Risk Assessment for

Petroleum Sites
a guide for businesses
Disclaimer
Cornwall Fire and Rescue Service provide this guide to assist businesses to improve fire safety in their
premises, but stress the person completing or reviewing the risk assessment must be competent. If you
choose to get advice or a specialist to complete your risk assessment, you are still legally responsible for
the safety in your premises and the risk assessment.
This template will give you an example of a risk assessment and illustrate some of the areas you should
consider. It must be stressed that it is only a guide, and you must ensure that your risk assessment is
suitable and sufficient, and detailed enough to comply with the Health and Safety at Work etc. Act 1974.
The content of the risk assessment and the identification and addressing of any significant findings are the
responsibility of the responsible person.
The use of this fire risk assessment template will not prejudice any enforcement action that may be taken
by Cornwall Fire and Rescue Service as a result of any safety deficiencies found during an audit, and does
not automatically demonstrate compliance with the law.
The Fire Service cannot carry out the risk assessment for you, but they can give you information and
advice on appropriate measures to protect your premises.
If after reading this guide you still feel you need more information about appropriate measures to take,
you can contact a Petroleum Officer from Cornwall Fire and Rescue Service for advice on:

Email
protection@fire.cornwall.gov.uk

St Austell Community Fire Station

Tel: 01726 223620 (office hours 9am to 5pm)

24 hr Fire Safety Advice

Tel: 0800 3581 999

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 Contents
1. Introduction
2. Legislation requirements
3. How to complete a risk assessment
4. Hazardous atmospheres
5. Creating a hazardous zone plan
6. Example of a hazardous zone plan
7. Bibliography
8. Risk assessment template
a) Hazardous zone plan
b) Risk assessment

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1. Introduction
The Dangerous Substances and Explosive Atmospheres Regulations 2002 places the onus on the
employer/responsible person to identify and assess the risks arising from the delivery, keeping and
dispensing of petroleum spirit and other motor fuels (such as liquefied petroleum gas).

Related legislation

 The Petroleum (Consolidation) Regulations 2014

 The Health and Safety at Work Act etc. 1974

 The Management of Health and Safety at Work Regulations 1999

 The Dangerous Substances and Explosive Atmospheres Regulations 2002

 The Regulatory Reform (Fire Safety) Order 2005

2. Legislation requirements
The employer / responsible person must:

 Find out what dangerous substances are present in their workplace/premises and what the fire
and explosion risks are (Petroleum spirit and LPG are both “dangerous substances” for this
purpose, but there may be others at the premises which will need to be considered);

 Put control measures in place to either remove those risks or, where this is not possible, to
control them;

 Put controls in place to reduce the effects of any incidents involving dangerous substances;

 Prepare plans and procedures to deal with accidents, incidents and emergencies involving
dangerous substances;

 Make sure that employees are properly informed about and trained to control or deal with the
risks from the dangerous substances. (This includes providing them with details of the substances
and with a copy of the significant findings of the risk assessment.);

 Identify and classify areas of the workplace/premises where explosive atmospheres may occur
and avoid ignition sources (for example from unprotected equipment) in those areas. Recording
these areas is best done by way of a plan – see section 6 on page for an example;

 Carry out a risk assessment and make a record of the significant findings of that
assessment, including the measures that have been or will be taken by the
employer/responsible person to control the risk.

 Keep a record of the risk assessment and significant findings available for inspection;

 Review the risk assessment periodically and following any significant changes.

The requirement to assess the risks from the dangerous substances should not be considered in
isolation. It should be carried out as part of the overall risk assessment required by Regulation 3 of the
Management of Health and Safety at Work Regulations 1999 rather than a separate exercise.

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  Appendix 1, attached, is a suggested format that you may wish to consider as a method of
recording the required information.

 Appendix 2 lists some of the control measures that may be necessary for each activity.

 Appendix 3 details the hazardous zones associated with a petrol filling station forecourt, along
with an example of the suggested drawing.

 Following this guidance is not necessarily the only way to comply with the legislation, however,
the advice offered here represents best practice.

3. How to complete a risk assessment

Divide the premises into areas/rooms/floors as necessary and carry out a risk assessment for each part.
You will also need to appreciate the impact one area or floor may have on other areas. During the
assessment and evaluation of the findings, you should bear in mind the following.

The recording of information within this document should be in a narrative format and not simply a yes or
no answer to a question.

Significant findings

Upon completion of the fire risk assessment, the significant findings should be recorded and the
significant findings should include:

 A record of the protective and preventative measures already in place to control the risks;

 What further action, if any needs to be taken to reduce risk sufficiently.

