Competent person forecourt operations

1. Competent Person Training for
Forecourt Operations
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2. Introduction
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Aim of this Training Programme
This training programme is directed at those with a
responsibility for the safe operation of retail stores where
petrol, other flammable liquids and fuels are stored and
dispensed into vehicle fuel tanks
The following modules will be covered:
 Responsibilities
 Fuels and Ignition Sources
 The Forecourt
 Dispensing
 Emergencies
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3. Responsibilities
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4. Responsibilities
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Outcomes for this Section
On completing this module you should understand
your responsibilities in relation to the nature of the
work you are asked to undertake

5. Responsibilities
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The site owner or operator must ensure that every
employee at a retail store fulfils the definition of a
competent person for the task they are required to
perform.
Tasks covered in this training include:
 Forecourt Controller: supervising & authorising
dispensing of fuel
 Forecourt Operative: working on the forecourt
A Competent Person means a person who possesses
sufficient training, experience and knowledge
appropriate to the nature of the work to be
undertaken. This training programme will give you
much of the training and knowledge you need.
Note that supervising deliveries of fuel by road
tanker is not covered in this training programme

6. Responsibilities
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You should be aware of the specific hazards and risks
associated with the storage and dispensing of petrol,
other flammable liquids and fuels.
You are responsible to take reasonable care not to
put other people - fellow employees, contractors and
members of the public - at risk by what you do or
don't do in the course of your work.
You should know how to operate any equipment
needed for your work including how to recognise and
report faults.
You should know what to do if something is wrong or
if there is an emergency.
Talk to your employer and discuss any concerns you
may have in relation to health and safety at the retail
store.

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Fuel & Ignition Sources
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8. Fuel & Ignition Sources
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Outcomes for this Section
On completing this module you should understand
the nature of the flammable liquids and fuels at the
retail store
Topics:
 Petrol
 Diesel & Kerosene
 Flash Point
 LPG
 Ignition Sources
 Health & Environmental Effects

9. Petrol
Petrol (or Unleaded Petrol) is a volatile liquid and
gives off flammable vapour at ambient
temperatures. This vapour is invisible
This vapour, when mixed with air in certain
proportions, forms a highly flammable atmosphere,
which can burn or explode if ignited
Petrol vapour is heavier than air. It does not disperse
easily in still air conditions and tends to sink to the
lowest level within its surroundings.
Fuel & Ignition Sources
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Petrol

10. Fuel & Ignition Sources
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Petrol
Flammable vapours will be released when petrol is
being handled or transferred, such as:
 Filling cars
 Filling containers
 Spillage
 Tanker unloading
A flammable atmosphere may exist around hose
connections, openings in petrol tanks and above
spilled petrol

11. Fuel & Ignition Sources
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Petrol
A flammable atmosphere may occur in an empty
petrol tank. It may also occur near clothing or other
absorbent materials or substances, which have been
contaminated with petrol
Petrol floats on water and, if it is spilt or leaks into
the ground, can be carried long distances by
watercourses, ducts, drains or groundwater. This can
lead to a fire or explosion hazard some distance from
where the petrol was actually released

12. Fuel & Ignition Sources
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Diesel & Kerosene
Diesel, Marked Gas Oil and Kerosene are not flammable at
ambient temperatures except in the following situations: -
• When heated or involved in a fire they will give off
flammable vapour. Once ignited these fuels will burn
fiercely.
• When diesel mist or spray is generated such as during
fast fill pumping and pumped deliveries to an
overground tank
These products are also heavily polluting as they will not
evaporate and will remain in the soil or groundwater
indefinitely.
Adblue
AdBlue is a liquid used to reduce the nitrous oxide
emissions of diesel engines. It is non-toxic and non-
flammable.

13. Fuel & Ignition Sources
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LPG
LPG stands for Liquidified Petroleum Gas. It is stored
under pressure in bottled gas form or bulk tanks. If
released in to the atmosphere the liquid immediately
vapourises.
This vapour, when mixed with air in certain
proportions, forms a highly flammable atmosphere,
which can burn or explode if ignited.
The gas is heavier than air and does not disperse
easily under still conditions or in poorly ventilated
areas. Like petrol vapour LPG tends to sink to the
lowest level of its surroundings and may accumulate
in access chambers, cavities, pits, drains or other
depressions.

