Fire Common Causes, Prevention and Mitigation Ian Gibson, EHS Programme Manager, MPA Cement

FIRE Oxygen Fuel Heat How it Starts! First a simple introduction to Fire and how it starts and spreads: To start, all fires need oxygen, heat and fuel. Oxygen can come from the atmosphere, oxidising agents or from bottled oxygen gas used for welding and cutting. Heat can come from any number of sources such as friction, welding slag, the process (heat from kilns and boilers etc), hot products, chemical reaction, electrical short circuit or cigarette ends. Fuels can include grease, oils, paper sacks, rubber, cable insulation etc. Remove any one of oxygen, heat or fuel and the fire cannot start or be sustained. Fire spreads by radiation, the heat felt when standing by the fire and in this case jumping from one burning dozer to the next; by convection (normally the most dangerous) and in this example rising up the stairwell and starting a further fire at the opposite end of the building; and perhaps less frequently by conduction and in this example travelling along an I girder and through a wall. In all the following incidents, the Oxygen was available from the atmosphere.

FIRE How it Spreads! Radiation Convection Conduction First a simple introduction to Fire and how it starts and spreads: To start, all fires need oxygen, heat and fuel. Oxygen can come from the atmosphere, oxidising agents or from bottled oxygen gas used for welding and cutting. Heat can come from any number of sources such as friction, welding slag, the process (heat from kilns and boilers etc), hot products, chemical reaction, electrical short circuit or cigarette ends. Fuels can include grease, oils, paper sacks, rubber, cable insulation etc. Remove any one of oxygen, heat or fuel and the fire cannot start or be sustained. Fire spreads by radiation, the heat felt when standing by the fire and in this case jumping from one burning dozer to the next; by convection (normally the most dangerous) and in this example rising up the stairwell and starting a further fire at the opposite end of the building; and perhaps less frequently by conduction and in this example travelling along an I girder and through a wall. In all the following incidents, the Oxygen was available from the atmosphere. Conduction

What the Law Says Regulatory Reform (Fire Safety) Order 2005: places the responsibility on individuals within an organisation to carry out risk assessments to identify, manage and reduce the risk of fire (including permitting for work in hazardous places/activities) Dangerous Substances and Explosive Atmospheres Regulations: employers to introduce control measures for dangerous substances and identify & classify explosive atmospheres. Building Regulations 2010: fire safety (including means of warning; escape routes; internal and external fire spread etc). The Construction (Design and Management) Regulations 2007: suitable and sufficient fire fighting equipment, fire detection & alarm systems. Others.... Essentially the law requires – fire risk assessments and effective detection, warning, fire fighting equipment and escape routes

The key is the FIRE RISK ASSESSMENT And this includes; A means of: escape giving warning fighting fires A means of escape A means of giving warning A means of fighting fire

MOBILE PLANT: Dumper Fire Incident A fire occurred on a Dumper -Cat 773E –model 2005, when it was parked up at the end of the shift . Investigation into the cause have identified that the auxiliary jump start battery cables, which run along the left front frame back toward the area of the left front suspension cylinder, had suffered deterioration whilst rubbing together over time. The battery cables pass over the steering hydraulic hoses inside the frame near the starter. The rubbing wore the insulation away on the positive battery cable and the rubber off the hydraulic hose. The two made contact and the fire started. Learning Points: Where possible avoid securing cables and hoses together. Where it is necessary additional insulation sleeving must be used. If the isolator key had been used then it is very unlikely that this fire would have occurred in the manner it did. All machinery should be electrically isolated when left unattended, removal of the isolator (where fitted) is also part of the Epic operator assessment. Where practical all mobile plant should be parked with sufficient spacing to prevent a fire spreading to other vehicles or structures. All mobile plant should be cleaned down and subject to a thorough visual inspection on a regular basis.  Systematic inspection of all components within a hydraulic or fuel supply circuit during routine part replacements.  Proactively monitoring of hydraulic hoses including checks on hose connections, clamps and pressure relief valves.  Adopt a risk based hydraulic hose management system.  Verify internal maintenance systems with additional quality checks by manufacturers or authorised service providers.  Evaluate isolation techniques such as shielding for potential engine heat sources or insulation of hoses near hot components.  Routine inspection of electrical systems for corrosion or insulation fatigue.  Consider the location and rating of protective devices such as fuses and wiring control.  Install, maintain and systematically inspect fire detection and automatic fire suppression systems on vehicles or plant operating at a higher risk of fire.  Install portable fire extinguishers on all mobile plant.  Provide appropriate training to all mobile plant staff on hydraulic hazards, fire detection and response procedures.

MOBILE PLANT: Other Issues to Consider Scenarios: Electrical short circuit leads to ignition of combustible material e.g. spilt fuel, lubricants. Leaking hydraulic fluid or fuel sprays onto hot engine components. Plastics etc come into contact with hot engine components/exhaust or block air inlets: an issue for landfill & recycling sites. Other Learning Points include: Undertake regular maintenance & inspection, with a focus on critical components such as hoses and their connections etc. Undertake routine inspection of electrical systems for corrosion or fatigue Shield heat sources (or insulate hoses near hot components). Specify fire detection and automatic suppression on new plant Provide training on hydraulic hazards, fire detection and response. Ensure that any retrofits such as visibility devices and associated wiring do not cross/chaff fuel lines or hydraulic pipes. Portable fire extinguishers should be readily available. Safe Systems for Charging Batteries  Systematic inspection of all components within a hydraulic or fuel supply circuit during routine part replacements.  Proactively monitoring of hydraulic hoses including checks on hose connections, clamps and pressure relief valves.  Adopt a risk based hydraulic hose management system.  Verify internal maintenance systems with additional quality checks by manufacturers or authorised service providers.  Evaluate isolation techniques such as shielding for potential engine heat sources or insulation of hoses near hot components.  Routine inspection of electrical systems for corrosion or insulation fatigue.  Consider the location and rating of protective devices such as fuses and wiring control.  Install, maintain and systematically inspect fire detection and automatic fire suppression systems on vehicles or plant operating at a higher risk of fire.  Install portable fire extinguishers on all mobile plant.  Provide appropriate training to all mobile plant staff on hydraulic hazards, fire detection and response procedures.

