Comprehensive procedures for above-ground and underground fuel storage tank installation, connection, testing, and commissioning with fire safety and environmental controls

Fuel Storage Tank Installation Safe Work Method Statement

WHS Act 2011 Compliant | AS 1940 Dangerous Goods Storage Certified

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Fuel storage tank installation involves the placement, connection, testing, and commissioning of tanks designed to store petroleum products including diesel, unleaded petrol, aviation fuel, kerosene, heating oil, and other flammable liquids in accordance with AS 1940 Storage and Handling of Flammable and Combustible Liquids. This Safe Work Method Statement provides comprehensive procedures for both above-ground storage tanks (typically ranging from 200 litres to 100,000 litres capacity) and underground storage tanks installed in excavations with environmental protection systems. Work encompasses site assessment and preparation, tank delivery and positioning using cranes or forklifts, foundation construction ensuring proper support and drainage, piping and electrical connection installation for fill points and dispensing equipment, tank venting and overfill protection systems, secondary containment bund construction for above-ground tanks, cathodic protection for underground tanks, leak detection system installation, tank testing including pressure testing and leak verification, regulatory compliance documentation, and final commissioning. Designed for Australian construction environments and aligned with Work Health and Safety Act 2011, AS 1940 dangerous goods storage standards, AS 4897 tank design standards, environmental protection legislation, and local authority approval conditions, these procedures ensure fuel storage tank installation is completed safely whilst managing fire and explosion hazards, environmental contamination risks, manual handling injuries, and working at heights during large tank installation.

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Overview

What this SWMS covers

Fuel storage tank installation represents a specialized construction activity requiring integration of civil works, mechanical piping, electrical systems, and strict compliance with dangerous goods legislation governing flammable liquid storage. Australian Standard AS 1940 establishes comprehensive requirements for fuel storage facility design, construction, and operation, mandating specific separation distances from buildings and property boundaries, fire protection systems, spillage containment, and tank construction standards that vary based on fuel type, storage capacity, and site exposure. Installation work must satisfy multiple regulatory frameworks including state-based dangerous goods regulations, environmental protection authority requirements for groundwater protection, local government building and development approvals, and workplace health and safety legislation addressing worker protection during construction activities. Fuel storage tanks serve diverse applications across Australian industries. Service stations and truck stops require underground storage tanks with multiple compartments storing different fuel grades, sophisticated leak detection systems monitoring interstitial spaces, and dispensing equipment meeting trade measurement requirements. Mining operations install large capacity above-ground tanks at remote sites, often in modular bunded configurations allowing progressive expansion as operations grow. Agricultural properties utilize smaller capacity tanks (typically 1,000 to 10,000 litres) for farm diesel storage, positioned for convenient access by farm machinery whilst maintaining required separation distances from buildings and watercourses. Construction sites employ temporary fuel storage supporting equipment fleets, requiring mobile tanks on trailer chassis or containerized installations that can relocate as work progresses. Backup generator installations in commercial buildings, hospitals, and data centers require dedicated fuel tanks sized for extended generator operation during power outages, frequently installed in basement locations with complex filling arrangements to deliver fuel from street level. Above-ground storage tanks dominate industrial and rural installations due to lower installation costs, easier leak detection through visual inspection, simplified maintenance access, and ability to relocate tanks if site requirements change. These tanks install on concrete foundations designed to withstand anticipated loads including full tank weight, potential impact from vehicles, and seismic forces in higher-risk locations. The foundation must provide adequate drainage preventing water accumulation beneath tanks whilst maintaining sufficient slope (typically 1:100) toward drainage points. Bund walls constructed from concrete, steel, or fabricated from the tank base itself provide secondary containment, sized to contain 110% of the largest tank capacity or 25% of total storage capacity for multi-tank installations, whichever is greater. Tank anchorage to foundations prevents flotation during flooding or movement during seismic events, using holddown straps or bolted brackets specified by the tank manufacturer and verified through engineering calculations. Underground storage tanks provide advantages in locations with space constraints, aesthetic requirements, or where above-ground tanks would obstruct vehicle movements. Installation requires excavation to adequate depth providing minimum 600mm cover over tank top, installation of granular bedding material supporting the tank uniformly without point loading, careful tank placement using cranes or excavators without damaging tank coatings, backfilling with clean sand or approved material placed in controlled layers preventing tank distortion, and installation of groundwater monitoring wells detecting any fuel leakage before contamination spreads. Modern underground tanks utilize double-wall construction with continuous interstitial monitoring, cathodic protection systems preventing external corrosion, and impact-resistant materials such as fibreglass-reinforced plastic resisting damage from ground movement. The installation complexity and higher initial costs are offset by space savings and protection from vehicle impact, vandalism, and bushfire exposure affecting above-ground installations. Piping systems connecting tanks to fill points, dispensing equipment, and vent terminations must satisfy AS 1940 requirements for material compatibility with stored fuel types, adequate mechanical strength to withstand anticipated pressures and external loads, corrosion protection for buried piping through coatings or cathodic protection, and leak-tight joints verified through pressure testing before backfilling or concealment. Fill points locate away from buildings and ignition sources, with clearly identified fuel types preventing cross-contamination, lockable caps preventing unauthorized filling, and spill containment capturing overflow during delivery. Vent pipes terminate at least 3 metres above ground level in locations preventing vapor accumulation in buildings or ignition by electrical equipment, fitted with flame arrestors preventing external fire propagation into tank vapor space. Dispensing systems incorporate emergency shutoff valves, overfill prevention devices, and leak detection monitoring beneath dispensing areas where spillage commonly occurs during fueling operations. Electrical installations associated with fuel tanks require particular attention to hazardous area classification under AS/NZS 60079 standards. Areas within certain distances of tank vents, fill points, and dispenser locations are classified as Zone 1 or Zone 2 hazardous areas where flammable vapor concentrations may occur. All electrical equipment including pumps, level gauges, and lighting within these zones must be certified for use in explosive atmospheres, installed by licensed electricians with appropriate additional training, and maintained to prevent deterioration of explosion protection. Tank grounding and bonding prevents static electricity accumulation during fuel transfer, with resistance between tank, piping, and earth electrode not exceeding 10 ohms as verified through testing during commissioning and periodic verification. Environmental protection represents a critical installation consideration, particularly for underground tanks where leakage can contaminate groundwater before detection. Most Australian jurisdictions require environmental protection licences or notifications for fuel storage installations exceeding specified capacities, mandating leak detection systems, groundwater monitoring programs, and financial assurance arrangements ensuring cleanup capability if contamination occurs. Installation must prevent stormwater entering bunded areas, provide oil-water separators treating any contaminated drainage, and incorporate spill response equipment including absorbent materials and spill containment barriers appropriate to the stored fuel volume and site drainage characteristics. Commissioning procedures verify all installation aspects meet regulatory requirements before fuel delivery commences. This includes pressure testing of tanks and piping systems to 150% of maximum operating pressure, typically maintained for 24 hours with no pressure loss indicating leak-tight integrity. Leak detection systems undergo functional testing verifying sensors respond to simulated leaks and alarm systems activate appropriately. Emergency shutoff systems are exercised confirming all fuel flow ceases when activated. Tank capacity is verified through strapping or calibration against manufacturer specifications, with calibration charts prepared for ongoing inventory management. Final inspection by regulatory authorities confirms compliance with approval conditions, with operating licences issued authorizing commencement of fuel storage operations.

