National Renewable Energy Laboratory 

Innovation for Our Energy Future 

A national laboratory of the U.S. Department of Energy

Office of Energy Efficiency & Renewable Energy

NREL is operated by Midwest Research Institute ● Battelle Contract No. DE-AC36-99-GO10337 

Assessment of the O2Diesel 

Operational Safety Program 

December 23, 2002 — June 30, 2007 

TIAX LLC 

Cupertino, California 

Subcontract Report 

NREL/SR-540-39720 

June 2006 
Assessment of the O2Diesel 

Operational Safety Program 

December 23, 2002 — June 30, 2007 

TIAX LLC 

Cupertino, California 

Prepared for 

O2Diesel, Inc. 

Newark, Delaware

NREL Technical Monitor: Kenneth Proc 

Prepared under Subcontract No. ZCL-3-32068-01 

Subcontract Report 

NREL/SR-540-39720 

June 2006 

National Renewable Energy Laboratory

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Operated for the U.S. Department of Energy 

Office of Energy Efficiency and Renewable Energy 

by Midwest Research Institute • Battelle 

Contract No. DE-AC36-99-GO10337
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Table of Contents 

List of Figures........................................................................................v 

List of Tables........................................................................................v 

Acronyms and Abbreviations.....................................................................vi 

Executive Summary........................................................................................................ vii 

Introduction........................................................................................................................1 

Overview of O2Diesel Safety Program .............................................................................3 

Development of the Field Assessment Protocol ................................................................6 

O2Diesel Site Inspections in Accordance with the Approved Protocol ............................8 

Site 1 — Nellis Air Force Base, Las Vegas, Nevada .............................................8 

Site 2 — E.J. Harrison & Sons, Ventura, California...........................................11 

Site 3 — Johnson County Transit, Olathe, Kansas..............................................13 

Site 4 — Lincoln StarTran, Lincoln, Nebraska....................................................16 

Results and Recommendations........................................................................................21 

Conclusions......................................................................................................................23 

References ..................................................................................................................26

Appendix A. CARB Verification of Emission Reductions for O2Diesel Fuel........... A-1 

Appendix B. O2Diesel Operator/Handler Training & Required Product Guidelines.B-1 

Appendix C. Site Manager Interview..........................................................................C-1 

Appendix D. General Site Personnel Questions......................................................... D-1 

Appendix E. Mechanic Interview ...............................................................................E-1 

Appendix F. Fuel Handler Interview .......................................................................... F-1 

Appendix G. Vehicle Operator Interview................................................................... G-1 

Appendix H. Site Infrastructure Checklist ................................................................. H-1

iv
List of Figures 

Figure 1. Safety sticker for O2DieselTM-fueled vehicles.......................................... 4 

Figure 2. O2DieselTM station at Nellis Air Force Base............................................. 9 

Figure 3. Blue Bird bus arriving for fuel at Nellis Air Force Base .......................... 9 

Figure 4. Flame arrestor and O2Diesel sticker on Blue Bird bus at Nellis Air Force 

Base......................................................................................................... 10 

Figure 5. Air Force personnel records data in a fuel log book at Nellis Air Force 

Base......................................................................................................... 10 

Figure 6. Eye wash station and safety-related postings located by O2DieselTM site at 

Nellis Air Force Base.............................................................................. 11 

Figure 7. Refuse hauler operating on O2Diesel at E.J. Harrison & Sons............... 12 

Figure 8. Fuel tank and O2Diesel sticker on refuse hauler at E.J. Harrison & Sons12 

Figure 9. Flame arrestor in place on refuse hauler fuel tank at E.J. Harrison & Sons

................................................................................................................. 13 

Figure 10. Emergency fuel shut-off button at Johnson County Transit ................... 14 

Figure 11. O2Diesel fuel dispenser at Johnson County Transit................................ 14 

Figure 12. Outside of O2Diesel fuel port on storage tank at Johnson County Transit15 

Figure 13. Inside of O2Diesel fuel port on storage tank at Johnson County Transit 15 

Figure 14. Transit bus fueled with O2Diesel at Lincoln StarTran............................ 17 

Figure 15. Flame arrestors and desiccant filters on underground storage tanks at 

Lincoln StarTran ..................................................................................... 17 

List of Tables 

Table 1. Site Manager Interviews......................................................................... 18 

Table 2. Other Site Personnel Interviews.............................................................. 19 

Table 3. Site Infrastructure Inspections................................................................ 20

v
Acronyms and Abbreviations 

AFB Air Force Base 

CARB California Air Resources Board 

DoD U.S. Department of Defense 

E-diesel ethanol-diesel 

FMEA failure mode and effects analysis 

JCT Johnson County Transit 

MSDS Material Safety Data Sheet 

NREL National Renewable Energy Laboratory 

vi
Executive Summary

O2Diesel, Inc. is currently commercializing an ethanol-diesel (E-diesel) blended fuel product, 

known commercially as O2DieselTM∗

 fuel—for use in heavy-duty, diesel-powered fleet vehicles 

and other equipment—that offers the advantages of reduced petroleum use, increased use of 

renewable fuel, and reduced vehicle emissions. While E-diesel fuels, such as O2Diesel fuel, 

offer the aforementioned benefits, their indiscriminate use has potential safety implications. The 

major concern with the use of E-diesel derives from its flammability characteristics. A 2003 

study funded by the National Renewable Energy Laboratory (NREL) recommended actions that 

could be taken to reduce these safety risks.1

O2Diesel incorporated all of the recommendations included in the NREL study and initiated a 

thorough safety program for the use of O2Diesel fuel. O2Diesel was also proactive in 

commissioning this report, which serves as an independent review of O2Diesel safety efforts. 

This report addresses possible areas of concern with regard to O2Diesel safety, and what might 

need to be undertaken to provide the safest possible fleet operations with O2Diesel fuel. 

The report progressed in four tasks: 

•

•

•

•

Task 1: Develop a complete understanding of the O2Diesel Operational Safety Procedures 

Task 2: Develop a field assessment protocol 

Task 3: Complete site inspections in accordance with proposed protocol 

Task 4: Recommendations and reporting. 

In Task 1 of the project, TIAX staff members were informed of and briefed about all aspects of 

the O2Diesel safety program. This was accomplished by having O2Diesel personnel deliver a 

presentation on its program to TIAX staff and by reviewing supplementary documents on the 

safety program. 

In Task 2 of the project, TIAX developed a field assessment protocol for use in subsequent 

O2Diesel site visits. The protocol was composed of a site inspection procedure and site 

personnel questionnaire. These items assessed whether appropriate safety equipment was in 

place; whether site personnel received adequate safety training and signed safety training forms; 

and site preparedness for hazardous events involving O2Diesel. 

In Task 3, TIAX visited four O2Diesel sites and performed interviews and inspections as 

specified in the field assessment protocol. TIAX visited sites located in Las Vegas, Nevada; 

Ventura, California; Olathe, Kansas; and Lincoln, Nebraska. During the visits, TIAX staff 

stepped though the site inspection procedure, documenting that: safety equipment was in place 

and functioning as intended; operating procedures were being followed; and all required training 

was conducted, and record-keeping requirements were met. 

∗

 O2Diesel fuel is a trademark of O2Diesel. 

vii
The results of the site visits in Task 3 suggest that operations at O2Diesel fuel sites follow safety 

program requirements very closely. Areas of uniform compliance include: 

•

•

•

•

•

•

•

•

•

•

•

Labels clearly marking all O2Diesel-fueled vehicles and fueling infrastructure 

Flame arrestors installed on all O2Diesel-fueled vehicles and on storage tank vents 

Desiccant filters installed on storage tank vents 

Safe-handling equipment and emergency response equipment readily available 

Site personnel knowledgeable about the product and basic E-diesel safety concerns. 

Although the required safety elements are predominantly in place and used according to 

established safety program requirements, there are elements of O2Diesel operations that could be 

addressed. Recommendations generated from the Task 3 site visits include steps O2Diesel might 

take to ensure the safest possible fleet operations with O2Diesel. These recommendations 

include: 

Developing a documented safety training refresher plan – training repeated at regular 

intervals after O2Diesel is introduced 

Requiring training safety forms to be signed by all employees at a site and kept in an easily 

accessible location 

Initiating a basic safety training form or presentation for vehicle operators at sites where they 

have limited contact with fueling infrastructure 

Developing a clear chain of command for safety training when new employees are brought 

on 

Including small O2Diesel stickers on the inside of vehicles, so the vehicle operator knows 

that the vehicle is not fueled with conventional diesel fuel in case of emergency or accident 

Verifying emergency fuel shut-off switches are clearly labeled at all sites and site personnel 

know location of such switches. 

These recommendations could be easily implemented and would help assure a level of 

standardization across all fuel sites. In areas that deviate from the documented O2Diesel safety 

program requirements, the E-Diesel NREL report should be consulted for the potential 

consequences of any inconsistencies. 

viii
Introduction 

O2Diesel, Inc. has been testing, demonstrating, and is now commercializing an ethanol-diesel 

fuel blend (E-diesel) for centrally fueled, heavy-duty vehicle fleets that offers the benefits of 

reduced petroleum dependency, increased renewable fuels use, and reduced vehicle emissions. 

The O2DieselTM∗

 fuel is a blend of 7.7 vol% ethanol, a proprietary fatty acid-based stabilizing 

additive (known as O2D05), and diesel fuel. While E-diesel fuels, such as O2Diesel fuel, offer 

the above-noted advantages, their indiscriminate use has potential safety implications. The 

major concern with the use of E-diesel derives from its flammability characteristics. E-diesel 

blends have the vapor pressure and flammability limits of ethanol. This means that ethanol 

concentrations in enclosed spaces—such as fuel storage and vehicle fuel tanks—are flammable 

over the temperature range of 55°F to 108°F, typical ambient temperatures, which falls between 

that of gasoline and diesel fuels. Thus, there is a somewhat higher risk of fire and explosion 

compared to diesel fuel, or even gasoline, use. 

In a study funded by the National Renewable Energy Laboratory (NREL), TIAX LLC performed 

a failure mode and effects analysis (FMEA), an industry- and government-recognized method of 

assessing risk, to evaluate the relative safety of E-diesel use compared to standard diesel fuel 

use.1

 This FMEA assessment concluded that—without fuel system infrastructure, fueling 

station, and vehicle modifications—E-diesel use poses a greater risk than diesel fuel or even 

gasoline use in comparable applications. All safety risks identified and ranked were risks of fire 

or explosion. The most significant safety risks were associated with the possibility of explosion 

in storage and vehicle fuel tanks, and the potential for spilled fuel fires resulting from traffic 

accidents involving fuel transportation tankers or fleet vehicles. 