14. Fuel & Ignition Sources
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Ignition Sources
When a flammable vapour to air mixture is exposed
to an ignition source a fire or explosion may occur.
This is referred to as a “Fire Triangle”. Three
elements – Oxygen, Ignition Source and a Fuel
Source are required before a fire or explosion can
occur. On a petrol forecourt it is vital that ignition
sources are controlled.

15. Fuel & Ignition Sources
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Ignition Sources
Possible ignition sources at a retail store can include:
 Smoking, use of lighters or matches
 Car engine running including exhaust gases and
ignition sparks
 Static electricity from fuel flow
 Electrical equipment (unless designed specifically
for the purpose)
 Mobile phone
 E-Cigarettes
 Battery operated devices
 Sparks
 Arson

16. Fuel & Ignition Sources
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Health & Environmental Effects
Long term and repeated skin contact with petroleum
products can cause dermatitis. You should always
wear suitable gloves when cleaning or touching any
surfaces that may be contaminated with petroleum.
Swallowing any petroleum product, eye or skin
contact is harmful to your health.
Excessive exposure to petrol vapour can be harmful
to your health when inhaled.
Petroleum products are harmful to the environment
and will contaminate soil and groundwater.

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The Forecourt
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18. The Forecourt
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Your supervisor should show you the position of the
following installations at your site:
 Tank manhole chambers
 Overground tanks (if applicable)
 Fill points for tanker unloading
 Vents for fuel tanks
 Fuel dispensers for vehicles
 Stage 1b vapour recovery system
 Stage 2 vapour recovery system (if applicable)
 Petroleum drainage channels and gullies
 Oil Interceptor access chamber(s)
 Oil Interceptor alarm (if applicable)
 Tank gauge
 Tank or line leak detection systems (if applicable)
 LPG Installations (if applicable)

19. The Forecourt
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Outcomes for this Section
On completing this module you should understand
how flammable liquids and fuels are stored, handled
and dispensed at the retail store
Topics:
 Fuel Storage
 Vapour Recovery Systems
 Drainage
 Hazardous Zones
 LPG
 Working on the Forecourt

20. The Forecourt
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Fuel Storage
Petrol, Diesel and other flammable fuels are
generally stored in underground steel tanks.
Modern tanks are double skin with a leak
detection system built into the space between the
tank skins.
Older tanks are single wall steel construction with
no leak detection systems.
These tanks are accessed through the tank
manhole chambers which you can see on your
forecourt.
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21. The Forecourt
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Fuel Storage
Pipework is connected to the tank manhole cover
and connects the tank to the fill points, vent pipes
and dispensers (petrol pumps).
Modern pipework is specially designed plastic
pipework, sometimes with double wall pipework
system to control any possible leaks.
Older pipework is galvanised steel.
Underground pipework may be checked for defects
or leaks by looking into the tank manhole chambers.
Pipework
Tank Manhole Chamber

22. The Forecourt
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Fuel Storage
Diesel, Marked Gas Oil and Kerosene may be
stored in overground steel or plastic tanks.
Overground tanks should be provided with a bund
to capture any spills or leaks.
Note that some overground tanks are self-bunded.
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23. The Forecourt
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Fuel Storage
Tanker Unloading is a hazardous activity due to the
large quantities of flammable liquids involved.
All unloading operations need to be supervised by
a competent person unless the site is approved for
Driver Controlled Deliveries.
Such a competent person needs specialised
training and this is not covered in these training
modules.
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24. Fuel Storage
Petrol is discharged from the road
tanker through the fill pipes into the
underground tanks. As the liquid in
the underground tank rises, the
vapour is forced up the vent pipe
and discharged to air at the top of
the vent pipe.
Petrol vapour is heavier
than air so it sinks to
lower levels when it
escapes from the vent
pipe.

25. The Forecourt
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Fuel Storage
The tank contents are measured by an electronic
tank gauge or in some cases physical dips. You
should be aware of the location of the tank
gauge, how it is operated and how to get a print-
out.
The following information is obtained from the
tank gauge:
 Tank number and grade
 Capacity
 Ullage (the volume or empty space left in the
tank)
Any alarms showing on the tank gauge should be
investigated.