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Why this SWMS matters

Fuel storage tank installation involves significant fire and explosion hazards as work creates potential ignition sources near flammable vapor sources. During tank delivery and positioning, spark-producing activities including crane operations, vehicle movements, and tool use occur in areas where fuel vapors may be present from tank residues, nearby existing storage, or fuel delivery operations. Tank welding or cutting during installation modifications generates open flames and hot surfaces capable of igniting flammable vapors. Without comprehensive hot work permits, continuous atmospheric monitoring for flammable gas concentrations, elimination of all ignition sources within hazardous areas defined by AS 1940, and readily accessible firefighting equipment specifically rated for flammable liquid fires (Class B foam or dry chemical extinguishers), fuel tank installation creates severe risk of catastrophic fires or explosions causing worker fatalities, extensive property damage, and environmental contamination from uncontrolled fuel releases. The Work Health and Safety Act 2011 classifies work involving storage and handling of dangerous goods as high-risk construction work requiring documented Safe Work Method Statements before commencement. WHS Regulations specifically address management of flammable and combustible liquids, requiring systematic risk assessment addressing fire and explosion hazards, implementation of controls following the hierarchy of controls with emphasis on elimination of ignition sources and minimizing flammable vapor concentrations, verification of worker competencies in dangerous goods handling, and emergency response procedures appropriate to the specific fuels and quantities being stored. State-based dangerous goods legislation imposes additional requirements including licensed storage facilities for quantities exceeding specified thresholds, approved tank designs and installations, separation distances from buildings and boundaries, and regular inspections by dangerous goods inspectors verifying ongoing compliance. Manual handling injuries during fuel tank installation result from lifting and positioning heavy tank components, piping assemblies, and installation equipment. Smaller tanks up to 1,000 litres capacity weigh 100-300kg when empty, requiring team lifting or mechanical aids for positioning. Larger tanks exceeding 10,000 litres capacity weigh multiple tonnes, demanding crane lifting operations. Tank piping including fill pipes, product lines, and vent pipes involves repetitive fitting, alignment, and connection work in awkward postures, particularly when working beneath tanks or in excavations. Without mechanical lifting equipment appropriately rated for tank weights, proper rigging techniques using certified lifting equipment, team lifting procedures with clear communication protocols for coordinated movements, and adequate work space allowing proper body positioning during pipe fitting work, installers develop acute back injuries from sudden overload and chronic musculoskeletal disorders from cumulative strain over the course of installation projects lasting days or weeks. Working at heights hazards occur during installation of large above-ground tanks requiring workers to access tank tops for vent installation, gauge mounting, and final painting or coating work. Tanks exceeding 3 metres height create fall risks when workers climb onto tank surfaces without proper access ladders and fall protection. Work on tank roofs to install manholes, vents, or level gauges requires fall protection systems as workers may slip on curved tank surfaces or step backward whilst focused on installation tasks. Without properly designed permanent access ladders meeting AS 1657 industrial access standards, fall protection anchorage points rated to 15kN and positioned to prevent falls to lower levels, and fall arrest harnesses worn by all workers accessing tank tops, installers suffer serious injuries or fatalities from falls. Falls from heights represent a leading cause of construction deaths, with investigations commonly finding work proceeded without adequate fall protection despite readily available control measures. Environmental contamination risks during installation include fuel spillage from tank testing activities, hydraulic oil leaks from installation equipment, concrete washout water containing alkaline materials, and sediment-laden stormwater runoff from excavation works. Underground tank installation disturbs soil potentially containing existing contamination from previous site uses, requiring characterization and appropriate management. Fuel delivered for commissioning testing creates spillage risk if tank capacities are exceeded, connections fail under pressure, or delivery procedures are inadequate. Without comprehensive environmental protection plans addressing all contamination sources, spill containment and cleanup equipment positioned before potential spill events, management of excavated soil according to contamination status, and stormwater controls preventing sediment discharge to waterways, fuel tank installation creates pollution incidents resulting in prosecution under environmental protection legislation, costly remediation requirements, and long-term site contamination affecting property values and development potential. Electrical hazards during fuel tank installation arise from temporary power supplies for construction equipment, installation of permanent electrical systems including pumps and level monitoring equipment, and work near overhead or underground electrical services. Installation of electrical equipment within hazardous areas classified under AS/NZS 60079 requires specialized competencies beyond standard electrical qualifications. Improper electrical installations can create ignition sources within flammable vapor zones, causing explosions or fires. Temporary construction lighting or power tools used within hazardous areas without proper explosion-protected ratings create immediate ignition risk. Without engagement of licensed electricians holding appropriate additional certification for hazardous area electrical work, verification that all electrical equipment is suitable for the classified zone in which it installs, testing and certification of electrical installations before energization, and ongoing inspection maintaining explosion protection integrity, fuel tank installations create serious electrical hazards potentially triggering catastrophic fire or explosion events. From a regulatory compliance perspective, fuel storage tank installations require multiple approvals and must satisfy numerous standards. Development approval from local government verifies tank location, capacity, and design complies with planning requirements including separation distances and environmental protection. Building approval confirms structural adequacy of foundations and bund walls. Environmental protection authority approval or notification addresses groundwater protection and contamination prevention. Dangerous goods storage licensing from state government confirms dangerous goods legislation compliance. Failure to obtain required approvals before installation commencement can result in work stop orders, requirements to remove installations, substantial penalties, and prosecution of responsible persons under various regulatory frameworks. Comprehensive SWMS documentation demonstrates systematic approach to all regulatory requirements, supporting approval applications, facilitating regulatory inspections, and providing evidence of due diligence if compliance issues arise during or after installation completion.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Fire and Explosion from Flammable Vapor Ignition

High

Fuel storage tank installation creates multiple potential ignition sources in proximity to flammable vapor sources from fuel residues in new tanks, vapors from nearby existing storage, or fuels delivered for commissioning testing. Spark-producing activities including crane operations where steel rigging contacts tank surfaces, vehicle movements generating static electricity discharges, power tool use without explosion-protected ratings, welding or cutting during tank modifications, and smoking or open flames from workers or visitors create ignition potential. Flammable vapors heavier than air accumulate in low-lying areas including excavations, bund enclosures, and confined spaces, creating explosive atmosphere concentrations. Static electricity generation during fuel transfer operations can discharge across inadequate bonding connections between delivery tanker, fill piping, and storage tank. Lightning strikes to ungrounded tank installations provide external ignition sources. Without continuous atmospheric monitoring using calibrated flammable gas detectors with audible alarms set at 10% Lower Explosive Limit, comprehensive elimination of all ignition sources within hazardous areas extending specified distances from vents and fill points as defined in AS 1940, prohibition of hot work unless specific permits with rigorous controls are implemented, proper tank and piping grounding and bonding verified through resistance testing, readily accessible Class B firefighting equipment rated for flammable liquid fires, and trained personnel understanding emergency response procedures, fuel tank installation creates catastrophic risk of explosions causing multiple fatalities and extensive property damage extending beyond immediate work area.

Manual Handling Injuries from Lifting Heavy Tank Components

High

Fuel tank installation involves extensive manual handling of heavy components including tank shells weighing hundreds to thousands of kilograms requiring mechanical lifting, piping assemblies weighing 20-50kg per section, valve and fitting installations requiring repetitive bending and reaching, and installation equipment including pumps, level gauges, and dispensing equipment with awkward dimensions complicating grip and control. Workers lift components from delivery trucks, carry materials to installation locations sometimes across rough terrain or into excavations, position components for connection requiring sustained holding whilst aligning threads or welding preparations, and work in confined spaces beneath tanks or in excavations with restricted movement preventing proper lifting postures. Team lifting operations require coordination between multiple workers to prevent uneven loading causing sudden overload on individual team members. Crane lifting operations require workers to guide loads into position, requiring proximity to suspended loads and creating struck-by risks if loads swing unexpectedly. Without mechanical lifting equipment appropriately rated for maximum component weights including cranes, forklifts, or specialized tank positioning equipment, proper rigging equipment including slings and shackles certified for lifting service with current inspection tags, team lifting procedures with designated coordinators providing clear verbal commands, adequate work space in excavations allowing proper body positioning and escape routes if suspended loads destabilize, and task rotation preventing continuous repetitive strain on the same muscle groups, installers develop acute back injuries requiring immediate medical intervention and extended time off work, and chronic musculoskeletal disorders affecting shoulders, knees, and spine that progressively worsen limiting long-term work capacity and quality of life.

Falls from Heights During Large Tank Installation and Access

High

Installation of above-ground fuel tanks exceeding 2 metres height requires workers to access tank tops for vent installation, gauge mounting, manhole installation, and final surface coating application. Workers climb onto curved tank surfaces where footing is unstable, particularly if surfaces are wet, oily, or frost-covered in cold weather. Tank access commonly occurs using temporary ladders that may be inadequately secured, positioned at incorrect angles, or extend insufficient distance above tank edge preventing safe step-off. Work on tank roofs requires workers to move backward whilst installing equipment, creating risk of stepping off edges or walking into openings being installed. Large tanks during installation may not have permanent access ladders yet installed, forcing workers to improvise access using scaffold or mobile elevating work platforms that may not position adequately adjacent to cylindrical tank surfaces. Wind loading on workers standing on exposed tank tops can destabilize balance, particularly when carrying tools or materials. Without permanently installed access ladders meeting AS 1657 requirements with adequate rung spacing, handrails extending above step-off points, and secure foundation anchoring, fall protection anchorage points strategically positioned on tank tops and rated to 15kN static load in any direction, full-body fall arrest harnesses properly fitted with shock-absorbing lanyards connected before ascending to heights, rescue equipment and trained personnel capable of retrieving fallen workers suspended in harnesses, and work prohibition during adverse weather conditions including high winds, installers suffer fatal or catastrophic injuries from falls to concrete surfaces or projecting pipework below.

