What Is A DSEAR Risk Assessment? A Complete Guide To DSEAR Regulations
If your business stores, handles, or uses flammable goods, liquids, gases, or other dangerous substances, understanding your responsibilities under DSEAR is essential. A DSEAR risk assessment identifies the risks these substances can create and establishes the measures needed to protect employees, contractors and other people who could be affected.
For businesses involved in fuel storage, distribution, manufacturing, agriculture, construction and other industries where dangerous substances are present, DSEAR can be an important part of wider health and safety management. The assessment considers everything from how substances are stored and transferred to the potential for leaks, ignition and explosive atmospheres.
This guide explains what a DSEAR risk assessment is, when a DSEAR assessment is required, which substances and activities it covers, and how businesses can reduce the health risks identified. It also looks at hazardous area classification, control measures and the role of DSEAR compliance in safe fuel storage.
Key takeaways
DSEAR stands for the Dangerous Substances and Explosive Atmospheres Regulations 2002 and applies to workplaces where dangerous substances create relevant safety risks.
A DSEAR risk assessment identifies hazards associated with dangerous substances and determines how risks from fire, explosion and other harmful events can be eliminated or controlled.
Flammable liquids, gases, vapours, combustible dusts, gases under pressure and substances corrosive to metals can fall within DSEAR.
Where explosive atmospheres could occur, the assessment may need to include hazardous area classification and appropriate control of ignition sources.
DSEAR requires businesses to put suitable control and mitigation measures in place and review them when circumstances change.
What is a DSEAR risk assessment?
A DSEAR risk assessment is a structured assessment of the risks created by dangerous substances used, stored or produced in a workplace.
DSEAR is concerned primarily with risks to safety arising from dangerous substances. These include fire, explosion, harmful energetic events, and, in certain circumstances, corrosion of metal. The assessment looks at the substances present, how they are used or stored, how they could be released, and what could happen if those substances come into contact with an ignition source or otherwise create a dangerous situation.
While a DSEAR report can form part of your wider health and safety documentation, the assessment should help duty holders identify potential risks and introduce effective control measures to eliminate or reduce those risks so far as is reasonably practicable.
For a business storing diesel, petrol, LPG or other fuels, a DSEAR assessment could consider storage tanks, pipework, pumps, filling operations, dispensing equipment, ventilation, ignition sources and the potential consequences of a leak or release.
What is DSEAR and who does it apply to?
DSEAR stands for the Dangerous Substances and Explosive Atmospheres Regulations 2002. The regulations place duties on employers and the self-employed to protect people from risks associated with dangerous substances in connection with work activities. DSEAR applies where:
dangerous substances are present, used, or produced at a workplace
those substances could create a risk to people's safety
the risk arises from fire, explosion, similar energetic events, or corrosion of metals
For businesses where DSEAR applies, completing an appropriate assessment and implementing suitable controls is a legal requirement.
The regulations can therefore apply to a wide range of workplaces, including manufacturing industries handling dangerous substances, warehouses, fuel storage sites, farms, construction sites, laboratories, workshops and commercial premises.
The Health and Safety Executive (HSE) explains that dangerous substances can include liquids, gases, vapours and dusts. Examples include flammable solvents, paints, fuels, LPG and other flammable gases, combustible dusts, gases under pressure, and substances corrosive to metals.
The risks associated with a substance depend on its properties and how it is used, stored or handled at work. This makes a site-specific assessment important rather than relying solely on the classification of an individual product.
When is a DSEAR assessment required?
There's no simple list of businesses that must automatically commission a standalone DSEAR assessment. The requirement arises when businesses handling such substances are present at work and could create relevant safety risks.
If you're asking "Do I need a DSEAR risk assessment?", consider whether your workplace stores, handles, processes or produces substances that could cause a fire, explosion, or other harmful event, such as:
storing petrol, diesel or other flammable fuels
using LPG or other flammable gases
storing or handling flammable liquids and solvents
manufacturing or processing products that produce combustible dust
transferring dangerous substances between containers or tanks
charging or using processes involving gases under pressure
using substances that could create explosive atmospheres
The assessment should be proportionate to the risks involved. A small quantity of a substance stored in a controlled environment may present a very different risk from bulk storage, frequent transfer or industrial processing.
Where a substance doesn't present a relevant safety risk in the circumstances, DSEAR doesn't require additional control measures simply because the substance has a particular classification.
