Oil & Fuel Hoses: Essential Maintenance and Safety Tips

The Hosemaster

March 19, 2025

Oil & Fuel Hoses: Essential Maintenance and Safety Tips

Oil and fuel play critical roles across numerous industries, from transportation and agriculture to construction and energy. However, handling the liquids carelessly can lead to severe consequences.

Robust safety precautions are a must-have, so if you use oil and fuel hoses, keep reading to learn the key maintenance and safety tips…

Why it's important to stay safe

Fuel and oil are indispensable for many different types of machinery spanning a broad range of industries, but its handling comes with inherent risks that demand vigilance. Recognising these hazards is the first step in preventing accidents and improving safety.

Fire and explosion risks

Fuel, particularly petrol and diesel, is highly flammable. Even at low temperatures, petrol emits vapours that can ignite with minimal effort. A single spark from static electricity, an electrical fault, or an open flame can trigger a catastrophic fire or explosion.

Vapours are especially dangerous as they can travel significant distances, accumulating in low-lying areas like drains or pits, where they may ignite unexpectedly.

Health hazards

Exposure to fuel and oil, and their vapours, pose significant health risks. Inhalation of fumes can lead to dizziness, headaches, or respiratory issues, while prolonged exposure may cause more severe conditions, including damage to the nervous system.

Skin contact can result in irritation, dryness, or chemical burns. In extreme cases, accidental ingestion can be life-threatening, requiring immediate medical attention.

Environmental concerns

Spills and leaks can have devastating environmental consequences. When fuel seeps into soil, it contaminates groundwater, affecting ecosystems and potentially entering drinking water supplies.

Spills on water surfaces create a slick that disrupts aquatic life and can spread over vast areas. The long-term impact includes soil degradation, loss of biodiversity, and harm to wildlife.

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With all of these in mind, it’s absolutely essential to ensure you follow proper maintenance and safety protocols to make sure that both your source material, and any oil or fuel hoses, are handled correctly.

Fuel safety precautions

Implementing robust safety measures not only protects lives but also makes sure you are compliant with regulations. Below, we’ll delve into the essential precautions for handling oil and fuel lines safely:

No smoking: this rule cannot be overstated. Smoking near fuel is a recipe for disaster, as even a stray ember can ignite flammable vapours.
Use approved containers: only use approved containers designed to prevent leaks and withstand pressure. Containers must meet relevant standards, such as British Standard 5410 for fixed tanks, OFTEC OST T100 for plastic tanks, or OFTEC OFS T200 for metal tanks.
Store correctly: store containers in ventilated areas, away from ignition sources, and use proper labelling to comply with UK regulations like the Control of Pollution (Oil Storage) (England) Regulations 2001.
Keep fire extinguishers nearby: make sure that fire extinguishers suitable for flammable liquids (Class B) are readily accessible. Regularly check that they are in working condition.
Spill response preparedness: equip your facility with spill kits containing absorbent materials, containment booms, and disposal bags. Train staff to respond swiftly and effectively to spills.
Personal protective equipment (PPE): PPE acts as the first line of defence against potential hazards. Make sure you wear the following when handling oil and fuel:

Eye protection: safety goggles shield eyes from splashes and vapours.
Hand and foot protection: chemical-resistant gloves and sturdy boots protect against spills and heavy equipment hazards.
Flame-resistant clothing: in environments with high fire risks, flame-resistant garments provide an additional layer of safety.

Regulatory compliance

Speaking of compliance, here is an overview of the key regulations and compliance requirements for handling oil and fuel in the UK:

Energy Act 2023: this introduced new powers for the Secretary of State to maintain continuity of core fuel supplies, including oil and renewable transport fuels, and to enhance industry resilience during emergencies.
Control of Major Accident Hazards (COMAH) Regulations 2015: this focuses on preventing major accidents involving hazardous substances, including oil, and ensuring preparedness for emergencies.
The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR): this addresses risks from substances that can cause fires or explosions, including fuel, and outlines safety measures for workplaces.
Oil Pollution Preparedness, Response and Co-operation (OPRC) Regulations 1998: this mandates oil-handling facilities to have contingency plans for oil spills to protect the environment.
Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations 2009 (CDG 2009): addresses the safe transport of dangerous goods, including oil and fuel, by road, rail, and waterways.
Control of Pollution (Oil Storage) (England) Regulations 2001: this requires secondary containment for above-ground oil storage containers to prevent spills and leaks.
Health and Safety at Work Act 1974: this sets out and ensures the health and safety of employees handling oil and fuel, with employer responsibilities clearly outlined.
Environmental Protection Act 1990: this addresses pollution control and waste management, including measures to prevent oil spills.
Water Environment (Oil Storage) (Scotland) Regulations 2006: this is similar to the English regulations but specific to Scotland, focusing on spill prevention and environmental protection.