Struck by Suspended Loads During Crane Lifting Operations

High

Large fuel tank installation requires crane lifting operations to position tanks weighing multiple tonnes from delivery vehicles onto prepared foundations or into excavations. Suspended tanks present massive struck-by hazards if loads swing uncontrollably due to wind or uneven lifting, rigging fails due to inadequate capacity or damaged equipment, crane boom contacts overhead obstructions causing load displacement, ground beneath crane support fails from inadequate bearing capacity, or tag lines are inadequate allowing load rotation. Workers must approach suspended loads to guide tanks into position, creating exposure to crush hazards if loads shift. Underground tank installation into excavations requires workers to be in the excavation positioning the tank whilst cranes lower loads overhead, creating extreme struck-by risk if rigging fails or ground stability allows excavation wall collapse. Multiple workers and trades may be present during tank positioning including plumbers making piping connections, electricians installing level gauges, and civil workers placing backfill, creating coordination challenges and potential for workers to enter exclusion zones beneath suspended loads. Without comprehensive lift plans prepared by competent persons specifying rigging configuration, crane capacity verification, ground preparation requirements, and exclusion zones preventing workers from approaching suspended loads except when essential for guiding operations, all rigging equipment inspected before use with current certification and adequate capacity ratings with minimum 5:1 safety factors, crane operators holding appropriate High Risk Work Licences for crane type and capacity, and exclusion zone enforcement through barriers and designated spotters preventing unauthorized entry, workers suffer fatal crush injuries from contact with suspended loads or catastrophic failures dropping multi-tonne tanks.

Excavation Collapse and Soil Instability Hazards

High

Underground fuel tank installation requires excavations typically 3-4 metres deep to accommodate tanks plus required cover, with plan dimensions extending several metres beyond tank footprint to allow working space for piping connections and backfilling operations. Excavation walls may be unstable depending on soil type, groundwater conditions, proximity to existing structures or services, and vibration from nearby traffic or construction activities. Sandy or gravelly soils provide minimal cohesion, requiring battering to safe angles or shoring immediately upon excavation. Clay soils can stand vertically initially but deteriorate with weather exposure or groundwater ingress. Groundwater inflow into excavations creates quicksand conditions where soil loses all bearing capacity, collapsing excavation walls and potentially causing tank flotation if backfilling proceeds whilst groundwater remains. Existing underground services including water mains, sewer lines, electrical cables, and telecommunications conduits may be damaged during excavation, creating additional hazards from released water pressure, sewer gas exposure, or electrical contact. Adjacent building foundations may be undermined if excavations extend within their zone of influence, causing structural damage or collapse. Without geotechnical assessment determining safe excavation slope angles or shoring requirements based on actual soil conditions, utility location services identifying all underground services before excavation with hand digging to expose services before mechanical excavation near marked locations, engineered shoring or benching systems installed by competent personnel before workers enter excavations exceeding 1.5 metres depth, groundwater control through dewatering pumps or well points maintaining dry excavation conditions, excavation monitoring for wall movement or water ingress requiring immediate worker evacuation, and daily inspections by competent persons before permitting entry, workers suffer burial causing rapid suffocation, crushing injuries from collapsed soil masses, or drowning in groundwater-flooded excavations.

Environmental Contamination from Fuel Spillage and Soil Disturbance

Medium

Fuel tank installation creates multiple environmental contamination pathways affecting soil, groundwater, and surface water. Fuel delivery for commissioning testing can result in overfilling tanks during initial filling operations before level gauges are calibrated or operators are familiar with tank capacities, spillage from failed connections or defective piping discovered during pressure testing, or release from tanks damaged during installation activities. Hydraulic equipment including cranes, excavators, and forklifts can leak hydraulic oil onto soil or into excavations, with hydraulic hose failures releasing large quantities rapidly. Concrete washout water from foundation construction contains highly alkaline materials harmful to aquatic ecosystems if discharged to waterways. Excavation in areas with existing soil contamination from previous industrial uses, leaking underground storage tanks, or historical spills exposes workers to contaminated soil and can spread contamination if not properly managed. Stormwater runoff from disturbed soil areas carries sediment to waterways, degrading water quality and aquatic habitat. Without spill containment equipment including drip trays beneath all fuel storage, absorbent materials and spill cleanup equipment positioned before fuel delivery, secondary containment for all refueling and hydraulic servicing activities, management of contaminated soil according to classification and regulatory requirements including sampling, classification, and appropriate disposal, concrete washout areas preventing alkaline water discharge, and erosion and sediment controls including silt fences and sediment basins around excavation perimeters, fuel tank installation creates pollution incidents resulting in prosecution under environmental protection legislation, regulatory clean-up orders requiring costly remediation potentially exceeding project value, long-term site contamination limiting future land use and creating ongoing liability for site owners and installation contractors.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Comprehensive Ignition Source Elimination Program

Elimination

Eliminate potential ignition sources within hazardous areas defined by AS 1940 extending specified distances from tank vents, fill points, and other vapor emission locations. This engineering control removes ignition hazards entirely, preventing fire and explosion incidents without relying on detection systems or firefighting response. All equipment, activities, and personnel within hazardous areas must be verified non-spark producing and incapable of generating temperatures exceeding fuel auto-ignition thresholds.

Implementation

1. Conduct hazardous area classification study following AS/NZS 60079.10.1 identifying Zone 0, Zone 1, and Zone 2 areas around all tank openings, with classification extending minimum 3 metres radius from vent terminations and 1.5 metres radius from fill points 2. Prohibit all smoking, open flames, and spark-producing activities within classified hazardous areas, establishing designated smoking areas at safe distances with prominent signage 3. Ensure all electrical equipment including temporary construction lighting, power tools, and communications devices used within hazardous areas are certified for explosive atmosphere use with appropriate certification markings (Ex d, Ex e, Ex i, or Ex n) 4. Require intrinsically safe hand tools constructed from non-sparking materials such as bronze, brass, or specialized alloys for any work within hazardous areas during fuel presence 5. Implement bonding and grounding for all conductive equipment including tanks, piping, fill points, and delivery tankers, verifying resistance to earth does not exceed 10 ohms through testing with calibrated earth resistance meter 6. Prohibit vehicles including delivery trucks, cranes, and mobile plant from entering hazardous areas unless fitted with spark arrestors on exhaust systems and verified safe for hazardous area operation 7. Establish hot work permit system prohibiting any welding, cutting, or grinding unless specific authorisation is provided after atmospheric testing confirms absence of flammable vapors and continuous monitoring is maintained 8. Eliminate static electricity accumulation through proper bonding of all fuel transfer components, limitation of fuel flow velocities during filling to below 7 metres per second, and provision of adequate time for static dissipation before disconnecting fill hoses 9. Install lightning protection systems for above-ground tanks exceeding 10 metres height or in locations with high lightning incidence, with air terminals and down conductors meeting AS 1768 requirements 10. Conduct daily pre-work inspections identifying any new ignition sources introduced to work areas, with immediate elimination of non-compliant equipment or activities before work proceeds

Mechanical Lifting Equipment for All Tank Components

Engineering

Provide appropriate mechanical lifting equipment including cranes, forklifts, hoists, or specialized tank positioning equipment for all fuel tank components exceeding 25kg single-person manual handling limit. Engineering controls through mechanical aids eliminate manual lifting hazards for tank shells, major piping assemblies, and heavy equipment components, preventing acute and chronic manual handling injuries to installation personnel.

