Rank: Forum user 
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Hi, looking for some help here.
Recently started with a company that specialises in upgrading new vehicles. One particular process involves removing the standard factory fitted fuel tank and replacing it with a new custom built tank.
The vehicles have around 5 litres of fuel in the tank when they arrive which requires safe removal. The tanks are fitted with anti-theft/anti-syphon devices which inhibits/makes difficult the removal of fuel from the tank. We work with both diesels and petrol vehicles.
You can buy fuel retrieval equipment (used by garage services to removal contaminated fuel from vehicles when they have been filled with wrong type of fuel) but they cannot guarantee the equipment will work on tanks fitted with anti-syphon devices.
At the moment we are removing the tanks by cutting the plastic fuel filler line and dropping the tank (with fuel in it!!). We then drain the fuel from the tank by physically removing the anti-syphon device - usually by wrenching out the plastic device with a screwdriver.
Obviously, this entire removal and retro-fit process is a concern as there is a significant risk of fire.
Does anyone have any experience of this or similar process, or provide me with some advice on writing a SSoW?
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Rank: Super forum user 
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Hi,
I've not done it in a proffesional context but have removed fuel from tanks when repairing my own cars. Are you able to uncouple the float? this usually gives direct access to the tank and you should be able to syphon all but the dreggs this way.
What are doing with the tanks that are being removed? if your not re-using them you could always fill them with something to render the fuel inert before carrying out the removal (disconnect the fuel line first so you don't contaminate the system)
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Rank: Super forum user
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Not familiar with having to remove but couldn't the fuel line to the engine be cut and then drained or so long as the tank is sealed can it no be removed if there is just 5 litres left in it. as you say you need to take precautions of a fire starting so ensuring all ignition sources are controlled or removed with be the first place to start also ensuring suitable fire extinguishers in place and employees trained how to use them as a general safety measure any way.
carried out a FRA at a large service garage that work on HGV's as well as carrying out welding and not one person could tell the correct fire extinguisher to use on a fuel fire or how to even operate a fire extinguisher seems ridiculous for such a high risk environment. especially when there was adequate provision of fire extinguisher throughout.
Phil
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Rank: Forum user
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If the old tank is scrapped, note that car recycling centres (scrapyards) now have decontamination kit that pierces and drains the tank to a closed receptacle for disposal. Sounds like you need one of these. They are commercially available as either standalone units or as a full depollution station.
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