Fuel handling and storage

Only designated persons are allowed to conduct fueling operations. Under 1917.156(a)(1), the standard is clear that fueling must be limited to those who have been designated by the employer to perform that task.

• Make sure the designated persons are trained for safe fueling procedures and understand the site-specific rules (e.g., no smoking, emergency shut-off locations).
• Keep a list or badge/authorization system so inspectors and supervisors can verify who is authorized to fuel.

Yes — engines must be stopped and operators may not be on the equipment during refueling operations. 1917.156(a)(3) requires that engines be stopped and operators not be on the equipment while fueling is taking place.

• This prevents ignition sources and accidental movement during fueling.
• If special procedures are needed for a particular piece of equipment, document and train workers on those procedures while meeting the standard's requirement.

If fuel is spilled, the filler cap must be replaced and the spillage must be disposed of before engines are started. 1917.156(a)(2) requires these immediate actions to reduce fire and vapour hazards.

• Clean up spills promptly using appropriate absorbents or collection methods and dispose of contaminated materials according to environmental and facility rules.
• Ensure ventilation or other controls are in place if vapors could accumulate before restarting engines.

Smoking and open flames are prohibited in areas used for fueling, fuel storage, or enclosed storage of equipment containing fuel. 1917.156(a)(4) sets this prohibition to prevent ignition of flammable vapors.

• Post clear “No Smoking” signs and remove ignition sources (welding, open flames, hot work) from these areas.
• Provide designated smoking areas well away from fueling and storage areas and enforce the rules.

No — equipment must be refueled only at designated locations. 1917.156(a)(5) requires refueling to occur only where the employer has designated safe fueling points.

• Designated locations should have required safety features (clearance from ignition sources, spill containment, emergency shut-offs) and be communicated to operators.
• Keep the fueling areas maintained and unobstructed for safe access and emergency response.

Portable containers must be metal, have tight closures (screw or spring covers), be equipped with spouts or equivalent pour-control devices, and leaking containers must not be used. 1917.156(a)(6) describes these minimum design and condition requirements.

• Use containers specifically designed for fuel transfer; avoid improvised or damaged containers.
• Inspect containers regularly for leaks and replace or repair any defective ones before use.

When dispensing flammable liquids in the open from a tank or fuel-delivery vehicle, dispensing hoses must not exceed 50 feet and any powered dispensing nozzles used must be of the automatic-closing type. See 1917.156(a)(7) and its subsections 1917.156(a)(7)(i) and 1917.156(a)(7)(ii).

• Keep hose lengths within the 50-foot limit to reduce tripping, leak, and static electricity risks.
• Use powered dispensing nozzles that close automatically to prevent accidental overflows or spills.

Liquid fuel dispensing devices must have an easily accessible and clearly identified shut-off device (for example, a switch or circuit breaker) to shut off power in an emergency. 1917.156(a)(8) requires this feature.

• Clearly label the shut-off device and train personnel on its location and use.
• Test shut-offs periodically as part of preventive maintenance and emergency drills.

Fuel pumps and similar dispensing devices must be mounted on a concrete island or otherwise protected against collision damage. 1917.156(a)(9) requires this protection to prevent vehicle impacts.

• Where mounting on a concrete island isn’t possible, provide barriers (bollards) or engineered protection to prevent impacts.
• Ensure protection doesn’t impede fuel access or emergency response.

Liquefied gas powered equipment must be fueled only at designated locations; equipment with permanently mounted fuel containers must be charged outdoors; and equipment must not be fueled or stored near underground entrances, elevator shafts, or other places where gas or fumes might accumulate. See 1917.156(b)(1) and its subsections 1917.156(b)(1)(i), 1917.156(b)(1)(ii), and 1917.156(b)(1)(iii).

• Designated fueling areas for liquefied gases should be outdoors or specifically engineered to avoid vapor build-up.
• Keep fueling and storage away from points where gas could enter enclosed spaces or building ventilation systems.

When removing or exchanging fuel containers, escaping fuel must be minimized by using automatic quick-closing couplings that close in both directions or by closing fuel container valves and allowing engines to run until residual fuel is exhausted. 1917.156(b)(2)(i) and its subparts 1917.156(b)(2)(i)(A) and 1917.156(b)(2)(i)(B) describe these acceptable methods.