Implementation

1. Conduct lift planning before tank delivery identifying maximum component weights, required crane capacity including allowances for rigging weight and dynamic loading, and site access for crane positioning 2. Engage mobile crane services appropriate to maximum tank weight and reach requirements, ensuring operators hold current High Risk Work Licences for crane type and capacity being operated 3. Verify crane load capacity charts for specific operating configurations including boom length, angle, and outrigger extension, maintaining lifts below rated capacity with adequate safety margins 4. Provide certified lifting equipment including wire rope slings rated to minimum 6-tonne capacity for small tanks or specialized spreader beams for large tanks, with all lifting gear inspected and tagged within previous 12 months 5. Utilize forklifts or telehandlers for positioning smaller components including piping, pumps, and dispensing equipment, with operators trained in load capacity verification and stable operating practices 6. Install temporary or permanent davits or gantry systems at tank locations requiring frequent equipment installation or removal, providing mechanical lifting advantage for workers 7. Implement tag line use for all suspended loads, allowing workers to control load position and prevent spinning without directly contacting loads or entering beneath suspended weights 8. Establish ground preparation requirements ensuring crane outrigger pads have adequate bearing capacity, with engineered matting or concrete pads provided where soil bearing is insufficient 9. Create exclusion zones around all crane operations preventing workers from approaching within 2 metres of suspended loads except when essential for guiding operations, with barriers or designated spotters enforcing exclusion 10. Maintain mechanical lifting equipment in safe operating condition through regular servicing, pre-start inspections documenting hydraulic system integrity, and immediate repair of any identified defects before continuing lifting operations

Continuous Atmospheric Monitoring for Flammable Vapors

Engineering

Implement continuous atmospheric monitoring using calibrated flammable gas detectors positioned in locations where vapor accumulation could occur, providing early warning of explosive atmosphere development before concentrations reach dangerous levels. Engineering controls through automatic detection and alarm systems allow immediate work cessation and area evacuation before fire or explosion hazards materialize, protecting workers who may not directly perceive colorless, odorless flammable vapors.

Implementation

1. Install fixed flammable gas detection systems in enclosed areas including pump rooms, basement tank installations, or confined spaces where vapors could accumulate, with sensors positioned at low levels where petroleum vapors heavier than air naturally collect 2. Provide portable flammable gas monitors for workers conducting activities within or adjacent to hazardous areas, with continuous sampling and audible alarms set to activate at 10% Lower Explosive Limit providing early warning 3. Ensure all gas detection equipment is calibrated within manufacturer's specified intervals using appropriate calibration gases matching expected vapor types, with calibration certificates maintained in site safety documentation 4. Test gas detectors daily before use using bump testing with known gas concentration, verifying sensor response and alarm function before permitting work in potentially hazardous areas 5. Establish action levels requiring immediate work cessation and area evacuation if flammable gas concentrations exceed 10% LEL, with work not resuming until continuous monitoring shows concentrations below 5% LEL for minimum 15 minutes 6. Position gas monitors with consideration of vapor density, air movement patterns, and potential emission sources, ensuring sensors are located where they will detect vapor releases before concentrations become hazardous to workers 7. Connect fixed gas detection systems to audible and visual alarms perceptible throughout work area even in high ambient noise environments, with alarm testing conducted weekly 8. Implement monitoring record keeping documenting gas concentrations throughout each work shift, identifying any exceedances and corrective actions taken, providing evidence of systematic hazard management 9. Train workers in gas detector operation including interpretation of readings, response to alarm activation, and limitations of detection equipment such as sensor cross-sensitivity or interference from other gases 10. Maintain adequate batteries or power supplies for all gas detection equipment, with spare charged batteries available on site and systematic battery replacement schedules preventing detector failure from power depletion

Engineered Excavation Shoring and Support Systems

Engineering

Install engineered shoring systems designed by qualified geotechnical engineers for all excavations exceeding 1.5 metres depth where workers must enter for tank positioning or piping installation work. Engineering controls through physical restraint of excavation walls eliminate collapse hazards without relying on worker behavior or soil stability predictions, providing absolute protection from burial hazards during underground tank installation.

Implementation

1. Engage geotechnical engineer to assess soil conditions through test pits or bore holes, determining soil classification, groundwater depth, and presence of any unstable layers requiring special consideration 2. Obtain engineered shoring design specifying support type (trench boxes, hydraulic shores, or sheet piling), installation sequence, maximum allowable unsupported height, and inspection requirements specific to site soil conditions 3. Procure or hire certified shoring equipment meeting design specifications, with current inspection certification confirming structural integrity and load capacity ratings 4. Install shoring progressively as excavation proceeds, maintaining maximum 1.5 metres unsupported excavation depth before shoring is positioned, preventing any worker entry into unsupported excavations 5. Ensure shoring systems provide full-height protection extending from excavation base to minimum 200mm above surrounding ground surface, eliminating any unprotected areas where soil collapse could occur 6. Verify shoring installation follows manufacturer's instructions and engineer's design, with hydraulic shores properly extended, struts adequately tightened, and all pins and connections fully engaged 7. Establish exclusion zones extending minimum 2 metres from excavation edges preventing stockpiled materials, mobile plant, or other surcharge loads from inducing additional pressure on excavation walls 8. Provide safe access and egress from shored excavations using properly secured ladders spaced at maximum 8 metre intervals, ensuring no worker is more than 4 metres from an exit point 9. Conduct daily inspections of shoring systems by competent person before permitting worker entry, checking for timber splitting, hydraulic leaks, ground movement, or water accumulation requiring corrective action 10. Maintain shoring in position until backfilling is substantially complete and workers no longer need to enter excavation, removing shoring progressively as backfill protects excavation walls from collapse

Hot Work Permit System with Atmospheric Testing

Administrative

Implement comprehensive hot work permit system requiring formal authorization before any welding, cutting, grinding, or spark-producing activities occur within or adjacent to fuel storage installation areas. Administrative controls through structured permit process ensure all fire prevention measures are verified before hot work commences, with continuous monitoring maintaining safe conditions throughout work duration.

Implementation

1. Designate responsible person with authority to issue hot work permits after verifying all preconditions are satisfied, typically site supervisor or safety coordinator with appropriate training 2. Require written hot work permit application identifying specific work location, duration, hot work type, and fire prevention measures to be implemented, with permit approval documented before work commences 3. Conduct pre-work atmospheric testing of all work areas and adjacent spaces using calibrated flammable gas detector, verifying readings below 5% Lower Explosive Limit before permit authorization 4. Implement continuous atmospheric monitoring throughout hot work duration using fixed or portable gas detectors positioned in work area with audible alarms, ceasing work immediately if flammable gas detected 5. Assign dedicated fire watch person with sole responsibility for monitoring hot work, equipped with appropriate fire extinguishers and trained in their use, maintaining watch throughout work and minimum 60 minutes after completion 6. Remove all combustible materials within 10 metres of hot work location, or cover materials with fire-resistant blankets rated for welding spark exposure if removal is impractical 7. Provide firefighting equipment appropriate to hot work location including minimum two 9kg dry chemical or foam extinguishers rated for Class B flammable liquid fires, plus water supply or additional extinguishers for large areas 8. Establish communication protocols between hot work personnel, fire watch, and site management, including radio contact allowing immediate work cessation if hazards are identified 9. Limit hot work permit validity to single work shift, requiring new atmospheric testing and permit authorization if work extends across multiple days or resumes after break periods 10. Document all hot work permits in site safety records including atmospheric test results, fire watch personnel, work duration, and any incidents or near misses requiring investigation

Fall Protection Systems for Tank Top Access

Personal Protective Equipment

Provide comprehensive fall protection equipment including full-body harnesses, shock-absorbing lanyards, and secure anchorage points for all work accessing tank tops or elevated positions exceeding 2 metres above ground level. PPE serves as final barrier preventing falls when engineering controls through guardrails or work platforms are not feasible for temporary installation work.

Implementation

1. Supply full-body fall arrest harnesses meeting AS/NZS 1891.1 standards with dorsal and frontal D-ring attachment points, sized and fitted to individual workers through professional fitting sessions 2. Provide shock-absorbing lanyards meeting AS/NZS 1891.1 rated for minimum 15kN static load with maximum 1.8 metre extended length preventing contact with lower levels after fall arrest 3. Install permanent anchorage points on large tank tops, designed and tested to withstand 15kN static load in any direction, with certification documentation maintained in project files 4. Utilize temporary anchorage devices including roof anchors or portable davit systems where permanent anchorages are not yet installed, with devices rated and certified for fall protection service 5. Implement 100% tie-off procedures requiring workers to maintain lanyard connection to rated anchorage at all times whilst above 2 metres, using dual-lanyard systems allowing continuous connection during position changes 6. Ensure anchorage points are positioned to prevent free fall distance exceeding 2 metres and prevent swing falls that could result in impact with projecting equipment or tank surfaces 7. Conduct pre-use inspection of all fall protection equipment before each use, checking harness webbing for cuts or abrasion, lanyard shock absorber for deployment indicating previous fall arrest, and connector gates for proper closing and locking 8. Provide rescue equipment and train designated personnel in emergency rescue procedures for workers suspended in fall arrest systems, ensuring rescue can be initiated within 10 minutes of fall occurrence preventing suspension trauma 9. Remove fall protection equipment from service immediately if involved in fall arrest event, with equipment destruction or return to manufacturer for recertification before further use 10. Document fall protection training for all workers including harness fitting, anchorage selection, emergency procedures, and hazard recognition, with competency verification before workers access heights

Comprehensive Spill Prevention and Response Procedures

Administrative

Establish detailed procedures preventing fuel spillage and environmental contamination through systematic controls at all potential release points, with immediate response capability if releases occur despite prevention measures. Administrative controls through documented procedures and trained personnel minimize environmental impact from fuel tank installation activities.