26. The Forecourt
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Petrol is pumped from the underground
tank to the dispenser and into the tank
of a customer’s car. As the car tank fills
with petrol, vapour is discharged
through the fill pipe to the atmosphere.
Vapour sinks to ground level as it
escapes from the tank.
Fuel Storage

27. The Forecourt
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Fuel Storage
The actual pump is normally contained in the
housing of the dispenser and draws the product from
the tank – known as a “SUCTION SYSTEM”. At some
sites there is a submersible pump in the tank
chamber that pushes the product into the
customer’s tank – known as a “PRESSURE SYSTEM”.
Pressure Systems are higher risk sites due to the
potential for more serious pipeline leaks caused by
the high pressure of fuel in the lines.
Suction Pump
or
Pressure Pump

28. Vapour Recovery Systems
To reduce the amount of petrol vapour
being released into the atmosphere
during petrol deliveries a Vapour
Recovery System is fitted. A vapour
return pipe is fitted to the vent
capturing the vapour and returning it
to the tanker through the vapour
recovery hose.
Pressure relief vent
This is known as a Stage
1b Vapour Recovery
System

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The Forecourt
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Vapour Recovery Systems
This is a typical vent stack with a Stage
1b vapour recovery system fitted to
the petrol vents
(the vapour recovery manifold is the
horizontal pipe connected to the 2
petrol vents at the top of the vent
stack)
The diesel tanks are not connected to
the manifold and are free venting.

30. The Forecourt
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Vapour Recovery Systems
Stage 2 vapour recovery captures
petrol vapour being released into the
atmosphere during petrol dispensing.
A co-axial nozzle and hose draws
vapour from the filler of the car’s fuel
tank. This vapour is pumped back into
the underground tank. All petrol filling
stations built or modified after 2012
should be fitted with Stage 2 vapour
recovery pumps.
Stage 2
Vapour Recovery System

31. The Forecourt
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Vapour Recovery Systems
A typical Stage 2 vapour recovery nozzle looks like
this.
Petrol
Pumped out
Vapour
sucked in

32. The Forecourt
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Drainage
There is a risk of spillage of petroleum at the tanker
off-loading area and at the dispensing area.
Drainage systems can be gully traps, channel drains
or slot channel drains. It is important that all
drainage systems are maintained clean against the
build-up of leaves, dirt or other material.
Slot Channel & Road Gully
Drainage Channel

33. The Forecourt
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Drainage
These areas are drained to an underground oil
interceptor which will capture any spilled product.
Oil will float on water so it will separate in the
interceptor chamber. The oil can be removed by
specialist vacuum tanker.
There are two main types of interceptor:
A single-chamber interceptor with a minimum
capacity of 7,600L and coalescer filter will contain
small to larger size petroleum spillages.
Single Chamber Interceptor

34. The Forecourt
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Drainage
A three-chamber interceptor has a capacity
of approximately 2,000L and will contain
small to medium size petroleum spillages.
These are generally in place at older sites.
All interceptors should be checked for the
build-up of petroleum. Some single-
chamber interceptors will be fitted with an
oil-alarm.
Three Chamber Interceptor

35. The Forecourt
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Hazardous Zones
ATEX (Atmosphere Explosive) is the name
commonly given to European Directives for
controlling explosive atmospheres.
Under the ATEX Directive the retail store must be
zoned on the basis of the probability of an
explosive vapour mixture forming.
Hazardous areas are classified into three
categories or zones.

36. The Forecourt
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Hazardous Zones
Zone 0: That part of a hazardous area in which a
flammable atmosphere is continually present or
present for long periods.
Zone 1: That part of a hazardous area in which a
flammable atmosphere is likely to occur in normal
operation.
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 for a
short period.
Hazardous zones at a petrol filling station are shown
in the following diagrams.

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41. The Forecourt
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Hazardous Zones
All retail stores should have a site-specific
Hazardous Area plan showing the hazardous
zones at your site.
You should be aware of these areas and the need
to prevent ignition sources.

42. The Forecourt
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Hazardous Zones
Equipment and protective systems intended to
be used in zoned areas are selected to meet the
requirements of the ATEX Directive.
The most prominent items of equipment in a
hazardous zone on the forecourt are the fuel
pumps (dispensers)
An ATEX reference is displayed on the ID Plate on
the dispenser along with an “Ex” symbol
demonstrating that it is safe to use in a
hazardous zone.

43. The Forecourt
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LPG
LPG Cylinders
Cylinders should be stored in a locked cage in a
safe area. The cage should be fitted with
suitable warning signs.
Customers should not be allowed to bring LPG
cylinders into the shop.
LPG cylinders should be checked for leaks by
ensuring the seal is intact before they are
supplied to customers.

