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Refuelling Of Plant Risk Assessment

Refuelling Of Plant Risk Assessment

  • • 100% Compliant with Australian WHS Acts & Regulations
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Refuelling Of Plant Risk Assessment

Product Overview

Identify and control organisational risks associated with Refuelling of Plant through a structured, management-level WHS Risk Management framework that addresses policy, planning, infrastructure and systems of work. This Risk Assessment supports compliance with the WHS Act, demonstrates executive Due Diligence, and helps protect your business from operational and legal liability.

Risk Categories & Hazards Covered

This document assesses risks and outlines management controls for:

  • Governance & WHS Duties: Assessment of officer due diligence, PCBUs’ responsibilities, consultation arrangements, and integration of refuelling risks into the broader WHS management system and risk management framework.
  • Fuel Procurement & Supply Chain Management: Management of supplier selection, delivery scheduling, fuel quality, chain-of-responsibility issues, and contractual controls for safe handling and transport of fuel.
  • Fuel Storage & Inventory Control: Assessment of tank siting, bunding, venting, overfill protection, leak detection, segregation from ignition sources, and systems for stock control and reconciliation.
  • Refuelling Infrastructure Design & Traffic Management: Evaluation of bowsers, hoses, dispensers, hardstands, lighting, signage, vehicle and plant movements, pedestrian segregation, and site layout to minimise collision and congestion risks.
  • Refuelling Policies, Procedures & Safe Systems of Work: Development of documented rules for pre-start checks, shutdown and isolation, no‑smoking and hot work controls, mobile phone restrictions, and standardised refuelling workflows for all plant.
  • Training, Competency & Worker Authorisation: Protocols for competency requirements, verification of training, supervision levels, licence checks, and authorisation of workers permitted to refuel or access fuel storage areas.
  • Equipment Selection, Inspection & Maintenance: Management of compliant fuel pumps, hoses, nozzles, emergency stops, earthing/bonding systems, static control, and scheduled inspection, testing and preventive maintenance programs.
  • Hazardous Chemicals & Dangerous Goods Management: Control of classification, labelling, Safety Data Sheets (SDS), placarding, manifests, segregation, decanting practices, and documentation for fuels and associated chemicals.
  • Environmental Protection & Spill Control: Assessment of ground and water contamination risks, stormwater protection, bund capacity, drainage controls, and waste management for contaminated soils and absorbents.
  • Emergency Preparedness, Spill Response & Fire Protection: Planning for fire and explosion scenarios, spill kits, extinguishers, alarms, evacuation routes, drills, and integration with local emergency services and site emergency plans.
  • Contractor, Visitor & Third‑Party Interface Management: Protocols for induction, access control, supervision, contractor management, and communication of refuelling hazards to delivery drivers and service providers.
  • Monitoring, Reporting & Incident Management: Systems for hazard reporting, incident investigation, corrective actions, near‑miss analysis, and trend monitoring related to refuelling operations.
  • Auditing, Review & Continuous Improvement: Scheduled audits, inspections, management reviews, and performance indicators to ensure refuelling controls remain effective, current and aligned with organisational objectives.

Who is this for?

This Risk Assessment is designed for Business Owners, Operations Managers, Fleet Managers and Safety Professionals responsible for planning, approving and overseeing refuelling of plant across workshops, depots and project sites.