Implementation

1. Conduct spill risk assessment identifying all potential release points including tank filling connections, pressure test ports, piping joints during installation, hydraulic equipment operation, and fuel delivery for commissioning 2. Position spill containment equipment including drip trays, absorbent pads, and portable containment berms beneath all connection points before work proceeds, with equipment adequate for volumes that could be released 3. Establish fuel delivery protocols for commissioning testing including verification of tank capacity before delivery, continuous monitoring during filling operations, automatic shutoff systems preventing overfilling, and operator training in emergency shutdown procedures 4. Maintain spill response kits at all work areas containing absorbent materials rated for petroleum products, non-sparking shovels for contaminated soil recovery, disposal bags meeting dangerous goods packaging requirements, and spill response instruction cards 5. Train all workers in spill response procedures including immediate work cessation upon release detection, ignition source elimination, containment of released materials using absorbents or berms, and notification of management for regulatory reporting 6. Implement secondary containment for all bulk fuel storage during commissioning, ensuring any releases are captured within bunded areas preventing environmental discharge 7. Establish clear responsibility assignment for spill response activities, identifying competent persons authorized to direct response operations and make decisions on regulatory notification requirements 8. Maintain emergency contact information for environmental regulators, specialized spill cleanup contractors, and site management, ensuring 24-hour contact capability if incidents occur outside normal working hours 9. Document all spills regardless of size in incident register, investigating root causes and implementing corrective actions preventing recurrence, with regulatory notification for reportable quantities 10. Conduct regular spill response drills testing worker knowledge and equipment adequacy, identifying gaps in procedures or resources requiring correction before actual incidents occur

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Personal protective equipment

Requirement: Steel-capped safety boots with penetration-resistant soles meeting AS/NZS 2210.3, oil-resistant sole material, and ankle support for work on uneven ground

When: Required for all fuel tank installation activities to protect feet from heavy component drops, penetration from sharp materials in excavations, and slips on fuel-contaminated surfaces

Requirement: Type 1 or Type 2 industrial safety helmet with 4-point suspension and chin strap for work beneath suspended loads, meeting impact resistance requirements

When: Required during all crane lifting operations, work in excavations where overhead collapse risk exists, and when working beneath elevated structures or equipment

Requirement: Class D day/night high visibility vest with fluorescent background material and retroreflective tape providing 360-degree visibility

When: Required during all outdoor fuel tank installation work, particularly when mobile plant or delivery vehicles are operating in work areas

Requirement: Cut-resistant gloves providing Level 3 or higher protection under AS/NZS 2161.2 whilst maintaining adequate tactile sensitivity for tool operation and fitting work

When: Required during handling of steel tanks with sharp edges, cutting and threading pipe, and installation of fittings with exposed threads

Requirement: Nitrile or neoprene gloves providing chemical resistance to petroleum products, tested for specific fuel types being stored with permeation data confirming adequate protection duration

When: Required when handling fuel during commissioning testing, working with sealants or coatings, or conducting any activity involving potential skin contact with fuels or petroleum products

Requirement: Impact-resistant safety glasses with side shields meeting impact resistance requirements, anti-fog coating for comfort in varying temperature conditions

When: Required during all fuel tank installation work to protect eyes from dust during excavation, metal particles during cutting or drilling, and chemical splash during coating application

Requirement: Full-body harness with dorsal and front D-rings, shock-absorbing lanyard appropriate to fall distances, all components meeting AS/NZS 1891.1 standards with current inspection tags

When: Required for all work accessing tank tops exceeding 2 metres height, working on temporary scaffolding or platforms, or any activity where fall exposure exists

Requirement: Disposable earplugs or earmuffs providing minimum 25 dB noise reduction rating appropriate for construction equipment noise levels

When: Required when operating power tools for tank cutting or modification, during excavation equipment operation, or in areas where noise exceeds 85 dB(A)

Requirement: Half-face P2 respirator or organic vapor cartridge respirator depending on contaminant type, properly fitted through fit testing procedures

When: Required when working in confined spaces with potential vapor exposure, applying coatings or sealants in enclosed areas, or during any activity where atmospheric monitoring indicates vapor concentrations approaching occupational exposure limits

Requirement: Long-sleeved shirts and long trousers in tightly woven light-colored fabric providing UPF 50+ protection, wide-brimmed hard hat brim attachment or separate hat for breaks, SPF 50+ sunscreen

When: Required for all outdoor fuel tank installation work during daylight hours to prevent sunburn and reduce long-term skin cancer risk from Australian sun exposure

Inspections & checks

Before work starts

✓Review fuel storage tank installation drawings, approval documentation, and AS 1940 compliance requirements understanding tank capacities, required separation distances, and fire safety systems
✓Verify all workers have completed dangerous goods awareness training and understand flammable liquid hazards, fire prevention measures, and emergency response procedures
✓Conduct hazardous area classification review identifying Zone 0, Zone 1, and Zone 2 areas where ignition source controls apply, with classification maps available to all workers
✓Inspect tank delivery ensuring tanks are undamaged, protective coatings are intact, openings are properly capped preventing contamination and debris entry, and lifting eyes or lugs are structurally sound
✓Verify excavation shoring design is available for underground installations, with engineered drawings specifying shoring type, support spacing, and maximum allowable excavation depth before support installation
✓Confirm mechanical lifting equipment including cranes, forklifts, or hoists are on site with current inspection certifications, adequate capacity for maximum tank weights, and operators holding appropriate high-risk work licences
✓Check atmospheric monitoring equipment including flammable gas detectors are calibrated within specified intervals, bump tested daily confirming sensor response, and alarm systems functioning audibly
✓Inspect all electrical equipment to be used within hazardous areas verifying explosion-protected certification, appropriate zone rating, and visible certification markings on equipment nameplates
✓Verify emergency response equipment is positioned including Class B fire extinguishers rated for flammable liquid fires, spill response kits with petroleum-rated absorbents, and first aid equipment with trained personnel
✓Conduct utility location services confirming all underground services are marked, hand digging verification is planned for marked service locations, and service owners have provided clearance for excavation
✓Establish site access controls preventing unauthorized entry, positioning warning signs identifying flammable liquid storage installation and hazardous area boundaries, and designating parking areas for delivery vehicles

During work

✓Maintain continuous atmospheric monitoring throughout all work activities, with workers trained to evacuate immediately if gas detector alarms activate indicating flammable vapor presence
✓Monitor excavation conditions before permitting worker entry each day, checking for water accumulation requiring pumping, soil movement indicating instability, or shoring damage requiring repair before work proceeds
✓Verify ignition source elimination is maintained within hazardous areas, immediately removing any smoking materials, unapproved electrical equipment, or spark-producing tools from classified zones
✓Inspect lifting operations ensuring exclusion zones are enforced beneath all suspended loads, tag lines are used to control load movement, and workers guide loads from safe positions outside crush zones
✓Check tank positioning and alignment during installation, verifying foundations are level within specified tolerances, drainage slopes are correct, and anchor bolt locations match design drawings
✓Monitor weather conditions particularly during crane operations, ceasing lifting activities if wind speeds exceed limits specified in crane load charts or if electrical storms approach work area
✓Verify proper rigging techniques during all lifting operations, ensuring slings are positioned at specified lifting points, load angles do not exceed equipment ratings, and all connections are properly seated
✓Inspect piping installation work ensuring proper material selection for fuel type being stored, adequate support preventing sagging, proper joint preparation for welding or threading, and protection during backfilling
✓Monitor backfilling operations for underground tanks, verifying specified material is used, placement occurs in controlled layers preventing tank distortion, and compaction is adequate without over-compacting causing tank damage
✓Check that all hot work if authorized under permit occurs only after atmospheric testing confirms absence of flammable vapors, fire watch is positioned with appropriate extinguishers, and continuous monitoring is maintained

