Gasoline Tank Removal/Fuel Pump
Replacement
Provided by Harleysville’s Risk Control Department
800-523-6344 ext 8100 www.harleysvillegroup.com/riskcontrol
Summary
The use and storage of flammable materials, combined with poor ventilation, and hot or spark-producing
processes all contribute to the general hazard associated with automobile repair operations. Explosions,
fires, and serious burn injuries to workers are among the more notable accidents. Many of these losses
can be linked to spilled fuel or leaking gasoline vapors ignited during the removal of a vehicle’s gasoline
tank. The specific causes of these accidents are varied, but in almost all cases, improper tools, unsafe
practices, and failure to follow approved procedures are at the root.
Automobile fuel tanks are removed for a number of reasons, including warranty work to repair or replace
fuel pumps and fuel gauge sending units, and to replace corroded, leaking, or damaged tanks from older
or crashed vehicles. The primary hazard associated with tank removal is the gasoline itself. Prior to the
removal of vehicle fuel tanks or repair work involving flame – or heat /spark producing devices – the
tanks must be safely drained and purged, or inerted, and tested according to applicable procedures
outlined in NFPA 326.
Unsafe handling of gasoline while draining tanks, including spillage, leakage, or failure to control
gasoline vapors from the tanks by proper ventilation can allow hazardous vapor accumulations in the
work area. Common sources of vapor ignition include: standard trouble lights - (which are not approved
for flammable environments), compressors, other sparking devices /tools, smoking, and nearby hot
operations – (welding, cutting, brazing, and grinding). Dropping the tanks and causing a spark, is another
common cause of fires and explosions during tank removal.
TO HELP PREVENT FIRES AND INJURIES, WE SUGGEST THE FOLLOWING:
1.
Never drain or siphon gasoline inside the building. – This is a procedure best done outside the
shop, in an area where there are no ignition sources. A Factory Mutual (FM) approved, portable
pump and storage tank designed for this purpose, and used in accordance with manufacturer’s
instructions, is an acceptable alternative.
2.
Organize the work area and provide the proper equipment for the job. – Get all the tools you’ll
need and have everything arranged so they are handy. Use the right tools for the job, especially
those used to drain and store the gasoline. Be sure the work area is free of trip and slip hazards, and
the floor is free of grease and oil. (Use only approved water-solutions or detergents, floor sweeping
compounds, and grease absorbents.) Make sure that there is adequate clear aisle space to permit
ready access to and the use of fire fighting equipment.
3.
Completely ventilate the shop before starting the work. – Since there will be fuel and gasoline
vapors present, eliminate all potential sources of ignition, such as cutting and welding, open-face
drop lights, portable heaters (that should never be allowed in the shop), static, and smoking.
4.
Review the guidelines below, and establish standard safe work procedures. Be sure that all
employees know and follow them. - Allow adequate time to do the job, so you or your employees
won’t be tempted to rush or take shortcuts.
This information may not address all hazardous conditions at your location
and does not warrant workplace safety or compliance with federal, state or local laws.
LCT 1000 (08/08)
Copyright 2008 Harleysville Mutual Insurance Companies
All rights reserved
Page 1 of 3
GASOLINE TANK REMOVAL PROCEDURES — INSIDE OF THE BUILDING.
This work should only be performed in a manner using National Fire Protection Association Standard
30A, Section 9.7.5 – Code for Motor Fuel Dispensing Facilities and Repair Garages as a guideline. This
standard allows the use of an approved portable pump and storage tank in lieu of draining the fuel tank
outside the building. A standard safe work procedure should be developed and followed that includes –
but is not limited to - the following:
1.
The area where the gasoline tank is drained and removed from a vehicle must be adequately
ventilated. Further, it must be isolated from activities and equipment that could cause an ignition of
the vapors.
2.
The vehicle battery should be disconnected. – (Disconnect the negative battery cable.)
3.
A Factory Mutual (FM) approved gasoline removal device (pump and portable storage tank)
should be obtained /used. - It should be used whenever gasoline is removed from vehicle tanks.