44. The Forecourt
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LPG
Autogas
LPG is stored and dispensed under pressure in
specialised overground tanks and dispensers.
The hazardous zones for these tanks and
dispensers should be detailed in the hazardous
area plans.
The dispenser and pumps should comply with
the ATEX Directive.

45. The Forecourt
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Working on the Forecourt
There is a constant level of vehicular traffic on the
forecourt. All staff & contractors working on the
forecourt or anywhere outside the building must
wear hi-visibility clothing.
If any significant work activity is being organised on
the forecourt the work area should be cordoned off
with bollards, traffic cones or even a work vehicle.
Suitable safety footwear should be worn on the
forecourt including steel toe-caps.
Cleaning and other forecourt tasks ideally should
take place during quite periods. Suitable gloves
should be worn when cleaning.

46. The Forecourt
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Working on the Forecourt
You should be aware of the positions of fire extinguishers
on the forecourt and how to operate them. These are
generally Dry Powder extinguishers.
You should also be aware of the position of oil absorbent
material and how it is used. For minor fuel spills you
should cordon off the area and clean up the spill as soon as
they occur.
Good housekeeping practices should be followed on the
forecourt at all times. In particular:
 Don’t allow combustible material, such as cardboard,
accumulate close to buildings or hazardous areas
 Remove any trip hazards such as incorrectly stored air-
hoses, manhole covers not seated correctly etc

47. 47
Dispensing
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48. Dispensing
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Outcomes for this Section
On completing this module you, as a forecourt controller,
should understand how to dispense flammable liquids and
fuels in a safe manner
Topics:
 Preparation
 Dispensing Procedures
 General Information
 Approved Containers

49. Dispensing
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Preparation
You should know how to operate the following equipment,
and how to recognise and reports faults:
 Point of Sale / Pump Controller equipment - activating
and controlling dispensers on the forecourt
 CCTV systems – shows views of all dispensing activities
 Emergency Pump Stops & Firemans Switch – shuts
down dispensing at all dispensers
 Public address system – allows communication with
customers on the forecourt
 Telephone - for contacting the emergency services if
required

50. Dispensing
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Preparation
Dispensers, especially hoses and nozzles, should be visually
checked before the site is opened for business to ensure
that no accidental or malicious damage has occurred whilst
the forecourt is closed.
You should be aware of the proper procedures to be
followed by customers using the dispensers on the
forecourt
Before you authorise a dispenser, you should ensure each
vehicle and the person using the dispenser can be seen
and that your view is not obstructed.

51. Dispensing
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Dispensing Procedures
If customers are not following safe procedures during
dispensing or the dispenser develops a fault, you should
stop dispensing at that pump and warn the customer.
If there is a fire, spill, leak, or other emergency during
dispensing, those operations should be stopped, the pump
stop activated and the nozzles returned to their housings.
Dispensing should not be restarted until all faults affecting
safety have been corrected or any incidents have been
dealt with.

52. Dispensing
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Dispensing Procedures
Persons under 16 years of age should not be sold petrol or
allowed operate dispensers. Ask for identification if
necessary.
Petrol should be dispensed only by means of forecourt
dispensers into the fuel tanks of internal combustion
engines (i.e. on cars, motorbikes, boats etc.) or into
suitable containers.

53. Dispensing
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Dispensing Procedures
No sources of ignition should be permitted during
dispensing of petrol, in particular:
 Customers should not be allowed to smoke, vape or use
smoking materials when dispensing petrol or within the
hazardous area associated with dispensers
 Customers should not use their mobile phone or any
other electrical device while dispensing petrol
 Engines of vehicles should be switched off before
dispensing starts
 Car doors should remain closed in case there is a source
of ignition in the car

54. Dispensing
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Dispensing Procedures
Pump hoses should not be kinked or over-
stretched.
When filling motor cycles with petrol the rider or
passenger should not be permitted to remain
seated on the machine.
After dispensing, nozzles should be firmly stowed
in their housing.

55. Dispensing
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General Information
Mobile phones may be used for pay-at-the pump facilities
but not during dispensing.
During dispensing of diesel there is no significant risk of
ignition. However, the procedures for petrol should be
followed for consistency of behaviour on the forecourt, and
in case anyone is dispensing petrol at an adjacent
dispenser.

