DSS236: Safety Share - Loader Fire Escalation Incident

In today’s episode of the Dust Safety Science podcast, we are doing a Safety Share about a loader fire escalation incident. It’s based on a Safety Alert for Manufacturing released by the BC Forest Safety Council and the Manufacturing Advisory Group in British Columbia. These alerts serve as valuable resources for sharing lessons learned from safety incidents.

What Happened During This Loader Fire?

So then, turning our attention to this specific loader fire, what happened? So the loader in this case, the loader operator, was gathering reject logs at the reject bin at a wood processing site. They smelt smoke and they looked behind them on the loader and saw a smouldering fire. They call it a ‘spark’ in the description, but some type of live fire combustion event that was quite small.

According to the report, the loader operator noticed a smolder and immediately radioed the mill. They proceeded to the fire pump house to extinguish the equipment with hoses. However, before reaching the pump hose, a significant amount of smoke emerged from the back of the loader and quickly developed into a large, intense fire. As a precaution, the loader was parked away from structures until the fire department arrived. Fortunately, no injuries were reported, but the loader suffered extensive damage.

The exact role of combustible dust in this incident is not explicitly mentioned, although the safety recommendations extensively address the issue. The report states that the fire investigator determined the cause to be a hydraulic leak, which was ignited by the turbo in the loader and rapidly intensified by the reverse fan system. Consequently, the fire escalated into a full-scale blaze.

The safety alert provides four recommendations:

If a fire is suspected, immediately park the vehicle in the nearest safe location and turn it off. Only attempt to extinguish the fire if it is small and manageable.
Consider establishing safe procedures for mobile equipment blowdown, taking into account the frequency of blowdowns and minimizing the risk of wood dust explosions.
For mobile equipment used in dusty areas, consider periodically blowing out the engine compartment every four hours or as necessary to keep it free from combustible materials.
Incorporate a visual inspection of the engine compartment for combustible buildup during pre-use inspections of mobile equipment.

While the safety recommendations primarily focus on combustible dust, the report also highlights the possibility of a hydraulic leak leading to smouldering and subsequent dust accumulation in the equipment. This could then melt the hydraulic line, resulting in rapid escalation of the fire. Therefore, it is crucial to consider various scenarios involving combustible dust when analyzing hazards.

What Are The Takeaways?

Apart from the recommendations, there are three additional key points to take away from this safety alert.

Knock-On Hazards Need to Be Considered

The first key takeaway is the importance of considering knock-on hazards during hazard analysis. In this specific incident, a smoldering fire caused the hydraulic hose to rupture, resulting in a leak that rapidly escalated the fire. It is crucial to understand the potential consequences, such as the potential disabling of sprinkler and power systems, to effectively respond to emergencies and mitigate risks. Awareness of these knock-on effects is essential.

Park Active Fires Away From Structures

The second takeaway, as mentioned in the recommendations, emphasizes the significance of parking an active fire away from structures. While it may seem obvious, even if you believe you can easily extinguish the fire or it may not pose a significant threat, it is wise to act prudently and relocate the fire away from other structures. Even if you are confident in your ability to extinguish the fire, it is crucial to keep it away from structures to prevent its spread.

Plan Fire Response in Advance

The third takeaway focuses on considering your site’s response to fires in advance. The framework suggested is “identify, respond, and recover.” It is essential to have a clear understanding of how employees can identify a fire or combustion event, how they should respond to it, and the guidelines they must follow. Additionally, establishing protocols for recovery once the fire is extinguished and returning to normal work operations is vital. Training plays a crucial role in identifying fires and recognizing potential knock-on effects, emphasizing the need to avoid blowdown near a fire.

Many incidents resulting in injuries and loss of life in the incident database occur due to fires or smoldering events rapidly escalating into deflagration events. Therefore, understanding these possibilities in advance is crucial. For instance, even using a water hose to clean off a loader can disperse enough dust to cause a deflagration, necessitating prior knowledge of such risks. This ties into the second aspect—responding. Having well-defined, documented rules that are understood by all employees and regularly tested is crucial. Establishing clear definitions, such as an incipient fire, is vital to determine appropriate responses and determine whether employees feel capable of handling the situation.

Response to Incipient Fire

The definition of an incipient fire may vary depending on the circumstances, but generally, it refers to a fire that remains small or is no larger than its initial size. It is crucial to assess the situation carefully. If the fire is growing rapidly, employees should not attempt to tackle it. Relying solely on employees’ judgment in the moment to determine if they can handle the fire is not a reliable assessment. Therefore, it is necessary to establish a clear definition of an incipient fire that takes into account specific site conditions and factors.

In addition to defining incipient fires, it is important to establish guidelines regarding the appropriate clothing to be worn when dealing with fires. A notable example is the video of firefighters in Abbotsford, BC, attempting to extinguish a silo fire, which resulted in a dust explosion.

That incident highlights the significance of wearing fire-retardant, fire-resistant, or full-turnout gear, even for trained firefighters. Without such protective clothing, they would have suffered severe injuries in the explosion. It is imperative to ensure that workers without proper protective gear do not attempt to handle such events. Strict guidelines should be in place regarding the specific type of clothing that must be worn to safeguard against potential hazards.

Furthermore, it is crucial to communicate to employees that if they are unsure or unable to recall the “if this, then that” rules or procedures for fighting a fire, they should refrain from doing so. If they feel nervous, scared, or reluctant to engage with the fire, they should avoid fighting it altogether. By establishing this mindset and incorporating it into the organizational culture, hesitation during firefighting efforts can be minimized, preventing potential exacerbation of the situation.

Conclusion

This loader fire escalation incident highlights the importance of understanding and addressing hazards related to combustible dust, as well as implementing proper safety measures. Overall, this Safety Share serves as a reminder to prioritize fire safety and address potential hazards in manufacturing environments. By implementing proper procedures, training, and safety measures, incidents can be minimized, and the well-being of employees and equipment can be safeguarded.

If you have questions about the contents of this or any other podcast episode, you can go to our ‘Questions from the Community’ page and submit a text message or video recording. We will then bring someone on to answer these questions in a future episode.