Fuel Management Safe Operating Procedure

Product Overview

Summary: This Fuel Management Safe Operating Procedure provides a clear, practical framework for safely purchasing, storing, dispensing and monitoring fuel across Australian workplaces. It helps you control fire and explosion risks, prevent environmental contamination, and demonstrate robust WHS compliance while keeping plant, fleet and site operations running efficiently.

Fuel is a critical input for many Australian businesses, but it also presents significant safety, environmental and operational risks if not tightly controlled. This Fuel Management SOP sets out a structured, end‑to‑end process for managing petrol, diesel and other common fuels, from delivery and bulk storage through to day‑to‑day dispensing, record‑keeping and incident response. It is designed to support compliance with WHS obligations and dangerous goods requirements while remaining practical for busy worksites, depots, farms and workshops.

The procedure addresses common problem areas such as uncontrolled decanting, poor labelling, ad‑hoc refuelling practices, lack of spill preparedness and inadequate inspection of tanks, bowsers and mobile fuel pods. It provides clear responsibilities, standardised checklists and step‑by‑step instructions so supervisors can be confident that fuel is being handled consistently and safely across shifts and locations. By implementing this SOP, businesses can reduce the likelihood of fires, spills, equipment downtime and regulatory non‑compliance, while also gaining better visibility over fuel usage and losses.

Key Benefits

• Reduce the risk of fire, explosion and serious injury associated with fuel storage and handling.
• Ensure compliance with Australian WHS, dangerous goods and environmental protection requirements.
• Standardise refuelling, fuel transfer and storage practices across all sites and shifts.
• Minimise fuel losses, contamination and equipment damage through clear inspection and maintenance routines.
• Improve incident readiness with defined spill response, emergency shutdown and notification procedures.

Who is this for?

• Fleet Managers
• Operations Managers
• Workshop Managers
• Site Supervisors
• WHS Managers
• Fuel Store Attendants
• Maintenance Supervisors
• Logistics and Transport Managers
• Agricultural and Farm Managers
• Construction Project Managers

Hazards Addressed

• Fire and explosion from flammable vapours and ignition sources
• Static electricity discharge during fuel transfer
• Spills and leaks leading to environmental contamination
• Inhalation of fuel vapours in poorly ventilated areas
• Skin and eye contact with fuels and fuel additives
• Manual handling injuries when moving fuel containers and hoses
• Slips, trips and falls from fuel spills around bowsers and refuelling areas
• Vehicle and plant collision risks in refuelling zones
• Burns from hot engine components during refuelling
• Confined space risks associated with some fuel storage installations

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Fuel Types Covered
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Risk Management and Hazard Identification for Fuel Operations
• 6.0 Fuel Procurement, Delivery and Acceptance Procedures
• 7.0 Fuel Storage Requirements (Fixed Tanks, Mobile Pods and Containers)
• 8.0 Labelling, Signage and Hazardous Area Controls
• 9.0 Refuelling and Fuel Dispensing Procedures (Vehicles, Plant and Equipment)
• 10.0 Use of Personal Protective Equipment (PPE)
• 11.0 Inspection, Maintenance and Housekeeping for Fuel Installations
• 12.0 Spill Prevention, Containment and Clean‑up Procedures
• 13.0 Fire Safety, Emergency Shutdown and Evacuation
• 14.0 Transport and Handling of Portable Fuel Containers
• 15.0 Environmental Protection and Waste Fuel Disposal
• 16.0 Incident Reporting, Investigation and Corrective Actions
• 17.0 Training, Induction and Competency Verification
• 18.0 Record‑Keeping, Fuel Inventory and Usage Monitoring
• 19.0 Review, Audit and Continuous Improvement of the Fuel Management System

Legislation & References

• Work Health and Safety Act 2011 (Cth) and corresponding state and territory WHS Acts and Regulations
• Dangerous Goods (Road and Rail Transport) legislation applicable in relevant state or territory
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 series: Explosive atmospheres (for hazardous area considerations)
• AS/NZS 3012: Electrical installations – Construction and demolition sites (where applicable)
• Safe Work Australia – Managing risks of hazardous chemicals in the workplace: Code of Practice
• Safe Work Australia – Managing risks of plant in the workplace: Code of Practice
• Environment Protection legislation and guidelines issued by relevant state or territory EPA