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.
A demoutable building that has been burnt.

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

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