The process of refuelling on industrial worksites carries several inherent risks.
High refuelling rates, extreme environmental conditions, hot engine components, and pressurised fuel, can quickly become a recipe for disaster if the correct infrastructure, system components, and processes are not in place.
Here are 4 ways you can mitigate the risk and ensure your site is refuelling as safely and efficiently as possible:
1) Invest in Zero-Pressure, Primary Overfill Protection
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The NSW Government released a Mine Safety Bulletin based on key learnings from a number of incidents where fires ignited during the refuelling process. One of the key recommendations put forward from their investigations was "using refuelling systems that do not rely on fuel tank pressurisation to stop fuel flow when the tanks are full". -
Traditional quick-fill systems automatically stop refuelling by momentarily pressurising the tank at the point of maximum fill, and using this signal to turn off the fuel nozzle. -
A Pressureless, Primary Tank Overfill Protection System, on the other hand, requires zero tank pressure for it to automatically terminate refuelling when the correct tank level is reached. -
The great thing about a Primary Overfill Protection system, like Fill Safe Zero or FillSafe Power, is that it does not override your existing dry-break system. It adds an additional layer of safety on top of your existing refuelling setup whilst retaining the traditional functionality as a backup. -
Using a Zero-Pressure Tank Overfill Protection solution prevents tank rupture, overfilling & underfilling, hazardous spills and reduces the likelihood of fires. -
FillSafe Zero, which is our mechanical tank overfill protection offering, is also a relatively low-cost investment. Some kits can cost less than a tank of diesel!
Check out this video to see Fill-Safe Zero in action:
2) Choose high-quality system components that are designed to work together and are fit for purpose
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Invest in high-quality Nozzles, Receivers and Vents that are fit for purpose and designed & configured to work optimally together -
Look for refuelling components featuring sturdy steel construction. Steel nozzle and receiver mating surfaces and a dependable ball locking mechanism prevents warping, dents and burring, and ensures a consistently 'fluid-tight connection'. This prevents avoidable leaks and spills and ensures nozzles can't 'fly off', spraying diesel and potentially injuring the operator. -
The Mine Safety Bulletin stresses the importance of "ensuring fuel dispensing flow rate and air vent capacity of fuel tanks is correctly matched", and "ensuring refuelling nozzles and fuel tank receivers are a matched set". Many incidents are caused by sites using components in ways they were not intended, failing to consider optimal flow rates across the whole system, or combining mismatched components.
TOP SAFETY TIP:
When using quick-fill diesel refuelling systems, NEVER tie off (or manually hold) the nozzle handle into the ‘On’ position. This is a key component of the automatic shutoff system. When nozzles cannot switch off as designed, tank rupture, fuel spillage and equipment fires can occur. Quick-fill refuelling system reliability issues can be overcome immediately with correct nozzle/receiver/vent selection. Never override refuelling shutoff systems.
Watch the video below to review an incident report where an operator overrode the diesel refuelling system:
3) Take a full system approach
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One of the most important points to consider when it comes to safety is that it's not enough to simply choose quality components. You need to look at how those components work together as a system to meet your unique needs. -
Components need to be configured to safely work together to deliver the flow rates you require, suit your individual equipment tank setups, and align with site processes & conditions.
Mark Fretwell, Banlaw Mechanical Engineer, stresses the point of not simply looking at individual components but how they work together as a complete solution:
99% of the time, people will blame the nozzle for reliability issues when it's typically the system as a whole that is a mismatch. Higher flow rates lead to higher pressure drop, and that is what causes premature nozzle shutoff. Just because a brochure says a single product will deliver 1000lpm, it doesn't mean that strapping 5 items together that are specified for that flow rate will equal a reliable 1000lpm system.
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A full system approach not only looks at how components work together, but also the automated safety processes you can put in place to protect your team and fuel-consuming assets. -
This includes putting in place safe, efficient, ergonomic Refuelling Infrastructure, including the use of Breakaway Valves, Loading Arms, Swivels, and a Fuel Management System to ensure only the correct fluid, is dispensed in the correct amount, into the correct machine. This approach provides a safe working environment that prevents major incidents and enables your team to perform daily tasks as efficiently as possible.
TOP SAFETY TIP:
Ensure fuel tank vent hoses are routed to the ground, rather than allowing vapours (and potentially diesel) to exit the vent exhaust port near electrical circuits and hot engine components.
4) Be proactive with your Maintenance
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Proactive maintenance is the key preventing serious incidents, protecting your people, and minimising costly unscheduled downtime and damage to equipment. -
In a diesel refuelling context, it begins with identifying risk scenarios that may cause leaks, spills, fires, or other hazards during the refuelling process and providing proactive maintenance solutions in line with the hierarchy of risk controls. -
Proactive Maintenance is an effective way of identifying and removing hazards before serious incidents can occur.
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You should have a clear maintenance plan in place with key maintenance dates based on your unique site infrastructure, equipment refuelling setups, and processes. -
Government regulators recommend carrying out a Failure Modes Effects Analysis (FMEA) to identify your site's lifecycle inspection and maintenance requirements. -
Banlaw has the specialist expertise to help you formulate a comprehensive maintenance plan and conduct thorough, actionable maintenance inspections at your site.
Replacing the tank in an excavator can cost ~$175,000 AUD while replacing the tank in a haul truck might cost ~$40,000 AUD. A fleet preventative maintenance contract starts at only $15,000 AUD so getting a specialist to look at your machines and facilities quickly pays for itself.
Contact an expert at Banlaw today and start a conversation about your refuelling systems. We can help you plan and monitor your maintenance, update your infrastructure and mobile assets to be more-safe, and deliver refuelling safety inspections and reports so you know which subjects to prioritise.
Useful Resources:
- Resources Regulators Report regarding Fires on Mobile Plant – September 2021
- Fires ignite while refuelling mobile plant with quick-fill fuel systems, NSW Goverment
- Fires Occur While Refuelling Plant, NSW Government
- [VIDEO] Pressurised Refuelling Systems 1: Lessons learned, Resources Safety & Health Queensland
- [VIDEO] Pressurised Refuelling Systems 2: Process overview, Resources Safety & Health Queensland