However, the study also concluded that the safety risks can be mitigated by adopting many of the 

infrastructure and vehicle modifications employed in the methanol fueled heavy-duty vehicle 

demonstration programs performed in the 1980s and early 1990s. Thus, recommended actions to 

reduce safety risks were: 

•

•

•

•

Limiting the use of E-diesel to centrally fueled vehicle fleets 

Equipping all fuel storage tank vents, the vehicle tank vent, and fill openings with flame 

arrestors designed for use with ethanol 

Establishing an electrical ground connection between the vehicle and the fueling station fuel 

dispenser 

Ensuring that vehicle fuel tank level detectors are of an intrinsically safe design. 

O2Diesel has incorporated all these recommendations, as well as other actions, into its O2Diesel 

fuel commercialization effort, making its use at least as safe as gasoline. In fact, these 

recommendations and the other actions have become the conditions of the California Air 

Resources Board (CARB) verification of O2Diesel fuels an alternative diesel fuel for use in 

∗

 O2Diesel fuel is a trademark of O2Diesel. 

1
centrally fueled fleets in the State of California to give verified vehicle emission reductions 

(September 23, 2003; see letter attached as Appendix A). 

Now that the O2Diesel fuel commercialization efforts are proceeding, O2Diesel believed it was 

an appropriate time to perform an independent safety review of the company’s current and future 

government-funded demonstration projects and commercial activities to determine the extent to 

which the company’s operations are addressing all known areas of concern with regard to the 

safe handling and use of the technology; and what, if anything else, might need to be undertaken 

to provide the safest possible fleet operations with O2Diesel fuel. 

The primary objective of this project was to perform an evaluation of the O2Diesel fuel handling 

safety program. This program includes specifications for flame arrestors for fuel storage and 

vehicle tanks, fuel dispensing processes and fuel transfer procedures, and fueling station and 

fleet vehicle operator safety training procedures. The effort proceeded in four tasks as follows: 

•

•

•

•

Task 1: Develop a complete understanding of the O2Diesel Operational Safety Procedures 

Task 2: Develop a field assessment protocol 

Task 3: Complete site inspections in accordance with proposed protocol 

Task 4: Recommendations and reporting. 

Tasks 1 through 3 are further explained in the proceeding sections of this site assessment safety 

report. The final product of the safety assessment, satisfying Task 4, is this report and the 

recommendations presented in Section 5. 

2
Overview of O2Diesel Safety Program 

The objective for Task 1 of the project was to bring TIAX staff to a level of complete 

understanding of the O2Diesel safety program. This was accomplished by holding a full day of 

training at the TIAX offices in Cupertino, California, on June 27, 2005. During the day, 

O2Diesel personnel presented their safety program and answered questions posed by TIAX staff. 

Topics of discussion included: 

•

•

•

•

•

•

Flame arrestor specifications and design details for storage tank vents, vehicle tank vents, 

and vehicle tank fill openings. This discussion included details on each of the vehicle fuel 

tank designs allowed in O2Diesel applications. 

Testing results from performance tests completed on acceptable flame arrestor designs. 

Design details for acceptable systems used to transfer O2Diesel fuel to and from fuel storage 

tanks and tanker truck tanks, and from fuel storage tanks to fleet vehicle tanks during vehicle 

fueling operations. 

Documented standard operating procedures for fuel transfer and fuel dispensing events. 

Fueling station and vehicle fleet personnel training programs developed and in routine use, 

including: new staff training requirements, required safety training form, and continuing 

staff refresher training. 

Other aspects of O2Diesel fuel deemed important and of interest by the O2Diesel staff 

conducting the presentation. 

Additional documents were provided to the TIAX team following the initial day of training. 

Specific details of the O2Diesel safety program, as presented by O2Diesel staff and documented 

in supplementary materials, are provided in the paragraphs that follow. 

The O2Diesel safety program requires that only centrally fueled vehicles operate on O2Diesel 

fuel. Fleets of vehicles are selected for use with O2Diesel fuel after all vehicles and the fuel 

supply infrastructure are profiled by O2Diesel technical staff. The technical staff, employed by 

O2Diesel, complete a series of forms that document specific vehicle and storage tank 

characteristics. Vehicle profiling forms record the sizes and types of approved flame arrestors 

required for each vehicle in the fleet. Additionally, any known problems or maintenance issues 

with the vehicles are documented. The storage tank profiling sheet covers such issues as storage 

tank condition, capacity and construction material, as well as potential safety concerns. Once 

this information is compiled, O2Diesel staff members determine vehicle and site compatibility 

with O2Diesel fuel. 

After vehicle and storage tank compatibility is established, flame arrestors are fitted to vehicle 

tank breather systems and fuel filler pipes to ensure that no ignition sources enter the vehicle fuel 

tank. These flame arrestors are installed by authorized O2Diesel technical staff. Prior to the 

introduction of O2Diesel fuel, storage and vehicle fuel tanks are drawn-down and purged of 

conventional diesel fuel. This step is taken to eliminate debris and remove any water from the 

tanks. The presence of water may cause additional safety concerns for E-diesel because of the 

potential for phase separation. O2Diesel staff brought a variety of flame arrestors to demonstrate 

the types of flame arrestors installed on O2Diesel-fueled vehicles and exhibit specific design 

3
details. The vehicle flame arrestors are custom-fit for each vehicle model and are verified for 

effectiveness by Southwest Research Institute and Underwriters Laboratories. Flame arrestors 

are also installed on storage tank breather systems, along with desiccant filters. The desiccant 

filter helps limit the fuel’s exposure to moisture in the atmosphere. 

Another important safety consideration is the ability to quickly identify and differentiate 

O2Diesel-fueled vehicles from vehicles fueled with conventional diesel. For this reason, all 

O2Diesel-fueled vehicles are clearly labeled with yellow cautionary stickers (Figure 1). The 

stickers identify O2Diesel-fueled vehicles, provide basic safety precautions, and include a 24-

hour hotline for additional information. Furthermore, O2Diesel-fueled vehicles undergoing 

repair in maintenance facilities should be clearly differentiated from vehicles fueled with 

conventional diesel fuel. O2Diesel recommends posting placards at the rear of an O2Dieselfueled vehicle when it is being serviced. 

Figure 1. Safety sticker for O2Diesel-fueled vehicles 

For fuel distribution and handling purposes, O2Diesel fuel is considered a Class 1 flammable 

fuel. This classification means that extraneous ignition sources, such as static electricity or an 

open flame, are key risk factors. Under most circumstances, handling the fuel with at least as 

much care as gasoline can mitigate the risk of fire or explosion. However, circumstances exist 

where O2Diesel fuel should be considered a greater risk and extra safety precautions should be 

taken. For this reason, fire extinguishers must be located nearby O2Diesel fuel infrastructure. 

Spill kits and safe-handling equipment—including gloves, coveralls, and eye protection—must 

also be located nearby and readily available to all site personnel. Additionally, safe handling and 

disposal of O2Diesel fuel must be conducted in accordance with applicable local, state, and 

federal regulations. 

In order to eliminate the risk of sparks generated by static electricity, vehicles are grounded 

during fuel-transfer events. Tankers filling underground or aboveground fuel storage tanks 

utilize cam locks on the hoses, and no additional grounding is required as part of this process. 

Some fuel sites are equipped with Emco-Wheaton (or similar), dry-lock fueling mechanisms. 

4
When this process is used, no additional grounding device is required. A grounding connection 

is used for fueling events when Emco-Wheaton connections are not available. Grounding of 

vehicles also takes place during transfer of the product between mobile sources, such as a fueling 

vehicle to fueling vehicle. 

In order to provide the safest possible distribution of the fuel, O2Diesel requires close 

cooperation with skilled and reputable fuel suppliers. Additionally, O2Diesel recognizes the 

importance of training fleet personnel—including site managers, mechanics, fuel handlers, and 

vehicle operators—on O2Diesel safe-operating procedures. For this reason, O2Diesel technical 

staff trains all site personnel prior to introducing O2Diesel fuel. Upon completion of the safety 

training, trainees are required to sign safety training forms verifying that they’ve received 

comprehensive safety training. Site personnel are also given copies of the O2Diesel 

Operator/Handler Training & Required Product Guidelines (see Appendix B), and additional 

copies are available onsite. 

Following the introduction of O2Diesel fuel, O2Diesel representatives regularly inspect sites to 

monitor ongoing compliance. In this manor, training is repeated and reinforced at intervals after 

the initial introduction of O2Diesel fuel. The following organizations have regulatory and 

technical oversight over O2Diesel fuel installations: U.S. Department of Energy/ NREL; U.S. 

Department of Defense (DoD) / U.S. Air Force; U.S. Environmental Protection Agency; CARB; 

California Department of Agriculture/Division of Measurement Standards; California State Fire 

Marshal; American Society for Testing & Materials; and National Conference on Weights & 

Measures. 

5
Development of the Field Assessment Protocol 

In Task 2 of the project, TIAX developed a field assessment protocol for use in the subsequent 

O2Diesel refueling site visits. This protocol was used to evaluate field compliance with the 

documented O2Diesel safety program. It assessed whether appropriate safety equipment was in 

place; whether site personnel received adequate safety training and signed safety training forms; 

and site preparedness for hazardous events involving O2Diesel fuel. 

TIAX developed a two-part field assessment protocol after reviewing all presentation materials 

and supporting O2DieselTM documents from Task 1. The protocol was comprised of: 1) an 

inspection procedure for the visits, and 2) a site personnel questionnaire and infrastructure 

checklist. 

TIAX proposed visiting four O2Diesel refueling sites located in Nevada, California, Kansas, and 

Nebraska. These sites represented a variety of vehicle applications and geographic regions 

where O2Diesel fuel was in use. The inspection procedure employed at each of the sites included 

the following components: 

•

•

•

•

•

•

Interview with the site manager 

Interview with a mechanic 

Interview with a fuel handler 

Interview with a vehicle operator 

Tour of the site to inspect the fueling infrastructure 

Photographing and documenting any safety hazards or concerns 

Upon arriving at a refueling site, TIAX staff intended to interview the site manager or person in 

charge of safety at the facility. The primary objective in talking with the site manager was to 

obtain a basic overview of facility operations and to understand the safety training process for 

site personnel. Site personnel include mechanics that service O2Diesel-fueled vehicles, fuel 

handlers, and vehicle operators. A fuel handler is an individual who routinely works with and 

handles O2Diesel fuel, particularly someone familiar with vehicle refueling and mobile-tomobile fuel transfers. 

Next, TIAX intended to interview a mechanic that services O2Diesel-fueled vehicles. The third 

interview was to take place with an experienced fuel handler. The last interview was to be 

conducted with the operator of an O2Diesel-fueled vehicle. The questionnaires later developed 

for these interviews were intended to help guide the conversations with site personnel and 

provide outlines for the interviews. 

A final aspect of the inspection procedure was to tour the facility and witness a refueling event. 

