Generator refuelling (11 December 2023)
A 20-year-old casual worker who was collecting and analysing grain samples became seriously injured when a newly purchased petrol-powered generator exploded. The explosion happened while the generator was being refuelled with a jerry can. The generator was expected to operate consistently for 14 hours and required refuelling about every 2 hours to constantly power a demountable office building and its equipment. The fire destroyed the generator and the demountable office building, and the young worker sustained severe burns to her face and body.
![Close up of a burnt generator.](https://www.safework.nsw.gov.au/__data/assets/image/0005/1291145/generator-refuelling-1.jpg)
![A demoutable building that has been burnt.](https://www.safework.nsw.gov.au/__data/assets/image/0006/1291146/generator-refuelling-2.jpg)
Photos of the burnt generator and demountable office building.
Safety information
Consider ‘reasonably practicable’ control measures to manage the risks associated with generator refuelling.
Ensure:
- a risk assessment is undertaken to ensure control measures are in place to eliminate any heat and possible ignition sources and control the accumulation of flammable and combustible substances when refuelling
- prior to refuelling, the engine and all electrical equipment are turned off and the engine allowed to cool as per the manufacturer’s instructions
- you follow manufacturer's recommendations, and operating procedures
- you establish designated refuelling areas on firm ground or earth and in a well-ventilated location
- you have suitable firefighting equipment in good working order that is easily accessible
- you use approved fuel containers and funnels to reduce the risk of generating static electricity while decanting petrol
- you provide instruction, training and supervision to all workers on the safe use, storage and handling of hazardous chemicals
- you wear appropriate personal protective equipment for the task.
Related guidance material
Further information
- Traumatic event management plan – SafeWork NSW
- Mental health at work – NSW Government
- Speak Up Save Lives App – SafeWork NSW
- Subscribe to SafeWork NSW newsletters and updates