Review and revision

The assessment should be reviewed or revised following any of the following:-

 Any changes to legislation

 Any significant change of work practices

 Any significant change in staff levels

 Staff changes or a new group of relevant persons

 Any structural or material alteration to the premises

 Any near miss or fire

 It is recommended that the assessment be reviewed at least annually

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4. Hazardous atmospheres
All flammable atmospheres and areas should be assessed as to which zone the risk area falls into,
flammable atmospheres are classified into three hazard groups which are:

 Zone 0: That part of a hazardous area in which a flammable atmosphere is continuously present
or present for long periods or for more than 1,000 hours per annum (e.g. inside petroleum tanks)

 Zone 1: That part of a hazardous area in which a flammable atmosphere is likely to occur in
normal operation or for between 10 and 1,000 hours per annum (e.g. near petroleum filling
pumps).

 Zone 2: That part of a hazardous area in which a flammable atmosphere is not likely to occur in
normal operation and, if it occurs, will exist only for a short period or for between 0.1 and 10 hours
per annum.

5. Creating a hazardous zone plan

To assist the assessor in completing an assessment, and employees in understanding the findings and
evacuation procedures/plans it is recommended that plan drawing of the premises is prepared, which
should be attached to the risk assessment. The plan should show all flammable atmospheres and which
zone it falls into, such as:

Zone 0 areas =

 Within any access chamber or pit in which there are tanker delivery hose connection point(s).

 Within an oil separator (petrol interceptor).

Zone 1 areas =

 1m radius around the road tanker delivery and vapour return hose connections extending down to
ground level.

 1m radius along the delivery hose route from the tanker connection point(s) to the tank
connection point(s).

 1m radius from a tank fill point (above ground)

 1m radius from the edge of the chamber if fill point is below ground.

 Within petrol tank access chambers which do not have tank fill points.

 2m radius around tank venting point(s) which do not have a stage 1b vapour recovery system.

 1m radius around a venting point of an oil separator (petrol interceptor)

 Within the access chamber of an oil separator (petrol interceptor).

 Within a 4.1m radius of a petrol delivery hose connection on a dispenser (without stage 2 vapour
recovery).

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Zone 2 areas =

 4m radius of tanker delivery hose connection point(s).

 4m radius of above ground off set fill connection(s).

 1 m radius around vapour return hose connection point.

 2m radius around tank venting points where the site has stage 1b vapour recovery installed.

 2m radius from the edge of an oil separator (petrol interceptor) access chamber.

 Within a 4.1m radius of a petrol delivery hose connection on a dispenser (with stage 2 vapour
recovery in operation).

Note: additional hazardous zones are present and must be identified on sites where LPG or other highly
flammable motor fuels are stored and dispensed.

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6. Example of a hazardous zone plan

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7. Bibliography
Detailed guidance on the various standards listed in the guidance note may be obtained from the following
bibliography.

Available from… Title

Energy Institute Design, Construction, Modification, Maintenance

61 New Cavendish and Decommissioning of Filling Stations
Street London
W1G 7AR
Telephone: 020 7467 7100
Fax: 020 7255 1472
E-mail: info@energyinst.org.uk
Web: www.energyinst.org.uk

The Stationery Office Fire safety in offices and shops

(Mail, Telephone, Fax & Internet Orders) ISBN-13: 978 1 85112 815 0

TSO Orders/Post Cash Dept The Petroleum (Consolidation) Regulations

PO Box 29 2014
Norwich
NR3 1GN The Health and Safety at Work etc. Act 1974

Telephone: 08706005522 The Management of Health and Safety at

Web: www.tsoshop.co.uk Work Regulations 1999

The Dangerous Substances and Explosive

Atmosphere Regulations 2002

The Regulatory Reform (Fire Safety) Order

2005

Petroleum Enforcement Liaison Group Petrol Filling Stations Guidance on Managing The
(PELG) Risk of Fire & Explosion (The Red Guide)

Web:
http://www.energyinst.org/technical/distribution-
and-marketing/filling-stations/pelg

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UKLPG Code of Practice 1: Part 1 2009 Edition - Bulk
Camden House LPG Storage at Fixed Installations : Design,
Warwick Road Installation and Operation of Vessels Located
Kenilworth Above Ground (January 2009)
Warwickshire
CV8 1TH Code of Practice 1: Part 3 - Bulk LPG Storage at
Fixed Installations: Examination and Inspection
Email: email@uklpg.org (2012)
Web: www.uklpg.org
Code of Practice 1: Part 4 - Bulk LPG Storage at
Fixed Installations: Buried/Mounded LPG Storage
Vessels (February 2008)

Code of Practice 11 - Autogas Installations (June

2001) incorporating Amendment 3, 2003

Code of Practice 20 - Automotive LPG Refuelling

Facilities (November 2001) incorporating
Amendment 1
2004

Code of Practice 22 - Design, Installation and

Testing of LPG Piping Systems : 2011

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8. Risk Assessment (delete or amend red text as required)
Premises details

Premises Name: Use of Premises:

Address: Name of the Responsible Person:

Post Code: Position or status:

Tel:

Date of Assessment: Date of Review:

Name of Lead Risk Assessor: Risk Assessment Reviewed by:

Position: Position:

General statement of policy

Provide a statement specifying the planning, organisation, control, monitoring and review of the risk
assessment.