The tour included: maintenance facilities; locations where O2Diesel fuel is handled or stored; 

storage tanks; fleet vehicles; and all associated infrastructure. Notes were generated on facility 

operations and included potential safety concerns or deficiencies. Photographs also documented 

the infrastructure and any areas of concern. 

6
The second part of the field assessment protocol was the site personnel questionnaire and 

infrastructure checklist. These documents were intended to resemble, in many respects, forms 

employed by environmental regulatory personnel in monitoring compliance with such 

regulations as those governing the operation of a hazardous waste facility. They addressed such 

items as: 

•

•

•

•

•

•

Are storage tank vents equipped with flame arrestors of approved design? 

Do all vehicles inspected during the visit have approved fill opening and tank vent flame 

arrestors in place? 

Is the required grounding device between the fuel dispenser and the vehicle fuel tank 

connected before fueling is initiated? 

Does the fueling operation proceed in accordance with all required safety procedures? 

Do fueling station and vehicle fleet personnel adhere to all safety requirements and 

procedures? 

Have all fueling station personnel received the required safety training, signed safety training 

forms, and possess adequate knowledge of O2Diesel fuel? 

A draft site inspection procedure and personnel questionnaire were submitted to O2Diesel for 

review and comment to ensure that the protocol was sufficiently comprehensive, did not omit 

items of importance, and was appropriate for use at O2Diesel facilities (i.e., does not address 

operations that are not performed). O2Diesel circulated the assessment protocol among its staff 

and fuel sites to obtain feedback. These comments were taken into consideration for the final 

site assessment protocol. The complete questionnaire and site inspection checklist can be found 

in Appendices C through H. 

7
O2Diesel Site Inspections in Accordance with the 

Approved Protocol 

In Task 3, TIAX visited the selected O2Diesel refueling sites and performed interviews and 

inspections as specified in the assessment protocol developed in Task 2. Site visits were 

scheduled via communications between O2Diesel and TIAX staff and the refueling site manager. 

The site manager hosted the TIAX visits and served as a point of contact with site personnel. An 

O2Diesel staff member accompanied TIAX to all of the sites in order to provide introductions 

and supporting information as necessary. During the visits, TIAX staff stepped though the site 

inspection procedure by conducting site personnel interviews and inspecting the site. TIAX staff 

documented that specified equipment was in place and functioning as intended; operating 

procedures were being followed; and all required training was conducted and record-keeping 

requirements were met. Brief summaries of each site visit are presented below. 

Site 1 — Nellis Air Force Base, Las Vegas, Nevada 

TIAX visited the O2Diesel refueling site at Nellis Air Force Base (AFB) on November 9, 2005. 

The O2Diesel fueling installation at Nellis AFB was the first site visited and exhibited all of the 

required safety elements documented in O2Diesel literature. O2Diesel and Air Force personnel 

were extremely conscientious when developing the site, and it received a Best Practice award 

from Clark County, Nevada, in 2005. In November 2005, Nellis AFB received the U.S. DoD 

Drake Award, the result of a competition between a number of military installations, which rated 

best performance in terms of fuel-handling efficiency, safety, and best practices. The O2Diesel 

refueling operation was cited as one of the reasons Nellis received this recognition. 

O2Diesel technical staff conducted formal safety training at the site prior to introducing O2Diesel 

fuel, and the required safety training forms are kept on file at the site. An O2Diesel 

representative visits the site every day of the week to make sure operations run smoothly. 

However, O2Diesel expects to cut back on the frequency of visits, to perhaps once a week, after 

a high level of confidence in the product is established. The site has clear incident and accident 

reporting procedures that include written record-keeping and appropriate oversight. 

Air Force personnel are required to inspect the fuel site daily and complete a safety checklist. 

Each O2Diesel-fueled vehicle is also inspected prior to beginning a shift. All of the appropriate 

safety precautions appear in place at Nellis AFB, safety equipment is readily available and 

clearly marked; and site personnel are knowledgeable about the product, infrastructure, and 

safety concerns. Mobile service trucks, street sweepers, and a number of Blue Bird buses are 

operating on O2Dieselfuel at the site. Photographs from Nellis AFB, Figures 1 through 5, exhibit 

portions of the site inspection. 

8
Figure 2. O2Diesel fueling station at Nellis AFB 

Figure 3. Blue Bird bus arriving for fuel at Nellis AFB 

9
Figure 4. Flame arrestor and O2Diesel sticker on Blue Bird bus at Nellis 

AFB 

Figure 5. Air Force personnel records data in a fuel log book at Nellis AFB 

10
Figure 6. Eye wash station and safety-related postings located by 

O2Diesel refueling site at Nellis AFB 

Site 2 — E.J. Harrison & Sons, Ventura, California 

TIAX visited the O2Diesel refueling site at E.J. Harrison & Sons on November 11, 2005. The 

fuel storage tanks at this installation are portable, but O2Diesel expects to install a permanent 

skid-mounted storage tank in the future. Installation of a permanent storage tank is dependent 

upon whether operations continue to run smoothly and O2Diesel fuel is approved as a best 

available control technology for the fleet. An O2Diesel representative visits the site regularly to 

monitor the installation and is readily available to site personnel if questions or safety concerns 

arise. The site has clear incident and accident reporting procedures that include written 

recordkeeping and appropriate oversight. 

O2Diesel technical staff conducted formal safety training at the site prior to introducing O2Diesel 

fuel and the required safety training forms are kept on file at the site. Appropriate safety 

precautions appear in place, safety equipment is available, and site personnel are knowledgeable 

about the product, infrastructure, and general safety concerns. The E.J. Harrison & Sons fleet 

operation was launched in November 2004 and is the longest-running, continuous O2Dieselfueled fleet operation. Site managers are responsible for training replacement personnel on 

O2Diesel safety, and O2Diesel technical staff is available to provide refresher training. Few 

personnel changes have occurred since the introduction of O2Diesel fuel, and refresher safety 

training is not yet needed or justified. 

Refuse haulers are the only vehicles at the site operating on O2Diesel fuel. In addition to smaller 

cautionary stickers placed on the vehicle fuel tanks, the refuse trucks also have large O2Diesel 

stickers located on the lower, right-hand corner on the back of each vehicle. These stickers serve 

as an extra distinguishing factor from vehicles fueled with conventional diesel fuel. Figures 6 

through 8 document the vehicle application, fuel tank, and flame arrestors exhibited at the site. 

11
Figure 7. Refuse hauler operating on O2Diesel fuel at E.J. Harrison & Sons 

Figure 8. Fuel tank and O2Diesel sticker on refuse hauler at E.J. Harrison & 

Sons 

12
Figure 9. Flame arrestor in place on refuse hauler fuel tank at E.J. 

Harrison & Sons 

Site 3 — Johnson County Transit, Olathe, Kansas 

TIAX visited the O2Diesel refueling site at Johnson County Transit (JCT) in Olathe, Kansas, on 

November 16, 2005. The storage tanks at the facility are permanent installations similar in 

design to Nellis AFB. Johnson County contracts its public transit operations out to Laidlaw 

International, Inc., a highly regarded national fleet management contractor. Laidlaw services and 

fuels all of the transit buses at the facility, and the entire fleet is running on O2Diesel fuel. An 

O2Diesel representative visits the site regularly to monitor the installation and is readily 

available to site personnel if questions or safety concerns arise. The site has clear incident and 

accident reporting procedures that include written record-keeping and appropriate oversight. 

All of the appropriate safety precautions appear in place, safety equipment is available, and site 

personnel are knowledgeable about the product. Laidlaw installed gasoline-sized fuel dispensers, 

rather than larger diesel nozzles, to slow the flow of O2Diesel fuel during vehicle refueling. This 

measure is effective at eliminating tank overflow since flame arrestors may have a tendency to 

restrict the flow speed of fuel into the vehicle tank. Fuel handlers report that the smaller-sized 

nozzles increase refueling time only slightly. 

JCT chose not to require formal safety training on O2Diesel fuel for vehicle operators, since they 

have limited interaction with the fueling infrastructure. However, operators are aware that the 

vehicles are not fueled with conventional diesel fuel. Although O2Diesel technical staff 

conducted formal safety training at the site prior to introducing O2Diesel fuel, the site manager 

did not recall site personnel signing the required safety training forms after completing the 

training. Site managers are responsible for training replacement personnel on O2Diesel safety, 

and O2Diesel technical staff is available to provide refresher training. Few personnel changes 

have occurred, since the introduction of O2Diesel fuel and refresher safety training is not yet 

13
needed or justified. All site personnel interviewed onsite knew the significance of flame 

arrestors on vehicle tanks. However, some site personnel thought requiring them was “overkill.” 

Figures 9 through 12 exhibit a fuel shut-off button, fuel dispenser, and storage tank fuel port at 

this site. 

Figure 10. Emergency fuel shut-off button at JCT 

Figure 11. O2Diesel fuel dispenser at JCT 

14
Figure 12. Outside of O2Diesel fuel port on storage tank at JCT 

Figure 13. Inside of O2Diesel fuel port on storage tank at JCT 

15
Site 4 — Lincoln StarTran, Lincoln, Nebraska 

TIAX visited the O2Diesel refueling site at Lincoln StarTran in Lincoln, Nebraska, on November 

17, 2005. The site has underground storage tanks, and fuel dispensers are located in a large, 

tunnel-like garage. All of the buses and para-transit vehicles at the facility are fueled with 

O2Diesel fuel. An O2Diesel representative visits the site regularly to monitor the installation and 

is readily available to site personnel if questions or safety concerns arise. 

Appropriate safety precautions appear to be in place; safety equipment is available; and site 

personnel are knowledgeable about the product, infrastructure, and general safety concerns. This 

is the only site visited with maintenance pits. The pits are up-to-code with Occupation Safety & 

Health Administration requirements and have appropriate ventilation systems in place. The site 

has clear incident and accident reporting procedures that include written recordkeeping and 

appropriate oversight. 

Lincoln StarTran chose not to require formal safety training on O2Diesel fuel for vehicle 

operators, since they have limited interaction with the fueling infrastructure. However, operators 

are aware that the vehicles are not fueled with conventional diesel fuel. Although O2Diesel 

technical staff conducted formal safety training at the site prior to introducing O2Diesel fuel, the 

site manager did not recall site personnel signing the required safety training forms after 

completing the training. All site personnel interviewed onsite knew the significance of flame 

arrestors on vehicle tanks. However, some site personnel thought requiring them was “overkill.” 

Site managers are responsible for training replacement personnel on O2Diesel safety, and 

O2Diesel technical staff is available to provide refresher training. Few personnel changes have 

occurred since the introduction of O2Diesel fuel and refresher safety training is not yet needed or 

justified. Figures 13 and 14 document a transit bus operating on O2Diesel fuel and underground 

storage tank vents at the site. 

The observations and results from the preceding site visits are summarized in Tables 1 through 3. 