HOTWORK: Some examples Sand & Gravel Wharf: Linatex lined pipe-work was ignited during Hotwork The fire started when Linatex lined pipe-work was ignited during hot work. Heat from Arc Welding ignited the Linatex lining and the pipes design meant that the lining sparked and continued combustion at such a rate, (fed by the suction of air, as in a chimney), that it soon spread. Once it had spread to the Screens and the conveyors, it became impossible to stop. All the incidents were subject to a Hotwork Permit.

HOTWORK: Learning Points When Linatex ignites, it is near impossible to extinguish and will migrate through the lined areas of the plant. ALL managers must review their hot work procedure when working on or near Linatex.  This should be a reminder to everyone of the need for sufficient Risk Assessments/SWP's with adequate precautions when undertaking hot work. Don’t just have a standby fire procedure, constantly damp down any lined areas around the hot working area. Insist that the isolation and lock off procedures are followed. (You may then be left with the problem that you can’t have pumps running, to water down the aforementioned areas. Consider hiring a small engine driven pump to be used whilst the plant is isolated.) Insist on a 30minute fire-watch after the works are complete. Ensure you have suitable communications in place to carry out the emergency procedures Ensure all persons undertaking hot work are trained and competent Specific details of the RMC Sand and Gravel Wharf Incident

HOTWORK: Some examples The Yeoman Bostrup ablaze at Glensanda following Hotwork on a Hopper. Yeoman Bostrup: Complacency due to frequency of Hotwork; Poor housekeeping (chemicals/oils stowed in gangways & workshops); Paper risk assessment did not take account of residual risks (so additional control measures not considered); crew not practicised in fire fighting in that area. Recommendations relate to better control, early detection, containment and fire fighting measures (e.g. smoke detectors, fire curtains). All the incidents were subject to a Hotwork Permit.

HOTWORK: Some examples “Hot Metal came into contact with combustible material on screen underpan” Screen Underpan (& Conveyor Fire): Contractor altered their method of work without updating their risk assessment or informing site management. Recommendations: If possible remove the rubber product or lining; contain sparks or hot debris, even after the work is finished. Wet the work area before and after ; water fire extinguishers must be available; Post a competent “Fire Watch”, Prepare an Emergency Plan; Take care if solvents or adhesives are used. All the incidents were subject to a Hotwork Permit.

HOTWORK: Other Issues to Consider Most incidents involve hot metal igniting combustible materials which very rapidly escalates out of control and spreads along conveyors etc to potentially wipe out the entire plant. Hotwork Permits are generally in place but deviations occur and welding splatter can end up in the most awkward corners etc. Hot work permit and fire watch should consider the areas up , down and sideways for sparks

PROCESS SAFETY: Coating Plant Incident A serious fire occurred at a Coating Plant. Fortunately this event caused no harm to any personnel but did cause significant damage to the plant Learning Points include: Visibility: To plant operator (line of sight or CCTV) Risk Assess provision of automatic detection and suppression Review pipes and fittings (replace or cover plastic parts) Fit and maintain fuseable link unless automatic device fitted. Fit cut offs fitted to all fuel lines. Pre-start/Shutdown checks of fuel lines Review storage of propane cylinders Review emergency plan (including out of hours)

SITE OFFICES & PORTACABINS ‘The cause of the fire is believed to have been either an electrical fault or something adjacent to a heat source catching alight’. Learning Points include ensuring that; Plug sockets are not overloaded; Clothing and other flammable materials are not left on heaters to dry; Work stations are kept tidy, with paper not left adjacent to computer cooling fans etc; All portable appliances are switched off at the mains when not in use & overnight; Portable Appliance Testing (PAT) is up to date and any faulty equipment removed; Smoking is only allowed in designated areas; Cigarettes & matches used in smoking areas are fully extinguished; Fire risk assessments have been carried out and actions are being followed; All electrical installations are visually inspected quarterly and fully inspected annually by competent persons. Notice boards are not situated above heaters A fire started in the Premix batcher cabin overnight. The cabin, canteen and all the contents were completely destroyed. A 5-month old truck mixer parked adjacent to the buildings was also destroyed. Fire brigade investigations have ruled out the involvement of any ‘third party’–the cause was not arson. Investigation concluded that the fire started within the batch cabin area. (Although arson was ruled out, the presenter may wish to highlight measures that could be taken to reduce the arson risk namely improving security, reducing gaps under doors and not storing flammable materials adjacent to external fences etc

Conclusion Do the basics (smoking policy, good housekeeping, storage of flammable materials etc). Good quality risk assessments, effective control measures, regularly reviewed. Regular maintenance and inspection. Manage Hot work Consider automatic detection & suppression Facilitate early detection and effective fire fighting Emergency plans that have been tested and appropriate warning systems/emergency lighting/ means of escape/signage etc. Competent employees and contractors

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