After work

✓Conduct pressure testing of all tanks and piping systems before backfilling or concealment, maintaining test pressure for specified duration and verifying no pressure loss indicating leakage
✓Verify tank grounding and bonding connections are installed and tested, with earth resistance measurements below 10 ohms documented in commissioning records
✓Inspect completed bund construction for above-ground tanks confirming bund capacity meets 110% largest tank volume, drainage valves are installed and locked closed, and bund walls are structurally sound
✓Check leak detection system installation and functionality, testing sensors respond to simulated leaks and alarm systems activate appropriately with signals perceptible in locations where response personnel are present
✓Verify vent installation meets AS 1940 requirements including minimum 3 metre height above ground, proper flame arrestor installation, and termination location preventing vapor accumulation near buildings or ignition sources
✓Inspect fill point installation confirming proper labeling identifying fuel type, lockable caps preventing unauthorized filling, adequate spillage containment, and separation from building openings and ignition sources
✓Document all testing results including pressure test records, leak detection verification, grounding resistance measurements, and visual inspections in commissioning documentation package
✓Verify emergency shutoff systems are installed and tested, confirming all fuel flow ceases when emergency stops are activated and reset procedures are understood by operating personnel
✓Conduct final site restoration ensuring all excavations are properly backfilled and compacted, temporary works are removed, construction debris is cleaned up, and erosion controls are functioning
✓Prepare as-built documentation showing final installation details including any variations from design drawings, test results, and recommendations for ongoing maintenance and inspection schedules
✓Obtain regulatory inspections and approvals as required before commissioning, including dangerous goods authority inspection, environmental protection authority verification, and local government final certification

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Conduct Site Assessment and Obtain Required Approvals

Begin fuel storage tank installation by conducting comprehensive site assessment verifying location suitability and obtaining all regulatory approvals before commencement. Review development consent or building approval documents confirming tank capacity, location, and design comply with approved plans. Verify AS 1940 separation distance requirements are satisfied including minimum distances to buildings, property boundaries, ignition sources, and environmentally sensitive areas such as watercourses. Conduct utility location search identifying all underground services including water mains, sewer lines, electrical cables, telecommunications conduits, and gas mains that may conflict with proposed tank location or excavation. Engage Dial Before You Dig service obtaining service location plans from all utility providers. Assess site access for delivery trucks and crane positioning, ensuring adequate maneuvering space, ground bearing capacity for heavy vehicle loading, and overhead clearance from power lines or other obstructions. Verify environmental approvals or notifications are in place if required based on tank capacity and fuel type, particularly for installations in environmentally sensitive locations. Obtain dangerous goods storage licence or approval from state dangerous goods authority if storage capacity exceeds regulatory thresholds. Conduct soil investigation through test pits or bore holes if underground tank installation is planned, determining soil type, bearing capacity, groundwater depth, and presence of any existing contamination requiring management. Identify fire protection requirements including separation distances, fire extinguisher types and quantities, and any fixed firefighting systems required by approval conditions. Prepare site safety plan addressing all identified hazards including excavation work, crane operations, working near services, and dangerous goods handling.

Safety considerations

Inadequate site assessment creates serious hazards if underground services are struck during excavation, ground bearing is insufficient for crane operations causing overturn, or separation distances are inadequate resulting in non-compliant installation. Proceeding without required approvals can result in work stop orders, installation removal requirements, and substantial penalties. Groundwater or contaminated soil discoveries during excavation without prior investigation cause costly delays and potential worker exposure to hazardous materials.

Prepare Site and Construct Tank Foundation

Prepare installation site and construct tank foundation providing adequate support, drainage, and access for fuel storage tank. Clear vegetation and remove topsoil from foundation footprint extending beyond tank outline to provide working space for installation activities. Excavate to foundation depth specified in design drawings, typically 150-300mm below finished ground level for above-ground tanks or full tank height plus cover for underground installations. Install formwork for concrete foundations using properly secured timber or steel forms maintaining required dimensions and preventing concrete blowout during pouring. Position reinforcement steel according to structural drawings, using bar chairs or plastic spacers maintaining required concrete cover on all faces. Verify foundation is level using laser level or precision surveying equipment, ensuring deviations do not exceed ±5mm over foundation plan area as excessive slope prevents proper tank seating and creates drainage issues. Install anchor bolt sleeves or embedded plates at locations specified for tank holddown systems, ensuring bolt spacing and projection heights match tank base bracket requirements. Pour concrete foundation using appropriate mix design providing adequate strength for anticipated loads, typically minimum 25 MPa compressive strength at 28 days. Vibrate concrete thoroughly eliminating air voids particularly around reinforcement and anchor bolt embedments. Finish foundation surface with slight slope toward drainage points, typically 1:100 gradient preventing water pooling beneath tanks. Cure concrete adequately before tank installation, maintaining moisture for minimum 7 days through water spray or application of curing compound, covering concrete during curing to prevent rapid drying causing cracking. For underground tank installations, excavate to depth providing minimum 600mm cover over tank top, install minimum 150mm granular bedding material providing uniform support without point loading, and verify excavation walls are stable or properly shored before tank positioning.

Safety considerations

Foundation work involves manual handling of reinforcement steel, formwork components, and concrete placement equipment creating back strain and crush hazards. Wet concrete is highly alkaline causing severe chemical burns if skin contact occurs without prompt washing. Excavations for underground tanks create collapse hazards if walls are unsupported or workers enter without proper shoring. Foundation defects discovered after tank installation may require costly tank removal for corrections.

Position Tank Using Crane or Mechanical Lifting Equipment

Position fuel storage tank onto prepared foundation or into excavation using appropriate mechanical lifting equipment selected based on tank size and weight. Conduct pre-lift planning meeting with all personnel involved including crane operator, riggers, and workers who will guide tank into position, reviewing lift plan, rigging configuration, exclusion zones, communication protocols, and emergency procedures. Verify crane is positioned on stable ground with outriggers properly extended and supported on adequate bearing surfaces, using timber mats or steel plates if ground conditions require load spreading. Inspect all lifting equipment including slings, shackles, spreader beams, and lifting eyes or lugs on tank, confirming current certification tags, adequate load ratings with minimum 5:1 safety factor, and absence of damage. Position tank for rigging access, typically using forklifts or excavators to move tank from delivery truck to rigging location whilst avoiding any damage to tank surfaces or protective coatings. Attach rigging to tank at manufacturer-specified lifting points only, never using fill pipes, vent connections, or ancillary fittings as lifting points. Test lift by raising tank slightly off ground and holding to verify rigging security and load balance before full lifting height. Establish exclusion zone with barriers or designated spotters preventing any workers from approaching within 2 metres of suspended load path. Lift tank to required height allowing clearance for positioning over foundation or into excavation, maintaining steady controlled movement without sudden accelerations or decelerations. Guide tank into final position using tag lines attached to tank ends, maintaining safe distance from suspended load whilst controlling horizontal movement. Lower tank slowly onto foundation or bedding material, verifying proper seating and alignment before releasing crane load. For underground tanks, verify tank is properly centered in excavation with adequate clearance to excavation walls before backfilling proceeds.

Safety considerations

Tank lifting presents extreme struck-by hazards if rigging fails, crane overturns from inadequate ground support, or workers enter beneath suspended loads. Multi-tonne tanks falling from even low heights generate catastrophic impacts. Wind loading on large tanks can cause uncontrolled swinging if tag lines are inadequate. Underground tank positioning requires workers to be in excavation creating both struck-by and burial hazards simultaneously.

