Safe Refuelling of Industrial Equipment and Machinery: Tips and Best Practices

Refuelling industrial equipment seems simple enough. Despite being a routine task, refuelling equipment requires careful consideration of numerous safety features. Unsafe fuel handling poses a safety hazard and can risk your operations, workers, and the environment. 

The solution? Take preventive measures. Here are six best practices you should follow when refuelling industrial equipment and other on-site heavy-duty machinery:

1. Understand Fuel Types and Their Specific Needs

First things first, know that every fuel type has its own refuelling needs. Whether you’re dealing with gasoline, diesel, or propane, make sure to follow specific refuelling rules.

For instance, diesel is less flammable than gasoline, but it is still dangerous. Leaks or spills must be avoided at all costs. In comparison, workers need to follow strict safety measures when storing gasoline, mainly to prevent vapor buildup. 

Knowing the ins and outs of different fuel types will help you take informed measures during refuelling. 

2. Take Pre-Fuelling Measures

Before you refuel industrial equipment, take the following measures:

• Turn off the engines and allow them to cool. This will prevent any accidental fires.
• Wear flame-resistant protective clothing.
• Don’t smoke or light flames in the immediate vicinity of refuelling.
• Perform refuelling in an open, well-ventilated area.

3. Use a High-Quality Fuel Transfer Pump

A fuel transfer pump is one of the primary tools you need while refuelling. It is designed to transfer fuel from one container to another, such as a storage tank to an industrial vehicle. A fuel transfer pump helps prevent spills during refuelling, reducing the possibility of safety hazards. 

You will find two types of fuel transfer pumps:

Electric transfer pumps: These are suitable for frequent and large-volume fuel transfers. Most electric pumps use DC power, such as 12V or 24V, which can be powered by vehicle batteries. Industrial users rely upon some of the best 12v fuel pumps for their refuelling needs. 

Manual transfer pumps: These are hand-operated and are suitable for small jobs.

4. Avoid Overfilling

This is incredibly important. Don’t “top off” or overfill tanks, thinking you’re streamlining operations or saving precious time. Instead, always leave room for fuel expansion. Fill up to 95% of the tank’s capacity to avoid ignition or other safety hazards. 

5. Take Steps for Proper Storage

Storage is a critical part of refuelling. Here are some regulatory tips you should follow:

• Label any fuel container with the fuel type. Mention any specific hazard warnings as well.
• Store fuel tanks in a well-ventilated area. This is especially true for gasoline, which emits highly flammable vapors.
• Invest in double-walled tanks to prevent spills or leaks. You can also use spill containment measures, such as drip pans and absorbent pads, to catch accidental spills. 

6. Ensure Regular Training 

Industrial refuelling is complicated. This is why it’s important to train workers regularly. Conduct training sessions and explain best refuelling practices so workers can safely handle refuelling equipment.

Moreover, have robust emergency measures in place. They should know how to respond to spills, fires, and other safety incidents.