Hazards & Risks Covered

Hazard Risk Description
1. Governance, WHS Duties and Risk Management Framework
  • • Lack of a documented WHS risk management procedure specific to refuelling of plant, buses and bulk tanks, leading to inconsistent controls across sites
  • • Officers and PCBUs not fully understanding or discharging their due diligence obligations under the WHS Act 2011 in relation to hazardous chemicals and plant
  • • Inadequate consultation with workers and Health and Safety Representatives (HSRs) about refuelling risks and proposed controls
  • • No formal process for reviewing refuelling incidents, near misses or audit findings, resulting in systemic issues persisting
  • • Poor integration of refuelling hazards into the broader organisational WHS Management System (WHSMS) and risk register
2. Fuel Procurement, Storage and Supply Chain Management
  • • Selection of fuel suppliers without verifying compliance with Australian Standards and WHS legislation for transport and delivery of hazardous chemicals
  • • Inadequate fuel quality control leading to contamination that may cause engine malfunction or plant failure during operation
  • • Poorly designed or non-compliant bulk storage tanks and fuel systems increasing the risk of leaks, spills, fire or explosion
  • • Lack of formal agreements with suppliers regarding delivery procedures, emergency response, and site safety requirements during tank refuelling
  • • Inadequate systems for monitoring fuel inventory, leading to ad hoc deliveries and unsafe refuelling practices under time pressure
3. Design and Layout of Refuelling Infrastructure and Traffic Management
  • • Poorly designed refuelling areas leading to vehicle and plant interactions with pedestrians and other mobile plant
  • • Inadequate segregation of refuelling zones from workshop activities, bus passenger areas, public access or general traffic routes
  • • Insufficient ventilation or inappropriate location of refuelling points increasing the risk of vapour build-up and ignition sources
  • • Lack of dedicated spill containment, drainage control and bunding around fuel storage and refuelling points
  • • Inadequate lighting and signage at refuelling points, increasing the risk of refuelling errors, slips, trips and collisions during low light conditions
4. Refuelling Policies, Procedures and Safe Systems of Work
  • • Absence of a unified organisational procedure for refuelling plant, buses and bulk tanks, leading to inconsistent practices across sites and shifts
  • • Procedures that focus only on operational steps and not on system-level controls such as authorisation, supervision and isolation of ignition sources
  • • Inadequate consideration of different refuelling contexts, such as on-road bus refuelling at public service stations, on-site bowsers and mobile fuel trucks on remote sites
  • • Lack of clear rules regarding engine shutdown, occupants remaining on buses, and movement of other plant in refuelling zones
  • • Failure to address concurrent work (e.g. maintenance tasks or loading activities) occurring near refuelling operations
5. Training, Competency and Authorisation of Workers
  • • Workers undertaking refuelling tasks without adequate induction, training or verification of competence for specific plant, buses and fuel systems
  • • Supervisors assuming competencies based on previous experience or licences without verifying understanding of site-specific refuelling procedures and emergency requirements
  • • Training that is one‑off and classroom‑only, with no ongoing refresher or competency assessment in the field
  • • Insufficient training for tank refuelling (bulk deliveries) including understanding of overfill protection, venting and communication with delivery drivers
  • • Inadequate awareness among workers of the health effects of fuel exposure, vapours and manual handling risks associated with refuelling equipment
6. Equipment Selection, Inspection, Maintenance and Reliability
  • • Use of non-compliant or poorly specified refuelling equipment, hoses and nozzles for the types of fuel and plant in use
  • • Lack of a planned inspection and maintenance regime for fuel pumps, bowsers, tanks, automatic shut‑off devices and spill containment systems
  • • Failure of level indicators, overfill protection or leak detection systems leading to undetected spills or tank overflows during refuelling
  • • Uncontrolled modifications or temporary repairs to refuelling equipment, increasing the risk of failure or ignition
  • • Poor compatibility between refuelling connectors and different plant or bus fuel inlets, leading to potential misfuelling or spills
7. Hazardous Chemicals Management and Documentation
  • • Incomplete or outdated Safety Data Sheets (SDS) for fuels and associated products, leading to incorrect control measures and emergency response
  • • Failure to maintain a hazardous chemicals register that accurately captures all fuel storage locations, quantities and container types
  • • Insufficient labelling of tanks, pipework and dispensing equipment, creating risk of misidentification and incorrect handling
  • • Lack of clarity regarding segregation and compatibility of different hazardous chemicals stored near refuelling areas
  • • Poor recordkeeping regarding fuel volumes, deliveries and disposals, affecting regulatory compliance and incident investigation
8. Emergency Preparedness, Spill Response and Fire Protection
  • • Inadequate planning and resourcing for spill response, resulting in delayed or ineffective control of fuel leaks during refuelling
  • • Insufficient or unsuitable fire protection systems (e.g. extinguishers, hydrants) for the type and volume of fuel stored and dispensed
  • • Workers not trained or drilled in emergency shutdown of refuelling equipment, spill containment and evacuation procedures
  • • Lack of integration between site emergency plans and external emergency services for significant fuel spills, fires or exposures
  • • Emergency equipment (spill kits, alarms, communication devices) not regularly inspected, maintained or clearly identified
9. Contractor, Visitor and Third-Party Interface Management
  • • Fuel delivery drivers and maintenance contractors performing tank refuelling or equipment servicing without adequate induction into site-specific WHS and refuelling controls
  • • Bus drivers refuelling at public service stations where the organisation has limited control over the environment and other road users
  • • Poor communication between site supervisors and third-party contractors about simultaneous operations near refuelling areas
  • • Differences between contractor company procedures and the host site rules, leading to confusion and inconsistent controls
  • • Lack of oversight or verification that contractors comply with permit systems, traffic management plans and spill response expectations
10. Monitoring, Reporting, Auditing and Continuous Improvement
  • • Lack of systematic monitoring of refuelling practices, leading to normalisation of unsafe shortcuts or non-compliance with procedures
  • • Under-reporting of near misses, minor spills or equipment faults related to refuelling activities
  • • Infrequent or ineffective WHS inspections and audits of refuelling areas, meaning emerging risks are not identified
  • • Failure to analyse incident data and trends related to refuelling of plant, buses and bulk tanks at an organisational level
  • • Corrective actions from incidents or audits not tracked to completion, resulting in recurrence of known issues

Need to add specific hazards for your workplace?

Don't worry if a specific hazard isn't listed above. Once you purchase, simply log in to your Client Portal and add your own custom hazards at no extra cost. We take care of the hard work—creating the risk ratings and control measures for free—to ensure your document is compliant within minutes.

Legislation & References

This document was researched and developed to align with:

  • Work Health and Safety Act 2011
  • Work Health and Safety Regulations 2017
  • AS/NZS ISO 31000:2018: Risk management — Guidelines
  • Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice: Guidance on safe storage, handling and risk control for fuels and other hazardous chemicals.
  • Safe Work Australia – Managing the Work Environment and Facilities Code of Practice: Requirements for safe workplace design, including traffic management and emergency access around refuelling areas.
  • Safe Work Australia – How to Manage Work Health and Safety Risks Code of Practice: Framework for identifying hazards, assessing risks and implementing control measures.
  • AS 1940: The storage and handling of flammable and combustible liquids, including design and management of fuel storage and dispensing systems.
  • AS/NZS 60079 (Series): Explosive atmospheres — Requirements for equipment and protection systems used where flammable vapours may be present.
  • AS 1851: Routine service of fire protection systems and equipment relevant to refuelling facilities.
  • AS 3745: Planning for emergencies in facilities, including emergency response arrangements for fuel spills and fires.
Standard Risk Assessment Features (Click to Expand)
  • Comprehensive hazard identification for all activities
  • Risk rating matrix with likelihood and consequence analysis
  • Existing control measures evaluation
  • Residual risk assessment after controls
  • Hierarchy of controls recommendations
  • Action priority rankings
  • Review and monitoring requirements
  • Consultation and communication records
  • Legal compliance references
  • Sign-off and approval sections

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Safe Work Australia Aligned