Install Tank Anchorage and Backfill Underground Installations

Secure tank to foundation using appropriate anchorage system preventing flotation, overturning, or movement from seismic events or impact loads. For above-ground tanks, install holddown straps or brackets connecting tank base to anchor bolts embedded in foundation, tightening connections to specified torque ensuring adequate restraint without over-tightening causing tank base distortion. Verify anchorage design and installation matches engineered specifications accounting for tank size, stored liquid weight, seismic zone, and wind exposure classification for site location. For underground tanks, commence backfilling immediately after tank positioning to prevent flotation if groundwater enters excavation. Use specified backfill material, typically clean sand or select fill free from rocks, debris, or material that could damage tank coating during placement. Place backfill in controlled lifts not exceeding 300mm thickness, working evenly around entire tank perimeter maintaining equal fill height on all sides preventing uneven loading that could distort cylindrical tank shapes. Compact backfill using appropriate equipment such as vibrating plate compactors or hand tampers, achieving specified density without over-compacting causing tank damage. For double-wall tanks, verify interstitial monitoring probes are installed and protected during backfilling, maintaining continuous monitoring during backfill placement to detect any leakage or damage to inner tank. Fill tank with water progressively as backfilling proceeds for large underground tanks, maintaining water level slightly above backfill level providing internal pressure preventing collapse under earth loading. Install cathodic protection groundbeds or magnesium anodes if specified for corrosion protection of steel underground tanks, connecting protection system before backfilling conceals access to tank surfaces. Verify minimum 600mm cover is achieved over tank top providing protection from vehicle loads and frost penetration in cold climate regions.

Safety considerations

Backfilling creates burial hazards if workers are in excavations during material placement. Mechanical compaction equipment operated too close to tank can damage coatings or distort tank structure. Water filling during backfilling prevents tank collapse but creates drowning hazard if workers fall into open tank access points. Inadequate anchorage allows tank movement potentially damaging piping connections and creating leak hazards during operation.

Install Piping, Venting, and Electrical Systems

Install all piping systems connecting tank to fill points, dispensing equipment, and vent terminations in accordance with AS 1940 requirements and approved design drawings. Install fill piping from street-accessible fill point location to tank inlet, using appropriate pipe material compatible with fuel being stored such as steel pipe meeting AS 1432 for underground installation with external corrosion protection. Ensure fill piping terminates near tank bottom reducing agitation and vapor generation during filling operations. Install product piping from tank outlet to dispensing equipment or building connection points, incorporating required shut-off valves, check valves preventing backflow, and emergency shut-off systems. Vent piping must extend minimum 3 metres above ground level, terminating in location at least 6 metres from buildings, property boundaries, or ignition sources, with open vent directed away from areas where personnel congregate. Install flame arrestor in vent piping preventing external fire propagation into tank vapor space, using approved device meeting AS 1940 specifications. For pressure or vacuum venting systems, install appropriate pressure/vacuum relief valves preventing tank overpressure or vacuum collapse during filling or product withdrawal. Install overfill prevention devices including float-operated valves, high-level alarms, or automatic shutoff systems preventing tank overflow during delivery. For tanks with pumped dispensing, install submersible or external pump units with appropriate electrical connections, leak detection beneath pump installation, and emergency shutoff capability. Install tank level gauging systems including dipstick access, float gauges, or electronic level sensors, ensuring accurate inventory management and leak detection capability. Engage licensed electrician to install all electrical systems within classified hazardous areas, using only explosion-protected equipment certified for appropriate zone rating, with all conduits, cable glands, and equipment enclosures maintaining explosion protection integrity. Install grounding and bonding connections between tank, piping, and earth electrode system, verifying resistance to earth not exceeding 10 ohms through testing with calibrated earth resistance meter.

Safety considerations

Piping installation involves manual handling of heavy pipe sections, cutting and threading operations creating sharp edges and metal particles, and working in awkward positions beneath tanks or in confined spaces. Electrical work within hazardous areas creates ignition hazards if non-approved equipment is used or explosion protection is compromised. Inadequate venting can result in tank overpressure or vacuum collapse causing catastrophic failure during operation. Poor grounding creates static electricity discharge hazards during fuel delivery operations.

Pressure Test Tank and Piping Systems

Conduct comprehensive pressure testing of tank and all piping systems verifying leak-tight integrity before backfilling underground installations or delivering fuel for commissioning. Review testing requirements specified in AS 1940 and manufacturer's installation instructions, determining test pressure (typically 150% of maximum operating pressure) and test duration (minimum 24 hours or as specified). For underground tanks, conduct testing before any backfilling allows access to tank surfaces for leak detection and repair if required. Seal all tank openings using appropriate blanking flanges or test caps rated for test pressure, ensuring all connections are secure and properly gasketed. Install calibrated pressure gauge or data logger capable of detecting small pressure changes indicating leakage, positioned where readings can be monitored without entering hazardous areas. Fill tank with water for large tanks or use compressed air for small tanks and piping systems, increasing pressure gradually to test pressure whilst monitoring for leaks. Pressurize piping systems using water or air depending on system design and accessibility for leak detection, isolating each section to be tested using installed valves or temporary test caps. Monitor pressure throughout test duration, recording initial pressure and pressure readings at regular intervals documenting any pressure loss. Investigate all pressure losses regardless of magnitude, conducting thorough visual inspection of all welds, joints, fittings, and tank surfaces identifying leak sources. Repair any identified leaks using appropriate methods such as re-welding defective joints, tightening threaded connections, or replacing defective components, then repeat pressure test verifying repairs are effective. For tanks that will operate under vacuum, conduct vacuum test applying specified vacuum level and verifying tank structure withstands vacuum without collapse or deformation. Document all test results including test pressures, duration, pressure loss if any, leak locations identified and repaired, and final test outcome in commissioning documentation package. Obtain independent verification of pressure testing by regulatory inspectors if required by approval conditions before proceeding to system commissioning.

Safety considerations

Pressure testing creates explosion hazards if air-pressurized systems are tested in presence of flammable vapors remaining from tank manufacturing or coating processes. Catastrophic tank failure during testing due to manufacturing defects or inadequate design can project tank fragments or release stored test pressure energy. Working beneath or near tanks under test pressure creates severe crush hazards if tanks fail. Inadequate testing procedures allow leaking installations to commence operation causing environmental contamination and fire hazards.

Commission Tank and Verify System Operation

Commission completed fuel storage tank installation verifying all systems operate correctly and safely before regular use commences. Conduct final visual inspection of entire installation checking all components are installed according to design drawings, all temporary construction equipment is removed, site is clean and free from debris, and access for ongoing maintenance is adequate. Test leak detection systems by simulating leaks at sensor locations, verifying sensors respond appropriately and alarm systems activate with signals perceptible in locations where response personnel are present. For interstitial monitoring systems in double-wall tanks, verify continuous monitoring is functioning with any alarm conditions investigated before commissioning proceeds. Test emergency shutoff systems by activating emergency stops verifying all pumps cease operation and motorized valves close automatically, then confirming system reset procedures are understood by operational personnel. Verify overfill prevention systems operate correctly by testing high-level alarms or automatic shutoff devices, ensuring delivery operations will cease before tank overflow occurs. Calibrate tank level gauging systems against known volumes, developing strapping tables or calibration curves allowing accurate inventory management throughout operational life. Install required signage including fuel type identification at fill points and dispensers, emergency contact information, no smoking signs within hazardous areas, and operating instructions for dispensing equipment. Arrange initial fuel delivery scheduling delivery during normal working hours when full personnel complement is available for emergency response if required, with delivery driver briefed on site-specific filling procedures and emergency shutdown locations. Monitor initial filling operation continuously, verifying all connections remain leak-free under operating pressure, vent systems function adequately without pressure buildup, and level gauging accurately indicates increasing fuel level. Conduct operational training for site personnel covering normal dispensing procedures, emergency shutdown protocols, spill response requirements, and ongoing inspection and maintenance requirements. Prepare operation and maintenance manual documenting all installed systems, manufacturer's instructions, testing and calibration schedules, emergency procedures, and regulatory compliance requirements. Notify dangerous goods regulatory authority of commissioning completion if required, arranging initial compliance inspection verifying installation meets all regulatory requirements before operating licence is issued.

Safety considerations

Initial fuel delivery creates maximum fire and explosion hazard as filling operations introduce flammable liquids for first time. Overfilling during initial delivery due to uncalibrated gauges or unfamiliarity with tank capacity causes environmental contamination and fire hazards. Inadequate commissioning verification allows defective installations to commence operation creating ongoing hazards. Poor operational training results in unsafe practices during routine fuel handling and inadequate emergency response capability.

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Frequently asked questions

What are the minimum separation distances required between fuel storage tanks and buildings or property boundaries under AS 1940?