What are dangerous substances under DSEAR?
Dangerous substances are substances or mixtures that can create risks to safety and create health risks because of their physical properties and how they are present or used at work. They can include:
Flammable liquids
Petrol, solvents, some paints, cleaning products and other low-flashpoint liquids can produce flammable vapours that may ignite when they reach an ignition source.
Flammable gases
LPG, propane, butane and other flammable gases can create fire and explosion risks if released and allowed to accumulate.
Combustible dusts
Waste dusts produced by activities such as woodworking, food processing or certain manufacturing processes can form explosive atmospheres when dispersed in air under the right conditions.
Gases under pressure
Gases stored under pressure can present explosion and other physical risks, even where their primary hazard is not flammability.
Substances corrosive to metals
DSEAR also covers substances that can corrode metal where this could damage structures or equipment and create a safety risk.
Safety data sheets are an important source of information when identifying the properties and hazards of substances present at a workplace. However, the assessment should consider how substances are actually stored and used, rather than relying solely on their safety data sheets.
What does a DSEAR risk assessment cover?
A suitable DSEAR assessment should examine the dangerous substances present and the activities associated with them. This can include:
the properties and quantities of substances involved
how substances are delivered, stored, transferred and used
the possibility of leaks, spills or uncontrolled releases
ventilation and the potential for dangerous atmospheres to accumulate
potential ignition sources
equipment and plant used in hazardous areas
existing control measures
people who could be exposed to the risks
emergency arrangements
potential consequences of a fire, explosion or other harmful event
The initial assessment should also consider how normal operations, maintenance, cleaning, breakdowns and foreseeable failures could affect risk.
For fuel storage, this could mean examining the tank and bund, fill points, dispensing equipment, valves, pipework and electrical equipment, as well as delivery and refuelling procedures.
DSEAR and fuel storage
DSEAR is particularly relevant to businesses that store and handle fuel because petrol, diesel and other fuels can create fire and explosion risks under the right conditions. A fuel storage DSEAR assessment may consider the complete storage and dispensing system, including:
above-ground fuel tanks
bunds and secondary containment
fill points and vents
pumps and dispensing equipment
pipework and valves
fuel delivery operations
electrical and other potential ignition sources
ventilation
vehicle refuelling areas
emergency shutdown and spill response procedures
The assessment should consider both normal operations and foreseeable abnormal situations, such as overfilling, equipment failure, leaks or accidental damage.
For businesses storing significant quantities of fuel, DSEAR can therefore form an important part of a wider approach to fuel storage safety and regulatory compliance.
Explosive atmospheres and hazardous area classification
One of the important aspects of DSEAR is identifying where an explosive atmosphere could occur.
An explosive atmosphere can form when a dangerous substance, such as a flammable propellant, gas, or vapour, mixes with air in a concentration that could ignite. This can occur following a leak, spill or release, particularly where ventilation is inadequate.
Where explosive atmospheres may occur, hazardous area classification may be required. Areas are generally classified according to the likelihood and duration of an explosive atmosphere being present. For gases and vapours, the commonly used DSEAR zones are:
Zone 0: An explosive atmosphere is present continuously, for long periods or frequently.
Zone 1: An explosive atmosphere is likely to occur occasionally during normal operation.
Zone 2: An explosive atmosphere isn't likely to occur during normal operation, but could exist for a short period if it does occur.
The classification helps determine the precautions required and the equipment and protective systems suitable for use in the area. Ignition sources must also be identified and controlled.
For fuel storage installations, hazardous area classification may therefore be relevant around tank vents, fill points, pumps, dispensing equipment and other locations where flammable vapours could potentially be released.
DSEAR control measures: how are risks reduced?
DSEAR requires control measures to eliminate risks where possible or reduce risk as far as is reasonably practicable.
The preferred approach is to eliminate the hazard, such as by replacing a dangerous substance with a less hazardous alternative or changing the process. Where this is not practical, suitable control measures should be introduced. Depending on the circumstances, these may include:
reducing the quantity of dangerous substances stored
preventing or minimising releases
controlling releases at source
providing suitable ventilation
preventing the formation of dangerous atmospheres
removing or controlling ignition sources
separating incompatible substances
controlling temperature or control settings and other operating conditions
using suitable equipment in hazardous areas
providing appropriate personal protective equipment where necessary
For fuel storage systems, control measures could include bunded tanks, secure pipework, overfill protection, leak detection, ventilation, suitable electrical equipment and controls around filling and dispensing.
