Fuel Safety: Protect Your Workplace and Prevent Risks

What is Fuel Safety?

Fuel safety refers to the proper handling, storage, and use of fuels such as gasoline, diesel, and propane to prevent accidents, fires, and environmental hazards. It involves following strict guidelines for labeling, containment, ventilation, and emergency response to reduce risks. Practicing fuel safety protects workers, property, and the environment while ensuring compliance with safety regulations.

Importance of Fuel Safety

Fuel safety is integral to gas station safety because every risk on-site, whether a fire, spill, or fume, stems from the fuel itself. Proper storage, handling, and dispensing practices are what keep these risks under control. Without strong fuel safety measures, a gas station can’t truly ensure a safe environment for workers or customers.

Maintaining fuel safety also means protecting the station from environmental and financial harm. Spills or leaks can lead to contamination, fines, and damage to public trust. By making fuel safety a priority, gas stations create a safer operation that’s sustainable and reliable for the long term.

Fuel safety is especially critical in retail environments where vehicle storage and fueling or charging activities occur regularly. Failure to follow Standard Operating Procedures (SOPs) not only endangers workers and customers but also increases the chance of environmental contamination from fuel or battery leaks. According to the United Nations Economic Commission for Europe (UNECE), nearly 40% of small- and medium-sized oil spills and 29% of large spills occur during typical operational activities like loading and unloading, highlighting the critical need for strict procedural adherence to prevent hazardous incidents and protect human health and the environment.

Key Risks

Teams seeking to enhance fuel safety must understand the key risks that come with handling fuel. Here are some of the main risks organizations must consider when handling fuel to reduce hazards and ensure the safety of employees and customers:

Fire and Explosion Hazards

Fuel is highly flammable, and even a small spark can ignite vapors, leading to fires or explosions. At gas stations, the risk increases with constant dispensing, vehicle traffic, and static electricity. Strict safety measures and proper equipment maintenance are essential to prevent such incidents.

Environmental Contamination

Fuel spills or leaks can seep into soil and water sources, causing long-lasting damage to ecosystems. Contamination can also affect nearby communities by polluting drinking water or harming wildlife. Preventing leaks through proper storage and quick spill response is critical for environmental protection.

Health Hazards

Exposure to fuel vapors or skin contact with gasoline and diesel can cause respiratory issues, dizziness, or skin irritation. Prolonged exposure may lead to more severe health effects, including organ damage. Providing proper protective equipment and ventilation helps reduce these risks for workers and customers.

Storage and Transportation Risks

Improper storage or unsafe transportation of fuel increases the likelihood of leaks, spills, or explosions. Tanks, containers, and vehicles must meet strict safety standards to handle the fuel safely. Regular inspections and adherence to regulations ensure that storage and transport remain secure.

Regulations and Standards

Organizations must follow relevant standards and regulations when practicing fuel safety. This not only ensures compliance but also enhances operational safety. Learn about the key standards and regulations for fuel safety in different countries and territories.

US

The Occupational Safety and Health Administration (OSHA) requires designated personnel to handle fueling, engines to be shut off during refueling, and strict prohibitions on smoking or open flames; spills must be addressed before restarting equipment. Dispensing devices need accessible emergency shut-offs and collision protection, and portable liquid-fuel containers must be metal with tight, spill-preventing closures. For liquefied gas, fueling is limited to designated (often outdoor) locations with leak checks, protected/vented cylinders, and storage away from exits or ignition sources.

EU

The EU’s Stage I directive (1994/63/EC) targets Volatile Organic Compound (VOC) emission control during petrol storage and distribution (e.g., floating roofs, vapour recovery back to tankers), while Stage II (2009/126/EC) captures vapours at the vehicle refueling stage. Stage II was updated via the Commission Directive 2014/99/EU, referencing EN 16321-2 measurement of capture efficiency, and related activities are also covered under the Industrial Emissions Directive. A 2017 Commission review found these measures effectively reduced VOC emissions.

Australia

Australia regulates fuel security and quality through four main laws: the Fuel Security Act 2021 (payments and minimum stockholding), Petroleum and Other Fuels Reporting Act 2017 (market reporting), Fuel Quality Standards Act 2000 (supply of quality liquid fuels), and Liquid Fuel Emergency Act 1984 (liquid fuel resources management during national emergencies). The department applies a risk-based compliance approach with published policies and a matrix to scale responses to non-compliance.

Canada

Canada consolidates access to regulatory texts, guidance, and reporting for multiple fuel rules, including Benzene in Gasoline, Sulphur in Gasoline and Diesel, Renewable Fuels, Gasoline Regulations, and dispensing flow-rate limits. These regulations aim to reduce pollutants, protect health and the environment, and standardize reporting and compliance.

Best Practices

Fuel safety should be a top priority for any company that handles fuel products, stores fuel-powered vehicles, and operates fuel-powered machinery and/or equipment. Companies should base their fuel safety practices around the regulations of the country in which they operate. The following best practices apply to gas stations worldwide:

Proper Storage and Labeling of Fuel Containers

Fuel must be stored in approved, clearly labeled containers to avoid confusion and accidental misuse. Containers should be kept in well-ventilated, designated areas away from heat, sparks, or open flames. Proper labeling and segregation also help during inspections and emergencies by making fuel types and hazards easy to identify.

Safe Transportation and Handling Procedures

Fuel should only be transported in certified containers or vehicles designed to handle flammable liquids. Workers must follow strict loading and unloading procedures to minimize spills, leaks, or static discharge. Using Personal Protective Equipment (PPE) and ensuring containers are sealed securely further reduces transportation risks.

Emergency Response Planning for Spills or Fires

A clear emergency response plan ensures workers know how to act quickly if a spill or fire occurs. This includes having spill kits, fire extinguishers, and communication protocols readily available. Regular drills and preparedness training strengthen the ability to contain incidents before they escalate.

Worker Training on Safe Fuel Practices

Employees must be trained to understand fuel hazards and the correct methods for handling, storing, and dispensing. Training should cover emergency procedures, the use of protective gear, and risk recognition. Ongoing refresher sessions also keep safety knowledge up to date and effective.

Regular Inspection and Maintenance of Fuel Systems

Fuel tanks, pumps, and pipelines need routine checks to detect leaks, corrosion, or mechanical failures before they become dangerous. Preventive maintenance reduces risks of spills, fires, and costly downtime. Documenting inspections also ensures compliance with regulations and creates accountability for safety practices.