What standards govern generator fuel system inspection and storage in Australia?

AS 1940 (Storage and handling of flammable and combustible liquids) governs bulk diesel storage including bunding venting electrical area classification spill containment and signage. AS 2790 (Electricity Generating Sets Stationary Diesel) covers fuel system maintenance for stationary diesel generators including filter and water separator service. NFPA 110 (Standard for Emergency and Standby Power Systems) specifies the on-site fuel quantity required to sustain the rated run time of an emergency standby power system. WHS Regulations 2011 Chapter 5 Part 5.1 requires the PCBU to maintain plant in safe working order which extends to the generator fuel supply system.

What is diesel bug and how is it detected?

Diesel bug refers to microbial contamination of diesel fuel by bacteria yeasts and fungi that grow at the water-fuel interface in stored diesel. It produces a black or dark grey sludge that blocks filters injectors and the transfer pump and can stall a generator within minutes of start-up. Detection involves drawing a fuel sample from the bottom of the storage tank and either visually inspecting for sludge using a dip-slide test strip (incubated for 48 to 72 hours) or sending a sample to a laboratory for culture and cetane testing. Diesel bug is most common in generators that sit idle for long periods and in coastal or humid environments.

How often should diesel fuel quality be tested?

Fuel quality should be tested every 12 to 24 months for standby generators with a documented on-site storage of more than 12 months supply. Generators in coastal humid or biofuel environments may justify annual or even six-monthly testing. The test should include water content sediment microbial growth (diesel bug) and cetane number (where required by site policy). Fuel polishing (filtration and water separation) is recommended whenever a test indicates contamination beyond the manufacturer specification. NFPA 110 references the on-site fuel run-time requirement but does not prescribe a specific testing interval so manufacturer guidance applies.

What is fuel polishing and when is it required?

Fuel polishing is the process of removing water sediment and microbial growth from stored diesel by circulating the fuel through high-efficiency filters and water separators while the fuel remains in the storage tank. It is required whenever a fuel quality test indicates contamination beyond manufacturer or AS 2790 limits or when the generator has been refuelled from an unknown source or has been in long-term standby for more than 12 to 24 months. Some facilities schedule routine fuel polishing every 12 to 24 months as a preventive measure rather than waiting for a test to fail. The polishing event is documented on the fuel system inspection record.

What is the AS 1940 bunding requirement for a generator fuel tank?

Under AS 1940 a bulk diesel storage tank must be provided with secondary containment (bunding) capable of holding at least 110 percent of the largest single tank within the bund or the volume of the largest tank plus 10 percent of the aggregate of all other tanks whichever is greater. The bund must be impervious to the stored fuel and free of cracks penetrations or unsealed drains. Bund water must be inspected before being released and managed in accordance with environmental protection requirements. Electrical equipment within the bund must comply with the hazardous area zone classification under AS/NZS 60079.

Free generator fuel system inspection checklist

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Free generator fuel system inspection checklist (PDF-ready). Covers day tank, fuel lines, filters, water separator and AS 1940 / NFPA 110 compliance.

Jarrod Milford

Commercial Director

Updated 18 May 2026

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Updated 18 May 2026

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What is a generator fuel system inspection checklist?

A generator fuel system inspection checklist is a structured form used by service technicians and facility maintenance staff to verify the condition of every component in a standby or prime power generator's fuel storage and delivery system. It covers the bulk storage tank (above-ground or below-ground) the day tank or sub-base tank the transfer pump the fuel lines and isolation valves the primary and secondary filters the water separator the injectors and the return line. The inspection also captures fuel quality testing (water content sediment microbial growth and cetane number) bunding and spill containment condition and compliance with AS 1940 (Storage and handling of flammable and combustible liquids) and NFPA 110 fuel supply requirements for emergency standby power systems.\n\nFuel contamination is the single most common cause of standby generator failure to start or fail to run during a real emergency. Diesel fuel degrades in storage through water ingress microbial growth (commonly called diesel bug) and sediment accumulation. A blocked primary filter starves the injector pump and stalls the engine within minutes of start-up. A leaking fuel line can drain a day tank between monthly tests and leave the generator unable to run when called upon. In Australia AS 1940 governs the storage and handling of diesel and other flammable liquids including bunding venting and electrical area classification. AS 2790 covers transportable generator fuel system requirements and NFPA 110 specifies on-site fuel storage capacity for life-safety standby systems. Maintaining a documented fuel system inspection per generator with photo evidence and fuel quality test results supports compliance and protects the building owner from liability after a fuel-related failure.

