SAFE WORK PROCEDURES

FUEL TANKS HANDLING AND REPAIR

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This procedure is designed for handling and repair of fuel tanks which are fitted to vehicles and mobile plant, or to small plant and equipment only.
Specific precautions for fuel tanks which have previously contained fuel MUST BE FOLLOWED at all times to minimise risk of fire and explosion.
Task sequence
Identified hazards in task
Key processes to be followed
Precautions / PPE required
1. General precautions
Harmful exposure
Wear protective clothing and equipment to prevent skin and eye contact.
Wear eye, hand protection, and
Falling object
Edges of fuel tanks can cause foot injury if fuel tank is dropped.
PVC apron, and foot protection.
Over-exertion/strain injury
Obtain assistance or use mechanical aids to lift and move larger tanks.
Observe correct handling practice.
2. Removal from vehicle
Fuel leak
Close fuel cock on tank, and plug or close off fuel lines on vehicle.
Cover exposed ends of fuel lines
Damage to wiring
Remove fuel tank gauge sender lead from tank before removal from vehicle. to prevent leak or contamination.
Fuel spill or leak
Drain fuel tank before removal from vehicle whenever possible.
Drain fuel into clean container.
Falling object
Support tank during removal operation to prevent it falling when unbolted.
Use jack or machine to support.
3. Handling and storage
Falling object
Use transmission jack or similar equipment to lower fuel tank from under
Where possible, lash or restrain
raised passenger vehicles or vehicles with underbody fuel tanks fitted.
tank to jack to prevent falling.
Spill or leak
Keep fuel tank in upright position until drained or being emptied.
Support tank to prevent spillage.
Store emptied tank in dry area away from heat and flames.
Close openings to control vapour.
4. Cleaning and purging
Fuel spill or leak
Eliminate all heat and ignition sources in area where draining will occur.
No smoking or ignition sources.
Ensure that adequate capacity container is available to drain fuel from tank.
Avoid spillage when draining.
Transfer drained fuel into container, seal and store in a safe location.
Ensure adequate spill kit on hand.
Open all vents, cocks, fillers and drains, before cleaning interior of tank.
Ventilate tank with forced fresh air
NOTE: Check whether interior baffles will interfere with cleaning process.
flow before and during work.
Purging of tanks
Water purging Fill tank with water preferably with detergent added to
Wear eye, hand and body
remove residues adhering to tank at a rate which can be handled by vents.
protection while purging.
Steam cleaning Use steam with detergent added to clean interior of the
Do not allow contaminated water
tank (may not be effective in tanks with interior baffles fitted).
to enter sewers or drains.
Inert gas purge interior of tank with gas (nitrogen or CO2 (as dry ice)).
NEVER purge with oxygen.
5. Welding and hot work
Explosion
Test atmosphere inside tank with approved flammable gas detector check
Do not cut or weld until tested.
through all openings and use flexible probe to check interior if baffled.
Use dry ice in tank for hot work.
If tank cannot be successfully purged, completely fill with water before
Do not allow air space which may
welding. (Note: Never use electric power tools on a water filled tank).
contain explosive mixture.
PRECAUTIONS:
The following precautions are to be observed, and suitable
safety and warning signs as indicated displayed in areas
where these procedures are carried out.

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ThisSafeWorkProcedurewasgeneratedon29/11/2013byASSAPtyLtdforuseonlybyCityofDarwin.

ASSA 2008

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