The transfer of all gasoline should take place outside of the building. All fuel drained from a
gasoline tank that is not to be disposed of should be stored in a UL-listed or FM approved safety can
or returned to standard underground storage tanks. Fuel to be disposed of shall be stored in tanks or
drums suitable for such purpose that are located outside the building until removed from the
premises. Such containers should be identified /labeled as having flammable contents
4.
Self-crimping radiator type clamps should seal all lines coming off of the tank. - This will help
control gasoline drips and vapors coming out of the lines.
5.
The tanks should be removed from the vehicle and then immediately taken outside of the building.
6.
A fire extinguisher rated for gasoline fires (Class B) should be on hand and readily accessible.
7.
In situations where the tank removal is done to facilitate fuel pump replacement, a non-sparking
chisel and non-sparking hammer should be used to knock out the locking ring and remove the old
fuel pump. The new fuel pump should then be installed. The fuel tank should be brought back into
the building and re-installed in the vehicle.
6.
The vehicle should be rolled out of the building and gasoline transferred back into the vehicle from
the approved removal and storage device.
Attached is an example of fuel transfer equipment that has received Factory Mutual approval. There are
other brands of fuel transfer equipment available; this device is shown only as an example. Please note
that all fuel transfer units must be used according to manufacturer instructions. This includes attaching
the grounding wire that is provided.
For additional information or assistance, please contact the Home Office Risk Control Central Services
Division at 1-800-523-6344, Ext. 8100.
This information may not address all hazardous conditions at your location
and does not warrant workplace safety or compliance with federal, state or local laws.
LCT 1000 (08/08)
Copyright 2008 Harleysville Mutual Insurance Companies
All rights reserved
Page 2 of 3
Goodall©
Gas•All Fuel Transfer Unit
53-526
ProTech Gas-All® Fuel Transfer and Storage Unit.
Two way rotary pump for siphoning or dispensing. Works great for
repairing today's hard to reach "in-tank" fuel pumps. Excellent for
shops, car lots, salvage yards and rental outlets. The two wheel
dolly design is easy to move.
Meets OSHA & FM Standards.
UPS/RPS Shipable.
High quality, rebuildable pump.
Flame arrestor neck/2" filler.
8' clear vinyl hose, 1/2" OD.
Ground wire and clamp.
14 ga. welded steel, powder coated.
Capacity: 25 gallons.
Dimensions: Height 42", width 20", depth 22".
Shipping weight: 85 lbs.
Goodall Mfg. Co.
7558 Washington Ave. So.
Eden Prairie, MN 55344
Call Toll Free 1-800-328-7730
Fax Tall Free 1-800-323-2617
www.goodallmfg.com
Information presented here was obtained from Goodall Mfg. Co. and other sources. Harleysville Insurance Company does not
recommend or endorse any specific products or manufacturers. This information is presented as an example of the type of
product which should be used to safely and effectively remove fuel from gasoline tanks as part of an overall standard procedure
for fuel tank work. There are numerous sources available on the Internet that provide detailed information on the removal of
various automotive components. Many of these instructions are manufacturer and vehicle-specific and include procedures on
how to relieve fuel system pressure and warnings about adjacent systems that could be affected in the tank removal. The specific
manufacturer’s procedures should be consulted prior to performing this operation.
Related Information:
1. What You Need To Know About …Auto Repair - [
http://autorepair.about.com/library/weekly/aa093000a.htm ]
2. Ontario Ministry of Labour – Alert: Gasoline Tank Removal [http://www.gov.on.ca/lab/ohs/i033.htm ]
The information and suggestions contained in this data sheet have been developed from sources believed to be reliable.
However, we accept no legal responsibility for the correctness or completeness of this material or its application to specific
factual situations.
This information may not address all hazardous conditions at your location
and does not warrant workplace safety or compliance with federal, state or local laws.
LCT 1000 (08/08)
Copyright 2008 Harleysville Mutual Insurance Companies
All rights reserved
Page 3 of 3