A recent NSW Resources Regulator investigation into a serious 2023 incident has highlighted the importance of identifying hazards during equipment refuelling at mine sites.
Two years ago on June 22, while working at an open-cut coal mine in NSW, an operator suffered burns to his hands, face and body when unleaded petrol came into contact with the hot engine components of a hot water pressure cleaner he was in the process of refuelling.
According to the regulator’s report, the incident occurred when the worker was hot washing the blue belt in the coal handling plant using a pressure cleaner mounted in a box trailer. Around midday, he stopped cleaning and began refuelling the cleaner’s tank. While pouring fuel, the worker noticed the airlock on the fuel container was closed.
Upon opening it, the petrol unexpectedly spilled, which was then followed by the detachment of the spout – as a result, the petrol splashed onto the hot engine and exhaust components.
Due to the surfaces’ high temperature, the fire engulfed both the container and the worker’s clothing.
Nearby workers extinguished the flames, and the injured worker removed the burning uniform and later shut down the still-running engine using the emergency stop button.
In its investigation, the regulator found that the mine operators had several appropriate safety systems in place and the worker was inducted, experienced, and qualified.
The regulator noted that, in this instance, the worker deviated from the established safe system of work by failing to stop the pressure cleaner before commencing refuelling, and refuelling the pressure cleaner without allowing it to cool down to a safe temperature.
In light of its findings, the regulator has made several recommendations for mine operators and contractors.
For operators, these include conducting an appropriate risk assessment to identify potential hazards associated with refuelling plant and equipment; developing and implementing safe work procedures that detail the step-by-step refuelling processes, including shutdown and cool-down times; and maintaining accessible firefighting equipment.
Workers must also comply with the approved safe work procedure, never attempt to refuel petrol-powered equipment while the engine is running, and conduct a visual inspection prior to refuelling to ensure no ignition sources are present, ventilation is sufficient, and all required PPE is worn.