 Planning – How the employer proposes to complete the fire risk assessment and determine
priorities in eliminating any hazards and reducing risks to persons.

 Organisation – How the organisation is structured. To include how health and safety information
is communicated to all employees, and what their involvement has been in complying with all
aspects of the fire risk assessment.

 Control - Identify the people (at all levels) who may have responsibility for carrying out the
management of health and safety issues throughout the workplace.

 Monitoring – Identify how the employer will measure the success of the health and safety policy.
This should include regular checks of fire precautions, investigation of causes of incidents and the
recording of other relevant information.

 Review – Identify a regular review procedure to include any identified deficiencies and a process by
which they can be rectified.

Signed: Print Name: Date:

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8a. Hazardous zone plan
Create a hazardous zone plan based on your premises here.

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8b. Risk assessment (delete amend red text as required)
Significant
Risk/Hazard Existing Control Measures Findings Any Action Required (Who &
Activity Associated with (risk adequately
controlled?) time scale)
Activity
Engineered Managed Yes No
Tanker unloading  Overfill/crossover Examples: Examples:
 Impact  Overfill prevention/high  Inspection /
level alarm maintenance
 Actions by unauthorised regime
personnel  Correct labelling of fill
points/signage  Staff training
 Spillage
 Stage 1b vapour  Delivery
 Uncontrolled vapour documentation
recovery
release
 Vent pipe location  Provision of
 Fire/explosion caused personal
by ignition of vapour  Location/protection of protective
following uncontrolled fill pipes (tanker stand) equipment
release of product  Impervious surface to  Implemented
 Leak tanker stand emergency
 Drainage of tanker procedure
 Ignition sources
stand/tank fill point  Forecourt
 Collision area to a retention closed during
 Reversing tanker system. deliveries
 Driver controlled  Tanker delivery
delivery equipment area coned and
 Adequate lighting cordoned off
 Staff
 Hazardous area
classification / supervision of
suitability of equipment forecourt and
vehicle
 Provision of fire- marshalling
fighting equipment &
absorbent material

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Storage of fuel  Leak Examples: Examples:
on site  Secondary  Staff training
 Uncontrolled vapour
release containment  Third party
 Fire/explosion caused  Leak detection system statistical
by ignition of vapour  Observation /
inventory
following uncontrolled monitoring well(s) reconciliation
release of product  Wet stock
 Stage 1b vapour
recovery reconciliation
 Inspection /
 Gauge systems
maintenance
 Automated regime and
reconciliation system records of
 Cathodic protection same
 Provision of fire-  Provision of
fighting equipment and personal
absorbent material protective
equipment

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Dispensing of fuel  Leak Examples: Examples:
by members of  Spillage  Dispensers to  Staff training
public approved standard
 Fire/explosion caused  Inspection /
by ignition of vapour  Dispensers operating a maintenance
following uncontrolled stage II vapour regime
release of product recovery system  Provision of
 Vehicular impact  Labelling / signage personal
 Adequate lighting
protective
 Vapour release equipment for
 Equipment failure  Impact check valves staff
(pressurised pumping /
 Ignition sources  Provision of first
lpg)
aid kit and first
 Members of public  Position of aid training
dispenser(s) (vision /
 Implemented
impact)
emergency
 Isolation / emergency procedure
switches
 Impact protection of
dispenser(s)
 Under pump valves
(suction)
 Loud speaker system
 Impervious forecourt
surface
 Drainage of dispensing
area to a retention
system
 Electrical equipment
suitable for hazardous
zone
 Provision of fire-
fighting equipment and
absorbent material

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Carrying out  Ignition sources Examples: Examples:
repair,  Leaks  Correct equipment to  Competent
maintenance or be used in hazardous contractors /
modification  Spillage areas safety passport
 Unauthorised personnel  Provision of suitable  Staff training
 Vapour release lifting equipment  Provision
available for access personal
 Fire/explosion caused chamber covers
by ignition of vapour protective
following uncontrolled  Provision of fire- equipment
release of product fighting equipment and  Emergency
absorbent material plan
 Impacts
 Provision of cones and
 Contractors
barriers documentation:
 Adequate lighting of
 clearance
working area certificates
 method
statement
 risk
assessment
 Visitors book

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 Regulatory  Fire/explosion caused Examples: Examples:
Reform (Fire by ignition of vapour  Suitable and sufficient  Staff training
Safety) Order following uncontrolled means of escape
2005: release of product  Maintenance of
Consideration of  Suitable and sufficient fire-fighting
 Fire caused by ignition provision of fire- equipment /
staff and public of combustible fighting equipment alarms /
within associated materials.
 Fire alarms and
separation
premises (or who
may be affected as detection  Emergency
a result of a fire at  Fire resisting
plan
the premises) separation  Fire Risk
 Emergency lighting
Assessment
 Competent
 Isolation switches
persons

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