AS 1940 specifies separation distances based on tank capacity and whether tanks are above-ground or underground. For above-ground tanks storing Class C1 flammable liquids (flash point 23-60°C like diesel), tanks up to 10,000 litres require minimum 1.5 metres from buildings and 1 metre from property boundaries. Larger tanks require increased distances calculated using risk assessment methodologies in the standard. Underground tanks generally require lesser separation distances, with tanks up to 10,000 litres permitted at property boundaries if adequately protected. Class C2 combustible liquids (flash point above 60°C) have reduced separation requirements. Separation to ignition sources including electrical switchboards, motors, and other spark-producing equipment must be minimum 3 metres. Fill points must be located minimum 3 metres from building openings and ignition sources. Vent terminations require minimum 6 metres separation from buildings, boundaries, and ignition sources. Where separation distances cannot be achieved, fire protection measures including fire-rated walls or deluge systems may allow reduced distances subject to regulatory approval. Always verify specific requirements with local dangerous goods authority as some jurisdictions impose requirements exceeding AS 1940 minimums.

What environmental protection measures are required for underground fuel tank installations to prevent groundwater contamination?

Environmental protection for underground fuel tanks requires multiple protective barriers preventing contamination if leaks occur. Modern installations mandate double-wall tank construction with continuous interstitial monitoring between inner and outer walls, providing immediate leak detection before fuel enters surrounding soil. Leak detection systems must be installed beneath tank and throughout piping systems, using electronic sensors or groundwater monitoring wells positioned to detect contamination before it migrates beyond site boundaries. Cathodic protection systems prevent corrosion of steel tanks through impressed current or sacrificial anode systems, with effectiveness verified through regular testing. Excavation backfill must exclude contaminated soil, with any existing contamination characterized and appropriately managed including potential removal and disposal at licensed facilities. Installations exceeding regulatory capacity thresholds require environmental protection licence applications demonstrating adequate leak detection, monitoring capability, and financial assurance for cleanup costs if contamination occurs. Some jurisdictions require groundwater monitoring wells installed downgradient from tank locations, with baseline sampling before commissioning and ongoing quarterly or annual sampling detecting any contamination. Emergency response plans must address fuel release scenarios including immediate shutdown procedures, containment methods, regulatory notification protocols, and cleanup contractor engagement. Comprehensive record keeping documenting leak detection system testing, cathodic protection monitoring, and groundwater sampling results demonstrates ongoing environmental due diligence and supports early contamination detection before extensive remediation becomes necessary.

What qualifications and training are required for workers installing fuel storage tanks and associated dangerous goods systems?

Fuel storage tank installation requires workers with appropriate dangerous goods training and relevant trade qualifications for specific installation activities. All workers must complete dangerous goods awareness training covering flammable liquid properties, fire and explosion hazards, emergency response procedures, and regulatory requirements under state-based dangerous goods legislation. Workers conducting crane operations must hold High Risk Work Licence for appropriate crane class including Derrick or Portal Boom Crane licence for small mobile cranes or appropriate larger crane class for major installations. Riggers and dogmen directing crane operations and attaching loads require Dogging licence for basic rigging or Rigging licence for advanced rigging work depending on load complexity. Confined space entry during tank cleaning or modification requires Confined Space Entry competency and atmospheric monitoring training. Electrical workers installing systems in hazardous areas must be licensed electricians with additional certification in hazardous area electrical work under AS/NZS 60079 standards. Welders performing any tank modifications or piping welding should hold appropriate welding qualification for materials and processes being used. Excavation workers entering shored excavations exceeding 1.5 metres depth should complete excavation safety training understanding shoring systems, safe entry procedures, and emergency egress. Site supervisors should complete additional training in dangerous goods management, hot work permit systems, and emergency response coordination. All workers require site-specific induction covering project hazards, approval conditions, emergency procedures, and coordination protocols. Employers must maintain training records and verify worker competencies meet position requirements before permitting work on fuel storage installations, with records available for regulatory inspection demonstrating systematic approach to competency management.

How should fuel tank installations in bushfire-prone areas be designed and installed to minimize fire risk?

Fuel tank installations in bushfire-prone areas designated as Bushfire Attack Level (BAL) zones require additional protection measures preventing ignition from ember attack, radiant heat, or direct flame contact. Tank location selection should maximize separation from vegetation and buildings, positioning tanks in low fuel areas with cleared zones extending minimum 10 metres from tanks in all directions. Above-ground tanks should be positioned on non-combustible surfaces such as concrete with no accumulation of leaf litter or other fuel beneath tanks. Tank cladding or shielding using non-combustible materials provides radiant heat protection, with installations in high BAL zones potentially requiring complete enclosure in fire-rated structures. Vegetation management must maintain cleared areas around tanks free from grass, shrubs, and overhanging tree branches that could ignite and expose tanks to direct flame contact. Vent terminations should be protected with ember-proof screens preventing ember entry to tank vapor space whilst maintaining adequate venting capacity. Fill points and dispensing areas should be clear of combustible materials and landscaping plants that could ignite during bushfire events. Emergency shutoff valves accessible from safe locations allow fuel supply isolation during bushfire approach without requiring personnel to approach tanks during dangerous conditions. Sprinkler systems or deluge protection provide active fire protection for high-value installations, with water supplies adequate for sustained operation during bushfire duration. Underground tanks provide superior bushfire protection as tanks are inherently protected from radiant heat and ember attack, with only fill points and vents requiring specific bushfire protection. Post-bushfire inspection procedures should verify tank integrity, vent and valve operation, and detection system function before resuming normal operations after bushfire exposure. Installation in bushfire zones should align with local planning overlays and bushfire protection requirements specific to the region and BAL rating applicable to the site location.

What ongoing maintenance and inspection requirements apply to fuel storage tank installations after commissioning?

Fuel storage tanks require comprehensive ongoing maintenance and inspection programs ensuring continued safe operation throughout service life. Daily inspections by operational personnel should check for visible leaks at piping connections and tank fittings, verify overfill prevention systems are operational, test emergency shutoff systems for functionality, and confirm no unauthorized modifications or damage has occurred. Weekly inspections should verify leak detection systems are operational with sensors responding to test signals, check firefighting equipment remains accessible and serviceable with pressure gauges indicating adequate charge, and inspect bund areas for stormwater accumulation requiring drainage or evidence of fuel contamination. Monthly inspections should test tank level gauges against manual dipstick readings verifying calibration accuracy, conduct inventory reconciliation comparing fuel deliveries, dispensed volumes, and measured tank contents identifying any unexplained losses indicating potential leakage, verify cathodic protection systems for underground tanks show adequate protection levels through reference electrode readings, and inspect vent terminations for blockages from insects, debris, or frost accumulation affecting venting capacity. Annual inspections by competent persons should comprehensively inspect all accessible tank surfaces, piping, valves, and fittings for corrosion or deterioration requiring repair, pressure test piping systems verifying leak-tight integrity, calibrate leak detection sensors and verify alarm function, test grounding and bonding resistance confirming values remain below 10 ohms, and verify explosion-protected electrical equipment maintains certification integrity. Five-yearly internal inspections of tanks may be required by regulatory authorities, necessitating tank emptying, cleaning, atmospheric testing, and confined space entry by qualified inspectors examining internal surfaces for corrosion, detecting any structural issues, and certifying fitness for continued service. All inspection and maintenance activities must be documented in permanent records maintained throughout tank service life, providing regulatory evidence of systematic maintenance and supporting warranty claims if premature failures occur. Any identified defects must be corrected promptly with tanks removed from service if defects compromise safety until repairs are completed and verified effective through appropriate testing and inspection.

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Risk Rating

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Fuel Storage Tank Installation Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Fire and Explosion from Flammable Vapor Ignition

Manual Handling Injuries from Lifting Heavy Tank Components

Falls from Heights During Large Tank Installation and Access

Struck by Suspended Loads During Crane Lifting Operations

Excavation Collapse and Soil Instability Hazards

Environmental Contamination from Fuel Spillage and Soil Disturbance

Control measures

Comprehensive Ignition Source Elimination Program

Mechanical Lifting Equipment for All Tank Components

Continuous Atmospheric Monitoring for Flammable Vapors

Engineered Excavation Shoring and Support Systems

Hot Work Permit System with Atmospheric Testing

Fall Protection Systems for Tank Top Access

Comprehensive Spill Prevention and Response Procedures

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Conduct Site Assessment and Obtain Required Approvals

Prepare Site and Construct Tank Foundation

Position Tank Using Crane or Mechanical Lifting Equipment

Install Tank Anchorage and Backfill Underground Installations

Install Piping, Venting, and Electrical Systems

Pressure Test Tank and Piping Systems

Commission Tank and Verify System Operation

Frequently asked questions

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