Table 1 summarizes the results of the site manager interviews. Table 2 summarizes the results of 

interviews with other site personnel, including mechanics, fuel handler, and vehicle operators 

(where appropriate). Table 3 summarizes the results of the site infrastructure inspections. 

Recommendations generated from these site visits are discussed further in Section 5 of this 

report. 

16
Figure 14. Transit bus fueled with O2Diesel at Lincoln StarTran 

Figure 15. Flame arrestors and desiccant filters on underground 

storage tanks at Lincoln StarTran

17
Table 1. Site Manager Interviews 

Area Inspected Passed 

Inspection Comments 

O2Diesel conducted a review of site and 

equipment before introducing O2Diesel fuel 9 Compliant with safety program at all sites inspected 

O2Diesel conducted a safety training program 

at the site 9 Compliant with safety program at all sites inspected 

Everyone that handles O2Diesel fuel onsite has 

been trained on O2Diesel safety 9 Compliant with safety program at all sites inspected; 2 of 4 sites chose to exclude 

vehicle operators from the safety training 

Everyone that handles O2Diesel fuel has 

signed a safety training form 

Compliant at 2 of 4 sites, unfamiliar with 

signature forms at remaining 2 sites 

inspected; recommend developing 

standard method of storing copies of 

forms onsite and submitting to O2Diesel 

Replacement personnel receive safety training 

when someone leaves 9 Compliant at all sites inspected; recommend developing a standard 

protocol for regular refresher training for 

all sites 

O2Diesel representatives are readily available 

if there are concerns or questions 9 Compliant with safety program at all sites inspected 

There have been no accidents to speak of 

involving O2Diesel fuel on the site 9 Compliant with safety program at all sites

An adequate accident/incident reporting 

mechanism is in place at the site 9 Compliant with safety program at all sites

Site manager is familiar with primary safety 

concerns of O2Diesel fuel 9 Compliant with safety program at all sites

O2Diesel fuel is a Class 1 flammable fuel and 

should be handled more cautiously than 

regular diesel fuel 

9 Compliant with safety program at all sites

Site manager is familiar with the hazards and 

potential for static discharge 9 Compliant with safety program at all sites

Site manager knows how to respond in case of 

an O2Diesel fuel spill, fire, or other hazardous 

event 

9 Compliant with safety program at all sites

Site manager is not aware of any health-related 

effects of using O2Diesel fuel at the site 9 Compliant with safety program at all sites

O2Diesel fuel is never used for applications 

other than fueling appropriate vehicles 9 Compliant with safety program at all sites

No significant problems or fuel spills have 

occurred during normal vehicle refueling 9 Compliant with safety program at all sites; site managers mention slightly 

longer time to fuel vehicles 

Site manager is familiar with importance of 

keeping water out of O2Diesel fuel 9 Compliant with safety program at all sites

Regular samples of O2Diesel fuel are taken 9 Compliant with safety program at all 

sites; regular samples submitted to 

O2Diesel lab in Delaware 

Site receives regular safety inspections by 

other agencies 9 Compliant with safety program at all sites

18
Table 2. Other Site Personnel Interviews 

Area Inspected Passed 

Inspection Comments 

Site personnel received safety training on 

O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected; vehicle operators 

excluded from training at 2 sites 

Site personnel know whom to contact 

with safety concerns or questions about 

O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected 

Site personnel are regularly notified of 

changes in the safety procedures 

associated with O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected 

Safety materials, including the safety 

training manual, are readily available to 

site personnel 9 

Compliant with safety program at all 

sites inspected 

Site personnel know where to find the 

Material Safety Data Sheet (MSDS) for 

O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected 

Site personnel are familiar with safe 

handling equipment and have items 

readily available 9 

Compliant at all sites inspected; 

equipment used at worker discretion 

depending on nature of task 

Site personnel know the significance of 

flame arrestors 9 

 Compliant at all sites inspected; 

thought to be overkill by some 

personnel at 2 sites 

Site personnel are familiar with the 

primary safety concerns of O2Diesel fuel 9 Compliant with safety program at all sites inspected 

Site personnel are familiar with the basic 

flammability characteristics of O2Diesel 

fuel 9 

Compliant at all sites inspected ; refer to 

handling O2Diesel as though it were 

gasoline 

Site personnel know how to respond in 

case of an O2Diesel fuel spill, fire, or 

other hazardous event 9 

Compliant with safety program at all 

sites inspected 

Site personnel dispose of spilled 

O2Diesel fuel in an appropriate manner 9 

Compliant at all sites inspected; no 

significant spills reported at sites 

inspected 

Site personnel have not experienced any 

health-related effects of working with 

O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected 

Site personnel know how to respond in 

case of accidental human contact or 

ingestion of O2Diesel fuel 9 

Compliant with safety program at all 

sites inspected 

O2Diesel fuel is never used for 

applications other than fueling 

appropriate vehicles 9 

Compliant with safety program at all 

sites inspected 

Signs are posted when servicing an 

O2Diesel-fueled vehicle in the 

maintenance area 

All vehicles in fleet are O2Diesel fuel at 

2 sites; signs determined unnecessary 

obstacles at other locations visited 

19
Table 3. Site Infrastructure Inspections 

Area Inspected Passed 

Inspection Observations and Comments 

Storage tank has an approved flame arrestor 

installed on the tank-breather system 9 Compliant with safety program at all sites inspected 

Storage tank has a proper desiccant filter 

installed on tank-breather system 9 Compliant with safety program at all sites inspected 

Desiccant filter is checked regularly 

9 

Viewing panel clearly visible; none of 

the installations have required a 

change of desiccant 

Storage tank has proper placards labeling it 

as an O2Diesel fuel tank 9 Compliant with safety program at all sites inspected 

Emergency fuel shut-off valve is easily 

accessible and marked 

 

Could be better marked on 2 of 4 

sites inspected, employees could be 

better informed of location 

Concrete blocks or other obstructions prevent 

objects from accidentally hitting storage tank 9 Compliant with safety program at all sites inspected 

Flame arrestors are installed on vehicle 

tanks: fuel-filler pipe and vehicle-breather 

system 9 

Compliant with safety program at all 

sites inspected 

O2Diesel-fueled vehicles are labeled with 

appropriate safety labels 9 Compliant with safety program at all sites inspected 

Vehicles are grounded during fuel transfer 

events 9 

Grounding devices exist at all sites 

inspected; frequency of use during 

regular refueling events uncertain 

Fire extinguishers and spill kits are readily 

available to site personnel 9 Compliant with safety program at all sites inspected 

Appropriate disposal containers are available 

to site personnel 9 Compliant with safety program at all sites inspected 

Safe-handling equipment is readily available 

to site personnel 9 Compliant with safety program at all sites inspected 

Copies of safety training manuals and the 

MSDS for O2Diesel fuel are readily available 

to site personnel 9 

Compliant with safety program at all 

sites inspected 

Maintenance pits, if used for servicing 

O2Diesel-fueled vehicles, meet code for 

handling flammable vapors 9 

Pits are located on the 1 site 

inspected and are equipped with 

appropriate ventilation 

20
Results and Recommendations 

The results of the site visits in Task 3 suggest that O2Diesel operations follow the documented 

safety program very closely. The vehicles, storage tanks, and associated infrastructure at all sites 

exhibited the required safety devices; and obvious care is taken when working with O2Diesel fuel 

at these sites. Furthermore, fuel transfer processes follow the documented protocol, and safety 

training procedures are well established. Areas of uniform compliance include: 

•

•

•

•

•

•

•

•

•

Labels clearly marking all O2Diesel-fueled vehicles and fueling infrastructure 

Flame arrestors installed on all O2Diesel-fueled vehicles and on storage tank vents 

Desiccant filters installed on storage tank vents 

Safe-handling equipment and emergency response equipment readily available 

Site personnel knowledgeable about the product and basic E-diesel safety concerns. 

Although recommended in the O2Diesel safety program guidelines, site and maintenance 

managers chose not to post placards in the maintenance departments when an O2Diesel-fueled 

vehicle is being serviced. At two sites, the entire fleet is operating on O2Diesel fuel; and 

therefore, appropriate safety precautions are taken around all vehicles. At the other sites 

inspected, however, site managers concluded that existing safety measures taken in the 

maintenance facilities were sufficient. 

In general, site personnel reported handling O2Diesel fuel as though it were gasoline and treating 

O2Diesel-fueled vehicles like gasoline-fueled vehicles. While the flammability characteristics of 

gasoline and ethanol are similar, this approach may have led some site personnel to question why 

gasoline vehicles do not require flame arrestors. E-diesel replaces conventional diesel fuel in 

applications where gasoline vehicles may not typically be used. Additionally, the increased risks 

of ignition associated with E-diesel could be partially attributed to unfamiliarity with the product. 

Although the required safety elements are predominantly in place and used according to 

established safety program requirements, there are elements of O2Diesel operations that could be 

addressed. The remainder of this section of the report focuses on recommendations generated 

from the Task 3 site visits. The focus of these recommendations includes steps O2Diesel might 

take to ensure the safest possible fleet operations with O2Diesel fuel. The recommendations also 

focus on possible actions that could be taken to improve the effectiveness of the program. 

Specific recommendations include: 

Developing a documented safety training refresher plan—training repeated at regular 

intervals after O2Diesel fuel is introduced. 

Requiring training safety forms to be signed by all employees at a site and kept in an easily 

accessible location, such as a 3-ring binder in the site manager’s office. 

Initiating basic safety training form or presentation for vehicle operators at sites where they 

have limited contact with fueling infrastructure. Although the operators at some sites are not 

part of the fueling and maintenance departments where O2Diesel-fueled vehicles are 

21
primarily housed, all operators should be aware of the increased risk of fire or explosion in 

case of a vehicle accident or fuel spill. 

•

•

•

Developing a clear chain of command for safety training when new employees are brought 

on. Forwarding copies of signed safety training forms to O2Diesel would allow O2Diesel to 

gauge rate of turnover and need for comprehensive refresher training. 

Including small O2Diesel stickers on the inside of vehicles, so the vehicle operator knows 

that the vehicle is not fueled with conventional diesel fuel in case of emergency or accident. 

Verifying that emergency fuel shut-off switches are clearly labeled at all sites and site 

personnel know location of such switches. 

These recommendations could be easily implemented, are already in place at some sites, and 

would help assure a level of standardization across all fuel sites. In areas that deviate from the 

documented O2Diesel safety program requirements, the E-Diesel FMEA report should be 

consulted for the potential consequences and associated risks of any inconsistencies. 

