Generator
Refuelling
Handling, storage and downpouring of petrol for the backup generator · External petrol storage area · Refilling the jerry can at the petrol station
Issued April 2026 · Next review April 2027
At a glance
- Task / activity
- Generator Refuelling — petrol handling and decanting
- Location
- External generator area (storage) · Generator location for refuelling · Petrol station for jerry refill
- Personnel required
- 1 trained worker
- Estimated duration
- 5–10 min for a refuel · 10 min for a station refill
- Prerequisite training
- Site induction · Petrol-handling sign-off · Familiar with External Petrol Storage sign · Spill response trained
What is this?
Refuelling the site backup generator from the on-site petrol jerry can, and refilling the jerry can at a petrol station when low. Petrol is the most volatile substance held by TDS — vapour ignites at room temperature.
Performed by 1 trained worker. The petrol jerry is stored EXTERNALLY at the generator area — never inside the main workshop. Jerry can quantity capped at 20 L.
What could hurt you?
- • Petrol vapour ignition — flash point ~-43 °C, vapours are heavier than air and can travel to a distant ignition source.
- • Aspiration hazard if swallowed (H304) — chemical pneumonitis even from a small swallowed amount.
- • Skin contact / defatting — repeated exposure dries and irritates skin.
- • Slip on spilled petrol or contaminated absorbent.
- • Static discharge during decant — earthing matters.
- • Hot-engine refuelling — vaporised petrol on hot manifold.
Mandatory PPE
Safety eyewear, nitrile gloves, long sleeves, non-slip safety footwear. Refuelling outdoors only — natural ventilation. No respirator required for short outdoor decants.
Petrol is the highest-hazard substance on site by class (3.1A). Discipline around ignition sources is non-negotiable.
STOP — Engine OFF and COOL before refuelling
Always shut down the generator and let it cool for at least 5 minutes before refuelling. Petrol vapour on a hot manifold or exhaust can flash-ignite. AND check ignition sources within 3 m: no smoking, no phones, no welding/grinding, no hot work nearby. If any vehicle in the workshop is running, isolate first. The single biggest fire risk on site is petrol vapour finding an ignition source.
Mandatory PPE
-
Safety eyewear
AS/NZS 1337.1 — protects from splash during pour. Wraparound lens preferred outdoors.
-
Nitrile gloves
EN ISO 374 — protects from skin defatting on splash. Replace if saturated.
-
Long sleeves
No flapping cuffs. Cotton or natural fibres preferred — synthetic fabrics can hold static charge.
-
Non-slip safety footwear
AS/NZS 2210.3 — slip-resistant sole on potentially fuel-contaminated ground.
Procedure
- 1
Pre-check before opening the petrol jerry: confirm no ignition sources within 3 m, no other workers in immediate area, generator engine OFF and COOL (≥5 min since shutdown), area dry (rain runoff into stormwater is a problem).
Hazards
- ⚠Vapour ignition from a missed ignition source — distant ignition possible (vapour heavier than air)
- ⚠Hot generator manifold — vapour flash risk
- ⚠Wet ground + spilled petrol → stormwater contamination
Controls
- ✓Visual sweep: no cigarettes, no phones in use, no welding/grinding within 3 m
- ✓Touch the generator engine block — if too hot to touch comfortably, wait longer
- ✓Move work away from drains; have spill kit within arm's reach
- •Confirm jerry can flame arrester is intact — replace jerry if damaged
- 2
Unlock and unchain the jerry can from the external storage point. Move to a level surface near the generator.
Hazards
- •Manual handling — 20 L jerry weighs ~17 kg full
- •Drop / slip on uneven ground
Controls
- •Two-handed grip on jerry handle. Bend at knees if lifting.
- •Move to a flat area for refuelling — do NOT pour on a slope
- •If jerry is full and difficult, use a hand trolley
- 3
Open the generator fuel cap slowly. Confirm tank is not over-filled before adding more.
Hazards
- •Vapour release from sealed tank — back-pressure
Controls
- •Open cap slowly to release pressure gradually
- •Stand to side of cap, not over it
- •Visually confirm tank level — do NOT just pour
- 4
Insert funnel. Pour petrol slowly from the jerry into the generator tank. Fill to ~95% only — leave headroom for vapour expansion.
Hazards
- ⚠Static discharge during pour — petrol generates static; ground/bond preferred
- ⚠Splash to face / eyes
- ⚠Overfill spill on hot engine surface
- •Skin contact through gloves if soaked
Controls
- ✓Keep jerry spout in CONTACT with funnel throughout pour (reduces static)
- ✓Pour slowly and steadily — fast pour increases splash and static
- ✓Watch the tank level — STOP at 95%, never fill to brim
- •Eyewear and gloves on for full pour
- •Wipe any spilled petrol from outside of tank/funnel before closing — vapour on hot surface = fire
- 5
Close generator fuel cap firmly. Cap the jerry can flame arrester immediately.
Hazards
- ⚠Vapour escape from open jerry while next steps proceed
Controls
- ✓Flame arrester goes back on the jerry FIRST, before funnel cleanup
- •Wipe down funnel; store funnel in petrol-only sealed container (no other contamination)
- •Confirm both caps are tight before walking away
- 6
Return the jerry can to its external storage point. Re-chain / re-secure. Confirm weatherproof cover in place.
Hazards
- •Jerry can falling / being knocked over if not re-secured
- •UV degradation of jerry plastic over time if cover missing
Controls
- •Re-chain to fixed point. Confirm chain is taut, not loose
- •Cover replaced even in fine weather — UV protection
- •Note jerry level (rough estimate) for refill planning
- 7
Restart the generator. Check for petrol smell or visible leak before walking away.
Hazards
- •Leaking fuel cap or tank seam — undetected vapour buildup
Controls
- •Stay with the generator for 60 seconds after restart
- •Sniff-check: any strong petrol smell = stop, isolate, find leak
- •If smell persists, do NOT continue — flag to owner
- 8
**Refilling the jerry can AT the petrol station** (when low): take jerry can to a station forecourt; place ON THE GROUND, not in the boot, not in the back of a vehicle. Use the petrol-station nozzle directly. Fill to ~95%. Cap immediately. Drive home upright in vehicle floorwell, not seat, not boot. Return to external storage.
Hazards
- ⚠Static spark from filling a jerry inside a vehicle boot/back — common ignition cause
- ⚠Vapour buildup in enclosed vehicle space during transport
- •Spill during transit
Controls
- ✓ALWAYS place jerry can ON THE GROUND at the forecourt — never in a vehicle
- ✓Drive home with the jerry upright in the vehicle floor or rear tray, ventilation on
- ✓Cap is fully sealed (not just hand-tight) before driving
- •Do NOT exceed 20 L in the jerry — site cap is 20 L
- 9
Disposal of contaminated absorbent or old petrol: bag absorbent in sealed bags; do NOT bin with general waste. Old/contaminated petrol goes to a licensed liquid waste handler (council trade-waste reception).
Hazards
- ⚠Petrol-soaked absorbent into general waste = fire risk
- ⚠Old petrol down a drain = stormwater contamination + fire risk
Controls
- ✓Bag absorbent in sealed plastic, store outside in a metal container until disposal
- ✓Old petrol → call licensed liquid waste handler. Christchurch CC trade-waste advice line as fallback.
- •Log disposal in the chemical disposal record