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Benefits of using this generator fuel system inspection checklist

Failure prevention: fuel contamination is the single most common cause of standby generator fail-to-run events and a structured inspection catches issues before the generator is called upon
AS 1940 compliance: documents bunding venting electrical area classification and storage practices required for diesel and other flammable liquids in Australia
NFPA 110 fuel supply assurance: confirms the on-site fuel quantity and condition required to sustain the rated run time of an emergency standby power system
Microbial growth detection: scheduled fuel quality testing identifies diesel bug before it blocks filters injectors and the transfer pump
Spill containment integrity: bunding alarms and shut-off valves are inspected so a fuel release is contained and does not contaminate stormwater or soil
Insurance and audit readiness: a completed fuel system inspection per generator with photographic evidence supports building compliance certificate renewal and protects the building owner during a regulator inspection

Benefits of digitising forms in MapTrack

When you digitise generator checklists in MapTrack, you get:

Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
Receive a digital PDF copy with every submission to your email.
Ability to share forms digitally.
Build conditional logic (show or hide questions based on answers).
Take pictures or attach photos. Not possible with a paper-based form.
Electronic signatures.
Edit forms later without reprinting.
Restrict permissions (who can view, complete or approve).
Build forms with AI (describe what you need and MapTrack suggests the form).
Trigger work orders automatically when a fault is logged during an inspection.
Track service intervals by hours, kilometres or calendar date in one place.
Attach supplier invoices and parts receipts to each maintenance record.

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What to include in a generator fuel system inspection checklist

This generator fuel system inspection checklist covers 10 key areas:

Generator and fuel system details: generator ID rated output fuel type bulk tank capacity day tank capacity and fuel grade specification
Bulk fuel tank: external condition (corrosion damage paintwork) gauge calibration vent and breather strainer secondary containment and bund integrity
Day tank or sub-base tank: external condition gauge level switches high and low level alarms float valve and overflow line
Transfer pump and lines: pump operation pump pressure flow rate fuel supply line fuel return line isolation valves and check valves
Primary and secondary filters: differential pressure indicator filter element condition change interval recorded and water separator bowl drained
Water separator: water content (drain a sample from the separator bowl) condition of the element and any sediment observed
Fuel quality: water content (visual or laboratory test) sediment microbial growth (lab culture or test strip) cetane number (where required by site policy) and fuel polishing history
Bunding and containment: bund free of fuel and water spill kit current and stocked emergency shut-off valve operational and fire suppression system within service date
Storage compliance: AS 1940 area classification signage manifest current dangerous goods placards in place and electrical equipment within hazardous area zone classification
Sign-off: technician name licence date defects identified corrective actions completed and next inspection due

How to use this generator fuel system inspection checklist

Inspect the bulk fuel storage tank: check the external tank condition for corrosion damage and paint peeling that exposes the steel. Confirm the level gauge calibration matches the actual fuel level. Inspect the vent breather strainer for blockage by dust insects or moisture which can collapse a tank during withdrawal. Walk the bund and confirm it is free of fuel and water and that the integrity of the bund liner is intact
Inspect the day tank or sub-base tank and transfer pump: check the day tank gauge against the high and low level switches verify the high level alarm and low level alarm operate by exercising the switches and confirming the controller indication. Run the fuel transfer pump and confirm flow rate isolation valve operation and that the return line is unobstructed. Listen for cavitation or unusual noise during pump operation
Inspect the fuel lines isolation valves and filters: walk every metre of supply line and return line and check for chafing fittings weeps and signs of fuel sweating around joints. Exercise each isolation valve and confirm the check valves are functional. Read the differential pressure indicator on the primary filter and replace the element if outside the manufacturer band. Drain the secondary filter water separator bowl and inspect for water and sediment
Test fuel quality: draw a sample from the bottom of the day tank using a clean fuel sampling pump. Visually inspect the sample for water (separated phase at the bottom) sediment and discolouration. For generators in standby for more than 12 months a laboratory test for water content microbial contamination and cetane number is recommended. Record the sample date sample location and test results on the inspection
Inspect bunding spill containment and storage compliance: confirm the bund is dry and the spill kit is current and stocked. Check the emergency shut-off valve location signage and operational test. Verify any fire suppression system covering the fuel storage is within its service date. Confirm AS 1940 hazardous area signage manifest and electrical area classification placards are in place and legible
Record findings and arrange remediation: photograph any defects record corrective actions and the responsible technician. Tag any failed components for replacement and update the asset register in MapTrack with the inspection completed corrective actions raised and the next due date for fuel quality testing and primary filter replacement

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How often should you complete this checklist?

A generator fuel system should be inspected at three levels. First a visual check of the bulk and day tank levels filters and bund should be performed monthly as part of the standard monthly exercising routine. Second a full fuel system inspection (lines pumps filters separator and bund) should be performed annually as part of the major service. Third a laboratory fuel quality test should be performed every 12 to 24 months or sooner if the generator is in long-term standby has been refuelled from an unknown source or shows signs of injector fouling.\n\nNFPA 110 requires the on-site fuel quantity to sustain the rated run time of an emergency standby power system and AS 1940 imposes inspection and maintenance requirements on bulk fuel storage installations. Generators that operate in coastal humid or biofuel environments accumulate water and microbial growth faster and should have more frequent fuel polishing and quality testing. In MapTrack each generator fuel system can be tracked as a serialised asset with inspection reminders set against calendar intervals and fuel quality test results stored against the asset record.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 1940
AS 2790
NFPA 110
AS/NZS 60079
WHS Regulations 2011 Chapter 5

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