22
Conclusions 

O2Diesel has made great strides in commercializing an E-diesel product, O2Diesel fuel—for use 

in centrally fueled, heavy-duty vehicles and other engines—that offers the advantages of reduced 

petroleum use, increased use of renewable fuel, and reduced vehicle emissions. While E-diesel 

fuels, such as O2Diesel fuel, offer the above-noted benefits, their indiscriminate use has potential 

safety implications. The major concern with the use of E-diesel derives from its flammability 

characteristics, which increases risk of fire and explosion. 

In a study funded by NREL, TIAX conducted an FMEA (September 2003) that concluded—

without fuel system infrastructure, fueling station, and vehicle modifications—E-diesel use poses 

significantly greater risk than diesel fuel or even gasoline use. However, the study also 

recommended actions to reduce safety risks, including: 

•

•

•

•

Limiting the use of E-diesel to centrally-fueled vehicle fleets 

Equipping all fuel storage tank vents, and the vehicle tank vent and fill openings with flame 

arrestors designed for use with ethanol 

Establishing an electrical ground connection between the vehicle and the fueling station fuel 

dispenser 

Ensuring that vehicle fuel tank level detectors are of an intrinsically safe design. 

O2Diesel has incorporated all of the recommendations included in the FMEA study, and initiated 

a well-documented and thorough safety program for the use of O2Diesel fuel. O2Diesel was also 

proactive in commissioning this report, which serves as an independent review of its current 

safety program and reports on the progress of O2Diesel safety efforts. This report addresses 

potential areas of concern with regard to the safe handling and use of O2Diesel fuel, and what 

might need to be undertaken to provide the safest possible fleet operations with O2Diesel fuel. 

23
References

1 Waterland, L.R..; Venkatesh, S.; Unnasch, S. Safety and Performance Assessment of 

Ethanol/Diesel Blends (E-Diesel), NREL-SR-540-34817, September 2003. Available for 

download at http://www.nrel.gov/docs/fy03osti/34817.pdf. 

24
Appendix A. CARB Verification of Emission Reductions for 

O2Diesel Fuel 

A-1
A-2
A-3
A-4
A-5 A-5

Appendix B. O2Diesel Operator/Handler Training & 

Required Product Guidelines 

B-1

Revised February 2006
Table of Contents 

Page Number 

A. GENERAL GUIDANCE 3 

B. RECOMMENDED HOUSEKEEPING & SAFETY PRACTICES 9 

C. FLEET OPERATIONS EXPERIENCE 13 

APPENDIX 1: MSDS SHEET 16 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

A General Guidance

1 Introduction 

O2DieselTM, developed and marketed in North America by O2Diesel, Inc. is a cleaner 

burning diesel fuel formulated from any available diesel blended with “reformulated 

ethanol” (fuel grade ethanol) treated with low dosages of O2D05 and other diesel 

performance additives. 

O2D05 is a patented and proprietary co-solvent package, developed by O2Diesel, 

Inc. that facilitates the blending of oxygenates such as ethanol into hydrocarbon fuels. 

It is considered “substantially similar” (no metallic content) under EPA regulations 

for use in on-highway diesel powered vehicles. O2DieselTM facilitates good engine 

performance and durability with low mileage de-merits, but visible improvements in 

exhaust emissions. 

As a responsible supplier, O2Diesel, Inc. considers it essential to emphasize the main 

features of O2DieselTM which can affect the storage and handling of this premium 

fuel. Further information can be found in the Material Safety Data Sheet (MSDS) for 

O2DieselTM (see Appendix 1). 

O2DieselTM has similar basic properties to standard diesel with a minor modification 

due to the presence of ethanol. Ethanol imparts improved combustion performance 

with the added bonus of cleaner exhaust emissions. However, ethanol slightly 

increases the vapor pressure of the blend and has a significantly lower flashpoint than 

diesel. As a consequence, O2DieselTM is a “Class 1” flammable fuel and should be 

handled with a similar standard of care as gasoline. 

Among other things, handlers and users of O2DieselTM must avoid smoking 

around, and prevent exposure to, sparks and flames when refueling 

equipment, transferring fuel, charging or servicing any vessels containing 

O2DieselTM including all storage tanks, etc. 

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O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

2 Recommended Uses 

O2DieselTM is recommended for use ONLY in fleet-operated compression ignition 

(CI) engines designed to run on diesel fuels. It must not be used under any 

circumstances in spark-ignition reciprocating engines or any other application (e.g. 

space heaters, etc.). Operators of centrally-fueled fleets and equipment are strongly 

advised that they must ensure that no other use of O2DieselTM be permitted under 

any circumstances, except that which is authorized by O2Diesel in cooperation with 

certified centrally-fueled fleet and equipment operators. 

3 Misuses or Abuses 

Under no circumstances is O2DieselTM to be used as a solvent, cleaning agent, heating 

fuel, or for lighting or brightening fires. It should never be siphoned by mouth or be 

stored or used near sources of heat or ignition. 

Under applicable federal and state laws & regulations, the improper disposal of 

O2DieselTM or any other similar substance to soil, waterways, or drains is illegal and 

carries severe criminal and civil penalties. Operators of centrally-fueled fleets and 

other equipment must take all steps, consistent with the required handling procedures 

for petroleum products, to prevent O2DieselTM from entering sewers, waterways, or 

into landfills. 

4 Hazards Identification 

O2DieselTM is a “Class 1B” flammable liquid with a flashpoint of 55 degrees 

Fahrenheit (16 degrees C) and can readily ignite under the following conditions: 

a. If O2DieselTM is fully exposed to the atmosphere (e.g. spill, open container), the 

liquid or vapors could ignite in the presence of an ignition source (e.g. spark, 

flame impingement), or 

b. When O2DieselTM is in a semi-closed situation (e.g. vehicle tank) vapors could 

build up in the space above the liquid surface and create a flammable mixture that 

could ignite in the presence of an ignition source and under certain ambient 

temperatures. 

Normal exposures in the open air do not present significant health risks, provided 

care is taken to avoid undue exposure to vapors. Other preventative steps must be 

taken by the centrally-fueled fleet operator to limit the areas of vulnerability described 

above. By following O2Diesel’s certification requirements, any hazards associated 

with O2DieselTM can be minimized to those of routine gasoline handling & safety. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 2 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

As with other motor fuels and chemicals, human exposure to high vapor 

concentrations can lead to nausea, headache, dizziness, and in extreme cases, loss of 

consciousness: May cause death in oxygen system depression. Minute amounts of 

petroleum hydrocarbons aspirated into the lungs during ingestion or vomiting may 

cause mild to severe pulmonary injury and possible death. 

Prolonged and repeated skin contact can lead to defatting of the skin, drying, cracking 

and dermatitis. 

Accidental ingestion can lead to chemical burning of the mouth, vomiting and 

aspiration into the lungs, which can lead to chemical pneumonitis, which can be fatal. 

5 First Aid Measures 

Inhalation 

Remove the affected person(s) to fresh air. If breathing has stopped, administer 

artificial respiration. Obtain medical assistance immediately. 

Skin 

Flush the contaminated skin with copious amounts of water. Wash contaminated 

clothing before reuse. 

Eyes 

Flush the eye with copious amounts of water for 15 minutes. Refer for medical 

attention. 

Ingestion 

If swallowed, do not induce vomiting. Allow victim to rinse mouth and then to drink 

2-4 cupfuls of water. Never give anything by mouth to an unconscious person. Call 

a physician. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 3 OF 20 REV. FEBRUARY 2006

 
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O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 4 OF 20 REV. FEBRUARY 2006

 

Fire Extinguisher 

Emergency Shut-Off 

6 Fire Fighting Measures 

Extinguishing Media: Large fire.......Foam/water fog- Never use water jet. 

Small fire.......Foam/Dry powder/CO2/ Sand/Earth 

Figure 1: 

A RECOMMENDED TANK AND 

DISPENSING CONFIGURATION 

WITH SUITABLE FIRE 

SUPPRESSION EQUIPMENT.

O2DieselTM Fuel Tank and Dispenser 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

7 Handling and Storage 

O2DieselTM is designed for use in closed systems and in vehicle fuel systems. During 

vehicle fueling and all other operations, extreme care must be taken to avoid any 

sources of ignition, including static discharge, smoking etc. Electrical continuity is 

required between the transport and storage vessels during product transfer. 

Figure 2: TYPICAL O2DIESELTM ABOVE-GROUND STORAGE TANK 

EQUIPPED WITH FLAME ARRESTORS, DESICCANT FILTERS, AND 

PROPER PLACARDS. 

The main conditions relating to the storage of O2DieselTM are the suitability of the 

storage vessel and the avoidance of ignition sources. O2DieselTM should never be 

stored in buildings occupied by people. The storage of O2DieselTM is subject to state 

and local regulations pertaining to Class 1B fuels. 

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O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

8 Recommended Protective Clothing 

Impervious gloves and overalls should be used where regular contact is likely, and 

goggles if there is a risk of splashing. 

9 Disposal Considerations 

Only licensed hazardous waste contractor should dispose of O2DieselTM. Treatment, 

storage, transportation, and disposal must be conducted in accordance with applicable 

federal, state/provincial and local regulations. 

10 Transport Information 

DOT 

 Proper Shipping Name Flammable Liquid, N.O.S. (diesel fuel, ethanol) 

 Hazard Class 3 

 I.D. No. (UN) UN 1993 

 Packing Group I 

 Marine Pollutant No 

 DOT Label (s) Flammable Liquid 

 

IMO 

 Proper Shipping Name Flammable Liquid, N.O.S. (diesel fuel, ethanol) 

 Hazard Class 3 

 LD. No. (UN/NA) UN 1993 

 Packing Group I 

 Special Information Flashpoint: 1 60C 

 Marine Pollutant No 

 IMO Label Flammable Liquid 

O2Diesel Corporation 

100 Commerce Drive 

Suite 301, 

Newark, Delaware 19713 

Toll Free: 888-266-6030 

Phone: 302-266-6000 

Fax: 302-266-7076 

info@o2diesel.net 

 

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O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

B Recommended Housekeeping & Safety Practices

1 Background 

O2DieselTM is a clean diesel technology that incorporates fuel ethanol into readilyavailable diesel fuels in a clear stable fuel formulation at all operational temperatures 

and in the presence of water. While O2DieselTM behaves almost identically to 

conventional diesel, and does not require any distribution system or engine 

modification, it is a fuel with some different properties and must be understood for 

those differences. This document is intended to provide fuel suppliers and end-users 

some basic information to ensure optimal performance of O2DieselTM. 

2 Fuel Specifications

In all respects but one, O2DieselTM meets or exceeds the specifications of 

ASTM D 975. the industry standard for diesel fuel sold in the United States. The 

only aspect of this specification which O2DieselTM does not meet is that for 

flashpoint, a relative measure of the propensity of the fuel to ignite under certain 

conditions. Diesel fuel typically has a high flashpoint (over 120oF), while ethanolblended fuels have a somewhat lower flashpoint (55oF). Thus, while diesel fuel is 

classified as combustible, due to its higher flashpoint, O2DieselTM is accordingly 

classified by the National Fire Protection Association (NFPA, see www.nfpa.org) as a 

“flammable liquid” (Class 1B) as are gasoline and other more volatile petroleum 

products. 

