Petroleum Gas Station Checklist

Use this sample Gas Station Checklist to create or update your inspection program across your gas stations.

While individual situations vary, the following sample checklist details specific issues that may be included in a gas station inspection checklist. This checklist comes from the Australian Department of Mines and Petroleum and is included here in case the information is moved or removed from their website.

General Requirements

1. Emergency procedures are available for fire, spillage, accident, equipment failure and other potential abnormalities or emergencies
2. Employees are trained in the use of emergency equipment
3. Emergency plan is regularly reviewed and updated as required
4. Spill kit is complete and readily available
5. Telephone is located adjacent to the control console
6. List of emergency telephone numbers, including the fire brigade, ambulance services and other emergency responders is prominently displayed near the control centre (console) telephone
7. Main emergency stop is available to shut off power to all dispensing units
8. Main emergency stop is readily accessible in an emergency (i.e. there is clear access to the emergency stop with no obstructions such as racks, shelves or spill kits)
9. Main emergency stop activation device (e.g. switch or button) is clearly labelled ‘EMERGENCY STOP’
10. Main emergency stop is routinely tested to ensure it functions properly
11. Note: Every emergency stop point at LP Gas installations must be tested at least monthly
12. Areas around the dispensers and payment unit are sufficiently lit to provide a safe working environment whenever the unit is available for service
13. Note: A user should be able to read the signs without strain. A minimum value of 50 lux is required for LP Gas filling and is recommended for flammable liquid filling)
14. Minimum of two powder-type fire extinguishers provided at service station
15. Minimum rating of at least 2A 60B(E) per extinguisher
16. Extinguishers are located near dispensers or other item being protected
17. Extinguishers are accessible without undue danger in an emergency
18. Fire extinguishers are routinely serviced at least every 6 months
19. Each extinguisher location is marked by a ‘FIRE EXTINGUISHER’ sign mounted at least 2 m above ground
20. Manifest is available and maintained
21. Site plan is available and maintained
22. Risk assessment is available and maintained
23. Material safety data sheets (MSDSs) are readily available and maintained
24. Dangerous goods register is available and maintained
25. Inventory records are maintained and reconciled for flammable and combustible liquids received, stored and dispensed
26. Whenever discrepancies in the records indicate possible leakage, the dangerous goods installation is checked and any leaks rectified
27. Records are maintained for operational training and retraining in use of the LP Gas system including, maintenance, inspection and managing abnormal incidents and near misses

Dispenser and Underground Tank Requirements

1. Emergency stop on each dispenser is regularly tested (e.g. monthly) for compliant operation
2. Impact protection is installed (e.g. bollards) or dispenser is located so potential damage (e.g. from vehicles) is minimised
3. Hoses are free of cracks, fractures, leakage, or movement between hose and fittings
4. Prominent ‘STOP ENGINE – NO SMOKING’ sign is displayed on or near the dispenser
5. Note: The standard ‘no smoking’ warning symbol may be used in lieu of the words ‘no smoking’
6. Lettering on the ‘STOP ENGINE – NO SMOKING’ sign is at least 50 mm high
7. There is no latching device on the nozzle of self-service dispensers or where there is a preset facility (i.e. a dispenser where a value or quantity of fuel may be pre-selected)

