Fuel Safety Inspection Checklist

What is a Fuel Safety Inspection Checklist?

A fuel safety inspection checklist helps gas stations and fleet operators manage fuel safely and responsibly. Handling fuel can be extremely dangerous, especially when done improperly around moving vehicles, retail stores, or near flammable hazards. A thorough checklist ensures vehicles and equipment are properly inspected, supports compliance with safety regulations, and promotes regular maintenance.

Importance

Fuel is one of the most dangerous substances due to its ability to ignite at almost any temperature, thanks to its very low flash point. According to the US National Fire Protection Association (NFPA), gas stations experience an average of 4,150 fires annually, resulting in injuries, fatalities, and about $30 million in property damage. Many of these incidents are preventable and often result from inadequate safety protocols for fuel management.

A fuel safety inspection checklist helps you organize all the important safety guidelines and inspections, so that nothing gets missed. Gas stations, service stations, petrol stations, fleets, and nearby convenience stores and retail locations can all implement it to strengthen safety management and stay compliant with government regulations.

What to Include in a Fuel Inspection Checklist

A well-prepared and thorough checklist is all you need to conduct effective gas station inspections. Be sure to include considerations for nearby retail shops, small vendors, and pedestrians when building your checklist.

Here’s what’s necessary in a fuel inspection checklist:

General Safety and Compliance

• Is the site free from any visible signs of fuel leaks or spills?

• Are environmental regulations (fuel handling, disposal, waste) being followed?

• Are proper waste disposal practices implemented and documented?

• Are all required safety records up to date (e.g., fueling/charging logs, inspection reports, incident reports)?

• Are employees trained and refreshed in emergency response protocols?

Fuel Storage Area

• Is the fuel storage area clean and free of debris?

• Are spill containers clean and properly maintained?

• Are fill tubes, vapor caps, and adapters in good working condition?

• Are fill caps and adapters secure and functioning properly?

• Is fuel inventory tracked and monitored accurately?

Dispenser and Charging Area

• Are hoses and nozzles compliant with recognized safety standards (e.g., SAE J1942, US Coast Guard, or OSHA)?

• Are nozzles well-maintained, with the spouts secure and free from damage?

• Are hose retractors present with a hose loop of 10 inches or less?

• Are fuel dispensers free of leaks or structural damage?

• Has the integrity of fuel dispensers and underground storage tanks been verified?

LPG Storage

• Is the LPG enclosure at least 20 feet away from fuel dispensers?

• Is the area free of weeds, vegetation, and combustible materials?

• Are LPG cylinders stacked upright and limited to no more than 3 per column?

• Are cylinders placed on a level, non-flammable, well-drained base?

Site Facilities and Maintenance

• Are all lights fully functional, providing clear visibility at night?

• Are electrical panels and junction boxes properly secured and safe to use?

• Are traffic and pedestrian pathways clear and well-marked??

• Is running water available on-site for cleaning and emergencies?

Fire Prevention and Emergency Controls

• Are there any fire hazards present?

• Are fire extinguishers present, accessible, and checked regularly?

• Are “No Smoking” signs visibly posted in all required areas?

• Is dry sand available for fire suppression?

• Are fire safety regulations being met?

How to Use this Checklist

Here is a step-by-step guide for gas station managers to integrate a safety checklist into their daily operations so they understand how to check for proper ventilation and the absence of fuel or oil leaks from vehicles:

• Download and Customize the Checklist – Adapt the checklist to fit the specific needs of your filling station.

• Prepare Safety Equipment – Set up traffic cones and wear safety vests to ensure visibility and protection during inspections.

• Inspect the Premises Using the Checklist – Work through each item, checking vent lines, valves, signage, and stickers for compliance, and ensuring no vapor shadows are present.

• Conduct a Visual Inspection – Watch for fuel or oil leaks around and beneath parked vehicles. Use the checklist to note your observations.

• Record and Address Issues – Document leaks, damaged ventilation components, or other hazards, and take corrective action immediately.

Daily use of this inspection checklist keeps vehicle fueling safety a priority, ensures early detection of damaged equipment, and helps maintain a safe environment at the gas station.

Sample Fuel Safety Inspection Report

Below is an example of a completed fuel safety inspection template for gas station managers, operators, or staff to use.

Preview Fuel Safety Inspection Sample Report