The ASTM D 975 flashpoint standard for diesel fuels exists to provide guidance on 

storage and handling of fuels, and experience has shown has no effect fuel/vehicle 

operational performance. Given that fact, O2DieselTM components are stored 

separately until they are to be blended at the terminal. Any subsequent blending of 

O2DieselTM and diesel may make the resultant mixture more flammable, therefore 

requiring more attention in storage than typical diesel fuels. 

Therefore, fuel handlers, fleet operators, drivers and maintenance s aff are t

advised that a significantly higher standard of care is required for the use of 

O2DieselTM than that which is required for “typical” diesel fuels. It is strongly 

recommended that the same safety precautions for storing, handling and using 

gasoline be implemented for the use of O2DieselTM. Therefore, it is necessary to 

control all sources of ignition, prevent spills, and limit fuel vapor releases of 

O2DieselTM. 

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O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

One performance characteristic of O2DieselTM that helps reduce the risk of ignition is 

the fact that the fuel is highly conductive, in contrast to conventional and “ultra low 

sulfur diesel” (ULSD) which is less conductive than “standard” diesel fuel and thus 

more prone to the build-up of dangerous static electricity. This positive characteristic 

is a valuable asset during refueling operations, but does not lessen the absolute 

need for end-users to follow all proper safety and handling procedu es for r

flammable fuels.

3 Tank Preparation 

Industry experience over the past 25 years has shown that water is the enemy of all 

ethanol-blended motor fuels, but that it is all but impossible to eliminate water from 

the fuel supply system. Steps should be undertaken from the moment ethanol and 

petroleum are blended, to ensure that the presence of water is reduced to the greatest 

extent possible. O2Diesel recommends that the fleet’s on-site tanks be cleaned and 

purged of “water bottoms” just prior to the introduction of O2DieselTM. Older tanks 

may require cleaning with a solvent and a high pressure/ high volume pump that will 

filter particles to the one micron range. The fuel should be used continuously and 

exclusively thereafter to ensure a nearly water-free environment. The presence of 

water in O2DieselTM will create a unique problem not associated with conventional 

diesel or gasoline. O2DieselTM can tolerate typical levels of water. The water is simply 

absorbed into the ethanol portion of the fuel. However, if water contamination 

exceeds a critical concentration then water, ethanol, and the proprietary additive will 

separate from the bulk diesel fuel and drop to the bottom of the tank. See the 

following photographs of properly-blended O2DieselTM compared with phaseseparated fuel: 

Figure 3a: 

EXAMPLE OF “CLEAR & BRIGHT”

O2DIESELTM MEETING THE FUEL’S 

SPECIFICATION. 

Figure 3b: 

EXAMPLE OF OPAQUE, CLOUDY 

APPEARANCE AND DISTINCT 

BROWN/BEIGE LINE OF PHASE 

SEPARATION DUE TO FUEL

CONTAMINATION.

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 8 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Additionally, fuel ethanol is an effective solvent and will efficiently clean the tank(s) 

into which it is introduced. Thus, particularly in older tanks, it should be expected 

that O2DieselTM will initially remove sediments, gum, rust, scale, and other foreign 

matter from the interior tank wall and send it through in suspension with the fuel. All 

filters should be monitored carefully and replaced if necessary, once O2DieselTM is 

introduced. Thereafter, the continuous use of O2DieselTM in that environment should 

cause no operational problems. 

For on-site fleet fuel storage tanks, the installation of desiccant filters is also required 

to limit the fuel’s exposure to sources of moisture from the atmosphere. Prior to the 

introduction of O2DieselTM into fleet vehicles, O2Diesel, Inc. will conduct a safety 

review of equipment, operations, and practices together with the fleet operator. 

Following a safety review, flame arrestors will be fitted when required as a safety 

precaution to the tank breather system to ensure that no flame front enters the fuel 

tank. Such systems are commonly available and should be properly directed or 

installed by O2Diesel-authorized technicians. All storage vessels and 

vehicle/equipment fuel tanks must be properly located, installed, and placarded under 

applicable national, state, and local fire codes and procedures (see Figures 1 and 2). 

4 Vehicle Preparation & Maintenance 

Prior to the introduction of O2DieselTM into fleet vehicles, O2Diesel, Inc. will 

conduct a safety review of equipment, operations, and practices together with the 

fleet operator. Following a safety review flame arrestors will be fitted when required 

as a safety precaution to the tank breather system and on the fuel filler pipe to ensure 

that no flame front enter the fuel tank. Such systems are commonly available and 

should be properly directed or installed by O2Diesel-authorized technicians on the 

equipment. 

As is the case with fuel storage tank maintenance, any water or sediment problems 

can exist in the vehicle fuel tank as well. Therefore, O2Diesel requires that vehicle or 

equipment fuel tanks be drawn-down and purged of conventional fuels just prior to 

the introduction of O2DieselTM. Water bottoms should be drained, if possible, and 

the fuel system fully inspected. 

Thereafter, during the first 4 - 6 weeks of O2DieselTM use, fuel filters should be 

monitored more closely than recommended by the original equipment manufacturer 

(OEM) for the presence of filter-clogging contaminants which ethanol will clean out 

of the fuel tanks. If necessary, fuel filters should be replaced at an earlier service 

interval. Afterward, continuous use of O2DieselTM will ensure normal operations 

because the fuel tank will be water and contaminant free. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 9 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

When a vehicle operating on O2DieselTM requires repairs or maintenance, it should be 

identified as such when parked and serviced in the maintenance area. 

Placards are available to identify an O2DieselTM vehicle. The placard should be 

located at the back of the bus while parked in the maintenance area. A Spill Kit and 

fire extinguisher must be located nearby. An example is provided below: 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 10 OF 20 REV. FEBRUARY 2006

Figure 4: PROPER MAINTENANCE FACILITY SAFETY PRECAUTIONS. 

5 Questions and Inquiries: 

For further information about the performance & technical characteristics of 

O2Diesel, or the product liability insurance policy provided by O2Diesel, please call 

(302) 266-6000 or (888) 266-6030 during regular business hours, or contact the 

company via the Internet at www.o2diesel.com. 

September 1, 2000 

Updated: April 1, 2001; October 1, 2002; May 29, 2003; October 16, 2003, October 29, 2003; November 19, 2003; 

December 23; 2003, January 30, 2004; Septermber 1, 2005; February 23, 2006 

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

C Fleet Operations Experience

O2Diesel has five years of fleet and laboratory test experience with O2DieselTM in the 

United States and Europe. Since February 2000, O2DieselTM has been successfully 

tested in millions of miles and thousands of hours of real-world, in-use fleet 

operations across North America. During that time, much knowledge has been 

gained in understanding the most significant difference between O2DieselTM and 

“typical” diesel fuels: flammability and flashpoint. 

The unauthorized, improper or ill-advised use of ethanol-diesel blended fuels can 

cause problems not typically associated with traditional diesel fuel and storage 

systems. One problem is the possibility of combustion occurring in the fuel tank due 

to the chemistry of the fuel ethanol component. Diesel tanks typically have too much 

oxygen present and insufficient fuel vapors to support combustion inside a fuel tank, 

thus lowering the risks associated with handling conventional diesel fuels. 

O2DieselTM, on the other hand, has an air:fuel ratio that is on the boundary of 

flammability which could, under certain circumstances, become ignitable. 

Prior to the introduction of O2DieselTM into fleet vehicles O2Diesel, Inc. will 

conduct a safety review of equipment, operations and practices together with the fleet 

operator. 

Steps have been taken in every O2Diesel-sponsored fleet demonstration to date to 

ensure that every precaution is taken to address any safety issue that could arise with 

the use of this fuel. In most instances, simply handling the fuel in a manner that is no 

different than a fleet would handle gasoline is sufficient. However, any O2Dieselcertified centrally-fueled fleet program must include: 

1. An O2Diesel-approved staff training program; 

2. A full inspection of the fleet equipment; 

3. A full safety inspection of the fleet’s refueling & maintenance facilities, including 

a review of safety practices; and 

4. Prior to the introduction of O2DieselTM, installation and use of fuel storage 

system and equipment flame suppression and fuel conductivity devices as 

recommended by the manufacturer and approved by state and local regulators. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 11 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

By way of background, two major aspects of flammability must be considered in 

assessing the flammability risk associated with handling and distributing fuel: 

• The fuel’s conductivity, and 

• The fuel’s vapor pressure and corresponding flashpoint. 

While O2DieselTM is volatile and has a lower flashpoint, it also has a conductivity of 

>20,000 pS/m, an extremely high charge dissipation rate, combined with an 

extremely low “relaxation” time: 

• For 1 pS/m -~ relaxation time = 18 seconds 

• For 100 pS/m -* relaxation time = 0.18 seconds 

• For >20,000 pS/m -~ relaxation time = instantaneous 

Consequently, static charge accumulation risks associated with O2DieselTM are 

substantially lower than those of “typical” diesel fuel. With O2DieselTM the charge 

dissipation rate is instantaneous, resulting in much lower risk of fire associated with 

static discharge. 

The key risk factor associated with using and handling O2DieselTM is based upon: 

• Whether the composition of the tank headspace vapors (air:fuel ratio) falls 

within the flammability bounds of O2DieselTM;

• The flashpoint of O2DieselTM; and 

• The operational temperatures of O2DieselTM fall within the “flammability range” 

of the fuel (~40o - 100oF). 

 

For distribution and handling purposes O2DieselTM is thus defined as a flammable 

(“Class 1) liquid (similar to gasoline). As with other volatile hydrocarbon fuels the 

key risk factor is an extraneous ignition source. i.e. a spark provided by an outside 

source. Examples include: 

• Any open flame; 

• A spark generated by a person who is not grounded (static electricity); 

• Filling a container that is not grounded; or 

• Smoking (cigarettes, etc.). 

Consequently, use of O2DieselTM fuel use is res ricted to con rolled, centrally- t t

fueled fleets which can be carefully monitored and guided on a regular basis 

by O2Diesel as a matter of sound pract ce and policy. i

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 12 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Prior to the introduction of O2DieselTM into fleet vehicles O2Diesel Inc. will conduct 

a safety review of equipment, operations, and practices together with the fleet 

operator. 

Safety and handling training of fleet operational personnel, including mechanics, 

drivers, fuel handlers, and service managers, is of the utmost importance. All 

personnel likely to handle engine/vehicles fueled with O2DieselTM must be properly 

trained using a curriculum developed by O2Diesel. As noted, this training takes the 

form of initial and ongoing seminars with supporting guidance documents and 

videotape presentations developed, provided, and required by O2Diesel. 