Liquid petroleum gas requirements

1. An emergency information panel (EIP) placard is posted on above-ground tanks or at tank storage areas
2. There is a sign at the above-ground tank or tank storage area showing the phone number of the tank owner or a contractor that provides 24-hour specialist advice for LP Gas Note: This information can be provided on the EIP
3. There is a sign at the above-ground tank or tank storage area showing either standard warning symbols of at least 100 mm diameter or words saying ‘FLAMMABLE GAS’ and ‘NO SMOKING’, or a warning sign (in lettering of at least 50 mm high) prohibiting smoking and ignition sources
4. If the area is isolated by a fence, the signs must be visible from outside the fence and all points of access
5. Each activation point for the LP Gas emergency shut-down system is marked ‘LP GAS EMERGENCY STOP’ in red lettering at least 40 mm high on a white background
6. Each activation point for the emergency shut-down system has a sign with instructions (in red or dark lettering at least 20 mm high on a white background) on how to activate the system Note: The instructions may be given on same sign as ‘LP GAS EMERGENCY STOP’
7. Tanks are at least 6 m from any other above-ground tank, package store or filling area for flammable or combustible materials
8. Tanks are at least 2 m from any vent outlet of a flammable liquid store (e.g. vents for underground tanks)
9. Tank impact protection is at least equivalent to highway crash barriers (i.e. ‘W’ guard railing), and is about 700 mm high and at least 1.5 m from the tank
10. There are no combustible materials within 3 m of the LP Gas tanks
11. The site has a clear exit for fuel tankers so vehicles leave by driving forward without needing to reverse
12. Tanks that are no longer in service have been decommissioned and gas-freed
13. For single tanks with a capacity of 8,000 Liters or less, there must be access to a tap with sufficient water pressure to operate a garden hose
14. Hose reels are installed near all tanks with capacities greater than 8,000 Liters
15. Note: Fire extinguishers of type 2A 60B(E) may be substituted for hose reels where there is a single tank with a capacity of 16,000 Liters or less and the water supply is insufficient
16. There are enough hose reels to ensure that water hose nozzles can reach everywhere within 5 m of the tank and tanker standing area
17. The ground below tanks and for at least 1.5 m beyond each tank is either paved or resistant to saturation by flammable liquids
18. Cylinder cages are outdoors
19. The capacity of each cylinder within a cage is 25 L or less
20. The maximum aggregate capacity of cylinders per cage, or groups of cages, is 2,500 L
21. The front of each cage has a dangerous goods class label (i.e. red diamond-shaped sign for Division 2.1 flammable gases) measuring 250 mm square
22. The front of each cage has a ‘FLAMMABLE GASES – NO SMOKING, NO FLAME’ warning sign Note: Standard warning symbols may be used instead
23. Cages are separated by at least 3 m from groups of cylinder cages (no more than 2,500 L per group)
24. Cages are separated by at least 1 m from any building opening
25. Cages are separated by at least 1 m from the hose reach of an LP Gas decanting cylinder
26. Cages are separated by at least 1.5 m horizontally from any ignition source
27. Cages are separated by at least 0.5 m vertically from any ignition source
28. Cages are separated by at least 1.5 m from any pit, drain, basement, public place 5 or fuel dispenser
29. Cages are separated by at least 5 m from any LP Gas tank
30. Cages are separated by at least 3 m from any above-ground tank containing dangerous goods other than LP
31. Cages are separated by at least 3 m horizontally from any accumulation of combustible materials (e.g. rubbish bin, firewood, engine oil)
32. Cages are separated by at least 2 m from any structure limiting access past the cage
33. Cages are clear on at least two sides from any wall, solid display or other item that could restrict air flow
34. There must be no smoking or ignition sources within 3 m of any point where flammable liquid might be exposed
35. Vehicle engines are switched off while refuelling
36. Pilot lights that could come into contact with flammable vapour must be turned off in camper vans and caravans before refuelling
37. Spillage and overfilling must be prevented during the filling of storage tanks
38. Fill and dip caps (e.g. underground tanks) must be maintained in a liquid-tight condition
39. Plastic containers that do not comply with AS/NZS 2906 are not permitted to be filled
40. Containers must be on the ground while being filled at a fuel dispenser (i.e. must not be in or on a vehicle or trailer)
41. There are procedures to manage spills, especially a spill of flammable liquid on clothing
42. Children under the age of 15 years are not permitted to operate fuel dispensers
43. There are no combustible materials in the fill point spill box for underground tanks
44. There is no liquid in the spill containment sumps (if fitted) under spill boxes

Originally posted by Resources Safety: Department of Mines and Petroleum in Australia as a publicly available resource.  The original post can be found here in case the information is moved or removed from their website.

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