56. Dispensing
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Approved Containers
Petrol should only be dispensed into approved portable
containers. There are generally two types of approved
containers
A plastic container
 Capacity 5 litres
 Made specifically for the purpose of containing petrol
 Marked or labelled with the words “Petrol” and “Highly
Flammable”

57. Dispensing
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Approved Containers
A metal container
 Capacity up to 20 litres
 Made specifically for the purpose of containing petrol
 Marked or labelled with the words “Petrol” and “Highly
Flammable”

58. Dispensing
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Approved Containers
Where portable containers are to be filled with petrol they
should be removed from inside vehicles and placed directly
on the ground.
Containers should be securely closed as soon as dispensing
finishes.
Customers should not be allowed to take filled or used
containers into the shop when paying for petrol.
If a customer plans to fill more than two containers with
petrol the site manager/supervisor should be informed so
that appropriate procedures are agreed and followed.

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Emergencies
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60. Emergencies
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Outcomes for this Section
On completing this module you should understand
how to react in any given emergency situation.

61. Emergencies
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Personal Safety
In any emergency situation you should always ensure
to take care of your own personal safety first and
foremost.
You should know, or have access to, the correct site
address including Eircode if needed when summoning
the emergency services.
Talk to your employer and discuss any concerns you
may have in relation to the correct course of action to
be taken in any emergency situation.

62. Emergencies
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Small Spillage
In the event of a small petrol or diesel spillage on the
forecourt:
 Alert other staff members or site management
 Shut down the dispenser if this is where the spill
occurred
 Cordon off the area with cones or other measures
 Small diesel spill: clean up with absorbent material and
dispose of safely
 Small petrol spill: wash into the interceptor drainage
system. It is acceptable to clean a petrol spill with
absorbent but be aware that the absorbent material
will remain flammable for a period of time and should
be treated accordingly

63. Emergencies
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Large Spillage
In the event of a large-scale petrol or diesel spillage, or
large-scale fire:
 Alert other staff members or site management
 Shut down all dispensers using the emergency pump
stop button
 Dial 112 or 999 and summon the Fire Service
 Close the site and evacuate all persons to the Assembly
Point
 Alert adjacent properties and persons in the case of a
large-scale fire or petrol spill

64. Emergencies
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Small Scale Fire
In the event of a small-scale fire, such as a waste bin fire:
 Alert other staff members or site management
 Shut down all dispensers using the emergency pump
stop button
 Attempt to extinguish the fire with an appropriate fire
extinguisher

65. Emergencies
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Splashes
In the event of a customer getting splashed with petrol on
their clothes:
 Keep customer away from sources of ignition and warn
them of the danger of catching fire
 Contaminated clothing should be removed. Ideally,
splash or spray water on the clothes to reduce the risk
of a static electricity spark
 If necessary, provide customer with paper overalls and
allow customer to use toilet facilities
 Inform customer that any contaminated skin should be
washed thoroughly
 Provide customer with a bag to retain clothing in,
preferably to be stored in the boot of the car. Inform
customer that clothing should be washed before
wearing and that they should refrain from smoking
whilst clothing is inside the vehicle or is worn.

66. Emergencies
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In the event of violence, personal injury,
robbery or other crime:
 In a robbery situation stay calm and follow
the robber’s instructions
 Raise the alarm using the panic button or
phone when it is safe to do so
 Call emergency services as required: Gardaí
/ Ambulance / Fire Service

67. Emergencies
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In the event of violence, personal injury, robbery or
other crime
 Provide assistance to any injured party and, if
appropriate, treatment
 Close the retail store and write down a
description of the robbers and/or details of the
incident
 Obtain names and contact details of any
witnesses
 Go to a safe place and wait for assistance
 Report the details to site management

68. Key Points
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A Competent Person means a person who possesses sufficient training, experience and knowledge
appropriate to the nature of the work to be undertaken. This training programme will give you
much of the training and knowledge you need.
You should be aware of the specific hazards and risks associated with the storage and dispensing of
petrol, other flammable liquids and fuels.
You are responsible to take reasonable care not to put other people - fellow employees, contractors
and members of the public - at risk by what you do or don't do in the course of your work.
You should know the procedures required to carry out the task assigned to you and how to operate
any equipment needed for your work including how to recognise and report faults.
You should know what to do if something is wrong or if there is an emergency.
Flammable vapours will be released when petrol is being handled or transferred, such as Filling cars
/ Containers, Spillages & Tanker unloading.
When a flammable vapour to air mixture is exposed to an ignition source a fire or explosion may
occur.
On a petrol forecourt it is vital that ignition sources are controlled.
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69. Assessment (pass mark 80%)
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