from service.

Step 19 – Respond to a Fuel Spill

Potential Hazards

• Fire or explosion.
• Vapor exposure.
• Slip hazard.
• Environmental release.

Required Controls

• Stop the source when it can be done safely.
• Warn others and restrict access to the area.
• Eliminate ignition sources when safe to do so.
• Use absorbents, booms, drain covers, or other compatible spill controls within the employee’s training and authorization.
• Evacuate and obtain emergency assistance when the release exceeds available response capabilities.

Step 20 – Respond to Fuel Exposure

Potential Hazards

• Eye irritation.
• Skin exposure.
• Inhalation.

Required Controls

• Follow SDS first-aid instructions.
• Flush eyes or skin as required and remove contaminated clothing when appropriate.
• Move affected personnel to fresh air when inhalation exposure is suspected and it can be done safely.
• Obtain medical evaluation when required by the exposure or SDS.
• Report the exposure according to applicable procedures.

Step 21 – Complete the Transfer

Potential Hazards

• Residual fuel.
• Drips.
• Unexpected discharge.

Required Controls

• Stop the pump or close the valve before removing the nozzle or hose.
• Allow residual fuel to drain into the receiving tank where appropriate.
• Remove the nozzle carefully and avoid splashing.
• Replace caps and closures securely.
• Return the nozzle and hose to their designated position.

Step 22 – Inspect and Clean the Fueling Area

Potential Hazards

• Residual spill.
• Slip hazard.
• Fire hazard.

Required Controls

• Inspect the ground and equipment for drips, leaks, or spilled fuel.
• Clean minor releases using approved methods.
• Dispose of contaminated absorbents and materials appropriately.
• Remove temporary containment only after the area is safe.
• Report equipment defects or recurring leaks.

Step 23 – Store Fuel Containers

Potential Hazards

• Fire.
• Vapor accumulation.
• Unauthorized access.

Required Controls

• Store fuel only in approved containers and designated locations.
• Keep containers closed and properly labeled.
• Protect fuel from ignition sources, heat, impact, and physical damage.
• Maintain required storage quantity limits, ventilation, separation, and containment.
• Secure storage areas against unauthorized access where required.

Step 24 – Transport Fuel

Potential Hazards

• Container movement.
• Spill.
• Fire.

Required Controls

• Use approved containers and transport methods.
• Secure containers upright against tipping, sliding, or impact.
• Protect containers from heat and physical damage.
• Do not transport leaking or unsecured fuel containers.
• Comply with applicable transportation and site requirements for the quantity and type of fuel moved.

General Safe Work Requirements

• Fuel shall be handled only in approved containers, tanks, and transfer systems.
• Smoking, open flames, hot work, and other uncontrolled ignition sources are prohibited in fueling and fuel-storage areas.
• Engines shall be shut down before fueling unless a specific approved procedure permits otherwise.
• Fueling equipment, hoses, nozzles, pumps, valves, and containers shall be inspected before use.
• Damaged, leaking, or malfunctioning fuel-handling equipment shall be removed from service.
• Manual fueling and transfer operations shall be attended and monitored to prevent overfilling.
• Bonding and grounding shall be used where required to control static electricity.
• Fuel containers shall remain closed except during authorized filling, dispensing, or inspection.
• Spill-control materials shall be readily available and environmental receptors protected as required.
• Fuel spills shall be controlled only within the employee’s level of training, authorization, PPE, and equipment.
• Fuel-contaminated absorbents, rags, and other waste shall be handled and disposed of according to applicable procedures.
• Portable fuel containers shall be secured during transport and stored in designated locations.
• Fuel shall not be transferred into unidentified, incompatible, damaged, or inadequately sized containers.
• Required fire extinguishing equipment and emergency access shall remain unobstructed.
• Work shall stop whenever ignition control, container condition, spill containment, equipment condition, or other required safeguards are inadequate.

Training

Employees involved in fuel handling shall receive training appropriate to the fuels, equipment, and tasks assigned. Training shall include fuel hazards and SDS information, approved containers, pre-use inspections, ignition-source control, vehicle and equipment shutdown, bonding and grounding where applicable, overfill prevention, spill prevention and response, PPE, environmental protection, portable-container handling, emergency procedures, and reporting requirements.

References

• OSHA 29 CFR 1926.152 – Flammable Liquids.
• OSHA 29 CFR 1910.106 – Flammable Liquids, where applicable.
• OSHA 29 CFR 1910.1200 – Hazard Communication.
• OSHA 29 CFR 1926.95 – Criteria for Personal Protective Equipment.
• Applicable Safety Data Sheets, manufacturer instructions, fire-code requirements, environmental requirements, and site-specific fuel-handling procedures.