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Starting the Year Safely: Lessons from a Fuel Fire on a NSW Quarry

Could your site be the next to face a preventable fuel fire incident?

As we start 2025, it’s crucial we take proactive steps in managing hydrocarbon risks on our work sites. A recent incident at a NSW quarry serves as a stark reminder of the importance of hydrocarbon safety. In late 2024, a worker suffered severe burns while refuelling a petrol-powered water pump. The incident highlights the risks associated with hydrocarbon handling and what can go wrong when safety measures are not effectively deployed.

Burned petrol-powered water pump at NSW quarry site, central to investigation into hydrocarbon safety and fuel fire risks

The Incident

In late 2024, a worker at a quarry suffered severe burns while refuelling a petrol-powered water pump. Preliminary inquiries suggest that the worker was wearing shorts at the time of the incident, which may have contributed to the severity of the burns. Beyond inadequate PPE, the investigation into the cause of the fire questions the appropriateness of workplace procedures, as well as the configuration, operation, and maintenance of the plant and fuelling equipment involved.

Key Takeaways for Improving Hydrocarbon Safety

While the investigation is still underway, there are several key practices that can help prevent similar incidents from occurring on your work sites:

Appropriate Fluid Transfer Processes

Fluid transfer safety icon symbolising appropriate fluid transfer processes to prevent fuel spills and minimise ignition risks
Fluid transfer safety icon symbolising appropriate fluid transfer processes to prevent fuel spills and minimise ignition risks

The first step to reducing the risk of hydrocarbon fires is to ensure that fluid transfer processes are carried out correctly. This includes ensuring that fuel transfers are performed at an appropriate rate to avoid spills and excessive vapour formation, to ensure filling is terminated at the safe fill level for each tank, and to ensure that risks from hot equipment parts, vapour, sprays, and ignition risks like static electricity and external sparks are minimised.

Worker Education

Icon symbolising worker education and training programs that contribute to hydrocarbon safety and reduce refuelling hazards
Icon symbolising worker education and training programs that contribute to hydrocarbon safety and reduce refuelling hazards

Ensuring that workers understand the risks associated with refuelling and hydrocarbon management is crucial. Training programs should cover the proper handling of flammable substances, emergency response procedures, and best practices for working with hazardous materials in the context of your own site processes, fleet, and filling hardware. The right education empowers workers to recognise risks, take appropriate actions to avoid them, and get their job done more efficiently as well.

Personal Protective Equipment (PPE)

Icon representing personal protective equipment (PPE), including flame-retardant clothing and safety glasses, crucial for worker safety during refuelling
Icon representing personal protective equipment (PPE), including flame-retardant clothing and safety glasses, crucial for worker safety during refuelling

Finally, workers must be equipped with appropriate PPE, including flame-retardant clothing, gloves, and eye protection. While PPE is a last line of defence, it plays a critical role in minimising the severity of injuries should an accident occur. Ensuring that workers are always properly equipped is non-negotiable in high-risk environments. Complacency leads to unfortunate reports being issued by your local Safe Work or Industry Regulator Organisation… or worse.

Is your site ready for 2025?

Let Banlaw help ensure your colleagues stay safe and your operation is compliant and efficient this year. Banlaw’s global Service Teams specialise in site asset and infrastructure audits, ensuring your refuelling and lubrication systems are optimised for safety and efficiency. Contact us today to schedule a system safety and functionality audit and make sure your operation is fully equipped to handle the risks of 2025.

Composite image showing burned petrol-powered water pump and a worker wearing appropriate PPE while safely fuelling equipment, emphasising hydrocarbon safety and PPE use

At the time of writing, the NSW Resource Regulator was still managing the formal investigation. Updates can be found by searching for reference RDOC24/205994 using your web browser.

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