Product Overview

Summary: This Fuel System Cleaning Safe Operating Procedure sets out a safe, consistent and compliant method for inspecting, cleaning and returning fuel systems to service. It helps Australian businesses manage fire and explosion risks, protect workers from hazardous substances, and maintain equipment reliability across vehicles, plant and fixed fuel installations.

Fuel system cleaning involves working with flammable liquids, vapours and pressurised components, often in confined or poorly ventilated spaces. Without a clear, risk-based procedure, routine maintenance tasks can quickly escalate into fire, explosion, chemical exposure or environmental incidents. This Fuel System Cleaning Safe Operating Procedure provides a structured method for isolating, depressurising, draining, cleaning and reinstating fuel systems on light and heavy vehicles, plant, equipment and static fuel storage, with a strong focus on hazard control and WHS compliance in Australian workplaces.

The SOP translates legislative and Australian Standard requirements into practical, workshop-ready instructions that technicians can follow step by step. It covers pre-start checks, safe handling and temporary storage of fuels, control of ignition sources, selection and use of compatible cleaning agents, management of vapours and spills, and verification that systems are safe to return to operation. By implementing this procedure, businesses can reduce incident rates, extend asset life, support consistent training across teams and demonstrate due diligence during internal audits, regulator inspections and incident investigations.

Key Benefits

• Reduce the risk of fire, explosion and fuel-related incidents during cleaning and maintenance activities.
• Ensure compliance with Australian WHS legislation and relevant fuel handling and hazardous chemicals requirements.
• Standardise fuel system cleaning practices across technicians, shifts and sites for consistent quality and safety.
• Improve equipment reliability and performance by ensuring contaminants are removed without damaging components.
• Minimise environmental impact and clean-up costs through controlled handling, containment and disposal of fuel and waste products.

Who is this for?

• Fleet Maintenance Managers
• Diesel Mechanics
• Automotive Technicians
• Workshop Supervisors
• Plant and Equipment Maintenance Supervisors
• Fuel System Specialists
• WHS Managers
• Service Centre Managers
• Facilities and Asset Managers
• Mining and Civil Maintenance Coordinators

Hazards Addressed

• Fire and explosion from flammable liquids and vapours
• Exposure to hazardous substances including petrol, diesel and cleaning solvents
• Static electricity ignition when handling fuels and cleaning agents
• Pressurised fuel release causing injection injuries or spray to eyes and skin
• Inhalation of harmful vapours in poorly ventilated or confined spaces
• Slips, trips and falls due to fuel spills and contaminated work areas
• Environmental contamination from uncontrolled fuel discharge or improper waste disposal
• Burns from contact with hot engine or exhaust components during maintenance
• Manual handling injuries when moving fuel tanks, drums or heavy components

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Fuel System Types Covered
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Tools, Equipment and Cleaning Agents
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre-Task Planning and Risk Assessment (JSA/SWMS)
• 8.0 Isolation, Depressurisation and De-energisation Procedures
• 9.0 Fuel Draining, Containment and Temporary Storage
• 10.0 Ventilation, Vapour Control and Atmospheric Testing (where applicable)
• 11.0 Step-by-Step Fuel System Cleaning Procedure
• 12.0 Control of Ignition Sources and Static Electricity
• 13.0 Spill Prevention, Response and Environmental Protection
• 14.0 Inspection, Reassembly and Leak Testing
• 15.0 Return-to-Service Checks and Documentation
• 16.0 Emergency Procedures (Fire, Exposure, Spills and Injection Injuries)
• 17.0 Waste Management and Disposal of Contaminated Materials
• 18.0 Training, Competency and Review Requirements
• 19.0 Recordkeeping, Auditing and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Hazardous Chemicals and General Risk and Workplace Management
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace: Code of Practice
• Safe Work Australia – Managing the Risk of Plant in the Workplace: Code of Practice
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 60079 (series): Explosive atmospheres (for work in hazardous areas around fuel installations)
• AS/NZS 4761: Competencies for working in a confined space (where applicable to fuel tanks and pits)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161: Occupational protective gloves – Selection, use and maintenance