The assessment should also consider mitigation measures that reduce the consequences if an incident occurs. These can include fire detection, emergency shutdown systems, suitable firefighting equipment, spill response procedures and emergency arrangements.
Who can carry out a DSEAR risk assessment?
DSEAR doesn't require an assessment to be completed by someone with a particular job title or qualification. The person carrying out the assessment must have the appropriate knowledge, experience, and understanding of the risks involved.
For straightforward situations, a suitably competent person within an organisation may be able to complete the assessment. More complex installations may require a specialist DSEAR assessor with experience in areas such as hazardous area classification, fuel storage, process safety or explosion protection.
The level of competence required should reflect the complexity and potential consequences of the risks. A business operating a bulk fuel storage facility with multiple tanks, pumps, transfer systems and potentially explosive atmospheres is likely to require a considerably more detailed assessment than a workplace storing a small quantity of flammable substances in a controlled environment.
When should a DSEAR assessment be reviewed?
A DSEAR assessment should not be treated as a document that is completed once and then forgotten. It should be reviewed when there is reason to believe the existing assessment is no longer valid or when there has been a significant change that could affect the risks. Triggers for review can include:
introducing a new dangerous or hazardous substance
increasing storage quantities
installing new tanks, plant or equipment
changing production processes
modifying ventilation or storage arrangements
introducing new ignition sources
changes to hazardous area classification
an incident, spill, leak or near miss
evidence that existing control measures are no longer effective
Regular review helps ensure that the safety management system continues to reflect actual site conditions.
DSEAR compliance and record keeping
DSEAR compliance is about putting the findings of the assessment into practice, not simply having a completed report.
Where five or more employees are employed, the significant findings of the safety risk assessment must be recorded. Businesses should also maintain relevant information about dangerous substances, control measures, emergency procedures, training and maintenance.
Employees and other relevant people should understand the risks associated with the substances they work with and know how to follow the required control measures.
Clear identification of pipes, containers and other equipment can also help employees and others recognise the dangerous substances present and respond appropriately.
If an assessment identifies significant risks, those risks should be addressed rather than simply documented. Depending on the findings, this could involve changing storage arrangements, upgrading equipment, improving ventilation, controlling ignition sources or introducing additional emergency measures.
Why choose The Petrol Tank Company?
At The Petrol Tank Company, we specialise in fuel storage systems for commercial operators across the UK. Our expertise in above-ground fuel storage gives us a detailed understanding of the dangerous substances, storage arrangements and potential ignition sources that need to be considered when assessing DSEAR risk.
We can help businesses identify practical fuel storage control measures, from appropriate tank and bunding systems to safe filling arrangements, pipework and equipment. For sites where petrol, diesel or other fuels create a risk of fire or explosive atmospheres, these measures can form an important part of wider DSEAR compliance.
With a practical understanding of fuel storage and the risks associated with dangerous substances, we can help businesses ensure their storage systems support the findings of a DSEAR risk assessment. This can help reduce fire and explosion risks, strengthen safety arrangements and provide greater confidence that fuel storage is being managed appropriately.
Frequently Asked Questions
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DSEAR applies where dangerous substances are present, used or produced at work and could create a relevant risk to people's safety through fire, explosion, similar energetic events, or corrosion of metals. The assessment and control measures required should reflect the level of risk.
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Potentially. Businesses storing or handling fuels such as petrol, diesel or LPG should assess whether the substances and activities create DSEAR risks. The extent of the assessment should reflect the quantity, storage arrangements, activities and potential hazards involved.
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A DSEAR assessment should be carried out by someone with suitable knowledge, experience and competence to understand the dangerous substances and risks involved. More complex fuel storage and industrial installations may require a specialist DSEAR assessor.
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There is no single universal review interval. The assessment should be reviewed when it may no longer be valid or when significant changes could affect the risks, such as new substances, equipment, processes, storage arrangements or following an incident.
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The business must take appropriate action to eliminate or reduce the risk so far as is reasonably practicable. This may involve changing processes or storage arrangements, improving ventilation, controlling ignition sources, upgrading equipment or introducing additional mitigation and emergency measures.