• Use quick-closing couplings wherever practical to reduce spills and vapor releases.
• If relying on engine-run-off, ensure the method is safe for that equipment and that procedures and training cover the hazards.

Pressure-relief valve openings must be in continuous contact with the vapor space (top) of the cylinder. 1917.156(b)(2)(ii) requires this to ensure relief valves function properly.

• Design and install relief valve openings so they are exposed to vapor, not liquid, to prevent improper operation.
• Verify relief valves and their tubing are unobstructed and routed to safe locations.

Fuel containers must be secured to prevent being jarred loose, slipping, or rotating; they must be located to prevent damage; compartments that house containers must be vented; and containers near engines or exhaust must be shielded from direct heat radiation. See 1917.156(b)(2)(iii) and 1917.156(b)(2)(iv).

• Use robust clamps, brackets, or housings to keep containers fixed in place.
• Provide ventilation for compartments and heat shields near hot surfaces to prevent overheating of the container.

Container installation must provide the container with at least the vehicle's road clearance under maximum spring deflection, measured to the bottom of the container or to the lowest fitting on the container or housing, whichever is lower. 1917.156(b)(2)(v) sets this requirement.

• Ensure the container and its fittings won't contact ground debris or obstacles when vehicle suspension compresses.
• Account for payload and operating conditions that could reduce clearance.

Valves and connections must be protected from contact damage, and permanent protection must be provided for fittings on removable containers. 1917.156(b)(2)(vi) requires these protections to reduce leak risk.

• Use guards, recessed housings, or shielded routing to prevent impact or abrasion to fittings.
• Inspect protective measures regularly and repair any damage promptly.

Defective containers must be removed from service. 1917.156(b)(2)(vii) requires removing any container that is damaged or unsafe.

• Tag and isolate defective containers and arrange for repair, testing, or disposal per manufacturer and regulatory guidance.
• Do not attempt to use a container that leaks, is dented severely, or has compromised fittings.

No — using matches or open flames to check for leaks is prohibited. 1917.156(b)(3)(ii) forbids this dangerous practice.

• Use approved leak-detection methods such as soapy-water solutions, approved electronic gas detectors, or other safe, non-ignition methods.
• Train employees on correct leak-detection techniques and emergency response if a leak is found.

Before recharging and again before reuse, containers must be examined for dents, scrapes and gouges; damage to valves and liquid-level gauges; debris in relief valves; leakage at valves or connections; and deterioration or loss of flexible seals in filling or servicing connections. See 1917.156(b)(3)(iii) and its subparts 1917.156(b)(3)(iii)(A)-(E).

• Document inspection results and remove containers from service if defects are found.
• Keep inspectors trained to recognize these specific defect categories.

Stored fuel containers must be located to minimize exposure to excessive temperatures and physical damage, must not be stored near exits, stairways, or areas normally used for egress, and outlet valves of containers in storage or transport must be closed with relief valves connected to vapor spaces. See 1917.156(b)(4) and its subparts 1917.156(b)(4)(i)-(iii).

• Store containers in cool, protected areas away from pedestrian egress paths and building exits.
• Verify outlet valves are closed and relief valve venting is properly routed before transporting or storing containers.

Liquefied-gas-fueled vehicles may be stored or serviced inside garages or shops only if there are no fuel system leaks. 1917.156(b)(5)(i) sets this condition to prevent vapor accumulation and fire/explosion hazards.

• Conduct leak checks before moving such vehicles indoors and before starting work on them inside enclosed spaces.
• If a leak is detected, perform repairs outdoors or in appropriately ventilated and approved areas.

No — Part 1917 specific requirements do not apply to designated waterfront facilities used solely for bulk storage, handling, and transfer of liquids or gases. OSHA's Letter of Interpretation on applicability to waterfront facilities explains that such facilities fall within the "marine terminal" definition and thus are excluded from many Part 1917 provisions (see the letter discussing 29 CFR 1917.1(a)(1)(i)).

• If you operate a designated waterfront facility, review the LOI and applicable regulations carefully and consult OSHA guidance for which standards (if any) still apply.
• Remember that other federal, state, or local rules (such as fire or environmental codes) may still regulate fuel handling and storage at such facilities.