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Maintaining oil and fuel hoses

We’ve covered the safety aspects of handling oil and fuel, now let’s look at the methods for correctly maintaining your hoses. Regular inspections are fundamental to maintaining hose integrity and preventing accidents. When performing an inspection, focus on these assessments:

Signs of wear: inspect hoses for cracks, abrasions, cuts, or any other signs of wear. Pay close attention to fittings and connections, as these are common failure points.
Annual hydrostatic testing: this process involves pressurising the hose with water to check for leaks or weaknesses. Hydrostatic tests reveal structural damage that may not be visible during a routine visual inspection.

Twists and kinks: incorrectly installed hoses may twist during operation, leading to internal stress and eventual failure. Check for any signs of twists or kinks, and fix where necessary.
Sharp bends: sharp bends can cause damage to the internal lining. To prevent overbending, maintain an adequate bend radius.
Sagging and abrasion: suspend hoses properly to avoid sagging. Contact with rough surfaces can lead to gradual abrasion, weakening the hose.

Implementing a regular maintenance schedule not only improves the safety of your oil or fuel hose, but also extends the hose’s lifespan, saving you time and money in the long run.

When hose replacement is necessary

Like it or not, no matter how well-maintained, hoses have a finite lifespan. They should be replaced under the following conditions:

Age: as a general rule, hoses should not be used for more than five years. Over time, materials degrade, increasing the likelihood of failure.
Degradation: signs of wear, such as cracks, hardening, or blistering, indicate that the hose has reached the end of its service life.
Incidents: if the hose has been subjected to an incident that causes structural damage, it should be replaced immediately, as unseen internal damage could compromise its integrity.
Leaks: any leakage, penetration, or significant abrasions are immediate indicators for replacement.
Environment: the environment in which the hose is subjected to can significantly impact the lifespan of the hose. This is especially true in rough environments, such as offshore vessels, where persistently harsh weather conditions can increase the rate of degradation.

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Emergency protocols

No matter how meticulous your safety measures are, emergencies can still arise when dealing with oil and fuel. The key to mitigating harm lies in having well-prepared and clearly understood emergency protocols, which must be immediately actionable to minimise damage.

1. Evacuation and notification

In the event of a spill due to hose failure, fire, or other fuel-related emergency, the first priority is to secure the safety of all personnel. Evacuate the area immediately and head to the designated assembly points. Notify the on-site supervisor or safety officer as soon as possible. If your facility is equipped with an alarm system, activate it to alert everyone on-site.

2. Contact emergency services

Provide precise details about the nature of the incident, including the type and amount of fuel or oil involved, the location, and any immediate threats. Stay on the line and follow all guidance provided by emergency personnel. Their expertise will be invaluable in managing the situation effectively.

3. Provide first aid

While waiting for the emergency services to arrive, you may be required to provide first aid to those injured in the incident. Follow these steps:

Burns: in the event of fuel-related burns, cool the affected area with lukewarm water and avoid applying ointments or creams. Seek professional medical assistance immediately.
Inhalation: for anyone exposed to vapours, move them to fresh air as quickly as possible. If they show signs of dizziness or respiratory distress, call for emergency medical help.
Skin contact: wash the area thoroughly with soap and water to remove any residue. For chemical burns or persistent irritation, seek medical attention.

4. In the event of a spill

Spills are among the most common fuel-related emergencies, and a swift, organised response can significantly mitigate damage.

Contain the spill: using spill containment systems such as absorbent booms, pads, or barriers to prevent the fuel from spreading to drains, waterways, or soil. For small spills, a quick response with appropriate materials can often prevent escalation.
Clean up properly: use absorbent materials to soak up the spill, and follow this with neutralising agents if applicable. Collect and dispose of used absorbent materials in accordance with local regulations to avoid environmental contamination.

Once the incident is over, always replace your oil or fuel hose. This is also time to evaluate your current set up and identify any recurring issues that might have led to the failure. Once corrected, you may be able to minimise the impact of future incidents.

5. In the event of a fire

In the event of a fire caused by fuel, time is of the essence. To minimise further risk, follow these steps:

Use the right extinguisher: only attempt to extinguish a fuel fire if it is safe to do so, and you have the proper equipment. Class B fire extinguishers, designed for flammable liquids, are essential.
Evacuate if necessary: if the fire is beyond control, evacuate immediately and leave it to emergency services. Personal safety should always take precedence.

Find quality oil and fuel hoses at The Hosemaster

Making sure your systems are safe should be a number one priority. This means you need to use the right oil and fuel hoses that are specifically designed for these conditions.

At The Hosemaster, we stock a huge range of hoses and fittings to fulfil your oil and fuel hose needs. We have decades of experience within the plumbing industry, which means you not only have access to superb supplies, but also expert advice when you require it.

If you have any further questions, you can get in touch with our team online, or give us a call on 01282 604 002.