July 30, 2002 

Updated: May 29, 2003; October 17, 2003, October 29, 2003, December 23, 2003; January 30, 2004; September 1, 2005; 

February 23, 2006. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 13 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Appendix 1 

O2DieselTM Finished Diesel 

Material Safety Data Sheet 

1 Company Identification

O2Diesel Corporation Product information 

100 Commerce Drive, Suite 301 In Case of Emergency 

Newark, DE 19713 Call Chemtrec: Toll Free - 800 424 9300 

 Intl - +1 703 527 3887 

2 Composition / Ingredient Information

Material CAS Number %

Diesel 68334-30-5 >82 

Ethanol 64-17-5 <8 

Proprietary Surfactants <3 

3 Hazardous Identification

Potential Health Effects 

Inhalation

Short term exposure can cause nausea, irritation, vomiting, difficulty breathing, headache, 

symptoms of drunkeness, disorientation, bluish skin color, coma. 

Skin Contact

Short term exposure can cause irritation and blisters. Long term exposure can cause kidney 

damage. 

Eye Contact

Can cause irritation. 

Ingestion

Short term exposure can cause nausea, vomiting, diarrhea, difficulty breathing, symptoms of 

drunkeness and lung congestion. 

Can cause respiratory tract irritation, skin irritation and central nervous system depression. 

Minute amounts of petroleum hydrocarbons aspirated into the lungs during ingestion or 

vomiting may cause mild to severe pulmonary injury and possible death. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 14 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Carcinogenicity Information 

IARC: Human Inadequate Evidence, Animal Limited Evidence, Group 3 

4 First Aid Measures

Inhalation 

If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is 

difficult, give oxygen. Call a physician. 

Skin Contact 

Flush skin with water after contact. Wash contaminated clothing before reuse. 

Eye Contact 

In case of contact immediately, flush eyes with plenty of water for at least 15 minutes. Call a 

physician. 

Ingestion 

If swallowed, do not induce vomiting. Allow victim to rinse his mouth and then to 

drink 2-4 cupfuls of water. Never give anything by mouth to an unconscious person. 

Call a physician. 

Notes to Physicians 

Activated charcoal mixture may be administered. To prepare activated charcoal mixture, 

suspend 50 grams activated charcoal in 400-ml water and mix thoroughly. Administer 

5 ml/kg or 350 ml for an average adult. 

Because of the danger of aspiration, emesis or gastric lavage should not be employed unless 

the risk is justified by the presence of additional toxic substances. Activated charcoal may 

induce vomiting, but may be given after emesis or lavage to absorb toxic additives. Steroid 

therapy in mild to moderate cases does not improve outcome. Bacterial pneumonia often 

occurs after exposure, but prophylactic antibiotics are not indicated and should be reserved 

for documented bacterial pneumonia. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 15 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

5 Fire Fighting Measures

Flammable Properties 

Flashpoint 55°F (12.8°C) 

Method PMCC 

Flammable Liquid 

Extinguishing Media 

Foam, Dry Chemical, CO2, Water Spray – do not use water jet. 

Fire Fighting Instructions 

Wear self-contained breathing apparatus. Wear full protective equipment. 

6 Accidental Release Measures

Note: Review FIRE FIGHTING MEASURES and HANDLING (PERSONNEL) 

SECTIONS before proceeding with clean up. Use appropriate PERSONAL PROTECTIVE 

EQUIPMENT during clean up. Soak up with sawdust, sand, oil dry or other absorbent 

material. Remove source of heat, sparks, flame, impact, friction, or electricity. Dike spill. 

Prevent material from entering sewers, waterways, or low areas. 

Spill Clean-Up 

Soak up with sawdust, sand, oil dry or other absorbent material. 

Accidental Release Measures 

Spills are very slippery and should be cleaned up promptly. 

7 Handling and Storage

Handling (Personnel) 

Avoid breathing vapors or mist. Avoid contact with eyes, skin, or clothing. Wash thoroughly 

after handling. 

Handling (Physical Aspects) 

Keep away from heat, sparks and flames. 

Storage 

Store in a well-ventilated place. Keep container tightly closed. Store in accordance with 

National Fire Protection Association recommendations. 

8 Exposure Controls

Engineering Controls 

Use only with adequate ventilation. Keep container tightly closed. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 16 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Personal Protective Equipment 

Eye/Face Protection 

Wear coverall chemical splash goggles or safety glasses. 

Respirators 

Where there is potential for airborne exposures in excess of applicable limits, wear 

NIOSH/MSHA approved respiratory protection. 

Protective Clothing 

Where there is potential for skin contact have available and wear as appropriate - 

Impervious gloves, apron, pants, hood and jacket. 

Exposure Limits

Diesel: 

 NIOSH recommended ................................................100 mg/m3 (14 ppm), 10 hr. TWA 

 TLV (ACGIH)...............................................................100 mg/m3, 8 hr TWA, Skin; A3 

Ethanol: 

 PEL (OSHA) .........................................................1,000 ppm, 1,900 mg/m3, 8 hr. TWA 

 TLV (ACGIH)...............................................................1,000 ppm, 1,880 mg/m3, 8 hr. TWA 

9 Physical and Chemical Properties

Physical Data 

Appearance .......................Yellow-brown 

Form...................................Oily liquid 

Odor...................................Mild petroleum odor 

Specific Gravity ................~0.86 @ 60/60°F (16/16°C) 

Density...............................~7.16 lb/gal @ 60°F (16°C) 

Solubility in water.............<15% 

10 Stability and Reactivity

Chemical Stability 

Stable at normal temperatures and storage conditions. 

Incompatibility

Incompatible with oxidizers. Avoid heat, flames, sparks and other sources of ignition. 

Containers may rupture or explode if exposed to heat. 

Decomposition 

Decomposes with heat. Hazardous gases/vapors produced are oxides of carbon and sulfur. 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 17 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

Polymerization

Will not occur. 

11 Toxicological Information

Animal Data 

Diesel: 

 Skin Irritation ................................................................. 500 μl/24 hr. skin-rabbit (severe) 

 Skin LD50....................................................................... >5 mL/kg rabbit 

Oral LD50....................................................................... 7500 mg/kg rat 

Ethanol: 

Skin LD50....................................................................... >20 mL/kg rabbit 

Oral LD50....................................................................... 11,500 mg/kg rat 

Inhalation ........................................................................>16,000 ppm 8 hr. ALC rat 

Animal studies have confirmed an association between the induction of cancer, primarily 

of the lung and diesel exhaust. Limited epidemiologic evidence also suggests an 

association between occupational exposure to diesel emissions and lung cancer (NIOSH, 

1988). 

12 Ecological Information

Ethanol: 96 hr. LC50 14,200 mg/L fathead minnows 

Diesel: None available. 

13 Disposal Considerations

Waste Disposal 

Treatment, storage, transportation, and disposal must be in accordance with applicable 

Federal, State/Provincial and Local regulations. 

14 Shipping Information

DOT 

Proper Shipping Name......................................... Flammable Liquid, N.O.S. (diesel fuel, ethanol) 

Hazard Class........................................................... 3 

I.D. No. (UN/NA) ...............................................UN 1993 

Packing Group....................................................... I 

Marine Pollutant .................................................... No 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 18 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

DOT Label (s)........................................................ Flammable Liquid 

IMO 

Proper Shipping Name......................................... Flammable Liquid, N.O.S. (diesel fuel, ethanol) 

Hazard Class........................................................... 3 

I.D. No. (UN/NA) ...............................................UN 1993 

Packing Group....................................................... I 

Special Information............................................... Flashpoint: 12.8°C (55oF) 

Marine Pollutant .................................................... No 

IMO Label.............................................................. Flammable Liquid 

Shipping Containers 

Steel Drums UN1A1/Y/100 

15 US Federal Regulations

TSCA Inventory Status ................Reported / Included

16 Other Information

NPCA-HMIS Rating 

Health.................................2* 

Flammability .....................3 

Reactivity ...........................0 

Personal Protection rating to be supplied by user depending upon use conditions. 

The data in this Material Safety Data Sheet relates only to the specific material designated herein 

and does not relate to use in combination with any other material or in any process. 

For product information, please call (888) 266-6030. 

Responsibility for MSDS: Dr. Ben Kaufman 

 (302) 266-6000 

 bkaufman@o2diesel.com

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 19 OF 20 REV. FEBRUARY 2006

 
O2DIESEL, INC. | 100 COMMERCE DRIVE, SUITE 301 | NEWARK, DE 19713 | USA 

NOTES: 

O2DIESELTM OPERATOR & HANDLER TRAINING AND REQUIRED PRODUCT GUIDELINES PAGE 20 OF 20 REV. FEBRUARY 2006

 
Appendix C. Site Manager Interview 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

2. Has O2Diesel conducted an O2Diesel-approved staff training program at your site?

3. Has everyone that handles O2Diesel fuel been trained?

5. Do all workers have access to a copy of the safety training manual? Where is it kept? 

7. Who trains site personnel on the safety of O2Diesel fuel?

8. Who trains replacement personnel when someone leaves?

9. Who trains the trainers at your facility?

ADDITIONAL NOTES

14. Are you aware of any accidents related to the use of O2Diesel fuel at your facility?

15. How are accidents at your site reported?

16. How are deficiencies in safety dealt with?

17. How are incidents reported at your site?

19. Under what circumstances are accident reports shared with O2Diesel?

20. Who reviews and signs accident reports at your site?

ADDITIONAL NOTES

Site Manager Interview

11. Have you ever contacted an O2Diesel representative or a supervisor with safety concerns?

12. Are O2Diesel personnel readily available and willing to help if you have concerns or questions?

13. Do you have input on the development of new or revised safety procedures involving O2Diesel fuel?

1. Did O2Diesel conduct a safety review of your equipment and operations before introducing O2Diesel to your site?

4. Has everyone handling this fuel signed a safety training form?

10. Where are your safety training forms? Do copies of the forms get passed along to O2Diesel or kept onsite?

6. Has O2Diesel performed a safety/performance inspection of your fleet and facilities since O2Diesel was introduced?

18. Are O2Diesel spills recorded as accidents or incidents? Is there a pool size that triggers a report?

O2Diesel Safety Protocol Questionnaire

Site Information

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

C-1
21. Does your facility practice emergency plans?

22. Do you know the primary safety concerns of O2Diesel fuel?

24. If an O2Diesel spill occurs, do you know how to respond? What would you do?

29. Are you aware of any health-related effects of using O2Diesel fuel at your facility (headache, dizziness)?

27. Do state and local safety regulations pertain to O2Diesel fuel?

26. Is O2Diesel ever used for any application other than fuel for diesel engines? 

ADDITIONAL NOTES

32. Are any non-fleet operated vehicles fueled with O2Diesel?

33. Are all O2Diesel storage containers and vehicles clearly labeled with appropriate O2Diesel placards?

35. Do you know why it is important to keep water out of the O2Diesel fuel?

36. Have you ever experienced phase separation of O2Diesel fuel?

ADDITIONAL NOTES

38. Does your site receive regular safety inspections conducted by other agencies? What areas of the facility are inspected?

