4 Ways to Ensure you are Refuelling Safely

The process of refuelling on industrial worksites carries several inherent risks.

High refuelling rates, extreme environmental conditions, hot engine components, and pressurised fuel, can quickly become a recipe for disaster if the correct infrastructure, system components, and processes are not in place.

Here are 4 ways you can mitigate the risk and ensure your site is refuelling as safely and efficiently as possible:
4 Ways to Ensure you are Refuelling Safely » Refuelling Safely
1) Invest in Zero-Pressure, Primary Overfill Protection

Check out this video to see Fill-Safe Zero in action:

2) Choose high-quality system components that are designed to work together and are fit for purpose


When using quick-fill diesel refuelling systems, NEVER tie off (or manually hold) the nozzle handle into the ‘On’ position. This is a key component of the automatic shutoff system. When nozzles cannot switch off as designed, tank rupture, fuel spillage and equipment fires can occur. Quick-fill refuelling system reliability issues can be overcome immediately with correct nozzle/receiver/vent selection. Never override refuelling shutoff systems.

Watch the video below to review an incident report where an operator overrode the diesel refuelling system:
3) Take a full system approach

Mark Fretwell, Banlaw Mechanical Engineer, stresses the point of not simply looking at individual components but how they work together as a complete solution:

99% of the time, people will blame the nozzle for reliability issues when it's typically the system as a whole that is a mismatch. Higher flow rates lead to higher pressure drop, and that is what causes premature nozzle shutoff. Just because a brochure says a single product will deliver 1000lpm, it doesn't mean that strapping 5 items together that are specified for that flow rate will equal a reliable 1000lpm system.


Ensure fuel tank vent hoses are routed to the ground, rather than allowing vapours (and potentially diesel) to exit the vent exhaust port near electrical circuits and hot engine components.

4) Be proactive with your Maintenance
Refuelling Safely Hierarchy of Controls
Heirarchy of Controls Model: National Institute for Occupational Safety and Health, 2021

Replacing the tank in an excavator can cost ~$175,000 AUD while replacing the tank in a haul truck might cost ~$40,000 AUD. A fleet preventative maintenance contract starts at only $15,000 AUD so getting a specialist to look at your machines and facilities quickly pays for itself.

Contact an expert at Banlaw today and start a conversation about your refuelling systems. We can help you plan and monitor your maintenance, update your infrastructure and mobile assets to be more-safe, and deliver refuelling safety inspections and reports so you know which subjects to prioritise.

Contact Us Now

Let's put together a plan to enhance your refuelling safety.
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