| Step | Potential Hazard | Control |
|---|---|---|
| Assess fueling location | Traffic exposure, poor lighting, uneven ground, ignition sources nearby | Choose a flat, well lit fueling area; keep vehicles away from hot work or open flames; use cones if fueling near traffic |
| Inspect fueling equipment | Leaking nozzles, damaged hoses, malfunctioning pumps, static buildup | Check hoses for cracks, verify nozzle shuts off properly, confirm grounding and bonding straps are intact |
| Don required PPE | Skin contact with fuel, slips from spills, eye irritation | Wear gloves and safety glasses; use high visibility vest if near roadway or equipment |
| Shut off engine before fueling | Fire hazard, static discharge ignition | Turn off engine, lights, and accessories; ensure no one is smoking nearby |
| Prepare fueling area | Slips, ignition from fuel splash, spills contaminating soil | Place absorbent pads nearby; keep fire extinguisher accessible; ensure footing is clear of ice, mud, or debris |
| Begin fueling | Fuel splashes, static ignition, overfilling tank | Touch nozzle to metal fill neck before fueling; maintain contact to reduce static; fill slowly; do not top off tank |
| Monitor fueling process | Overflow, leaks, distracted operator | Stay at nozzle at all times; watch gauge or sound of tank; stop immediately if spill or leak occurs |
| Handle fuel containers (if refilling cans) | Spills, fumes, improper container pressurization | Use approved DOT rated containers; place container on ground before filling; never fill inside truck bed or on equipment |
| Clean minor spills | Slip hazard, environmental contamination | Use absorbent pads; dispose of contaminated material properly; report larger spills immediately |
| Replace cap and secure equipment | Vapor release, contamination, loose cap causing spill during travel | Tighten cap securely; check for leaks; store hoses and pumps properly |
| Restart equipment safely | Ignition of trapped vapors, equipment movement | Allow vapors to dissipate; start engine only after fueling area is clear; verify no tools or debris remain nearby |
| Final inspection | Residual fuel, smells indicating leaks | Check around tank and ground for drips; report any mechanical fuel leaks |
| Remove traffic control | Exposure to passing vehicles | Remove cones or signage only when fueling operation is complete and area is safe; maintain lookout |
Safety glasses
Cut resistant gloves or fuel resistant gloves
Steel toe boots
High visibility vest if fueling in or near a work zone
Long pants and long sleeves
Always have a complete, well-stocked first aid kit available.
JSA Category: General Maintenance and Shop Operations
* The steps, hazards, and controls displayed above may be incomplete or not suit your department's needs. All job safety analyses should be a completed with frontline worker input to ensure that each potential hazard is identified and mitigated.
Please read about The Essentials Elements of a Solid Job Safety Anaylsis here.
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| Step | Potential Hazard | Control |
|---|---|---|
| Assess fueling location | Traffic exposure, poor lighting, uneven ground, ignition sources nearby | Choose a flat, well lit fueling area; keep vehicles away from hot work or open flames; use cones if fueling near traffic |
| Inspect fueling equipment | Leaking nozzles, damaged hoses, malfunctioning pumps, static buildup | Check hoses for cracks, verify nozzle shuts off properly, confirm grounding and bonding straps are intact |
| Don required PPE | Skin contact with fuel, slips from spills, eye irritation | Wear gloves and safety glasses; use high visibility vest if near roadway or equipment |
| Shut off engine before fueling | Fire hazard, static discharge ignition | Turn off engine, lights, and accessories; ensure no one is smoking nearby |
| Prepare fueling area | Slips, ignition from fuel splash, spills contaminating soil | Place absorbent pads nearby; keep fire extinguisher accessible; ensure footing is clear of ice, mud, or debris |
| Begin fueling | Fuel splashes, static ignition, overfilling tank | Touch nozzle to metal fill neck before fueling; maintain contact to reduce static; fill slowly; do not top off tank |
| Monitor fueling process | Overflow, leaks, distracted operator | Stay at nozzle at all times; watch gauge or sound of tank; stop immediately if spill or leak occurs |
| Handle fuel containers (if refilling cans) | Spills, fumes, improper container pressurization | Use approved DOT rated containers; place container on ground before filling; never fill inside truck bed or on equipment |
| Clean minor spills | Slip hazard, environmental contamination | Use absorbent pads; dispose of contaminated material properly; report larger spills immediately |
| Replace cap and secure equipment | Vapor release, contamination, loose cap causing spill during travel | Tighten cap securely; check for leaks; store hoses and pumps properly |
| Restart equipment safely | Ignition of trapped vapors, equipment movement | Allow vapors to dissipate; start engine only after fueling area is clear; verify no tools or debris remain nearby |
| Final inspection | Residual fuel, smells indicating leaks | Check around tank and ground for drips; report any mechanical fuel leaks |
| Remove traffic control | Exposure to passing vehicles | Remove cones or signage only when fueling operation is complete and area is safe; maintain lookout |
Safety glasses
Cut resistant gloves or fuel resistant gloves
Steel toe boots
High visibility vest if fueling in or near a work zone
Long pants and long sleeves