37. Has O2Diesel been used continuously and exclusively since it was introduced into the fuel storage tank? 

34. Have you experienced any problems when fueling vehicles with O2Diesel? If so, what problems?

25. If a small O2Diesel-related fire occurs, do you know how to respond? What would you do? What if the fire were large?

30. In terms of risk of explosion or fire, is O2Diesel about as safe, safer, or less safe than regular diesel? Than gasoline? 

31. Do you know why static discharge is a hazard when transferring O2Diesel fuel between vessels or vehicles? Why?

28. If someone were to come in physical contact with O2Diesel (skin exposure, ingestion), do you know how to respond?

34. Are regular samples of the O2Diesel fuel in your storage tank taken? Who samples the fuel?

 YES NO

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 UNSURE

C-2
Appendix D. General Site Personnel Questions 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

1. Have you received training on the safety of O2Diesel fuel? Who trained you?

2. Have you been responsible for training anyone on O2Diesel fuel safety?

7. Are safety materials readily available to you?

ADDITIONAL NOTES

11. Is O2Diesel capable of igniting (catching fire) in the regular atmosphere?

12. Is O2Diesel capable of igniting in a vehicle tank? 

14. If an O2Diesel spill occurs, do you know how to respond? What would you do?

15. Can you show me where the spill kit and fire extinguisher are kept?

ADDITIONAL NOTES

13. If a small O2Diesel-related fire occurs, do you know how to respond? What would you do? What if the fire were large?

3. Do you know where to go or who to ask if you have safety-related questions about O2Diesel? 

8. Do you know where to find the material safety data sheet (MSDS) for O2Diesel?

10. If someone were to come in contact with O2Diesel (skin exposure, ingestion, etc), do you know how to respond?

4. Have you ever contacted an O2Diesel representative or a supervisor with safety questions or concerns?

5. Are you regularly notified of any changes in the safety procedures of O2Diesel fuel or vehicles? Who would notify you?

6. Have you ever given feedback on safety procedures or potential hazards related to O2Diesel fuel at your facility?

9. If a hazardous event involving O2Diesel was to occur, do you know how to respond? Give me an example.

0

0

0

0

0

General Questions

O2Diesel Safety Protocol Questionnaire

Site Information

0

0

0

0

0

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

D-1
Appendix E. Mechanic Interview 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

1. Do you know the primary safety concerns of O2Diesel fuel?

2. Have you ever disposed of O2Diesel in the soil, waterways, or down drains? 

3. Do you have any hazardous waste disposal containers?

6. Is there safe handling equipment nearby, including gloves, overalls, and goggles?

ADDITIONAL NOTES

11. Is O2Diesel ever used for any application other than fuel for diesel engines? 

14. If you use a maintenance pit, is the pit to code for handling flammable vapors?

ADDITIONAL NOTES

12. Would O2Diesel make a safe solvent or cleaning agent? 

0

0

0

13. When undertaking a fuel system repair on an O2Diesel vehicle, is a hoist or maintenance pit used?

5. Do you use any safety equipment when handling or working near O2Diesel fuel, vehicles, or storage facilities? 

Mechanic Questions

0

0

0

7. Has anyone you know experienced nausea, headache, or loss of consciousness when handling O2Diesl or working near it?

0

0

0

0

O2Diesel Safety Protocol Questionnaire

Site Information

10. In terms of risk of explosion or fire, is O2Diesel about as safe, safer, or less safe than regular diesel fuel? Than gasoline? 

4. Do you use any special safety precautions when handling O2Diesel fuel or working with O2Diesel storage facilities?

9. Have you noticed any atypical deterioration of fuel lines or other equipment that come in contact with O2Diesel fuel?

8. Do you post signs when an O2Diesel vehicle is being serviced in the maintenance area? Where are they posted? Stored?

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

E-1
Appendix F. Fuel Handler Interview 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

1. Do you know the primary safety concerns of O2Diesel fuel?

2. Have you ever disposed of O2Diesel in the soil, waterways, or down drains? 

4. Is O2Diesel ever used for any application other than fuel for diesel engines? 

ADDITIONAL NOTES

ADDITIONAL NOTES

9. Do you know the significance of a flame arrestor? What is it's significance?

14. Are any non-fleet operated vehicles fueled with O2Diesel?

15. Are all vehicles fueled with O2Diesel clearly labeled with appropriate O2Diesel labels?

5. Has anyone you know experienced nausea, headache, or loss of consciousness when handling O2Diesl or working near it?

6. Have you experienced any problems when fueling vehicles with O2Diesel? If so, what problems?

7. Has O2Diesel fuel ever overflowed out of a vehicle tank or spilled onto the ground?, If so, would this incident be recorded? 

13. Can you show me where the grounding device is kept and how it is properly used?

11. Do you know why static discharge is a hazard when transferring O2Diesel fuel between vessels or vehicles? Why?

12. Is an appropriate grounding mechanism always maintained between the two transfer vessels during fuel transfer events?

10. In terms of risk of explosion or fire, is O2Diesel about as safe, safer, or less safe than regular diesel fuel? Than gasoline? 

8. Can you show me where the emergency shut-off valve is?

3. Do you use any safety equipment when handling or working near O2Diesel fuel, vehicles, or storage facilities? 

0

Fuel Handler Questions

0

0

0

0

0

0

0

0

0

O2Diesel Safety Protocol Questionnaire

Site Information

 YES NO

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

F-1
Appendix G. Vehicle Operator Interview 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

1. Do you know the primary safety concerns of O2Diesel fuel?

6. Do you have a material data safety sheet (MSDS) for O2Diesel in your vehicle?

ADDITIONAL NOTES

0

5. Would you take any special procedures if your O2Diesel vehicle were involved in a traffic accident? What precautions?

8. In terms of risk of explosion or fire, is O2Diesel about as safe, safer, or less safe than regular diesel fuel? Than gasoline? 

2. Do you know why static discharge is a hazard when transferring O2Diesel fuel between vessels or vehicles? Why?

7. Has anyone you know experienced nausea, headache, or loss of consciousness when handling O2Diesl or working near it?

4. Have you experienced any problems when refueling with O2Diesel? If so, what problems?

3. Do you know the significance of a flame arrestor? What is it's significance?

0

0

0

0

0

O2Diesel Safety Protocol Questionnaire

Site Information

Vehicle Operator Questions

0

0

0

0

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

G-1
Appendix H. Site Infrastructure Checklist 

PREPARED BY

DATE PREPARED

SITE NAME 

SITE ADDRESS CITY STATE ZIP CODE

SITE MANAGER TITLE

PHONE NUMBER EMAIL

DATE VISITED 

2. Does the storage tank have a proper desiccant filter installed?

3. Is the desiccant filter checked regularly?

4. Has the desiccant filter been replaced since the tank was first placed in operation?

6. Is the emergency shut-off valve easily accessible and marked?

8. Is any O2Diesel stored in buildings occupied by people?

10. Are all vehicles fueled with O2Diesel clearly labeled with appropriate O2Diesel labels?

ADDITIONAL NOTES

11. Are vehicles properly grounded during fuel transfer events?

12. Are fire extinguishers and spill kits readily available to site personnel?

13. Are appropriate disposal containers, ie hazardous waste containers, available in the maintenance facilities?

15. Are copies of safety training manuals and MSDS readily available to site personnel?

ADDITIONAL NOTES

14. Are safe handling equipment (gloves, overalls, goggles) readily available to site personnel?

5. Does the storage tank have proper placards labeling it as an O2Diesel storage container?

1. Does the storage tank vent have an approved flame arrestor installed – on the tank breather system?

7. Are there concrete blocks or other obstructions to prevent a vehicle or equipment from running into the storage container?

9. Are flame arrestors installed on vehicle tanks – fuel filler pipe and tank breather system?

0

Site Infrastructure Checklist

O2Diesel Safety Protocol Questionnaire

Site Information

0

0

0

0

0

0

0

0

0

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

 YES NO UNSURE

H-1
F1146-E(12/2004) 

REPORT DOCUMENTATION PAGE Form Approved 

OMB No. 0704-0188

The public reporting burden for this collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, 

gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this 

collection of information, including suggestions for reducing the burden, to Department of Defense, Executive Services and Communications Directorate (0704-0188). Respondents 

should be aware that notwithstanding any other provision of law, no person shall be subject to any penalty for failing to comply with a collection of information if it does not display a 

currently valid OMB control number. 

PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ORGANIZATION.

1. REPORT DATE (DD-MM-YYYY)

June 2006 

2. REPORT TYPE

Subcontract Report 

3. DATES COVERED (From - To)

12/23/2002 - 6/30/2007 

5a. CONTRACT NUMBER

DE-AC36-99-GO10337 

5b. GRANT NUMBER

4. TITLE AND SUBTITLE

Assessment of the O2Diesel Operational Safety Programs: 

December 23, 2002 — June 30, 2007 

5c. PROGRAM ELEMENT NUMBER

5d. PROJECT NUMBER

NREL/SR-540-39720 

5e. TASK NUMBER

BB05.4810 

6. AUTHOR(S)

TIAX LLC 

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

O2Diesel, Inc. 

100 Commerce Dr., Ste. 301 

Newark, Delaware 

8. PERFORMING ORGANIZATION 

REPORT NUMBER

ZCL-3-32068-01 

10. SPONSOR/MONITOR'S ACRONYM(S)

NREL 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Renewable Energy Laboratory 

1617 Cole Blvd. 

Golden, CO 80401-3393 11. SPONSORING/MONITORING 

AGENCY REPORT NUMBER

NREL/SR-540-39720 

12. DISTRIBUTION AVAILABILITY STATEMENT

National Technical Information Service 

U.S. Department of Commerce 

5285 Port Royal Road 

Springfield, VA 22161 

13. SUPPLEMENTARY NOTES

NREL Technical Monitor: Kenneth Proc 

14. ABSTRACT (Maximum 200 Words)

This report assesses O2Diesel's operational safety program for using its ethanol-diesel blended fuel. 

15. SUBJECT TERMS

ethanol-diesel; fuel blend; biodiesel handling 

16. SECURITY CLASSIFICATION OF: 19a. NAME OF RESPONSIBLE PERSON 

a. REPORT 

Unclassified 

b. ABSTRACT 

Unclassified

c. THIS PAGE 

Unclassified

17. LIMITATION 

OF ABSTRACT

UL 

18. NUMBER 

OF PAGES 

19b. TELEPHONE NUMBER (Include area code)

Standard Form 298 (Rev. 8/98) 

Prescribed by ANSI Std. Z39.18